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130G Excavator

Diagnostic

OPERATION AND TEST MANUAL

(T3/S3a) models 130G (PIN: 1FF130GX__D040001 - )

TM12554 10SEP15 (ENGLISH)

For complete service information also see:


130G Excavator Repair (PIN: 1FF130GX_
TM12557
_D040001-)
JDLink (MTG) Technical Manual TM114519
PowerTech E 4.5 and 6.8L Diesel Engines
Level 16 Electronic Fuel System With CTM502
Denso HPCR
PowerTech 4.5L & 6.8L Diesel Engines
Tier 1/Stage I, Tier 2/Stage II, Tier
CTM104
3/Stage IIIA, Tier 3/Stage IIA Tier 3/Stage
III, (Base Engine)
JDLINK/ZXLINK Machine Monitoring
CTM10006
System

John Deere Construction and Forestry


130G Excavator Diagnostic (g) by Belgreen v2.1

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

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<- Go to Global Table of contents 130G Excavator Diagnostic
130G Excavator Diagnostic (g) by Belgreen v2.1

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.

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GENERAL INFORMATION (g) by Belgreen v2.0

Technical Information Feedback Form


We need your help to continually improve our technical publications. Please copy this page and FAX or mail your comments,
ideas and improvements.

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!

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130G Excavator Diagnostic (g) by Belgreen v2.1

Section 9000 - GENERAL INFORMATION


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

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Section 9000 - GENERAL INFORMATION Group 01: Safety

Group 01 - Safety
Recognize Safety Information

Safety alert Symbols

Safety Alert Symbols

This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert for the
potential of personal injury.

Follow the precautions and safe operating practices highlighted by this symbol.

A signal word — DANGER, WARNING, or CAUTION — is used with the safety alert symbol. DANGER identifies the most serious
hazards.

On your machine, DANGER signs are red in color, WARNING signs are orange, and CAUTION signs are yellow. DANGER and
WARNING signs are located near specific hazards. General precautions are on CAUTION labels.

Follow Safety Instructions

Safety Messages

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Section 9000 - GENERAL INFORMATION Group 01: Safety

Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition.
Replace missing or damaged safety signs. Use this operator’s manual for correct safety sign placement. Be sure that new
equipment components and repair parts include the current safety signs. Replacement safety signs are available from your
John Deere dealer.

There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in
this operator′s manual.

Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction.

Keep your machine in proper working condition. Unauthorized modifications to the machine could impair the function or safety
and affect machine life.

If you do not understand any part of this manual and need assistance, contact your John Deere dealer.

Operate Only If Qualified


Do not operate this machine unless the operator′s manual has been read carefully, and you have been qualified by supervised
training and instruction.

Operator should be familiar with the job site and surroundings before operating. Try all controls and machine functions with the
machine in an open area before starting to work.

Know and observe all safety rules that may apply to every work situation and work site.

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Section 9000 - GENERAL INFORMATION Group 01: Safety

Wear Protective Equipment

Protective Clothing

Guard against injury from flying pieces or metal or debris; wear goggles or safety glasses.

Wear close fitting clothing and safety equipment appropriate to the job.

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating
machine.

Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear suitable hearing protection such as earmuffs
or earplugs to protect against objectionable or uncomfortable loud noises. Radio or music headphones are not suitable to use
for hearing protection.

Avoid Unauthorized Machine Modifications


John Deere recommends using only genuine John Deere replacement parts to ensure machine performance. Never substitute
genuine John Deere parts with alternate parts not intended for the application as these can create hazardous situations or
hazardous performance. Non-John Deere parts, or any damage or failures resulting from their use are not covered by any John
Deere warranty.

Modifications of this machine, or addition of unapproved products or attachments, may affect machine stability or reliability,
and may create a hazard for the operator or others near the machine. The installer of any modification which may affect the
electronic controls of this machine is responsible for establishing that the modification does not adversely affect the machine or
its performance.

Always 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.

Control Pattern Selector—If Equipped


This machine may be equipped with a control pattern selector valve. Ensure all bystanders are clear of machine and area is

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Section 9000 - GENERAL INFORMATION Group 01: Safety

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

Add Cab Guarding for Special Uses


Special work situations or machine attachments could create an environment with falling or flying objects. Working near an
overhead bank, demolition work, using a hydraulic hammer or winch, working in a forestry application or wooded area, or
working in a waste management application, for example, could require added guarding to protect the operator.

Additional level II FOPS (falling object protective structure), forestry protection packages, and special screens or guarding
should be installed when falling or flying objects could enter or damage the machine. A rear screen should always be used with
a winch to protect against a snapping cable. Before operating in any special work environments, follow the operator protection
recommendations of the manufacturer of any specialized attachment or equipment. Contact your authorized John Deere dealer
for information on protective guarding.

Inspect Machine

Inspect Machine

Inspect machine carefully each day by walking around it before starting.

Keep all guards and shields in good condition and properly installed. Fix damage and replace worn or broken parts
immediately. Pay special attention to hydraulic hoses and electrical wiring.

Stay Clear of Moving Parts

Stay Clear of Moving Parts

Entanglements in moving parts can cause serious injury.

Stop engine before examining, adjusting, or maintaining any part of machine with moving parts.

Keep guards and shields in place. Replace any guard or shield that has been removed for access as soon as service or repair is
complete.

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Section 9000 - GENERAL INFORMATION Group 01: Safety

Avoid High-Pressure Fluids

High Pressure

Inspect hydraulic hoses periodically – at least once per year – for leakage, kinking, cuts, cracks, abrasion, blisters, corrosion,
exposed wire braid or any other signs of wear or damage.

Replace worn or damaged hose assemblies immediately with John Deere approved replacement parts.

Escaping fluid under pressure can penetrate the skin causing serious injury.

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying
pressure.

Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours
or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such
information is available in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling
1-800-822-8262 or +1 309-748-5636.

Avoid High-Pressure Oils

Avoid High Pressure Oils

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Section 9000 - GENERAL INFORMATION Group 01: Safety

Avoid High-Pressure Oils

This machine uses a high-pressure hydraulic system. Escaping oil under pressure can penetrate the skin causing serious injury.

Never search for leaks with your hands. Protect hands. Use a piece of cardboard to find location of escaping oil. Stop
engine and relieve pressure before disconnecting lines or working on hydraulic system.

If hydraulic oil penetrates your skin, see a doctor immediately. Injected oil must be removed surgically within
hours or gangrene could result. Contact a knowledgeable medical source or the Deere & Company Medical Department in
Moline, Illinois, U.S.A.

Work In Ventilated Area

Engine exhaust fumes

Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust
fumes from the area with an exhaust pipe extension.

If you do not have an exhaust pipe extension, open the doors and get outside air into the area.

Prevent Fires

Handle Fuel Safely


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Section 9000 - GENERAL INFORMATION Group 01: Safety

Clean Machine Regularly

Carry A Fire Extinguisher

Handle Fuel Safely: Store flammable fluids away from fire hazards. Never refuel machine while smoking or when near sparks
or flame.

Clean Machine Regularly: Keep trash, debris, grease and oil from accumulating in engine compartment, around fuel lines,
hydraulic lines, exhaust components, and electrical wiring. Never store oily rags or flammable materials inside a machine
compartment.

Maintain Hoses and Wiring: Replace hydraulic hoses immediately if they begin to leak, and clean up any oil spills. Examine
electrical wiring and connectors frequently for damage.

Keep A Fire Extinguisher Available: Always keep a multipurpose fire extinguisher on or near the machine. Know how to use
extinguisher properly.

Prevent Battery Explosions

Battery Explosions

Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.

Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.

Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

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Section 9000 - GENERAL INFORMATION Group 01: Safety

Handle Chemical Products Safely

Material Safety Data Sheet

Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere
equipment include such items as lubricants, coolants, paints, and adhesives.

A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety
procedures, and emergency response techniques.

Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and
how to do the job safely. Then follow procedures and recommended equipment.

(See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment.)

Dispose of Waste Properly

Recycle Waste

Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere
equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries.

Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking
from them.

Do not pour waste onto the ground, down a drain, or into any water source.

Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a
certified air conditioning service center to recover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John
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Section 9000 - GENERAL INFORMATION Group 01: Safety

Deere dealer.

Prepare for Emergencies

First Aid Kit

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

Clean Debris from Machine

Clean Debris From Machine

Keep engine compartment, radiator, batteries, hydraulic lines, exhaust components, fuel tank, and operator′s station clean and
free of debris.

Clean any oil spills or fuel spills on machine surfaces.

Temperature in engine compartment could go up immediately after engine is stopped. BE ON GUARD FOR FIRES DURING THIS
PERIOD.

Open access door(s) to cool the engine faster, and clean engine compartment.

Use Steps and Handholds Correctly

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Section 9000 - GENERAL INFORMATION Group 01: Safety

Use Handholds And Steps

Prevent falls by facing the machine when you get on and off. Maintain 3-point contact with steps and handrails. Never use
machine controls as handholds.

Use extra care when mud, snow, or moisture present slippery conditions. Keep steps clean and free of grease or oil. Never
jump when exiting machine. Never mount or dismount a moving machine.

Start Only From Operator′s Seat

Operate Only From Operators Seat

Avoid unexpected machine movement. Start engine only while sitting in operator′s seat. Ensure that all controls and working
tools are in proper position for a parked machine.

Never attempt to start engine from the ground. Do not attempt to start engine by shorting across the starter solenoid
terminals.

Use and Maintain Seat Belt

Use and Maintain Seat Belt

Use seat belt when operating machine . Remember to fasten seat belt when loading and unloading from trucks and during
other uses.

Examine seat belt frequently. Be sure that webbing is not cut or torn. Replace seat belt immediately if any part is damaged or

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Section 9000 - GENERAL INFORMATION Group 01: Safety

does not function properly.

The complete seat belt assembly should be replaced every three years, regardless of appearance.

Prevent Unintended Machine Movement

Unintended Machine Movement

Be careful not to accidentally actuate control levers when coworkers are present. Pull pilot shutoff lever to locked (UP) position
during work interruptions. Pull pilot shutoff lever to locked (UP) position and stop engine before allowing anyone to approach
machine.

Always lower work equipment to the ground and pull pilot shutoff lever to locked (UP) position before standing up or leaving
the operator′s seat. Stop engine before exiting.

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Section 9000 - GENERAL INFORMATION Group 01: Safety

Avoid Work Site Hazards

Work Site Hazards

Work Site Hazards

Work Site Hazards

Avoid contact with gas lines, buried cables, and water lines. Call utility line location services to identify all
underground utilities before digging.

Prepare work site properly . Avoid operating near structures or objects that could fall onto the machine. Clear away debris
that could move unexpectedly if run over.

Avoid boom or arm contact with overhead obstacles or overhead electrical lines. Never move any part of machine or
load closer than 3 m (10 ft) plus twice the line insulator length to overhead wires.

Keep bystanders clear at all times. Keep bystanders away from raised booms, attachments, and unsupported loads. Avoid
swinging or raising booms, attachments, or loads over or near bystanders. Use barricades or a signal person to keep vehicles
and pedestrians away. Use a signal person if moving machine in congested areas or where visibility is restricted. Always keep
signal person in view. Coordinate hand signals before starting machine.

Operate only on solid footing with strength sufficient to support machine. When working close to an excavation, position
travel motors away from the hole.
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Section 9000 - GENERAL INFORMATION Group 01: Safety

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

Keep Riders Off Machine

Keep Riders Off Machine

Only allow operator on machine.

Riders are subject to injury. They may fall from machine, be caught between machine parts, or be struck by foreign objects.

Riders may obstruct operator’s view or impair the ability to operate machine safely.

Avoid Backover Accidents

Avoid Backover Accidents

Before moving machine, be sure that all persons are clear of machine path. Turn around and look directly for best
visibility. Use mirrors to assist in checking all around machine. Keep windows and mirrors clean, adjusted, and in good repair.

Be certain reverse warning alarm is working properly.

Use a signal person when backing if view is obstructed or when in close quarters. Keep signal person in view at all
times. Use prearranged hand signals to communicate.

Do not rely on the rear camera and radar object detection systems to determine if personnel are behind the machine. The
system has limitations due to maintenance practices, environmental conditions, and operating range.

Inspect and Maintain ROPS


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

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Section 9000 - GENERAL INFORMATION Group 01: Safety

The protection offered by ROPS could be impaired if ROPS is subjected to structural damage, is involved in an overturn
incident, or is in any way altered by welding, bending, drilling, or cutting.

If ROPS was loosened or removed for any reason, inspect it carefully before operating the machine again.

To maintain the ROPS:

Replace missing hardware using correct grade hardware.


Check hardware torque.
Check isolation mounts for damage, looseness, or wear; replace them if necessary.
Check ROPS for cracks or physical damage.

Avoid Machine Tip Over

Use Seat Belt

Unloading Machine

Do Not Jump

Use seat belt at all times.

Do not jump if the machine tips. You will be unlikely to jump clear and the machine may crush you.

Load and unload from trucks or trailers carefully. Be sure truck is wide enough and on a firm level surface. Use loading
ramps and attach them properly to truck bed. Avoid trucks with steel beds because tracks slip more easily on steel.

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Section 9000 - GENERAL INFORMATION Group 01: Safety

Be careful on slopes. Use extra care on soft, rocky or frozen ground. Machine may slip sideways in these conditions. When
traveling up or down slopes, keep the bucket on uphill side and just above ground level.

Be careful with heavy loads. Using oversize buckets or lifting heavy objects reduces machine stability. Extending a heavy
load or swinging it over side of undercarriage may cause machine to tip.

Ensure solid footing. Use extra care when operating near banks or excavations that may cave-in and cause machine to tip or
fall.

Use Special Care When Lifting Objects

Use Special Care When Lifting Objects

Never use this machine to lift people.

Never lift a load above another person. Keep bystanders clear of all areas where a load might fall if it breaks free. Do not leave
the seat when there is a raised load.

Do not exceed lift capacity limits posted on machine and in this manual. Extending heavy loads too far or swinging over
undercarriage side may cause machine to tip over.

Use proper rigging to attach and stabilize loads. Be sure slings or chains have adequate capacity and are in good condition. Use
tether lines to guide loads and prearranged hand signals to communicate with co-workers.

Add and Operate Attachments Safely


Always verify compatibility of attachments by contacting your authorized dealer. Adding unapproved attachments could affect
machine stability or reliability and could create a hazard for others near the machine.

Ensure that a qualified person is involved in attachment installation. Add guards to machine if operator protection is required or
recommended. Verify that all connections are secure and attachment responds properly to controls.

Carefully read attachment manual and follow all instructions and warnings. In an area free of bystanders and obstructions,
carefully operate attachment to learn its characteristics and range of motion.

Park and Prepare for Service Safely

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Section 9000 - GENERAL INFORMATION Group 01: Safety

Do Not Operate Tag

Support Machine Properly

Warn others of service work. Always park and prepare machine for service or repair properly.

Park machine on a level surface and lower equipment to the ground.


Place pilot shutoff lever in locked (UP) position. Stop engine and remove key.
Attach a “Do Not Operate” tag in an obvious place in the operator′s station.

Securely support machine or attachment before working under it.

Do not support machine with any hydraulically actuated equipment.


Do not support machine with cinder blocks or wooden pieces that may crumble or crush.
Do not support machine with a single jack or other devices that may slip out of place.

Understand service procedures before beginning repairs. Keep service area clean and dry. Use two people whenever the
engine must be running for service work.

Service Cooling System Safely

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Section 9000 - GENERAL INFORMATION Group 01: Safety

Cooling System

Explosive release of fluids from pressurized cooling system can cause serious burns.

Do not service radiator through the radiator cap. Only fill through the surge tank filler cap. Shut off engine. Only remove surge
tank filler cap when cool enough to touch with bare hands. Slowly loosen cap to relieve pressure before removing completely.

Remove Paint Before Welding or Heating

Toxic Fumes

Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.

Remove paint before heating:

Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an
approved respirator before heating or welding.
If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.
If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper
containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or
heating.

Do not use a chlorinated solvent in areas where welding will take place.

Do all work in an area that is well ventilated to carry toxic fumes and dust away.

Dispose of paint and solvent properly.

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DIAGNOSTICS (g) by Belgreen v2.0

Make Welding Repairs Safely

Heating Near Pressurized Fluid Lines

IMPORTANT:

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

Do not weld or apply heat on any part of a reservoir or tank that has contained oil or fuel. Heat from welding and cutting can
cause oil, fuel, or cleaning solution to create gases which are explosive, flammable, or toxic.

Avoid welding or heating near pressurized fluid lines. Flammable spray may result and cause severe burns if pressurized lines
malfunction as a result of heating. Do not let heat go beyond work area to nearby pressurized lines.

Remove paint properly. Do not inhale paint dust or fumes. Use a qualified welding technician for structural repairs. Make sure
there is good ventilation. Wear eye protection and protective equipment when welding.

Drive Metal Pins Safely

Hardened Metal Parts

Always wear protective goggles or safety glasses and other protective equipment before striking hardened parts. Hammering
hardened metal parts such as pins and bucket teeth could dislodge chips at high velocity.

Use a soft hammer or a brass bar between hammer and object to prevent chipping.

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130G Excavator Diagnostic (g) by Belgreen v2.1

Section 9001 - DIAGNOSTICS


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

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130G Excavator Diagnostic (g) by Belgreen v2.1

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

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130G Excavator Diagnostic (g) by Belgreen v2.1

Engine Control Unit (ECU) Diagnostic Trouble Codes ....................................................................... 188


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

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130G Excavator Diagnostic (g) by Belgreen v2.1

Air Conditioner Controller (ACF) Diagnostic Trouble Codes .............................................................. 221


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

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Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Group 10 - Main Controller (MCZ) Diagnostic Trouble Codes


Main Controller (MCZ) Diagnostic Trouble Codes
For additional information on the main controller circuit, see Main Controller (MCZ) Circuit Theory of Operation . (Group
9015-15.)

Main controller diagnostic trouble codes (DTCs) can be displayed on the monitor, connection with Service ADVISOR ™ , or by
connection with MPDr.

See Reading Diagnostic Trouble Codes With Monitor Display . (Group 9015-20.)
See Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application . (Group 9015-20.)
See MPDr Application . (Group 9015-20.)

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Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Controller Area Network 0 (CAN 0) Circuit Diagnostics


There are three CAN networks on this machine. This diagnostic procedure is for the CAN 0 network. For more diagnostic
information on other CAN networks, see appropriate CAN circuit diagnostics.

See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.)


See Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.)
See Interface Controller Area Network (N-CAN) Diagnostics . (Group 9001-10.)

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Controller Area Network (CAN 0) Diagnostics


( 1 ) CAN 0 Connector Check

Action:

Check harness connections to the following controllers for damage, corrosion, or debris.

Main contoller (MCZ) (A3) and monitor controller (DSZ) (A4). See Cab Harness (W1) Component Location . (Group
9015-10.)
Engine control unit (ECU) (A1). See Machine Harness (W2) Component Location . (Group 9015-10.)
Modular telematics gateway (MTG) (A6000). See Engine Interface Harness (W5) Component Location . (Group 9015-10.)
Service ADVISOR ™ diagnostic connector (X1). See Machine Harness (W2) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to MCZ and DSZ Continuity Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) MCZ and DSZ Continuity Check

Action:

Key switch in OFF position.

Disconnect cab harness-to-main controller 31-pin connector A (X31).

Disconnect monitor controller 28-pin connector A (X20).

Check for continuity between:

Pin 28 of cab harness-to-main controller 31-pin connector A (X31). and pin 24 of monitor controller 28-pin connector A
(X20).
Pin 29 of cab harness-to-main controller 31-pin connector A (X31). and pin 23 of monitor controller 28-pin connector A
(X20).

Is continuity indicated?

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Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to MCZ and ECU Continuity Check.

NO:Open circuit, repair or replace harness. See appropriate harness.

( 3 ) MCZ and ECU Continuity Check

Action:

Key switch in OFF position.

Disconnect engine control unit (ECU)-to-engine harness connector 2 (X15).

Disconnect cab harness-to-main controller 31-pin connector A (X31).

Check for continuity between:

Pin B1 of engine control unit (ECU)-to-engine harness connector 2 (X15) and pin 28 of cab harness-to-main controller 31-
pin connector A (X31).
Pin A1 of engine control unit (ECU)-to-engine harness connector 2 (X15) and pin 29 of cab harness-to-main controller 31-
pin connector A (X31).

Is continuity indicated?

Result:

YES:Go to MCZ and Service ADVISOR™ Diagnostic Connector Continuity Check.

NO:Open circuit, repair or replace harness. See appropriate harness.

( 4 ) MCZ and Service ADVISOR™ Diagnostic Connector Continuity Check

Action:

Key switch in OFF position.

Disconnect cab harness-to-main controller 31-pin connector A (X31).

Check for continuity between:

Pin C of Service ADVISOR™ diagnostic connector (X1) and pin 28 of cab harness-to-main controller 31-pin connector A
(X31).
Pin D of Service ADVISOR™ diagnostic connector (X1) and pin 29 of cab harness-to-main controller 31-pin connector A
(X31).

Is continuity indicated?

Result:

YES:Go to MCZ and Modular Telematics Gateway (MTG) Continuity Check.

NO:Open circuit, repair or replace harness. See appropriate harness.

( 5 ) MCZ and Modular Telematics Gateway (MTG) Continuity Check

Action:

Key switch in OFF position.

Disconnect modular telematics gateway (MTG) control unit 48-pin connector (X6014).

Disconnect cab harness-to-main controller 31-pin connector A (X31).

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Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Check for continuity between:

Pin H1 of modular telematics gateway (MTG) control unit 48-pin connector (X6014) and pin 29 of cab harness-to-main
controller 31-pin connector A (X31).
Pin H2 of modular telematics gateway (MTG) control unit 48-pin connector (X6014) and pin 28 of cab harness-to-main
controller 31-pin connector A (X31).

Is continuity indicated?

Result:

YES:Go to MCZ and CAN 0 Termination Resistor (R12) Continuity Check

NO:Open circuit, repair or replace harness. See appropriate harness.

( 6 ) MCZ and CAN 0 Termination Resistor (R12) Continuity Check

Action:

Key switch OFF.

Disconnect cab harness-to-main controller 31-pin connector A (X31).

Check for continuity between:

Pin B of CAN 0 termination resistor (R12) and pin 29 of cab harness-to-main controller 31-pin connector A (X31).
Pin A of CAN 0 termination resistor (R12) and pin 28 of cab harness-to-main controller 31-pin connector A (X31).

Is continuity indicated?

Result:

YES:Go to MCZ Short to Ground Check.

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

( 7 ) MCZ Short to Ground Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).

Check for continuity between:

Pin 2 of cab harness-to-main controller 30-pin connector D (X34) and pins 1 and 2 of cab harness-to-main controller 24-
pin connector E (X35).
Pin 3 of cab harness-to-main controller 30-pin connector D (X34) and pins 1 and 2 of cab harness-to-main controller 24-
pin connector E (X35).
Pin 2 of cab harness-to-main controller 30-pin connector D (X34) and pins 4, 5, and 6 of cab harness-to-main controller
26-pin connector F (X36).
Pin 3 of cab harness-to-main controller 30-pin connector D (X34) and pins 4, 5, and 6 of cab harness-to-main controller
26-pin connector F (X36).

Is continuity indicated?

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Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

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

NO:Go to DSZ Short to Ground Check.

( 8 ) DSZ Short to Ground Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).

Check for continuity between:

Pin 24 of monitor controller 28-pin connector A (X20) and pin 22 of monitor controller 28-pin connector A (X20).
Pin 23 of monitor controller 28-pin connector A (X20) and pin 22 of monitor controller 28-pin connector A (X20).
Pin 24 of monitor controller 28-pin connector A (X20) and pins 35 and 36 of monitor controller 36-pin connector B (X21).
Pin 23 of monitor controller 28-pin connector A (X20) and pins 35 and 36 of monitor controller 36-pin connector B (X21).

Is continuity indicated?

Result:

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

NO:Go to ECU Short to Ground Check.

( 9 ) ECU Short to Ground Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).

Check for continuity between:

Pin 2 of engine control unit (ECU)-to-engine harness connector 2 (X15) and pins 21, 27, 43, and 44 of engine control unit
(ECU)-to-engine harness connector 2 (X15).
Pin 3 of engine control unit (ECU)-to-engine harness connector 2 (X15) and pins 21, 27, 43, and 44 of ECU engine control
unit (ECU)-to-engine harness connector 2 (X15).

Is continuity indicated?

Result:

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

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

( 10 ) Service ADVISOR™ Diagnostic Connector Short to Ground Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).

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Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Check for continuity between:

Pin C and pin A of Service ADVISOR™ diagnostic connector (X1).


Pin D and pin A of Service ADVISOR™ diagnostic connector (X1).

Is continuity indicated?

Result:

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

NO:Go to Modular Telematics Gateway (MTG) Short to Ground Check.

( 11 ) MTG Short to Ground Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).

Check for continuity between:

Pin H1 and pin F3 of modular telematics gateway (MTG) control unit 48-pin connector (X6014).
Pin H2 and pin F3 of modular telematics gateway (MTG) control unit 48-pin connector (X6014).

Is continuity indicated?

Result:

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

NO:Go to MCZ Short to Power Check

( 12 ) MCZ Short to Power Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).

Check for continuity between:

Pin 2 of cab harness-to-main controller 30-pin connector D (X34) and pins 2, 5, and 6 of cab harness-to-main controller
24-pin connector E (X35).
Pin 3 of cab harness-to-main controller 30-pin connector D (X34) and pins 2, 5, and 6 of cab harness-to-main controller
24-pin connector E (X35).
Pin 2 of cab harness-to-main controller 30-pin connector D (X34) and pins 3, 4, and 10 of cab harness-to-main controller
26-pin connector F (X36).
Pin 3 of cab harness-to-main controller 30-pin connector D (X34) and pins 3, 4, and 10 of cab harness-to-main controller
26-pin connector F (X36).

Is continuity indicated?

Result:

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

NO:Go to DSZ Short to Power Check.

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Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

( 13 ) DSZ Short to Power Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).

Check for continuity between:

Pin 24 of monitor controller 28-pin connector A (X20) and pins 16 and 17 of monitor controller 28-pin connector A (X20).
Pin 23 of monitor controller 28-pin connector A (X20) and pins 16 and 17 of monitor controller 28-pin connector A (X20).
Pin 24 of monitor controller 28-pin connector A (X20) and pins 17 and 18 of monitor controller 36-pin connector B (X21).
Pin 23 of monitor controller 28-pin connector A (X20) and pins 17 and 18 of monitor controller 36-pin connector B (X21).

Is continuity indicated?

Result:

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

NO:Go to ECU Short to Power Check.

( 14 ) ECU Short to Power Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).

Check for continuity between:

Pin 2 and pins 7, 13, 14, 23, and 24 of engine control unit-to-engine harness connector 2 (X15).
Pin 3 and pins 7, 13, 14, 23, and 24 of engine control unit-to-engine harness connector 2 (X15).

Is continuity indicated?

Result:

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

NO:Go to MTG Short to Power Check.

( 15 ) MTG Short to Power Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).

Check for continuity between:

Pin H1 and pins L1, M1, and M2 of modular telematics gateway (MTG) control unit 48-pin connector (X6014).
Pin H2 and pins L1, M1, and M2 of modular telematics gateway (MTG) control unit 48-pin connector (X6014).

Is continuity indicated?

<- Go to Section TOC Section 9001 page 7 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

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

NO:Go to Service ADVISOR™ Diagnostic Connector Short to Power Check.

( 16 ) Service ADVISOR™ Diagnostic Connector Short to Power Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).

Check for continuity between:

Pin C and pin B of Service ADVISOR™ diagnostic connector (X1).


Pin D and pin B of Service ADVISOR™ diagnostic connector (X1).

Is continuity indicated?

Result:

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

NO:Go to MCZ CAN High and Low Side Continuity Check

( 17 ) MCZ CAN High and Low Side Continuity Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).

Check for continuity between pin 2 and pin 3 of cab harness-to-main controller 30-pin connector D (X34).

Is continuity indicated?

Result:

YES:Open circuit, repair or replace harness. See appropriate harness.

NO:Go to DSZ CAN High and Low Side Continuity Check.

( 18 ) DSZ CAN High and Low Side Continuity Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).

Check for continuity between pin 23 and pin 24 of monitor controller 28-pin connector A (X20).

Is continuity indicated?

<- Go to Section TOC Section 9001 page 8 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Open circuit, repair or replace harness. See appropriate harness.

NO:Go to ECU CAN High and Low Side Continuity Check.

( 19 ) ECU CAN High and Low Side Continuity Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).

Check for continuity between pin 2 and pin 3 on engine control unit (ECU)-to-engine harness connector 2 (X15).

Is continuity indicated?

Result:

YES:Open circuit, repair or replace harness. See appropriate harness.

NO:Go to MTG CAN High and Low Side Continuity Check.

( 20 ) MTG CAN High and Low Side Continuity Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).

Check for continuity between pin H1 and pin H2 on modular telematics gateway (MTG) control unit 48-pin connector (X6014).

Is continuity indicated?

Result:

YES:Open circuit, repair or replace harness. See appropriate harness.

NO:Go to Service ADVISOR™ Diagnostic Connector CAN High and Low Side Continuity Check.

( 21 ) Service ADVISOR™ Diagnostic Connector CAN High and Low Side Continuity Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).

Check for continuity between pin C and pin D on Service ADVISOR™ diagnostic connector (X1).

Is continuity indicated?

Result:

YES:Open circuit, repair or replace harness. See appropriate harness.

NO:Go to CAN 0 Termination Resistor (R12) High and Low Side Continuity Check

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Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

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

Action:

Key switch OFF.

Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU) ,and modular telematics
gateway (MTG).

Check for continuity between R12 connector pins A and B.

Is continuity indicated?

Result:

YES:CAN wires short circuit.Repair or replace harness. See Cab Harness (W1) Wiring Diagram . (Group 9015-10.) See Machine
Harness (W2) Wiring Diagram . (Group 9015-10.) See Engine Interface Harness (W5) Wiring Diagram . (Group 9015-10.)

NO:Go to MCZ CAN Resistance Check.

( 23 ) MCZ CAN Resistance Check

Action:

Key switch in OFF position.

Disconnect cab harness-to-main controller 30-pin connector D (X34).

Check resistance between pin 2 and pin 3 on cab harness-to-main controller 30-pin connector D (X34).

Is resistance between 50—70 ohms?

Result:

YES:Go to Code Check.

NO:Go to DSZ CAN Resistance Check.

( 24 ) Code Check

Action:

Connect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).

Turn key switch to ON position.

Clear all codes and check for DTCs.

Are CAN communication codes still present?

Result:

YES:Main controller (MCZ) malfunction.Replace (MCZ), see Main Controller (MCZ) Remove and Install . (Group 9015-20.)

NO:Go to DSZ CAN Resistance Check.

( 25 ) DSZ CAN Resistance Check

Action:

Key switch in OFF position.

<- Go to Section TOC Section 9001 page 10 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Disconnect monitor controller 28-pin connector A (X20).

Check resistance between pin 23 and pin 24 on monitor controller 28-pin connector A (X20).

Is resistance between 110—130 ohms?

Result:

YES:Go to Code Check.

NO:Go to ECU CAN Resistance Check.

( 26 ) Code Check

Action:

Connect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).

Turn key switch to ON position.

Clear all codes and check for DTCs.

Are CAN communication codes still present?

Result:

YES:Monitor controller (DSZ) malfunction.Replace (DSZ), see Monitor Controller (DSZ) Remove and Install . (Group 9015-20.)

NO:Go to ECU CAN Resistance Check.

( 27 ) ECU CAN Resistance Check

Action:

Key switch in OFF position.

Disconnect engine control unit (ECU)-to-engine harness connector 2 (X15).

Check resistance between pin 2 and pin 3 on engine control unit (ECU)-to-engine harness connector 2 (X15).

Is resistance between 110—130 ohms?

Result:

YES:Go to Code Check.

NO:Go to Service ADVISOR ™ Resistance Check.

( 28 ) Code Check

Action:

Connect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).

Turn key switch to ON position.

Clear all codes and check for DTCs.

Are CAN communication codes still present?

<- Go to Section TOC Section 9001 page 11 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Engine control unit (ECU) malfunction.Replace (ECU), see Engine Control Unit (ECU) Remove and Install . (Group 9015-20.)

NO:Go to Service ADVISOR™ Resistance Check.

( 29 ) Service ADVISOR™ Resistance Check

Action:

Key switch in OFF position.

Check resistance between pin C and pin D on Service ADVISOR™ diagnostic connector (X1).

Is resistance between 110—130 ohms?

Result:

YES:Clear codes and check for DTCs.

NO:Checks complete.

<- Go to Section TOC Section 9001 page 12 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Controller Area Network 1 (CAN 1) Circuit Diagnostics


There are four CAN networks on this machine. This diagnostic procedure is for the CAN 1 network. For more diagnostic
information on other CAN networks, see appropriate CAN circuit diagnostics.

Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.)


Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.)
Interface Controller Area Network (N-CAN) Diagnostics . (Group 9001-10.)

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Controller Area Network (CAN 1) Diagnostic Procedure


( 1 ) CAN 1 Connector Check

Action:

Check harness connections to the following controllers for damage, corrosion, or debris.

Main contoller (MCZ) (A3) and monitor controller (DCZ) (A4). See Cab Harness (W1) Component Location . (Group
9015-10.)
Machine controller (BCZ) (A11), data converter (A5), and radio (A6). See Cab Harness (W1) Component Location . (Group
9015-10.)
Air conditioner controller (ACF) (A7). See Heater and Air Conditioner Harness (W41) Component Location . (Group
9015-10.)
Service ADVISOR ™ diagnostic connector (X1). See Machine Harness (W2) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to MCZ and Data Converter Continuity Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) MCZ and Data Converter Continuity Check

Action:

Key switch in OFF position.

Disconnect cab harness-to-main controller 30-pin connector D (X34).

Disconnect data converter (A5).

Check for continuity between:

Pin 5 on cab harness-to-main controller 30-pin connector D (X34) and pin 5 on data converter (A5).
Pin 4 on cab harness-to-main controller 30-pin connector D (X34) and pin 11 on data converter (A5).

Is continuity indicated?

<- Go to Section TOC Section 9001 page 13 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to MCZ and DSZ Continuity Check.

NO:Open circuit, repair or replace harness. See appropriate harness.

( 3 ) MCZ and DSZ Continuity Check

Action:

Key switch in OFF position.

Disconnect cab harness-to-main controller 30-pin connector D (X34).

Disconnect monitor controller 28-pin connector A (X20).

Check for continuity between:

Pin 4 on cab harness-to-main controller 30-pin connector D (X34) and pin 26 on monitor controller 28-pin connector A
(X20).
Pin 5 on cab harness-to-main controller 30-pin connector D (X34) and pin 25 on monitor controller 28-pin connector A
(X20).

Is continuity indicated?

Result:

YES:Go to MCZ and BCZ Continuity Check.

NO:Open circuit, repair or replace harness. See appropriate harness.

( 4 ) MCZ and BCZ Continuity Check

Action:

Key switch in OFF position.

Disconnect cab harness-to-main controller 30-pin connector D (X34).

Disconnect machine controller 20-pin connector B (X11).

Check for continuity between:

Pin 4 on cab harness-to-main controller 30-pin connector D (X34) and pin 1 on machine controller 20-pin connector B
(X11).
Pin 5 on cab harness-to-main controller 30-pin connector D (X34) and pin 11 on machine controller 20-pin connector B
(X11).

Is continuity indicated?

Result:

YES:Go to MCZ and Radio Continuity Check.

NO:Open circuit, repair or replace harness. See appropriate harness.

( 5 ) MCZ and Radio Continuity Check

Action:

Key switch in OFF position.

Disconnect cab harness-to-main controller 30-pin connector D (X34).

<- Go to Section TOC Section 9001 page 14 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Disconnect radio connector (A6).

Check for continuity between:

Pin 4 on cab harness-to-main controller 30-pin connector D (X34) and pin 4 on radio connector (A6).
Pin 5 on cab harness-to-main controller 30-pin connector D (X34) and pin 12 on radio connector (A6).

Is continuity indicated?

Result:

YES:Go to MCZ and ACF Continuity Check.

NO:Open circuit, repair or replace harness. See appropriate harness.

( 6 ) MCZ and ACF Continuity Check

Action:

Key switch in OFF position.

Disconnect cab harness-to-main controller 30-pin connector D (X34).

Disconnect air conditioner controller (A7).

Check for continuity between:

Pin 4 on cab harness-to-main controller 30-pin connector D (X34) and pin 10 on air conditioner controller (A7).
Pin 5 on cab harness-to-main controller 30-pin connector D (X34) and pin 11 on air conditioner controller (A7).

Is continuity indicated?

Result:

YES:Go to MCZ Short to Ground Check.

NO:Open circuit, repair or replace harness. See appropriate harness.

( 7 ) MCZ Short to Ground Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).

Check for continuity between:

Pin 4 on cab harness-to-main controller 30-pin connector D (X34) and pins 1 and 2 on cab harness-to-main controller 24-
pin connector E (X35).
Pin 5 on cab harness-to-main controller 30-pin connector D (X34) and pins 1 and 2 on cab harness-to-main controller 24-
pin connector E (X35).
Pin 4 on cab harness-to-main controller 30-pin connector D (X34) and pins 4, 5, and 6 on cab harness-to-main controller
26-pin connector F (X36).
Pin 5 on cab harness-to-main controller 30-pin connector D (X34) and pins 4, 5, and 6 on cab harness-to-main controller
26-pin connector F (X36).

Is continuity indicated?

<- Go to Section TOC Section 9001 page 15 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

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

NO:Go to Data Converter Short to Ground Check.

( 8 ) Data Converter Short to Ground Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).

Check for continuity between:

Pin 5 on data converter (A5) and pins 14 and 15 on data converter (A5) connector.
Pin 11 on data converter (A5) and pins 14 and 15 on data converter (A5) connector.

Is continuity indicated?

Result:

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

NO:Go to DSZ Short to Ground Check.

( 9 ) DSZ Short to Ground Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).

Check for continuity between:

Pin 25 on monitor controller 28-pin connector A (X20) and pin 22 on monitor controller 28-pin connector A (X20).
Pin 26 on monitor controller 28-pin connector A (X20) and pin 22 on monitor controller 28-pin connector A (X20).
Pin 25 on monitor controller 28-pin connector A (X20) and pins 35 and 36 on monitor controller 36-pin connector B (X21).
Pin 26 on monitor controller 28-pin connector A (X20) and pins 35 and 36 on monitor controller 36-pin connector B (X21).

Is continuity indicated?

Result:

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

NO:Go to BCZ Short to Ground Check.

( 10 ) BCZ Short to Ground Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).

Check for continuity between:

<- Go to Section TOC Section 9001 page 16 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

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

Is continuity indicated?

Result:

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

NO:Go to Radio Short to Ground Check.

( 11 ) Radio Short to Ground Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).

Check for continuity between:

Pin 4 and pin 15 on radio connector (A6).


Pin 12 and pin 15 on radio connector (A6).

Is continuity indicated?

Result:

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

NO:Go to ACF Short to Ground Check.

( 12 ) ACF Short to Ground Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).

Check for continuity between:

Pin 10 on air conditioner controller connector (A7) and pins 4 and 9 on connector (A7).
Pin 11 on air conditioner controller connector (A7) and pins 4 and 9 on connector (A7).

Is continuity indicated?

Result:

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

NO:Go to MCZ Short to Power Check.

( 13 ) MCZ Short to Power Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,

<- Go to Section TOC Section 9001 page 17 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

and air conditioner controller (ACF).

Check for continuity between:

Pin 4 of cab harness-to-main controller 30-pin connector D (X34) and pins 5 and 6 of cab harness-to-main controller 24-
pin connector E (X35).
Pin 5 of cab harness-to-main controller 30-pin connector D (X34) and pins 5 and 6 of cab harness-to-main controller 24-
pin connector E (X35).
Pin 4 of cab harness-to-main controller 30-pin connector D (X34) and pins 1, 2, 3, and 4 of cab harness-to-main controller
26-pin connector F (X36).
Pin 5 of cab harness-to-main controller 30-pin connector D (X34) and pins 1, 2, 3, and 4 of cab harness-to-main controller
26-pin connector F (X36).

Is continuity indicated?

Result:

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

NO:Go to Data Converter Short to Power Check.

( 14 ) Data Converter Short to Power Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).

Check for continuity between:

Pin 5 on data converter (A5) and pins 1, 2, and 7 on data converter (A5) connector.
Pin 11 on data converter (A5) and pins 1, 2, and 7 on data converter (A5) connector.

Is continuity indicated?

Result:

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

NO:Go to DSZ Short to Power Check.

( 15 ) DSZ Short to Power Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).

Check for continuity between:

Pin 25 of monitor controller 28-pin connector A (X20) and pins 16 and 17 of connector A (X20).
Pin 26 of monitor controller 28-pin connector A (X20) and pins 16 and 17 of connector A (X20).
Pin 25 of monitor controller 28-pin connector A (X20) and pins 17 and 18 of monitor controller 36-pin connector B (X21).
Pin 26 of monitor controller 28-pin connector A (X20) and pins 17 and 18 of monitor controller 36-pin connector B (X21).

Is continuity indicated?

<- Go to Section TOC Section 9001 page 18 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

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

NO:Go to BCZ Short to Power Check.

( 16 ) BCZ Short to Power Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).

Check for continuity between:

Pin 1 and pin 19 on machine controller 20-pin connector B (X11).


Pin 11 and pin 19 on machine controller 20-pin connector B (X11).
Pin 1 on machine controller 20-pin connector B (X11) and pin 4 on machine controller 8-pin connector A (X10).
Pin 11 on machine controller 20-pin connector B (X11) and pin 4 on machine controller 8-pin connector A (X10).

Is continuity indicated?

Result:

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

NO:Go to Radio Short to Power Check.

( 17 ) Radio Short to Power Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).

Check for continuity between:

Pin 4 on radio connector (A6) and pins 8 and 16 on connector (A6).


Pin 12 on radio connector (A6) and pins 8 and 16 on connector (A6).

Is continuity indicated?

Result:

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

NO:Go to ACF Short to Power Check.

( 18 ) ACF Short to Power Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).

Check for continuity between:

<- Go to Section TOC Section 9001 page 19 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Pin 10 and pin 7 on air conditioner controller connector (A7).


Pin 11 and pin 7 on air conditioner controller connector (A7).

Is continuity indicated?

Result:

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

NO:Go to MCZ CAN High and Low Side Continuity Check.

( 19 ) MCZ CAN High and Low Side Continuity Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).

Check for continuity between pin 4 and pin 5 of cab harness-to-main controller 30-pin connector D (X34).

Is continuity indicated?

Result:

YES:Open circuit, repair or replace harness. See appropriate harness.

NO:Go to Data Converter CAN High and Low Side Continuity Check.

( 20 ) Data Converter CAN High and Low Side Continuity Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).

Check for continuity between pin 5 and pin 11 on data converter (A5).

Is continuity indicated?

Result:

YES:Open circuit, repair or replace harness. See appropriate harness.

NO:Go to DSZ CAN High and Low Side Continuity Check.

( 21 ) DSZ CAN High and Low Side Continuity Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).

Check for continuity between pin 25 and pin 26 of monitor controller 28-pin connector A (X20).

Is continuity indicated?

<- Go to Section TOC Section 9001 page 20 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Open circuit, repair or replace harness. See appropriate harness.

NO:Go to BCZ CAN High and Low Side Continuity Check.

( 22 ) BCZ CAN High and Low Side Continuity Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).

Check for continuity between pin 1 and pin 11 on machine controller 20-pin connector B (X11).

Is continuity indicated?

Result:

YES:Open circuit, repair or replace harness. See appropriate harness.

NO:Go to Radio CAN High and Low Side Continuity Check.

( 23 ) Radio CAN High and Low Side Continuity Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).

Check for continuity between pin 5 and pin 11 on radio connector (A6).

Is continuity indicated?

Result:

YES:Open circuit, repair or replace harness. See appropriate harness.

NO:Go to ACF CAN High and Low Side Continuity Check.

( 24 ) ACF CAN High and Low Side Continuity Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).

Check for continuity between pin 10 and pin 11 on air conditioner controller connector (A7).

Is continuity indicated?

Result:

YES:Open circuit, repair or replace harness. See appropriate harness.

NO:Go to MCZ CAN Resistance Check.

<- Go to Section TOC Section 9001 page 21 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

( 25 ) MCZ CAN Resistance Check

Action:

Key switch in OFF position.

Disconnect cab harness-to-main controller 30-pin connector D (X34).

Check resistance between pin 4 and pin 5 on cab harness-to-main controller 30-pin connector D (X34).

Is resistance between 50—70 ohms?

Result:

YES:Go to Code Check.

NO:Go to Data Converter CAN Resistance Check.

( 26 ) Code Check

Action:

Connect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio, and
air conditioner controller (ACF).

Turn key switch to ON position.

Clear all codes and check for DTCs.

Are CAN communication codes still present?

Result:

YES:Main controller (MCZ) malfunction.Replace (MCZ), see Main Controller (MCZ) Remove and Install . (Group 9015-20.)

NO:Go to Data Converter CAN Resistance Check.

( 27 ) Data Converter CAN Resistance Check

Action:

Key switch in OFF position.

Disconnect data converter (A5).

Check resistance between pin 5 and pin 11 on data converter (A5).

Is resistance between 50—70 ohms?

Result:

YES:Go to Code Check.

NO:Go to DSZ CAN Resistance Check.

( 28 ) Code Check

Action:

Connect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio, and
air conditioner controller (ACF).

Turn key switch to ON position.


<- Go to Section TOC Section 9001 page 22 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Clear all codes and check for DTCs.

Are CAN communication codes still present?

Result:

YES:Data converter malfunction.Replace data converter, see Data Converter Remove and Install . (Group 9015-20.)

NO:Go to DSZ CAN Resistance Check.

( 29 ) DSZ CAN Resistance Check

Action:

Key switch in OFF position.

Disconnect monitor controller 28-pin connector A (X20).

Check resistance between pin 25 and pin 26 on monitor controller 28-pin connector A (X20).

Is resistance between 110—130 Ω?

Result:

YES:Go to Code Check.

NO:Go to BCZ CAN Resistance Check.

( 30 ) Code Check

Action:

Connect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio, and
air conditioner controller (ACF).

Turn key switch to ON position.

Clear all codes and check for DTCs.

Are CAN communication codes still present?

Result:

YES:Monitor controller (DSZ) malfunction.Replace DSZ, see Monitor Controller (DSZ) Remove and Install . (Group 9015-20.)

NO:Go to BCZ CAN Resistance Check.

( 31 ) BCZ CAN Resistance Check

Action:

Key switch in OFF position.

Disconnect machine controller 20-pin connector B (X11).

Check resistance between pin 1 and pin 11 on machine controller 20-pin connector B (X11).

Is resistance between 110—130 Ω?

Result:

YES:Go to Code Check.


<- Go to Section TOC Section 9001 page 23 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

NO:Go to Radio CAN Resistance Check.

( 32 ) Code Check

Action:

Connect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio, and
air conditioner controller (ACF).

Turn key switch to ON position.

Clear all codes and check for DTCs.

Are CAN communication codes still present?

Result:

YES:Machine controller (BCZ) malfunction.Replace BCZ, see Machine controller (BCZ) Remove and Install . (Group 9015-20.)

NO:Go to Radio CAN Resistance Check..

( 33 ) Radio CAN Resistance Check

Action:

Key switch in OFF position.

Disconnect radio connector (A6).

Check resistance between pin 4 and pin 12 on radio connector (A6).

Is resistance between 50—70 Ω?

Result:

YES:Go to Code Check.

NO:Go to ACF CAN Resistance Check.

( 34 ) Code Check

Action:

Connect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio, and
air conditioner controller (ACF).

Turn key switch to ON position.

Clear all codes and check for DTCs.

Are CAN communication codes still present?

Result:

YES:Radio malfunction.Replace radio.

NO:Go to ACF CAN Resistance Check.

( 35 ) ACF CAN Resistance Check

Action:

Key switch in OFF position.


<- Go to Section TOC Section 9001 page 24 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Disconnect air conditioner controller (A7).

Check resistance between pin 10 and pin 11 on air conditioner controller (A7).

Is resistance between 50—70 Ω?

Result:

YES:Clear codes and check for DTCs.

NO:Checks complete.

<- Go to Section TOC Section 9001 page 25 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Interface Controller Area Network (N-CAN) Diagnostics


There are four CAN networks on this machine. This diagnostic procedure is for the N-CAN network. For more diagnostic
information on other CAN networks, see appropriate CAN circuit diagnostics.

Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.)


Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.)
Interface Controller Area Network (N-CAN) Diagnostics . (Group 9001-10.)

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Interface Controller Area Network (N-CAN) Diagnostics


( 1 ) N-CAN Connector Check

Action:

Check harness connections to the following controllers for damage, corrosion, or debris.

Data converter (A5). See Cab Harness (W1) Component Location . (Group 9015-10.)
Modular telematics gateway (MTG) (A6000). See Engine Interface Harness (W5) Component Location . (Group 9015-10.)
Service ADVISOR ™ diagnostic connector (X1). See Machine Harness (W2) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Data Converter and Service ADVISOR™ Diagnostic Connector Continuity Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Data Converter and Service ADVISOR™ Diagnostic Connector Continuity Check

Action:

Key switch in OFF position.

Disconnect data converter (A5).

Check for continuity between:

Pin 6 on data converter (A5) and pin J of Service ADVISOR™ diagnostic connector (X1).
Pin 12 on data converter (A5) and pin H of Service ADVISOR™ diagnostic connector (X1).

Is continuity indicated?

Result:

YES:Go to Data Converter to Interface CAN Resistor 1 (R10) Continuity Check.

NO:Open circuit, repair or replace harness. See appropriate harness.

( 3 ) Data Converter to Interface CAN Resistor 1 (R10) Continuity Check

<- Go to Section TOC Section 9001 page 26 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Action:

Key switch in OFF position.

Disconnect data converter (A5).

Check for continuity between:

Pin 6 on data converter (A5) and pin B of interface CAN resistor 1 (R10).
Pin 12 on data converter (A5) and pin A of interface CAN resistor 1 (R10).

Is continuity indicated?

Result:

YES:Go to Data Converter to Modular Telematics Gateway (MTG) Connector Continuity Check.

NO:Open circuit, repair or replace harness. See appropriate harness.

( 4 ) Data Converter to Modular Telematics Gateway (MTG) Connector Continuity Check

Action:

Key switch in OFF position.

Disconnect data converter (A5).

Check for continuity between:

Pin 6 on data converter 17-pin connector () and pin G1 of modular telematics gateway (MTG) control unit 48-pin
connector (X6014).
Pin 12 on data converter 17-pin connector () and pin G2 of modular telematics gateway (MTG) control unit 48-pin
connector (X6014).

Is continuity indicated?

Result:

YES:Go to Data Converter Short to Ground Check.

NO:Open circuit, repair or replace harness. See appropriate harness.

( 5 ) Data Converter Short to Ground Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).

Check for continuity between:

Pin 6 on data converter 17-pin connector () and pins 14 and 15 on connector ().
Pin 12 on data converter 17-pin connector () and pins 14 and 15 on connector ().

Is continuity indicated?

Result:

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

<- Go to Section TOC Section 9001 page 27 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

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

( 6 ) Service ADVISOR™ Diagnostic Connector Short to Ground Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).

Check for continuity between:

Pin H and pin A on Service ADVISOR™ diagnostic connector (X1).


Pin J and pin A on Service ADVISOR™ diagnostic connector (X1).

Is continuity indicated?

Result:

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

NO:Go to Interface CAN Resistor 1 (R10) Short to Ground Check.

( 7 ) Interface CAN Resistor 1 (R10) Short to Ground Check

Action:

Key switch in OFF position.

Disconnect modular telematics gateway (MTG) control unit 48-pin connector (X6014).

Check for continuity between interface CAN resistor 1 (R10) pin A and ground.

Check for continuity between interface CAN resistor 1 (R10) pin B and ground.

Is there continuity between CAN circuit and ground circuit?

Result:

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

NO:Go to MTG Short to Ground Check.

( 8 ) MTG Short to Ground Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).

Check for continuity between:

Pin G1 and pin F3 of modular telematics gateway (MTG) control unit 48-pin connector (X6014).
Pin G2 and pin F3 of modular telematics gateway (MTG) control unit 48-pin connector (X6014).

Is continuity indicated?

<- Go to Section TOC Section 9001 page 28 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

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

NO:Go to Data Converter Short to Power Check.

( 9 ) Data Converter Short to Power Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).

Check for continuity between:

Pin 6 on data converter 17-pin connector () and pins 1, 2, and 7 on connector ().
Pin 12 on data converter 17-pin connector () and pins 1, 2, and 7 on connector ().

Is continuity indicated?

Result:

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

NO:Go to DSZ Short to Power Check.

( 10 ) Service ADVISOR™ Diagnostic Connector Short to Power

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).

Check for continuity between:

Pin H and pin B of Service ADVISOR™ diagnostic connector (X1).


Pin J and pin B of Service ADVISOR™ diagnostic connector (X1).

Is continuity indicated?

Result:

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

NO:Go to MTG Short to Power Check.

( 11 ) MTG Short to Power Check

Action:

Key switch in OFF position.

Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).

Check for continuity between:

Pin G1 and pins L1, M1, and M2 of modular telematics gateway (MTG) control unit 48-pin connector (X6014).
Pin G2 and pins L1, M1, and M2 of modular telematics gateway (MTG) control unit 48-pin connector (X6014).

<- Go to Section TOC Section 9001 page 29 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Is continuity indicated?

Result:

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

NO:Go to Service ADVISOR™ Diagnostic Connector Short to Power Check.

( 12 ) Data Converter CAN High and Low Side Continuity Check

Action:

Key switch in OFF position.

Disconnect data converter connector, modular telematics gateway (MTG) connector, and interface CAN resistor 1 (R10).

Check for continuity between pin 6 and pin 12 on data converter 17-pin connector ().

Is continuity indicated?

Result:

YES:Open circuit, repair or replace harness. See appropriate harness.

NO:Go to Service ADVISOR™ Diagnostic Connector CAN High and Low Side Continuity Check.

( 13 ) Service ADVISOR™ Diagnostic Connector CAN High and Low Side Continuity Check

Action:

Key switch in OFF position.

Disconnect data converter connector, modular telematics gateway (MTG) connector, and interface CAN resistor 1 (R10).

Check for continuity between pin H and pin J on Service ADVISOR™ diagnostic connector (X1).

Is continuity indicated?

Result:

YES:Open circuit, repair or replace harness. See appropriate harness.

NO:Go to MTG CAN High and Low Side Continuity Check.

( 14 ) MTG CAN High and Low Side Continuity Check

Action:

Key switch in OFF position.

Disconnect data converter connector, modular telematics gateway (MTG) connector, and interface CAN resistor 1 (R10).

Check for continuity between pin G1 and pin G2 on modular telematics gateway (MTG) control unit 48-pin connector (X6014).

Is continuity indicated?

Result:

YES:Open circuit, repair or replace harness. See appropriate harness.

NO:Go to Data Converter Resistance Check.

<- Go to Section TOC Section 9001 page 30 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

( 15 ) Data Converter Resistance Check

Action:

Key switch in OFF position.

Disconnect data converter 17-pin connector ().

Check resistance between pin 6 and pin 12 on data converter 17-pin connector ().

Is resistance between 50—70 ohms?

Result:

YES:Go to Code Check.

NO:Go to Service ADVISOR™ Diagnostic Connector Resistance Check.

( 16 ) Code Check

Action:

Connect all connectors to data converter connector, modular telematics gateway (MTG) connector, and interface CAN resistor 1
(R10).

Turn key switch to ON position.

Clear all codes and check for DTCs.

Are CAN communication codes still present?

Result:

YES:Data converter malfunction.Replace data converter, see Data Converter Remove and Install . (Group 9015-20.)

NO:Go to Service ADVISOR™ Diagnostic Connector Resistance Check.

( 17 ) Service ADVISOR™ Diagnostic Connector Resistance Check

Action:

Key switch in OFF position.

Check resistance between pin H and pin J on Service ADVISOR™ diagnostic connector (X1).

Is resistance between 50—70 ohms?

Result:

YES:Go to Code Check.

NO:Check CAN bus terminator. See Electrical Component Checks . (9015-20.)

( 18 ) Code Check

Action:

Connect all connectors to data converter connector, modular telematics gateway (MTG) connector, and interface CAN resistor 1
(R10).

Turn key switch to ON position.

Clear all codes and check for DTCs.


<- Go to Section TOC Section 9001 page 31 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Are CAN communication codes still present?

Result:

YES:Check CAN bus terminator. See Electrical Component Checks . (9015-20.)

NO:Go to MTG Resistance Check

( 19 ) MTG Resistance Check

Action:

Key switch in OFF position.

Check resistance between pin G1 and pin G2 on modular telematics gateway 48-pin connector (X6014).

Is resistance between 50—70 ohms?

Result:

YES:Go to DTC Check.

NO:Check CAN bus terminator. See Electrical Component Checks . (9015-20.)

( 20 ) DTC Check

Action:

Connect all connectors to data converter connector, modular telematics gateway (MTG) connector, and interface CAN resistor 1
(R10).

Turn key switch to ON position.

Clear all codes and check for DTCs.

Are CAN communication codes still present?

Result:

YES:MTG malfunction.

NO:Checks complete.

<- Go to Section TOC Section 9001 page 32 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Engine Controller Area Network (Engine CAN) Diagnostics


There are four CAN networks on this machine. This diagnostic procedure is for the Engine CAN network. For more diagnostic
information on other CAN networks, see the appropriate CAN circuit diagnostics.

Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.)


Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.)
Interface Controller Area Network (N-CAN) Diagnostics . (Group 9001-10.)
Engine Controller Area Network (Engine CAN) Diagnostics . (Group 9001-10.)

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Engine Controller Area Network (Engine CAN) Diagnostics


( 1 ) Engine CAN Connector Check

Action:

Check harness connections to the following controllers for damage, corrosion, or debris.

Engine control unit (ECU) (A1) and variable geometry turbocharger (VGT) (A2). See Machine Harness (W2) Component
Location . (Group 9015-10.)
Service ADVISOR ™ diagnostic connector (X1). See Machine Harness (W2) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to VGT and ECU Continuity Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) VGT and ECU Continuity Check

Action:

Key switch OFF.

Check for continuity between variable geometry turbocharger (VGT) pin 15 and engine control unit (ECU) pin 110 (X15).

Check for continuity between variable geometry turbocharger (VGT) pin 16 and engine control unit (ECU) pin 88 (X15).

Is there continuity between the connectors?

Result:

YES:Go to Continuity Check VGT to Engine CAN Termination Resistor (R8).

NO:Open circuit in CAN between VGT and ECU connector (X15).Repair or replace harness. See Machine Harness (W2) Wiring
Diagram . (Group 9015-10.) See Engine Harness (W4) Wiring Diagram . (Group 9015-10.)

( 3 ) Continuity Check VGT to Engine CAN Termination Resistor (R8)

<- Go to Section TOC Section 9001 page 33 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Action:

Key switch OFF.

Check for continuity between variable geometry turbocharger (VGT) pin 15 and engine CAN termination resistor (R8) pin A.

Check for continuity between variable geometry turbocharger (VGT) pin 16 and engine CAN termination resistor (R8) pin B.

Is there continuity between the connectors?

Result:

YES:Go to VGT Short to Ground Check.

NO:Open circuit in CAN between VGT and engine CAN termination resistor. Repair or replace harness. See Machine Harness
(W2) Wiring Diagram . (Group 9015-10.) See Engine Harness (W4) Wiring Diagram . (Group 9015-10.)

( 4 ) VGT Short to Ground Check

Action:

Key switch OFF.

Disconnect variable geometry turbocharger (VGT) connector.

Check for continuity between VGT pin 15 and VGT pin 14.

Check for continuity between VGT pin 16 and VGT pin 14.

Is there continuity between the CAN circuit and ground circuit?

Result:

YES:CAN circuit short to ground.Repair or replace harness. See Machine Harness (W2) Wiring Diagram . (Group 9015-10.) See
Engine Harness (W4) Wiring Diagram . (Group 9015-10.)

NO:Go to Engine CAN termination resistor (R8) Short to Ground Check.

( 5 ) Engine CAN termination resistor (R8) Short to Ground Check

Action:

Key switch OFF.

Disconnect variable geometry turbocharger (VGT) connector.

Check for continuity between engine CAN termination resistor (R8) pin A and ground.

Check for continuity between engine CAN termination resistor (R8) pin B and ground.

Is there continuity between CAN circuit and ground circuit?

Result:

YES:CAN circuit short to ground.Repair or replace harness. See Machine Harness (W2) Wiring Diagram . (Group 9015-10.) See
Engine Harness (W4) Wiring Diagram . (Group 9015-10.)

NO:Go to Engine Control Unit (ECU) Short to Ground Check.

( 6 ) Engine Control Unit (ECU) Short to Ground Check

<- Go to Section TOC Section 9001 page 34 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Action:

Key switch OFF.

Disconnect variable geometry turbocharger (VGT) connector and engine control unit (ECU).

Check for continuity between ECU pin 110 and pins 61, 62, 63, 64, 65, 66, 97, 119, and 137.

Check for continuity between ECU pin 88 and pins 61, 62, 63, 64, 65, 66, 97, 119, and 137.

Is there continuity between CAN circuit and ground circuit?

Result:

YES:CAN circuit short to ground.Repair or replace harness. See Machine Harness (W2) Wiring Diagram . (Group 9015-10.) See
Engine Harness (W4) Wiring Diagram . (Group 9015-10.)

NO:Go to VGT Short to Power Check.

( 7 ) Variable Geometry Turbocharger (VGT) Short to Power Check

Action:

Key switch OFF.

Disconnect variable geometry turbocharger (VGT) connector.

Check for continuity between VGT pin 15 and VGT pin 13.

Check for continuity between VGT pin 16 and VGT pin 13.

Is there continuity between the CAN circuit and power circuit?

Result:

YES:CAN circuit short to power.Repair or replace harness. See Machine Harness (W2) Wiring Diagram . (Group 9015-10.) See
Engine Harness (W4) Wiring Diagram . (Group 9015-10.)

NO:Go to Go to Engine Control Unit (ECU) Short to Power Check.

( 8 ) Go to Engine Control Unit (ECU) Short to Power Check

Action:

Key switch OFF.

Disconnect variable geometry turbocharger (VGT) connector and engine control unit (ECU).

Check for continuity between ECU pin 110 and pins 67, 89, 111, 133, and 134.

Check for continuity between ECU pin 88 and pins 67, 89, 111, 133, and 134.

Is there continuity between CAN circuit and power circuit?

Result:

YES:CAN circuit short to power.Repair or replace harness. See Machine Harness (W2) Wiring Diagram . (Group 9015-10.) See
Engine Harness (W4) Wiring Diagram . (Group 9015-10.)

NO:Go to Variable Geometry Turbocharger (VGT) CAN High and Low Side Continuity Check.

( 9 ) Variable Geometry Turbocharger (VGT) CAN High and Low Side Continuity Check

<- Go to Section TOC Section 9001 page 35 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Action:

Key switch OFF.

Disconnect variable geometry turbocharger (VGT), engine control unit (ECU) connectors and engine CAN termination resistor
(R8).

Check for continuity between VGT pin 15 and 16.

Is there continuity between CAN circuit?

Result:

YES:CAN wires short circuit.Repair or replace harness. See Machine Harness (W2) Wiring Diagram . (Group 9015-10.) See
Engine Harness (W4) Wiring Diagram . (Group 9015-10.)

NO:Go to Engine Control Unit (ECU) Resistance Check.

( 10 ) Engine Control Unit (ECU) High and Low Side Continuity Check

Action:

Key switch OFF.

Disconnect variable geometry turbocharger (VGT), engine control unit (ECU) connectors and engine CAN termination resistor
(R8).

Check for continuity between ECU pin 88 and 110.

Is there continuity between CAN circuit?

Result:

YES:ECU wires short circuit.Repair or replace harness. See Machine Harness (W2) Wiring Diagram . (Group 9015-10.) See
Engine Harness (W4) Wiring Diagram . (Group 9015-10.)

NO:Go to Variable Geometry Turbocharger (VGT) Resistance Check.

( 11 ) Variable Geometry Turbocharger (VGT) Resistance Check

Action:

Key switch OFF.

Disconnect variable geometry turbocharger (VGT).

Check for continuity between VGT pin 15 and 16.

Is resistance between 50—70Ω?

Result:

YES:Go to Engine Control Unit (ECU) Resistance Check.

NO:Check CAN bus terminator. See Electrical Component Checks . (9015-20.)

( 12 ) Engine Control Unit (ECU) Resistance Check

Action:

Key switch OFF.

<- Go to Section TOC Section 9001 page 36 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Disconnect engine control unit (ECU) connector (X15).

Check for continuity between ECU pins 88 and 110.

Is resistance between 110—130Ω?

Result:

YES:Checks complete.

NO:ECU malfunction. Repair or replace. See Engine Control Unit (ECU) Remove and Install . (9015-20.)

011000.02- Abnormal EEPROM


360

Abnormal EEPROM Diagnostic Procedure


( 1 ) Code Check

Action:

Clear and check again for diagnostic trouble codes.

Is DTC 011000.02—Abnormal EEPROM still present?

Result:

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

YES:Code is still present, but machine is still operable. Go to Machine Function Check.

NO:Main controller (MCZ) is OK.

( 2 ) Machine Function Check

Action:

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

Result:

YES:Machine may be operated, but it is recommended that the main controller (MCZ) be replaced.

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

011001.02- Abnormal RAM


360

Abnormal RAM Diagnostic Procedure


( 1 ) Code Check

Action:

Clear and check again for diagnostic trouble codes.

Is DTC 011001.02—Abnormal RAM still present?

Result:

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

<- Go to Section TOC Section 9001 page 37 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

YES:Code is still present, but machine is still operable. Go to Machine Function Check.

NO:Main controller (MCZ) is OK.

( 2 ) Machine Function Check

Action:

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

Result:

YES:Machine may be operated, but it is recommended that the main controller (MCZ) be replaced.

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

011002.02- Abnormal A/D Converter


360

Abnormal A/D Converter Diagnostic Procedure


( 1 ) Code Check

Action:

Clear and check again for diagnostic trouble codes.

Is DTC 011002.02—Abnormal A/D Converter still present?

Result:

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

YES:Code is still present, but machine is still operable. Go to Machine Function Check.

NO:Main controller (MCZ) is OK.

( 2 ) Machine Function Check

Action:

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

Result:

YES:Machine may be operated but it is recommended that the main controller (MCZ) be replaced.

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

011003.03- Abnormal Sensor Voltage


360
Individual sensor or component Diagnostic Trouble Code (DTC) may also be present within this code. Engine speed dial may not
function correctly when this code is present.

Abnormal Sensor Voltage Diagnostic Procedure


( 1 ) Sensor Check

Action:

Key switch: Off

<- Go to Section TOC Section 9001 page 38 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

If other sensor DTCs are present, diagnose all other DTCs before continuing.

Clear and check again for DTCs.

Is DTC 011003.03— Abnormal Sensor Voltage still present?

Result:

YES:Main controller (MCZ) malfunction. Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)

NO:Sensor malfunction. Replace appropriate sensor.

011006.02- Engine Controller Communication Error


360
Engine Controller Communication Error

For more information:

See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.)


See Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.)
See Interface Controller Area Network (N-CAN) Diagnostics . (Group 9001-10.)

011007.02- (CAN 0) Data Converter Communication Error 1


360
(CAN 0) Data Converter Communication Error 1

For more information:

See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.)


See Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.)
See Interface Controller Area Network (N-CAN) Diagnostics . (Group 9001-10.)

011008.02- (CAN 1) Data Converter Communication Error 2


360
(CAN 1) Data Converter Communication Error 2

For more information:

See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.)


See Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.)
See Interface Controller Area Network (N-CAN) Diagnostics . (Group 9001-10.)

011009.02- (CAN 0) Monitor Controller Communication Error 1


360
(CAN 0) Monitor Controller Communication Error 1

For more information:

See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.)


See Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.)
See Interface Controller Area Network (N-CAN) Diagnostics . (Group 9001-10.)

011010.02- (CAN 1) Monitor Controller Communication Error 2


360
(CAN 1) Monitor Controller Communication Error 2

For more information:

See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.)


See Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.)
See Interface Controller Area Network (N-CAN) Diagnostics . (Group 9001-10.)

<- Go to Section TOC Section 9001 page 39 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011100.02- Abnormal Engine Speed


360
Engine speed detected 4000 rpm or above.

Abnormal Engine Speed Diagnostic Procedure

→NOTE:

The main controller (MCZ) receives engine speed via the CAN 0 network from the engine control unit
(ECU).

( 1 ) Engine Speed Check

Action:

Verify engine speed with Service ADVISOR ™ or MPDr.

See MPDr Connection Procedure . (Group 9015-20.)


See Service ADVISOR™ Connection Procedure . (Group 9015-20.)

For information on engine speeds, see Engine Speed Control System Operation . (Group 9010-05.)

Is engine speed within specification?

Result:

YES:CAN 0 communication malfunction. See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.)

NO:Verify engine speed using optical tachometer on crankshaft belt pulley.

<- Go to Section TOC Section 9001 page 40 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011101.03- Engine Control Dial Sensor Circuit High Input


360
Engine control dial (R15) signal voltage is high (above 4.78 V).

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Engine Control Dial Sensor Circuit High Input Diagnostic Procedure


( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Cab harness-to-switch panel connector 3 (X29) and cab harness-to-main controller 30-pin connector D (X34). See Cab
Harness (W1) Component Location . (Group 9015-10.)
Machine harness splice connector (X98) and cab harness-to-machine harness 100-pin connector (X3). See Machine
Harness (W2) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Voltage Check

NO:Repair or replace connector. See appropriate harness.

( 2 ) Voltage Check

Action:

Key switch in OFF position.

Disconnect cab harness-to-switch panel connector 3 (X29).

Turn key switch to ON position.

Check voltage between pins 4 and 6 of cab harness-to-switch panel connector 3 (X29).

Is approximately 5 volts indicated?

Result:

YES:Go to Signal Voltage Check.

NO:Repair or replace harness. See appropriate harness.

( 3 ) Signal Voltage Check

Action:

Key switch in OFF position.

Disconnect cab harness-to-main controller 30-pin connector D (X34).


<- Go to Section TOC Section 9001 page 41 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Turn key switch to ON position.

Check between pin 16 of cab harness-to-main controller 30-pin connector D (X34) and machine ground for voltage.

Is voltage above 4.78 V indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Harness Check.

( 4 ) Harness Check

Action:

Key switch in OFF position.

Disconnect cab harness-to-switch panel connector 3 (X29).

Disconnect main controller connectors (X31— X36).

Check for continuity between pin 16 of cab harness-to-main controller 30-pin connector D (X34) to all pins on all main controller
connectors.

Is continuity indicated between any circuits?

Result:

YES:Circuit is short to power. Repair or replace harness. See appropriate harness.

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

<- Go to Section TOC Section 9001 page 42 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011101.04- Engine Control Dial Sensor Circuit Low Input


360
Engine control dial (R15) signal voltage is low (below 0.22 V).

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Engine Control Dial Sensor Circuit Low Input Diagnostic Procedure


( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Cab harness-to-switch panel connector 3 (X29) and cab harness-to-main controller 30-pin connector D (X34). See Cab
Harness (W1) Component Location . (Group 9015-10.)
Machine harness splice connector (X98) and cab harness-to-machine harness 100-pin connector (X3). See Machine
Harness (W2) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Voltage Check

Action:

Key switch in OFF position.

Disconnect cab harness-to-switch panel connector 3 (X29).

Turn key switch to ON position.

Check voltage between pins 4 and 6 of cab harness-to-switch panel connector 3 (X29).

Is approximately 5 volts indicated?

Result:

YES:Go to Open Circuit Check.

NO:Repair or replace harness. See appropriate harness.

( 3 ) Open Circuit Check

Action:

Key switch in OFF position.

Disconnect cab harness-to-switch panel connector 3 (X29).


<- Go to Section TOC Section 9001 page 43 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Disconnect cab harness-to-main controller 30-pin connector D (X34).

Disconnect cab harness-to-main controller 26-pin connector F (X36).

Check for continuity between:

Pin 4 of cab harness-to-switch panel connector 3 (X29) and pin 25 of cab harness-to-main controller 26-pin connector F
(X36).
Pin 5 of cab harness-to-switch panel connector 3 (X29) and pin 16 of cab harness-to-main controller 30-pin connector D
(X34).

Is continuity indicated?

Result:

YES:Go to Short Circuit Check.

NO:Repair or replace harness. See appropriate harness.

( 4 ) Short Circuit Check

Action:

Key switch in OFF position.

Disconnect cab harness-to-switch panel connector 3 (X29).

Check for continuity between:

Pin 4 of cab harness-to-switch panel connector 3 (X29) and machine ground.


Pin 5 of cab harness-to-switch panel connector 3 (X29) and machine ground.

Is continuity indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

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

<- Go to Section TOC Section 9001 page 44 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011200.03- Pump 1 Delivery Pressure Sensor Circuit High Input


360
Pump 1 delivery pressure sensor (B35) signal voltage is high (above 4.5 V).

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Pump 1 Delivery Pressure Sensor Circuit High Input Diagnostic


Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Pump 1 delivery pressure sensor (B35) and pump harness splice connector (X97). See Pump Harness (W8) Component
Location . (Group 9015-10.)
Machine harness splice connector (X98) and pump harness-to-machine harness connector (X40). See Machine Harness
(W2) Component Location . (Group 9015-10.)
Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main controller 17-pin connector C (X33).
See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate sensors after check is completed.

Disconnect pump 1 delivery pressure sensor (B35).

Disconnect pump 2 delivery pressure sensor (B37).

Connect pump 1 delivery pressure sensor (B35) connector to pump 2 delivery pressure sensor (B37).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011200.03—Pump 1 Delivery Pressure Sensor Circuit High Input.

Is code active?

<- Go to Section TOC Section 9001 page 45 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Voltage Check.

NO:Pump 1 delivery pressure sensor (B35) malfunction. Replace sensor.

( 3 ) Voltage Check

Action:

Key switch in OFF position.

Disconnect pump 1 delivery pressure sensor (B35).

Turn key switch to ON position.

Check between pin 2 of pump 1 delivery pressure sensor (B35) connector and machine ground for voltage.

Is voltage indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Harness Check.

( 4 ) Harness Check

Action:

Key switch in OFF position.

Disconnect pump 1 delivery pressure sensor (B35).

Disconnect main controller connectors (X31—X36).

Check for continuity between pin 14 of cab harness-to-main controller 17-pin connector C (X33) to all pins on all main controller
connectors.

Is continuity indicated between any circuits?

Result:

YES:Circuit is short to power. Repair or replace harness. See appropriate harness.

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

<- Go to Section TOC Section 9001 page 46 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011200.04- Pump 1 Delivery Pressure Sensor Circuit Low Input


360
Pump 1 delivery pressure sensor (B35) signal voltage is low (below 0.1 V).

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Pump 1 Delivery Pressure Sensor Circuit Low Input Diagnostic


Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Pump 1 delivery pressure sensor (B35) and pump harness splice connector (X97). See Pump Harness (W8) Component
Location . (Group 9015-10.)
Machine harness splice connector (X98) and pump harness-to-machine harness connector (X40). See Machine Harness
(W2) Component Location . (Group 9015-10.)
Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main controller 17-pin connector C (X33).
See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate sensors after check is completed.

Disconnect pump 1 delivery pressure sensor (B35).

Disconnect pump 2 delivery pressure sensor (B37).

Connect pump 1 delivery pressure sensor (B35) connector to pump 2 delivery pressure sensor (B37).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011200.04—Pump 1 Delivery Pressure Sensor Circuit Low Input.

Is code active?

<- Go to Section TOC Section 9001 page 47 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Voltage Check.

NO:Pump 1 delivery pressure sensor (B35) malfunction. Replace sensor.

( 3 ) Voltage Check

Action:

Key switch in OFF position.

Disconnect pump 1 delivery pressure sensor (B35).

Turn key switch to ON position.

Check voltage between pin 1 and pin 3 of pump 1 delivery pressure sensor (B35) connector.

Is approximately 5 V indicated?

Result:

YES:Go to Open Circuit Check.

NO:Repair or replace harness. See appropriate harness.

( 4 ) Open Circuit Check

Action:

Key switch in OFF position.

Pump 1 delivery pressure sensor (B35) disconnected.

Disconnect cab harness-to-main controller 17-pin connector C (X33).

Disconnect cab harness-to-main controller 26-pin connector F (X36).

Check for continuity between:

Pin 3 of pump 1 delivery pressure sensor (B35) connector and pin 25 of cab harness-to-main controller 26-pin connector F
(X36).
Pin 2 of pump 1 delivery pressure sensor (B35) connector and pin 14 of cab harness-to-main controller 17-pin connector C
(X33).

Is continuity indicated?

Result:

YES:Go to Short Circuit Check.

NO:Repair or replace harness. See appropriate harness.

( 5 ) Short Circuit Check

Action:

Key switch in OFF position.

Pump 1 delivery pressure sensor (B35) disconnected.

Check for continuity between:

<- Go to Section TOC Section 9001 page 48 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

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

Is continuity indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

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

<- Go to Section TOC Section 9001 page 49 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011202.03- Pump 2 Delivery Pressure Sensor Circuit High Input


360
Pump 2 delivery pressure sensor (B37) signal voltage is high (above 4.5 V).

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Pump 2 Delivery Pressure Sensor Circuit High Input Diagnostic


Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Pump 2 delivery pressure sensor (B37) and pump harness splice connector (X97). See Pump Harness (W8) Component
Location . (Group 9015-10.)
Machine harness splice connector (X98) and pump harness-to-machine harness connector (X40). See Machine Harness
(W2) Component Location . (Group 9015-10.)
Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main controller 17-pin connector C (X33).
See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate sensors after check is completed.

Disconnect pump 2 delivery pressure sensor (B37).

Disconnect pump 1 delivery pressure sensor (B35).

Connect pump 2 delivery pressure sensor (B37) connector to pump 1 delivery pressure sensor (B35).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011202.03—Pump 2 Delivery Pressure Sensor Circuit High Input.

Is code active?

<- Go to Section TOC Section 9001 page 50 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Voltage Check.

NO:Pump 2 delivery pressure sensor (B37) malfunction. Replace sensor.

( 3 ) Voltage Check

Action:

Key switch in OFF position.

Disconnect pump 2 delivery pressure sensor (B37).

Turn key switch to ON position.

Check between pin 2 of pump 2 delivery pressure sensor (B37) connector and machine ground for voltage.

Is voltage indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Harness Check.

( 4 ) Harness Check

Action:

Key switch in OFF position.

Disconnect pump 2 delivery pressure sensor (B37).

Disconnect main controller connectors (X31—X36).

Check for continuity between pin 15 of cab harness-to-main controller 17-pin connector C (X33) to all pins on all main controller
connectors.

Is continuity indicated between any circuits?

Result:

YES:Circuit is short to power. Repair or replace harness. See appropriate harness.

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

<- Go to Section TOC Section 9001 page 51 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011202.04- Pump 2 Delivery Pressure Sensor Circuit Low Input


360
Pump 2 delivery pressure sensor (B37) signal voltage is low (below 0.1 V).

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Pump 2 delivery pressure sensor open or short to ground.

Pump 2 Delivery Pressure Sensor Circuit Low Input Diagnostic


Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Pump 2 delivery pressure sensor (B37) and pump harness splice connector (X97). See Pump Harness (W8) Component
Location . (Group 9015-10.)
Machine harness splice connector (X98) and pump harness-to-machine harness connector (X40). See Machine Harness
(W2) Component Location . (Group 9015-10.)
Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main controller 17-pin connector C (X33).
See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate sensors after check is completed.

Disconnect pump 2 delivery pressure sensor (B37).

Disconnect pump 1 delivery pressure sensor (B35).

Connect pump 2 delivery pressure sensor (B37) connector to pump 1 delivery pressure sensor (B35).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011202.04—Pump 2 Delivery Pressure Sensor Circuit Low Input.
<- Go to Section TOC Section 9001 page 52 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Is code active?

Result:

YES:Go to Voltage Check.

NO:Pump 2 delivery pressure sensor (B37) malfunction. Replace sensor.

( 3 ) Voltage Check

Action:

Key switch in OFF position.

Disconnect pump 2 delivery pressure sensor (B37).

Turn key switch to ON position.

Check voltage between pin 1 and pin 3 of pump 2 delivery pressure sensor (B37) connector.

Is approximately 5 V indicated?

Result:

YES:Go to Open Circuit Check.

NO:Repair or replace harness. See appropriate harness.

( 4 ) Open Circuit Check

Action:

Key switch in OFF position.

Pump 2 delivery pressure sensor (B37) disconnected.

Disconnect cab harness-to-main controller 17-pin connector C (X33).

Disconnect cab harness-to-main controller 26-pin connector F (X36).

Check for continuity between:

Pin 3 of pump 2 delivery pressure sensor (B37) connector and pin 25 of cab harness-to-main controller 26-pin connector F
(X36).
Pin 2 of pump 2 delivery pressure sensor (B37) connector and pin 15 of cab harness-to-main controller 17-pin connector C
(X33).

Is continuity indicated?

Result:

YES:Go to Short Circuit Check.

NO:Repair or replace harness. See appropriate harness.

( 5 ) Short Circuit Check

Action:

Key switch in OFF position.

Pump 2 delivery pressure sensor (B37) disconnected.

<- Go to Section TOC Section 9001 page 53 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Check for continuity between:

Pin 2 of pump 2 delivery pressure sensor (B37) connector and machine ground.
Pin 3 of pump 2 delivery pressure sensor (B37) connector and machine ground.

Is continuity indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

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

<- Go to Section TOC Section 9001 page 54 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011206.03- Pump 1 Flow Control Pressure Sensor Circuit High Input


360
Pump 1 control pressure sensor (B36) signal voltage is high (above 4.5 V).

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Pump 1 Flow Control Pressure Sensor Circuit High Input Diagnostic


Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Pump 1 control pressure sensor (B36) and pump harness splice connector (X97). See Pump Harness (W8) Component
Location . (Group 9015-10.)
Machine harness splice connector (X98) and pump harness-to-machine harness connector (X40). See Machine Harness
(W2) Component Location . (Group 9015-10.)
Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main controller 17-pin connector C (X33).
See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate sensors after check is completed.

Disconnect pump 1 control pressure sensor (B36).

Disconnect pump 2 control pressure sensor (B38).

Connect pump 1 control pressure sensor (B36) connector to pump 2 control pressure sensor (B38).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011206.03—Pump 1 Flow Control Pressure Sensor Circuit High Input.

Is code active?

<- Go to Section TOC Section 9001 page 55 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Voltage Check.

NO:Pump 1 control pressure sensor (B36) malfunction. Replace sensor.

( 3 ) Voltage Check

Action:

Key switch in OFF position.

Disconnect pump 1 control pressure sensor (B36).

Turn key switch to ON position.

Check between pin 2 of pump 1 control pressure sensor (B36) connector and machine ground for voltage.

Is voltage indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Harness Check.

( 4 ) Harness Check

Action:

Key switch in OFF position.

Disconnect pump 1 control pressure sensor (B36).

Disconnect main controller connectors (X31—X36).

Check for continuity between pin 8 of cab harness-to-main controller 17-pin connector C (X33) to all pins on all main controller
connectors.

Is continuity indicated between any circuits?

Result:

YES:Circuit is short to power. Repair or replace harness. See appropriate harness.

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

<- Go to Section TOC Section 9001 page 56 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011206.04- Pump 1 Flow Control Pressure Sensor Circuit Low Input


360
Pump 1 control pressure sensor (B36) signal voltage is low (below 0.1 V).

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Pump 1 Flow Control Pressure Sensor Circuit Low Input Diagnostic


Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Pump 1 control pressure sensor (B36) and pump harness splice connector (X97). See Pump Harness (W8) Component
Location . (Group 9015-10.)
Machine harness splice connector (X98) and pump harness-to-machine harness connector (X40). See Machine Harness
(W2) Component Location . (Group 9015-10.)
Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main controller 17-pin connector C (X33).
See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate sensors after check is completed.

Disconnect pump 1 control pressure sensor (B36).

Disconnect pump 2 control pressure sensor (B38).

Connect pump 1 control pressure sensor (B36) connector to pump 2 control pressure sensor (B38).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011206.04—Pump 1 Flow Control Pressure Sensor Circuit Low Input.

Is code active?

<- Go to Section TOC Section 9001 page 57 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Voltage Check.

NO:Pump 1 control pressure sensor (B36) malfunction. Replace sensor.

( 3 ) Voltage Check

Action:

Key switch in OFF position.

Disconnect pump 1 control pressure sensor (B36).

Turn key switch to ON position.

Check voltage between pin 1 and pin 3 of pump 1 control pressure sensor (B36) connector.

Is approximately 5 V indicated?

Result:

YES:Go to Open Circuit Check.

NO:Repair or replace harness. See appropriate harness.

( 4 ) Open Circuit Check

Action:

Key switch in OFF position.

Pump 1 control pressure sensor (B36) disconnected.

Disconnect cab harness-to-main controller 17-pin connector C (X33).

Disconnect cab harness-to-main controller 26-pin connector F (X36).

Check for continuity between:

Pin 1 of pump 1 control pressure sensor (B36) connector and pin 25 of cab harness-to-main controller 26-pin connector F
(X36).
Pin 2 of pump 1 control pressure sensor (B36) connector and pin 8 of cab harness-to-main controller 17-pin connector C
(X33).

Is continuity indicated?

Result:

YES:Go to Short Circuit Check.

NO:Repair or replace harness. See appropriate harness.

( 5 ) Short Circuit Check

Action:

Key switch in OFF position.

Pump 1 control pressure sensor (B36) disconnected.

Check for continuity between:

<- Go to Section TOC Section 9001 page 58 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

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

Is continuity indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

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

<- Go to Section TOC Section 9001 page 59 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011208.03- Pump 2 Flow Control Pressure Sensor Circuit High Input


360
Pump 2 control pressure sensor (B38) signal voltage is high (above 4.5 V).

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Pump 2 Flow Control Pressure Sensor Circuit High Input Diagnostic


Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Pump 2 control pressure sensor (B38) and pump harness splice connector (X97). See Pump Harness (W8) Component
Location . (Group 9015-10.)
Machine harness splice connector (X98) and pump harness-to-machine harness connector (X40). See Machine Harness
(W2) Component Location . (Group 9015-10.)
Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main controller 17-pin connector C (X33).
See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate sensors after check is completed.

Disconnect pump 2 control pressure sensor (B38).

Disconnect pump 1 control pressure sensor (B36).

Connect pump 2 control pressure sensor (B38) connector to pump 1 control pressure sensor (B36).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011208.03—Pump 2 Flow Control Pressure Sensor Circuit High Input.

Is code active?

<- Go to Section TOC Section 9001 page 60 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Voltage Check.

NO:Pump 2 control pressure sensor (B38) malfunction. Replace sensor.

( 3 ) Voltage Check

Action:

Key switch in OFF position.

Disconnect pump 2 control pressure sensor (B38).

Turn key switch to ON position.

Check between pin 2 of pump 2 control pressure sensor (B38) connector and machine ground for voltage.

Is voltage indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Harness Check.

( 4 ) Harness Check

Action:

Key switch in OFF position.

Disconnect pump 2 control pressure sensor (B38).

Disconnect main controller connectors (X31—X36).

Check for continuity between pin 17 of cab harness-to-main controller 17-pin connector C (X33) to all pins on all main controller
connectors.

Is continuity indicated between any circuits?

Result:

YES:Circuit is short to power. Repair or replace harness. See appropriate harness.

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

<- Go to Section TOC Section 9001 page 61 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011208.04- Pump 2 Flow Control Pressure Sensor Circuit Low Input


360
Pump 2 control pressure sensor (B38) signal voltage is low (below 0.1 V).

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Pump 2 Flow Control Pressure Sensor Circuit Low Input Diagnostic


Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Pump 2 control pressure sensor (B38) and pump harness splice connector (X97). See Pump Harness (W8) Component
Location . (Group 9015-10.)
Machine harness splice connector (X98) and pump harness-to-machine harness connector (X40). See Machine Harness
(W2) Component Location . (Group 9015-10.)
Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main controller 17-pin connector C (X33).
See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate sensors after check is completed.

Disconnect pump 2 control pressure sensor (B38).

Disconnect pump 1 control pressure sensor (B36).

Connect pump 2 control pressure sensor (B38) connector to pump 1 control pressure sensor (B36).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011208.04—Pump 2 Flow Control Pressure Sensor Circuit Low Input.

Is code active?

<- Go to Section TOC Section 9001 page 62 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Voltage Check.

NO:Pump 2 control pressure sensor (B38) malfunction. Replace sensor.

( 3 ) Voltage Check

Action:

Key switch in OFF position.

Disconnect pump 2 control pressure sensor (B38).

Turn key switch to ON position.

Check voltage between pin 1 and pin 3 of pump 2 control pressure sensor (B38) connector.

Is approximately 5 V indicated?

Result:

YES:Go to Open Circuit Check.

NO:Repair or replace harness. See appropriate harness.

( 4 ) Open Circuit Check

Action:

Key switch in OFF position.

Pump 2 control pressure sensor (B38) disconnected.

Disconnect cab harness-to-main controller 17-pin connector C (X33).

Disconnect cab harness-to-main controller 26-pin connector F (X36).

Check for continuity between:

Pin 1 of pump 2 control pressure sensor (B38) connector and pin 25 of cab harness-to-main controller 26-pin connector F
(X36).
Pin 2 of pump 2 control pressure sensor (B38) connector and pin 13 of cab harness-to-main controller 17-pin connector C
(X33).

Is continuity indicated?

Result:

YES:Go to Short Circuit Check.

NO:Repair or replace harness. See appropriate harness.

( 5 ) Short Circuit Check

Action:

Key switch in OFF position.

Pump 2 control pressure sensor (B38) disconnected.

Check for continuity between:

<- Go to Section TOC Section 9001 page 63 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

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

Is continuity indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

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

<- Go to Section TOC Section 9001 page 64 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011301.03- Swing Pilot Pressure Sensor Circuit High Input


360
Swing pressure sensor (B33) signal voltage is high (above 4.5 V).

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Swing Pilot Pressure Sensor Circuit High Input Diagnostic Procedure


( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Swing pressure sensor (B33) and machine harness splice connector (X98). See Machine Harness (W2) Component
Location . (Group 9015-10.)
Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main controller 30-pin connector D (X34).
See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate sensors after check is completed.

Disconnect swing pressure sensor (B33).

Disconnect travel pressure sensor (B34).

Connect swing pressure sensor (B33) connector to travel pressure sensor (B34).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011301.03—Swing Pilot Pressure Sensor Circuit High Input.

Is code active?

<- Go to Section TOC Section 9001 page 65 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Voltage Check.

NO:Swing pressure sensor (B33) malfunction. Replace sensor.

( 3 ) Voltage Check

Action:

Key switch in OFF position.

Disconnect swing pressure sensor (B33).

Turn key switch to ON position.

Check between pin 2 of swing pressure sensor (B33) connector and machine ground for voltage.

Is voltage indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Harness Check.

( 4 ) Harness Check

Action:

Key switch in OFF position.

Disconnect swing pressure sensor (B33).

Disconnect main controller connectors (X31—X36).

Check for continuity between pin 15 of cab harness-to-main controller 30-pin connector D (X34) to all pins on all main controller
connectors.

Is continuity indicated between any circuits?

Result:

YES:Circuit is short to power. Repair or replace harness. See appropriate harness.

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

<- Go to Section TOC Section 9001 page 66 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011301.04- Swing Pilot Pressure Sensor Circuit Low Input


360
Swing pressure sensor (B33) signal voltage is low (below 0.1 V).

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Swing Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure


( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Swing pressure sensor (B33) and machine harness splice connector (X98). See Machine Harness (W2) Component
Location . (Group 9015-10.)
Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main controller 30-pin connector D (X34).
See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate sensors after check is completed.

Disconnect swing pressure sensor (B33).

Disconnect travel pressure sensor (B34).

Connect swing pressure sensor (B33) connector to travel pressure sensor (B34).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011301.04—Swing Pilot Pressure Sensor Circuit Low Input.

Is code active?

<- Go to Section TOC Section 9001 page 67 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Voltage Check.

NO:Swing pressure sensor (B33) malfunction. Replace sensor.

( 3 ) Voltage Check

Action:

Key switch in OFF position.

Disconnect swing pressure sensor (B33).

Turn key switch to ON position.

Check voltage between pin 1 and pin 3 of swing pressure sensor (B33) connector.

Is approximately 5 V indicated?

Result:

YES:Go to Open Circuit Check.

NO:Repair or replace harness. See appropriate harness.

( 4 ) Open Circuit Check

Action:

Key switch in OFF position.

Swing pressure sensor (B33) disconnected.

Disconnect cab harness-to-main controller 30-pin connector D (X34).

Disconnect cab harness-to-main controller 26-pin connector F (X36).

Check for continuity between:

Pin 1 of swing pressure sensor (B33) connector and pin 25 of cab harness-to-main controller 26-pin connector F (X36).
Pin 2 of swing pressure sensor (B33) connector and pin 15 of cab harness-to-main controller 30-pin connector D (X34).

Is continuity indicated?

Result:

YES:Go to Short Circuit Check.

NO:Repair or replace harness. See appropriate harness.

( 5 ) Short Circuit Check

Action:

Key switch in OFF position.

Swing pressure sensor (B33) disconnected.

Check for continuity between:

Pin 1 of swing pressure sensor (B33) connector and machine ground.


Pin 2 of swing pressure sensor (B33) connector and machine ground.

<- Go to Section TOC Section 9001 page 68 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Is continuity indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

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

<- Go to Section TOC Section 9001 page 69 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011302.03- Boom Up Pilot Pressure Sensor Circuit High Input


360
Boom up pressure sensor (B30) signal voltage is high (above 4.5 V).

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Boom Up Pilot Pressure Sensor Circuit High Input Diagnostic Procedure


( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Boom up pressure sensor (B30) and machine harness splice connector (X98). See Machine Harness (W2) Component
Location . (Group 9015-10.)
Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main controller 30-pin connector D (X34).
See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate sensors after check is completed.

Switch boom up pressure sensor (B30) connector to another properly working pressure sensor.

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011302.03—Boom Up Pilot Pressure Sensor Circuit High Input.

Is code active?

Result:

YES:Go to Voltage Check.

NO:Boom up pressure sensor (B30) malfunction. Replace sensor.

<- Go to Section TOC Section 9001 page 70 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

( 3 ) Voltage Check

Action:

Key switch in OFF position.

Disconnect boom up pressure sensor (B30).

Turn key switch to ON position.

Check between pin 2 of boom up pressure sensor (B30) connector and machine ground for voltage.

Is voltage indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Harness Check.

( 4 ) Harness Check

Action:

Key switch in OFF position.

Disconnect boom up pressure sensor (B30).

Disconnect main controller connectors (X31—X36).

Check for continuity between pin 6 of cab harness-to-main controller 30-pin connector D (X34) to all pins on all main controller
connectors.

Is continuity indicated between any circuits?

Result:

YES:Circuit is short to power. Repair or replace harness. See appropriate harness.

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

<- Go to Section TOC Section 9001 page 71 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011302.04- Boom Up Pilot Pressure Sensor Circuit Low Input


360
Boom up pressure sensor (B30) signal voltage is low (below 0.1 V).

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Boom Up Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure


( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Boom up pressure sensor (B30) and machine harness splice connector (X98). See Machine Harness (W2) Component
Location . (Group 9015-10.)
Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main controller 30-pin connector D (X34).
See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate sensors after check is completed.

Switch boom up pressure sensor (B30) connector to another properly working pressure sensor.

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011302.04—Boom Up Pilot Pressure Sensor Circuit Low Input.

Is code active?

Result:

YES:Go to Voltage Check.

NO:Boom up pressure sensor (B30) malfunction. Replace sensor.

<- Go to Section TOC Section 9001 page 72 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

( 3 ) Voltage Check

Action:

Key switch in OFF position.

Disconnect boom up pressure sensor (B30).

Turn key switch to ON position.

Check voltage between pin 1 and pin 3 of boom up pressure sensor (B30) connector.

Is approximately 5 V indicated?

Result:

YES:Go to Open Circuit Check.

NO:Repair or replace harness. See appropriate harness.

( 4 ) Open Circuit Check

Action:

Key switch in OFF position.

Boom up pressure sensor (B30) disconnected.

Disconnect cab harness-to-main controller 30-pin connector D (X34).

Disconnect cab harness-to-main controller 26-pin connector F (X36).

Check for continuity between:

Pin 1 of boom up pressure sensor (B30) connector and pin 25 of cab harness-to-main controller 26-pin connector F (X36).
Pin 2 of boom up pressure sensor (B30) connector and pin 6 of cab harness-to-main controller 24-pin connector D (X34).

Is continuity indicated?

Result:

YES:Go to Short Circuit Check.

NO:Repair or replace harness. See appropriate harness.

( 5 ) Short Circuit Check

Action:

Key switch in OFF position.

Boom up pressure sensor (B30) disconnected.

Check for continuity between:

Pin 1 of boom up pressure sensor (B30) connector and machine ground.


Pin 2 of boom up pressure sensor (B30) connector and machine ground.

Is continuity indicated?

Result:

YES:Repair or replace harness. See appropriate harness.


<- Go to Section TOC Section 9001 page 73 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

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

<- Go to Section TOC Section 9001 page 74 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011303.03- Arm In Pilot Pressure Sensor Circuit High Input


360
Arm in pressure sensor (B31) signal voltage is high (above 4.5 V).

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Arm In Pilot Pressure Sensor Circuit High Input Diagnostic Procedure


( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Arm in pressure sensor (B31) and machine harness splice connector (X98). See Machine Harness (W2) Component
Location . (Group 9015-10.)
Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main controller 30-pin connector D (X34).
See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate sensors after check is completed.

Switch arm in pressure sensor (B31) connector to another properly working pressure sensor.

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011303.03—Arm In Pilot Pressure Sensor Circuit High Input.

Is code active?

Result:

YES:Go to Voltage Check.

NO:Arm in pressure sensor (B31) malfunction. Replace sensor.

<- Go to Section TOC Section 9001 page 75 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

( 3 ) Voltage Check

Action:

Key switch in OFF position.

Disconnect arm in pressure sensor (B31).

Turn key switch to ON position.

Check between pin 2 of arm in pressure sensor (B31) connector and machine ground for voltage.

Is voltage indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Harness Check.

( 4 ) Harness Check

Action:

Key switch in OFF position.

Disconnect arm in pressure sensor (B31).

Disconnect main controller connectors (X31—X36).

Check for continuity between pin 7 of cab harness-to-main controller 30-pin connector D (X34) to all pins on all main controller
connectors.

Is continuity indicated between any circuits?

Result:

YES:Circuit is short to power. Repair or replace harness. See appropriate harness.

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

<- Go to Section TOC Section 9001 page 76 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011303.04- Arm In Pilot Pressure Sensor Circuit Low Input


360
Arm in pressure sensor (B31) signal voltage is low (below 0.1 V).

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Arm In Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure


( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Arm in pressure sensor (B31) and machine harness splice connector (X98). See Machine Harness (W2) Component
Location . (Group 9015-10.)
Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main controller 30-pin connector D (X34).
See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate sensors after check is completed.

Switch arm in pressure sensor (B31) connector to another properly working pressure sensor.

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011303.04—Arm In Pilot Pressure Sensor Circuit Low Input.

Is code active?

Result:

YES:Go to Voltage Check.

NO:Arm in pressure sensor (B31) malfunction. Replace sensor.

<- Go to Section TOC Section 9001 page 77 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

( 3 ) Voltage Check

Action:

Key switch in OFF position.

Disconnect arm in pressure sensor (B31).

Turn key switch to ON position.

Check voltage between pin 1 and pin 3 of arm in pressure sensor (B31) connector.

Is approximately 5 V indicated?

Result:

YES:Go to Open Circuit Check.

NO:Repair or replace harness. See appropriate harness.

( 4 ) Open Circuit Check

Action:

Key switch in OFF position.

Arm in pressure sensor (B31) disconnected.

Disconnect cab harness-to-main controller 30-pin connector D (X34).

Disconnect cab harness-to-main controller 26-pin connector E (X36).

Check for continuity between:

Pin 1 of arm in pressure sensor (B31) connector and pin 25 of cab harness-to-main controller 26-pin connector F (X36).
Pin 2 of arm in pressure sensor (B31) connector and pin 7 of cab harness-to-main controller 30-pin connector D (X34).

Is continuity indicated?

Result:

YES:Go to Short Circuit Check.

NO:Repair or replace harness. See appropriate harness.

( 5 ) Short Circuit Check

Action:

Key switch in OFF position.

Arm in pressure sensor (B31) disconnected.

Check for continuity between:

Pin 1 of arm in pressure sensor (B31) connector and machine ground.


Pin 2 of arm in pressure sensor (B31) connector and machine ground.

Is continuity indicated?

Result:

YES:Repair or replace harness. See appropriate harness.


<- Go to Section TOC Section 9001 page 78 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

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

<- Go to Section TOC Section 9001 page 79 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011304.03- Travel Pilot Pressure Sensor Circuit High Input


360
Travel pressure sensor (B33) signal voltage is high (above 4.5 V).

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Travel Pilot Pressure Sensor Circuit High Input Diagnostic Procedure


( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Travel pressure sensor (B34) and machine harness splice connector (X98). See Machine Harness (W2) Component
Location . (Group 9015-10.)
Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main controller 30-pin connector D (X34).
See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate sensors after check is completed.

Disconnect travel pressure sensor (B34).

Disconnect swing pressure sensor (B33).

Connect travel pressure sensor (B34) connector to swing pressure sensor (B33).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011304.03—Travel Pilot Pressure Sensor Circuit High Input.

Is code active?

<- Go to Section TOC Section 9001 page 80 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Voltage Check.

NO:Travel pressure sensor (B34) malfunction. Replace sensor.

( 3 ) Voltage Check

Action:

Key switch in OFF position.

Disconnect travel pressure sensor (B34).

Turn key switch to ON position.

Check between pin 2 of travel pressure sensor (B34) connector and machine ground for voltage.

Is voltage indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Harness Check.

( 4 ) Harness Check

Action:

Key switch in OFF position.

Disconnect travel pressure sensor (B34).

Disconnect main controller connectors (X31—X36).

Check for continuity between pin 9 of cab harness-to-main controller 30-pin connector D (X34) to all pins on all main controller
connectors.

Is continuity indicated between any circuits?

Result:

YES:Circuit is short to power. Repair or replace harness. See appropriate harness.

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

<- Go to Section TOC Section 9001 page 81 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011304.04- Travel Pilot Pressure Sensor Circuit Low Input


360
Travel pressure sensor (B34) signal voltage is low (below 0.1 V).

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Travel Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure


( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Travel pressure sensor (B34) and machine harness splice connector (X98). See Machine Harness (W2) Component
Location . (Group 9015-10.)
Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main controller 30-pin connector D (X34).
See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate sensors after check is completed.

Disconnect travel pressure sensor (B34).

Disconnect swing pressure sensor (B33).

Connect travel pressure sensor (B34) connector to swing pressure sensor (B33).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011304.04—Travel Pilot Pressure Sensor Circuit Low Input.

Is code active?

<- Go to Section TOC Section 9001 page 82 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Voltage Check.

NO:Travel pressure sensor (B34) malfunction. Replace sensor.

( 3 ) Voltage Check

Action:

Key switch in OFF position.

Disconnect travel pressure sensor (B34).

Turn key switch to ON position.

Check voltage between pin 1 and pin 3 of travel pressure sensor (B34) connector.

Is approximately 5 V indicated?

Result:

YES:Go to Open Circuit Check.

NO:Repair or replace harness. See appropriate harness.

( 4 ) Open Circuit Check

Action:

Key switch in OFF position.

Travel pressure sensor (B34) disconnected.

Disconnect cab harness-to-main controller 30-pin connector D (X34).

Disconnect cab harness-to-main controller 26-pin connector F (X36).

Check for continuity between:

Pin 1 of travel pressure sensor (B34) connector and pin 25 of cab harness-to-main controller 26-pin connector F (X36).
Pin 2 of travel pressure sensor (B34) connector and pin 9 of cab harness-to-main controller 30-pin connector D (X34).

Is continuity indicated?

Result:

YES:Go to Short Circuit Check.

NO:Repair or replace harness. See appropriate harness.

( 5 ) Short Circuit Check

Action:

Key switch in OFF position.

Travel pressure sensor (B34) disconnected.

Check for continuity between:

Pin 1 of travel pressure sensor (B34) connector and machine ground.


Pin 2 of travel pressure sensor (B34) connector and machine ground.

<- Go to Section TOC Section 9001 page 83 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Is continuity indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

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

<- Go to Section TOC Section 9001 page 84 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011307.03- Front Attachment Pilot Pressure Sensor Circuit High Input


360
Front attachment pressure sensor (B32) signal voltage is high (above 4.5 V).

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Front Attachment Pilot Pressure Sensor Circuit High Input High


Diagnostic Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Front attachment pressure sensor (B32) and machine harness splice connector (X98). See Machine Harness (W2)
Component Location . (Group 9015-10.)
Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main controller 30-pin connector D (X34).
See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate sensors after check is completed.

Switch front attachment pressure sensor (B32) connector to another properly working pressure sensor.

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011307.03—Front Attachment Pilot Pressure Sensor Circuit High Input.

Is code active?

Result:

YES:Go to Voltage Check.

NO:Front attachment pressure sensor (B32) malfunction. Replace sensor.


<- Go to Section TOC Section 9001 page 85 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

( 3 ) Voltage Check

Action:

Key switch in OFF position.

Disconnect front attachment pressure sensor (B32).

Turn key switch to ON position.

Check between pin 2 of front attachment pressure sensor (B32) connector and machine ground for voltage.

Is voltage indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Harness Check.

( 4 ) Harness Check

Action:

Key switch in OFF position.

Disconnect front attachment pressure sensor (B31).

Disconnect main controller connectors (X31—X36).

Check for continuity between pin 14 of cab harness-to-main controller 30-pin connector D (X34) to all pins on all main controller
connectors.

Is continuity indicated between any circuits?

Result:

YES:Circuit is short to power. Repair or replace harness. See appropriate harness.

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

<- Go to Section TOC Section 9001 page 86 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011307.04- Front Attachment Pilot Pressure Sensor Circuit Low Input


360
Front attachment pressure sensor (B32) signal voltage is low (below 0.1 V).

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Front Attachment Pilot Pressure Sensor Circuit Low Input Diagnostic


Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Front attachment pressure sensor (B32) and machine harness splice connector (X98). See Machine Harness (W2)
Component Location . (Group 9015-10.)
Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main controller 30-pin connector D (X34).
See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate sensors after check is completed.

Switch front attachment pressure sensor (B32) connector to another properly working pressure sensor.

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011307.04—Front Attachment Pilot Pressure Sensor Circuit Low Input.

Is code active?

Result:

YES:Go to Voltage Check.

NO:Front attachment pressure sensor (B32) malfunction. Replace sensor.


<- Go to Section TOC Section 9001 page 87 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

( 3 ) Voltage Check

Action:

Key switch in OFF position.

Disconnect front attachment pressure sensor (B32).

Turn key switch to ON position.

Check voltage between pin 1 and pin 3 of front attachment pressure sensor (B32) connector.

Is approximately 5 V indicated?

Result:

YES:Go to Open Circuit Check.

NO:Repair or replace harness. See appropriate harness.

( 4 ) Open Circuit Check

Action:

Key switch in OFF position.

Front attachment pressure sensor (B32) disconnected.

Disconnect cab harness-to-main controller 30-pin connector D (X34).

Disconnect cab harness-to-main controller 26-pin connector F (X36).

Check for continuity between:

Pin 1 of front attachment pressure sensor (B32) connector and pin 25 of cab harness-to-main controller 26-pin connector
F (X36).
Pin 2 of front attachment pressure sensor (B32) connector and pin 14 of cab harness-to-main controller 30-pin connector
D (X34).

Is continuity indicated?

Result:

YES:Go to Short Circuit Check.

NO:Repair or replace harness. See appropriate harness.

( 5 ) Short Circuit Check

Action:

Key switch in OFF position.

Front attachment pressure sensor (B32) disconnected.

Check for continuity between:

Pin 1 of front attachment pressure sensor (B32) connector and machine ground.
Pin 2 of front attachment pressure sensor (B32) connector and machine ground.

Is continuity indicated?

<- Go to Section TOC Section 9001 page 88 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Repair or replace harness. See appropriate harness.

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

<- Go to Section TOC Section 9001 page 89 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011400.02- Pump 2 Flow Rate Limit Solenoid Valve Abnormal Feedback


360
Pump 2 flow rate limit solenoid (marked SB) (Y20) current above 920 mA and below 70 mA.

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Pump 2 Flow Rate Limit Solenoid Valve Abnormal Feedback Diagnostic


Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Pump 2 flow rate limit solenoid (Y20) and pump harness-to-machine harness connector (X40). See Pump Harness (W8)
Component Location . (Group 9015-10.)
Cab harness-to-machine harness 100-pin connector (X3). See Machine Harness (W2) Component Location . (Group
9015-10.)
Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate solenoids after check is completed.

Key switch in OFF position.

Disconnect pump 2 flow rate limit solenoid (marked SB) (Y20).

Disconnect torque control solenoid (marked ST) (Y21).

Connect pump 2 flow rate limit solenoid (Y20) connector to torque control solenoid (Y21).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011400.02—Pump 2 Flow Rate Limit Solenoid Feedback Abnormal.

Is code active?
<- Go to Section TOC Section 9001 page 90 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Continuity Check.

NO:Pump 2 flow rate limit solenoid (Y20) malfunction. Replace solenoid.

( 3 ) Continuity Check

Action:

Key switch in OFF position.

Disconnect pump 2 flow rate limit solenoid (Y20).

Disconnect cab harness-to-main controller 31-pin connector A (X31).

Check for continuity between:

Pin 1 of pump 2 flow rate limit solenoid (Y20) connector to pin 7 cab of harness-to-main controller 31-pin connector A
(X31).
Pin 2 of pump 2 flow rate limit solenoid (Y20) connector to pin 6 cab of harness-to-main controller 31-pin connector A
(X31).

Is continuity indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Short Circuit Check.

( 4 ) Short Circuit Check

Action:

Key switch in OFF position.

Pump 2 flow rate limit solenoid (Y20) disconnected.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between:

Pin 1 of pump 2 flow rate limit solenoid (Y20) connector to machine ground.
Pin 6 of cab harness-to-main controller 31-pin connector A (X31) to machine ground.

Is continuity indicated?

Result:

YES:Go to Harness Check.

NO:Short to ground. Repair or replace harness. See appropriate harness.

( 5 ) Harness Check

Action:

Key switch in OFF position.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between pin 6 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.

<- Go to Section TOC Section 9001 page 91 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Is continuity indicated between any pins?

Result:

YES:Short to power. Repair or replace harness. See appropriate harness.

NO:Go to Solenoid Check.

( 6 ) Solenoid Check

Action:

Key switch in OFF position.

Disconnect pump 2 flow rate limit solenoid (Y20).

Test pump 2 flow rate limit solenoid (Y20) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)

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

Result:

YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)

NO:Pump 2 flow rate limit solenoid (Y20) malfunction. Replace solenoid.

<- Go to Section TOC Section 9001 page 92 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011400.03- Pump 2 Flow Rate Limit Solenoid Valve Feedback High Current
360
Pump 2 flow rate limit solenoid (marked SB) (Y20) current above 920 mA.

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Pump 2 Flow Rate Limit Solenoid Valve Feedback High Current


Diagnostic Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Pump 2 flow rate limit solenoid (Y20) and pump harness-to-machine harness connector (X40). See Pump Harness (W8)
Component Location . (Group 9015-10.)
Cab harness-to-machine harness 100-pin connector (X3). See Machine Harness (W2) Component Location . (Group
9015-10.)
Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate solenoids after check is completed.

Key switch in OFF position.

Disconnect pump 2 flow rate limit solenoid (marked SB) (Y20).

Disconnect torque control solenoid (marked ST) (Y21).

Connect pump 2 flow rate limit solenoid (Y20) connector to torque control solenoid (Y21).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011400.03—Pump 2 Flow Rate Limit Solenoid Valve Feedback High Current.

Is code active?
<- Go to Section TOC Section 9001 page 93 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Continuity Check.

NO:Pump 2 flow rate limit solenoid (Y20) malfunction. Replace solenoid.

( 3 ) Continuity Check

Action:

Key switch in OFF position.

Disconnect pump 2 flow rate limit solenoid (Y20).

Disconnect cab harness-to-main controller 31-pin connector A (X31).

Check for continuity between:

Pin 1 of pump 2 flow rate limit solenoid (Y20) connector to pin 7 cab of harness-to-main controller 31-pin connector A
(X31).
Pin 2 of pump 2 flow rate limit solenoid (Y20) connector to pin 6 cab of harness-to-main controller 31-pin connector A
(X31).

Is continuity indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Harness Check.

( 4 ) Harness Check

Action:

Key switch in OFF position.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between pin 6 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.

Is continuity indicated between any pins?

Result:

YES:Short to power. Repair or replace harness. See appropriate harness.

NO:Go to Solenoid Check.

( 5 ) Solenoid Check

Action:

Key switch in OFF position.

Disconnect pump 2 flow rate limit solenoid (Y20).

Test pump 2 flow rate limit solenoid (Y20) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)

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

<- Go to Section TOC Section 9001 page 94 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)

NO:Pump 2 flow rate limit solenoid (Y20) malfunction. Replace solenoid.

<- Go to Section TOC Section 9001 page 95 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011400.04- Pump 2 Flow Rate Limit Solenoid Valve Feedback Low Current
360
Pump 2 flow rate limit solenoid (marked SB) (Y20) current below 70 mA.

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Pump 2 Flow Rate Limit Solenoid Valve Feedback Low Current


Diagnostic Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Pump 2 flow rate limit solenoid (Y20) and pump harness-to-machine harness connector (X40). See Pump Harness (W8)
Component Location . (Group 9015-10.)
Cab harness-to-machine harness 100-pin connector (X3). See Machine Harness (W2) Component Location . (Group
9015-10.)
Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate solenoids after check is completed.

Key switch in OFF position.

Disconnect pump 2 flow rate limit solenoid (marked SB) (Y20).

Disconnect torque control solenoid (marked ST) (Y21).

Connect pump 2 flow rate limit solenoid (Y20) connector to torque control solenoid (Y21).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011400.04—Pump 2 Flow Rate Limit Solenoid Valve Feedback Low Current.

Is code active?
<- Go to Section TOC Section 9001 page 96 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Continuity Check.

NO:Pump 2 flow rate limit solenoid (Y20) malfunction. Replace solenoid.

( 3 ) Continuity Check

Action:

Key switch in OFF position.

Disconnect pump 2 flow rate limit solenoid (Y20).

Disconnect cab harness-to-main controller 31-pin connector A (X31).

Check for continuity between:

Pin 1 of pump 2 flow rate limit solenoid (Y20) connector to pin 7 cab of harness-to-main controller 31-pin connector A
(X31).
Pin 2 of pump 2 flow rate limit solenoid (Y20) connector to pin 6 cab of harness-to-main controller 31-pin connector A
(X31).

Is continuity indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Short Circuit Check.

( 4 ) Short Circuit Check

Action:

Key switch in OFF position.

Pump 2 flow rate limit solenoid (Y20) disconnected.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between:

Pin 1 of pump 2 flow rate limit solenoid (Y20) connector to machine ground.
Pin 6 of cab harness-to-main controller 31-pin connector A (X31) to machine ground.

Is continuity indicated?

Result:

YES:Go to Solenoid Check.

NO:Short to ground. Repair or replace harness. See appropriate harness.

( 5 ) Solenoid Check

Action:

Key switch in OFF position.

Disconnect pump 2 flow rate limit solenoid (Y20).

Test pump 2 flow rate limit solenoid (Y20) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)

<- Go to Section TOC Section 9001 page 97 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

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

Result:

YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)

NO:Pump 2 flow rate limit solenoid (Y20) malfunction. Replace solenoid.

<- Go to Section TOC Section 9001 page 98 130G Excavator Diagnostic


Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011401.02- Torque Control Solenoid Valve Abnormal Feedback


360
Torque control solenoid (marked ST) (Y21) current above 920 mA and below 70 mA.

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Torque Control Solenoid Valve Abnormal Feedback Diagnostic


Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Torque control solenoid (Y21) and pump harness-to-machine harness connector (X40). See Pump Harness (W8)
Component Location . (Group 9015-10.)
Cab harness-to-machine harness 100-pin connector (X3). See Machine Harness (W2) Component Location . (Group
9015-10.)
Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate solenoids after check is completed.

Key switch in OFF position.

Disconnect torque control solenoid (marked ST) (Y21).

Disconnect pump 2 flow rate limit solenoid (marked SB) (Y20).

Connect torque control solenoid (Y21) connector to pump 2 flow rate limit solenoid (Y20).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011401.02—Torque Control Solenoid Valve Abnormal Feedback.

Is code active?
<- Go to Section TOC Section 9001 page 99 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Continuity Check.

NO:Torque control solenoid (Y21) malfunction. Replace solenoid.

( 3 ) Continuity Check

Action:

Key switch in OFF position.

Disconnect torque control solenoid (Y21).

Disconnect cab harness-to-main controller 31-pin connector A (X31).

Check for continuity between:

Pin 1 of torque control solenoid (Y21) connector to pin 3 cab of harness-to-main controller 31-pin connector A (X31).
Pin 2 of torque control solenoid (Y21) connector to pin 2 cab of harness-to-main controller 31-pin connector A (X31).

Is continuity indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Short Circuit Check.

( 4 ) Short Circuit Check

Action:

Key switch in OFF position.

Torque control solenoid (Y21) disconnected.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between:

Pin 1 of torque control solenoid (Y21) connector to machine ground.


Pin 2 of cab harness-to-main controller 31-pin connector A (X31) to machine ground.

Is continuity indicated?

Result:

YES:Go to Harness Check.

NO:Short to ground. Repair or replace harness. See appropriate harness.

( 5 ) Harness Check

Action:

Key switch in OFF position.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between pin 2 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.

Is continuity indicated between any pins?

<- Go to Section TOC Section 9001 page 100 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Short to power. Repair or replace harness. See appropriate harness.

NO:Go to Solenoid Check.

( 6 ) Solenoid Check

Action:

Key switch in OFF position.

Disconnect torque control solenoid (Y21).

Test torque control solenoid (Y21) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)

Is torque control solenoid (Y21) within specification?

Result:

YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)

NO:Torque control solenoid (Y21) malfunction. Replace solenoid.

<- Go to Section TOC Section 9001 page 101 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011401.03- Torque Control Solenoid Valve Feedback High Current


360
Torque control solenoid (marked ST) (Y21) current above 920 mA.

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Torque Control Solenoid Valve Feedback High Current Diagnostic


Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Torque control solenoid (Y21) and pump harness-to-machine harness connector (X40). See Pump Harness (W8)
Component Location . (Group 9015-10.)
Cab harness-to-machine harness 100-pin connector (X3). See Machine Harness (W2) Component Location . (Group
9015-10.)
Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate solenoids after check is completed.

Key switch in OFF position.

Disconnect torque control solenoid (marked ST) (Y21).

Disconnect pump 2 flow rate limit solenoid (marked SB) (Y20).

Connect torque control solenoid (Y21) connector to pump 2 flow rate limit solenoid (Y20).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011401.03—Torque Control Solenoid Valve Feedback High Current.

Is code active?
<- Go to Section TOC Section 9001 page 102 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Continuity Check.

NO:Torque control solenoid (Y21) malfunction. Replace solenoid.

( 3 ) Continuity Check

Action:

Key switch in OFF position.

Disconnect torque control solenoid (Y21).

Disconnect cab harness-to-main controller 31-pin connector A (X31).

Check for continuity between:

Pin 1 of torque control solenoid (Y21) connector to pin 3 of cab harness-to-main controller 31-pin connector A (X31).
Pin 2 of torque control solenoid (Y21) connector to pin 2 of cab harness-to-main controller 31-pin connector A (X31).

Is continuity indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Harness Check.

( 4 ) Harness Check

Action:

Key switch in OFF position.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between pin 2 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.

Is continuity indicated between any pins?

Result:

YES:Short to power. Repair or replace harness. See appropriate harness.

NO:Go to Solenoid Check.

( 5 ) Solenoid Check

Action:

Key switch in OFF position.

Disconnect torque control solenoid (Y21).

Test torque control solenoid (Y21) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)

Is torque control solenoid (Y21) within specification?

Result:

YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group

<- Go to Section TOC Section 9001 page 103 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

9015-20.)

NO:Torque control solenoid (Y21) malfunction. Replace solenoid.

<- Go to Section TOC Section 9001 page 104 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011401.04- Torque Control Solenoid Valve Feedback Low Current


360
Torque control solenoid (marked ST) (Y21) current below 70 mA.

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Torque Control Solenoid Valve Feedback Low Current Diagnostic


Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Torque control solenoid (Y21) and pump harness-to-machine harness connector (X40). See Pump Harness (W8)
Component Location . (Group 9015-10.)
Cab harness-to-machine harness 100-pin connector (X3). See Machine Harness (W2) Component Location . (Group
9015-10.)
Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate solenoids after check is completed.

Key switch in OFF position.

Disconnect torque control solenoid (marked ST) (Y21).

Disconnect pump 2 flow rate limit solenoid (marked SB) (Y20).

Connect torque control solenoid (Y21) connector to pump 2 flow rate limit solenoid (Y20).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011401.04—Torque Control Solenoid Valve Feedback Low Current.

Is code active?
<- Go to Section TOC Section 9001 page 105 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Continuity Check.

NO:Torque control solenoid (Y21) malfunction. Replace solenoid.

( 3 ) Continuity Check

Action:

Key switch in OFF position.

Disconnect torque control solenoid (Y21).

Disconnect cab harness-to-main controller 31-pin connector A (X31).

Check for continuity between:

Pin 1 of torque control solenoid (Y21) connector to pin 3 of cab harness-to-main controller 31-pin connector A (X31).
Pin 2 of torque control solenoid (Y21) connector to pin 2 of cab harness-to-main controller 31-pin connector A (X31).

Is continuity indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Short Circuit Check.

( 4 ) Short Circuit Check

Action:

Key switch in OFF position.

Torque control solenoid (Y21) disconnected.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between:

Pin 1 of torque control solenoid (Y21) connector to machine ground.


Pin 2 of cab harness-to-main controller 31-pin connector A (X31) to machine ground.

Is continuity indicated?

Result:

YES:Go to Solenoid Check.

NO:Short to ground. Repair or replace harness. See appropriate harness.

( 5 ) Solenoid Check

Action:

Key switch in OFF position.

Disconnect torque control solenoid (Y21).

Test torque control solenoid (Y21) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)

Is torque control solenoid (Y21) within specification?

<- Go to Section TOC Section 9001 page 106 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)

NO:Torque control solenoid (Y21) malfunction. Replace solenoid.

<- Go to Section TOC Section 9001 page 107 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

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


360
Dig regenerative solenoid (marked SF) (Y22) current above 920 mA and below 70 mA.

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

4-Spool Solenoid Valve Unit (SF) Abnormal Feedback Diagnostic


Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Dig regenerative solenoid (Y22) and cab harness-to-machine harness 100-pin connector (X3). See Machine Harness (W2)
Component Location . (Group 9015-10.)
Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate solenoids after check is completed.

Key switch in OFF position.

Disconnect dig regenerative solenoid (marked SF) (Y22).

Disconnect arm regenerative solenoid (marked SC) (Y23).

Connect dig regenerative solenoid (Y22) connector to arm regenerative solenoid (Y23).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011402.02—3-Spool Solenoid Valve Unit (SF) Abnormal Feedback.

Is code active?

<- Go to Section TOC Section 9001 page 108 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Continuity Check.

NO:Dig regenerative solenoid (Y22) malfunction. Replace solenoid.

( 3 ) Continuity Check

Action:

Key switch in OFF position.

Disconnect dig regenerative solenoid (Y22).

Disconnect cab harness-to-main controller 31-pin connector A (X31).

Check for continuity between:

Pin 1 of dig regenerative solenoid (Y22) connector to pin 15 of cab harness-to-main controller 31-pin connector A (X31).
Pin 2 of dig regenerative solenoid (Y22) connector to pin 14 of cab harness-to-main controller 31-pin connector A (X31).

Is continuity indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Short Circuit Check.

( 4 ) Short Circuit Check

Action:

Key switch in OFF position.

Dig regenerative solenoid (Y22) disconnected.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between:

Pin 1 of dig regenerative solenoid (Y22) connector to machine ground.


Pin 14 of cab harness-to-main controller 31-pin connector A (X31) to machine ground.

Is continuity indicated?

Result:

YES:Go to Harness Check.

NO:Short to ground. Repair or replace harness. See appropriate harness.

( 5 ) Harness Check

Action:

Key switch in OFF position.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between pin 14 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.

Is continuity indicated between any pins?

<- Go to Section TOC Section 9001 page 109 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Short to power. Repair or replace harness. See appropriate harness.

NO:Go to Solenoid Check.

( 6 ) Solenoid Check

Action:

Key switch in OFF position.

Disconnect dig regenerative solenoid (Y22).

Test dig regenerative solenoid (Y22) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)

Is dig regenerative solenoid (Y22) within specification?

Result:

YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)

NO:Dig regenerative solenoid (Y22) malfunction. Replace solenoid.

<- Go to Section TOC Section 9001 page 110 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

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


360
Dig regenerative solenoid (marked SF) (Y22) current above 920 mA.

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

4-Spool Solenoid Valve Unit (SF) Feedback High Input Diagnostic


Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Dig regenerative solenoid (Y22) and cab harness-to-machine harness 100-pin connector (X3). See Machine Harness (W2)
Component Location . (Group 9015-10.)
Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate solenoids after check is completed.

Key switch in OFF position.

Disconnect dig regenerative solenoid (marked SF) (Y22).

Disconnect arm regenerative solenoid (marked SC) (Y23).

Connect dig regenerative solenoid (Y22) connector to arm regenerative solenoid (Y23).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011402.03—3-Spool Solenoid Valve Unit (SF) Feedback High Input.

Is code active?

<- Go to Section TOC Section 9001 page 111 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Continuity Check.

NO:Dig regenerative solenoid (Y22) malfunction. Replace solenoid.

( 3 ) Continuity Check

Action:

Key switch in OFF position.

Disconnect dig regenerative solenoid (Y22).

Disconnect cab harness-to-main controller 31-pin connector A (X31).

Check for continuity between:

Pin 1 of dig regenerative solenoid (Y22) connector to pin 15 of cab harness-to-main controller 31-pin connector A (X31).
Pin 2 of dig regenerative solenoid (Y22) connector to pin 14 of cab harness-to-main controller 31-pin connector A (X31).

Is continuity indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Harness Check.

( 4 ) Harness Check

Action:

Key switch in OFF position.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between pin 14 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.

Is continuity indicated between any pins?

Result:

YES:Short to power. Repair or replace harness. See appropriate harness.

NO:Go to Solenoid Check.

( 5 ) Solenoid Check

Action:

Key switch in OFF position.

Disconnect dig regenerative solenoid (Y22).

Test dig regenerative solenoid (Y22) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)

Is dig regenerative solenoid (Y22) within specification?

Result:

YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group

<- Go to Section TOC Section 9001 page 112 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

9015-20.)

NO:Dig regenerative solenoid (Y22) malfunction. Replace solenoid.

<- Go to Section TOC Section 9001 page 113 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

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


360
Dig regenerative solenoid (marked SF) (Y22) current below 70 mA.

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

4-Spool Solenoid Valve Unit (SF) Feedback Low Input Diagnostic


Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Dig regenerative solenoid (Y22) and cab harness-to-machine harness 100-pin connector (X3). See Machine Harness (W2)
Component Location . (Group 9015-10.)
Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate solenoids after check is completed.

Key switch in OFF position.

Disconnect dig regenerative solenoid (marked SF) (Y22).

Disconnect arm regenerative solenoid (marked SC) (Y23).

Connect dig regenerative solenoid (Y22) connector to arm regenerative solenoid (Y23).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011402.04—3-Spool Solenoid Valve Unit (SF) Feedback Low Input.

Is code active?

<- Go to Section TOC Section 9001 page 114 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Continuity Check.

NO:Dig regenerative solenoid (Y22) malfunction. Replace solenoid.

( 3 ) Continuity Check

Action:

Key switch in OFF position.

Disconnect dig regenerative solenoid (Y22).

Disconnect cab harness-to-main controller 31-pin connector A (X31).

Check for continuity between:

Pin 1 of dig regenerative solenoid (Y22) connector to pin 15 of cab harness-to-main controller 31-pin connector A (X31).
Pin 2 of dig regenerative solenoid (Y22) connector to pin 14 of cab harness-to-main controller 31-pin connector A (X31).

Is continuity indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Short Circuit Check.

( 4 ) Short Circuit Check

Action:

Key switch in OFF position.

Dig regenerative solenoid (Y22) disconnected.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between:

Pin 1 of dig regenerative solenoid (Y22) connector to machine ground.


Pin 14 of cab harness-to-main controller 31-pin connector A (X31) to machine ground.

Is continuity indicated?

Result:

YES:Go to Solenoid Check.

NO:Short to ground. Repair or replace harness. See appropriate harness.

( 5 ) Solenoid Check

Action:

Key switch in OFF position.

Disconnect dig regenerative solenoid (Y22).

Test dig regenerative solenoid (Y22) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)

Is dig regenerative solenoid (Y22) within specification?

<- Go to Section TOC Section 9001 page 115 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)

NO:Dig regenerative solenoid (Y22) malfunction. Replace solenoid.

<- Go to Section TOC Section 9001 page 116 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

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


360
Arm regenerative solenoid (marked SC) (Y23) current above 920 mA and below 70 mA.

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

4-Spool Solenoid Valve Unit (SC) Abnormal Feedback Diagnostic


Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Arm regenerative solenoid (Y23) and cab harness-to-machine harness 100-pin connector (X3). See Machine Harness (W2)
Component Location . (Group 9015-10.)
Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate solenoids after check is completed.

Key switch in OFF position.

Disconnect arm regenerative solenoid (marked SC) (Y23).

Disconnect dig regenerative solenoid (marked SF) (Y22).

Connect arm regenerative solenoid (Y23) connector to dig regenerative solenoid (Y22).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011403.02—3-Spool Solenoid Valve Unit (SC) Abnormal Feedback.

Is code active?

<- Go to Section TOC Section 9001 page 117 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Continuity Check.

NO:Arm regenerative solenoid (Y23) malfunction. Replace solenoid.

( 3 ) Continuity Check

Action:

Key switch in OFF position.

Disconnect arm regenerative solenoid (Y23).

Disconnect cab harness-to-main controller 31-pin connector A (X31).

Check for continuity between:

Pin 1 of arm regenerative solenoid (Y23) connector to pin 11 of cab harness-to-main controller 31-pin connector A (X31).
Pin 2 of arm regenerative solenoid (Y23) connector to pin 10 of cab harness-to-main controller 31-pin connector A (X31).

Is continuity indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Short Circuit Check.

( 4 ) Short Circuit Check

Action:

Key switch in OFF position.

Arm regenerative solenoid (Y23) disconnected.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between:

Pin 1 of arm regenerative solenoid (Y23) connector to machine ground.


Pin 10 of cab harness-to-main controller 31-pin connector A (X31) to machine ground.

Is continuity indicated?

Result:

YES:Go to Harness Check.

NO:Short to ground. Repair or replace harness. See appropriate harness.

( 5 ) Harness Check

Action:

Key switch in OFF position.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between pin 10 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.

Is continuity indicated between any pins?

<- Go to Section TOC Section 9001 page 118 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Short to power. Repair or replace harness. See appropriate harness.

NO:Go to Solenoid Check.

( 6 ) Solenoid Check

Action:

Key switch in OFF position.

Disconnect arm regenerative solenoid (Y23).

Test arm regenerative solenoid (Y23) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)

Is arm regenerative solenoid (Y23) within specification?

Result:

YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)

NO:Arm regenerative solenoid (Y23) malfunction. Replace solenoid.

<- Go to Section TOC Section 9001 page 119 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

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


360
Arm regenerative solenoid (marked SC) (Y23) current above 920 mA.

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

4-Spool Solenoid Valve Unit (SC) Feedback High Input Diagnostic


Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Arm regenerative solenoid (Y23) and cab harness-to-machine harness 100-pin connector (X3). See Machine Harness (W2)
Component Location . (Group 9015-10.)
Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate solenoids after check is completed.

Key switch in OFF position.

Disconnect arm regenerative solenoid (marked SC) (Y23).

Disconnect dig regenerative solenoid (marked SF) (Y22).

Connect arm regenerative solenoid (Y23) connector to dig regenerative solenoid (Y22).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011403.03—3-Spool Solenoid Valve Unit (SC) Feedback High Input.

Is code active?

<- Go to Section TOC Section 9001 page 120 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Continuity Check.

NO:Arm regenerative solenoid (Y23) malfunction. Replace solenoid.

( 3 ) Continuity Check

Action:

Key switch in OFF position.

Disconnect arm regenerative solenoid (Y23).

Disconnect cab harness-to-main controller 31-pin connector A (X31).

Check for continuity between:

Pin 1 of arm regenerative solenoid (Y23) connector to pin 11 of cab harness-to-main controller 31-pin connector A (X31).
Pin 2 of arm regenerative solenoid (Y23) connector to pin 10 of cab harness-to-main controller 31-pin connector A (X31).

Is continuity indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Harness Check.

( 4 ) Harness Check

Action:

Key switch in OFF position.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between pin 10 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.

Is continuity indicated between any pins?

Result:

YES:Short to power. Repair or replace harness. See appropriate harness.

NO:Go to Solenoid Check.

( 5 ) Solenoid Check

Action:

Key switch in OFF position.

Disconnect arm regenerative solenoid (Y23).

Test arm regenerative solenoid (Y23) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)

Is arm regenerative solenoid (Y23) within specification?

Result:

YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group

<- Go to Section TOC Section 9001 page 121 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

9015-20.)

NO:Arm regenerative solenoid (Y23) malfunction. Replace solenoid.

<- Go to Section TOC Section 9001 page 122 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

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


360
Arm regenerative solenoid (marked SC) (Y23) current below 70 mA.

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

4-Spool Solenoid Valve Unit (SC) Feedback Low Input Diagnostic


Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Arm regenerative solenoid (Y23) and cab harness-to-machine harness 100-pin connector (X3). See Machine Harness (W2)
Component Location . (Group 9015-10.)
Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate solenoids after check is completed.

Key switch in OFF position.

Disconnect arm regenerative solenoid (marked SC) (Y23).

Disconnect dig regenerative solenoid (marked SF) (Y22).

Connect arm regenerative solenoid (Y23) connector to dig regenerative solenoid (Y22).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011403.04—3-Spool Solenoid Valve Unit (SC) Feedback Low Input.

Is code active?

<- Go to Section TOC Section 9001 page 123 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Continuity Check.

NO:Arm regenerative solenoid (Y23) malfunction. Replace solenoid.

( 3 ) Continuity Check

Action:

Key switch in OFF position.

Disconnect arm regenerative solenoid (Y23).

Disconnect cab harness-to-main controller 31-pin connector A (X31).

Check for continuity between:

Pin 1 of arm regenerative solenoid (Y23) connector to pin 11 of cab harness-to-main controller 31-pin connector A (X31).
Pin 2 of arm regenerative solenoid (Y23) connector to pin 10 of cab harness-to-main controller 31-pin connector A (X31).

Is continuity indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Short Circuit Check.

( 4 ) Short Circuit Check

Action:

Key switch in OFF position.

Arm regenerative solenoid (Y23) disconnected.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between:

Pin 1 of arm regenerative solenoid (Y23) connector to machine ground.


Pin 10 of cab harness-to-main controller 31-pin connector A (X31) to machine ground.

Is continuity indicated?

Result:

YES:Go to Solenoid Check.

NO:Short to ground. Repair or replace harness. See appropriate harness.

( 5 ) Solenoid Check

Action:

Key switch in OFF position.

Disconnect arm regenerative solenoid (Y23).

Test arm regenerative solenoid (Y23) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)

Is arm regenerative solenoid (Y23) within specification?

<- Go to Section TOC Section 9001 page 124 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)

NO:Arm regenerative solenoid (Y23) malfunction. Replace solenoid.

<- Go to Section TOC Section 9001 page 125 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

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


360
Power dig solenoid (marked SG) (Y24) current above 920 mA and below 70 mA.

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

4-Spool Solenoid Valve Unit (SG) Abnormal Feedback Diagnostic


Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Power dig solenoid (Y24) and cab harness-to-machine harness 100-pin connector (X3). See Machine Harness (W2)
Component Location . (Group 9015-10.)
Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate solenoids after check is completed.

Key switch in OFF position.

Disconnect power dig solenoid (marked SG) (Y24).

Disconnect arm regenerative solenoid (marked SC) (Y23).

Connect power dig solenoid (Y24) connector to arm regenerative solenoid (Y23).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011407.02—3-Spool Solenoid Valve Unit (SG) Abnormal Feedback.

Is code active?

<- Go to Section TOC Section 9001 page 126 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Continuity Check.

NO:Power dig solenoid (Y24) malfunction. Replace solenoid.

( 3 ) Continuity Check

Action:

Key switch in OFF position.

Disconnect power dig solenoid (Y24).

Disconnect cab harness-to-main controller 31-pin connector A (X31).

Check for continuity between:

Pin 1 of power dig solenoid (Y24) connector to pin 12 of cab harness-to-main controller 31-pin connector A (X31).
Pin 2 of power dig solenoid (Y24) connector to pin 13 of cab harness-to-main controller 31-pin connector A (X31).

Is continuity indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Short Circuit Check.

( 4 ) Short Circuit Check

Action:

Key switch in OFF position.

Power dig solenoid (Y24) disconnected.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between:

Pin 1 of power dig solenoid (Y24) connector to machine ground.


Pin 13 of cab harness-to-main controller 31-pin connector A (X31) to machine ground.

Is continuity indicated?

Result:

YES:Go to Harness Check.

NO:Short to ground. Repair or replace harness. See appropriate harness.

( 5 ) Harness Check

Action:

Key switch in OFF position.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between pin 13 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.

Is continuity indicated between any pins?

<- Go to Section TOC Section 9001 page 127 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Short to power. Repair or replace harness. See appropriate harness.

NO:Go to Solenoid Check.

( 6 ) Solenoid Check

Action:

Key switch in OFF position.

Disconnect power dig solenoid (Y24).

Test power dig solenoid (Y24) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)

Is power dig solenoid (Y24) within specification?

Result:

YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)

NO:Power dig solenoid (Y24) malfunction. Replace solenoid.

<- Go to Section TOC Section 9001 page 128 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

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


360
Power dig solenoid (marked SG) (Y24) current above 920 mA.

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

4-Spool Solenoid Valve Unit (SG) Feedback High Input Diagnostic


Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Power dig solenoid (Y24) and cab harness-to-machine harness 100-pin connector (X3). See Machine Harness (W2)
Component Location . (Group 9015-10.)
Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate solenoids after check is completed.

Key switch in OFF position.

Disconnect power dig solenoid (marked SG) (Y24).

Disconnect arm regenerative solenoid (marked SC) (Y23).

Connect power dig solenoid (Y24) connector to arm regenerative solenoid (Y23).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011407.03—3-Spool Solenoid Valve Unit (SG) Feedback High Input.

Is code active?

<- Go to Section TOC Section 9001 page 129 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Continuity Check.

NO:Power dig solenoid (Y24) malfunction. Replace solenoid.

( 3 ) Continuity Check

Action:

Key switch in OFF position.

Disconnect power dig solenoid (Y24).

Disconnect cab harness-to-main controller 31-pin connector A (X31).

Check for continuity between:

Pin 1 of power dig solenoid (Y24) connector to pin 12 of cab harness-to-main controller 31-pin connector A (X31).
Pin 2 of power dig solenoid (Y24) connector to pin 13 of cab harness-to-main controller 31-pin connector A (X31).

Is continuity indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Harness Check.

( 4 ) Harness Check

Action:

Key switch in OFF position.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between pin 13 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.

Is continuity indicated between any pins?

Result:

YES:Short to power. Repair or replace harness. See appropriate harness.

NO:Go to Solenoid Check.

( 5 ) Solenoid Check

Action:

Key switch in OFF position.

Disconnect power dig solenoid (Y24).

Test power dig solenoid (Y24) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)

Is power dig solenoid (Y24) within specification?

Result:

YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group

<- Go to Section TOC Section 9001 page 130 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

9015-20.)

NO:Power dig solenoid (Y24) malfunction. Replace solenoid.

<- Go to Section TOC Section 9001 page 131 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

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


360
Power dig solenoid (marked SG) (Y24) current below 70 mA.

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

4-Spool Solenoid Valve Unit (SG) Feedback Low Input Diagnostic


Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Power dig solenoid (Y24) and cab harness-to-machine harness 100-pin connector (X3). See Machine Harness (W2)
Component Location . (Group 9015-10.)
Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate solenoids after check is completed.

Key switch in OFF position.

Disconnect power dig solenoid (marked SG) (Y24).

Disconnect arm regenerative solenoid (marked SC) (Y23).

Connect power dig solenoid (Y24) connector to arm regenerative solenoid (Y23).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011407.04—3-Spool Solenoid Valve Unit (SG) Feedback Low Input.

Is code active?

<- Go to Section TOC Section 9001 page 132 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Continuity Check.

NO:Power dig solenoid (Y24) malfunction. Replace solenoid.

( 3 ) Continuity Check

Action:

Key switch in OFF position.

Disconnect power dig solenoid (Y24).

Disconnect cab harness-to-main controller 31-pin connector A (X31).

Check for continuity between:

Pin 1 of power dig solenoid (Y24) connector to pin 12 of cab harness-to-main controller 31-pin connector A (X31).
Pin 2 of power dig solenoid (Y24) connector to pin 13 of cab harness-to-main controller 31-pin connector A (X31).

Is continuity indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Short Circuit Check.

( 4 ) Short Circuit Check

Action:

Key switch in OFF position.

Power dig solenoid (Y24) disconnected.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between:

Pin 1 of power dig solenoid (Y24) connector to machine ground.


Pin 13 of cab harness-to-main controller 31-pin connector A (X31) to machine ground.

Is continuity indicated?

Result:

YES:Go to Solenoid Check.

NO:Short to ground. Repair or replace harness. See appropriate harness.

( 5 ) Solenoid Check

Action:

Key switch in OFF position.

Disconnect power dig solenoid (Y24).

Test power dig solenoid (Y24) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)

Is power dig solenoid (Y24) within specification?

<- Go to Section TOC Section 9001 page 133 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)

NO:Power dig solenoid (Y24) malfunction. Replace solenoid.

011408.02- 2-Spool Solenoid Valve Unit (SJ) Abnormal Feedback


360

Not applicable to this machine.

011408.03- 2-Spool Solenoid Valve Unit (SJ) Feedback High Input


360

Not applicable to this machine.

011408.04- 2-Spool Solenoid Valve Unit (SJ) Feedback Low Input


360

Not applicable to this machine.

011409.02- 2-Spool Solenoid Valve Unit (SZ) Abnormal Feedback


360

Not applicable to this machine.

011409.03- 2-Spool Solenoid Valve Unit (SZ) Feedback High Input


360

Not applicable to this machine.

011409.04- 2-Spool Solenoid Valve Unit (SZ) Feedback Low Input


360

Not applicable to this machine.

<- Go to Section TOC Section 9001 page 134 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

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


360
Arm 2 flow control solenoid (marked SD) (Y27) current above 920 mA and below 70 mA.

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

4-Spool Solenoid Valve Unit (SD) Abnormal Feedback Diagnostic


Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Arm 2 flow control solenoid (Y27) and cab harness-to-machine harness 100-pin connector (X3). See Machine Harness
(W2) Component Location . (Group 9015-10.)
Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate solenoids after check is completed.

Key switch in OFF position.

Disconnect arm 2 flow control solenoid (marked SD) (Y27).

Disconnect arm regenerative solenoid (marked SC) (Y23).

Connect arm 2 flow control solenoid (Y27) to arm regenerative solenoid (Y23).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011428.02—4-Spool Solenoid Valve Unit (SD) Abnormal Feedback.

Is code active?

<- Go to Section TOC Section 9001 page 135 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Continuity Check.

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

( 3 ) Continuity Check

Action:

Key switch in OFF position.

Disconnect arm 2 flow control solenoid (Y27).

Disconnect cab harness-to-main controller 31-pin connector A (X31).

Check for continuity between:

Pin 1 of arm 2 flow control solenoid (Y27) connector to pin 8 cab of harness-to-main controller 31-pin connector A (X31).
Pin 2 of arm 2 flow control solenoid (Y27) connector to pin 9 cab of harness-to-main controller 31-pin connector A (X31).

Is continuity indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Short Circuit Check.

( 4 ) Short Circuit Check

Action:

Key switch in OFF position.

Arm 2 flow control solenoid (Y27) disconnected.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between:

Pin 1 of arm 2 flow control solenoid (Y27) connector to machine ground.


Pin 27 of cab harness-to-main controller 31-pin connector A (X31) to machine ground.

Is continuity indicated?

Result:

YES:Go to Harness Check.

NO:Short to ground. Repair or replace harness. See appropriate harness.

( 5 ) Harness Check

Action:

Key switch in OFF position.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between pin 27 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.

Is continuity indicated between any pins?

<- Go to Section TOC Section 9001 page 136 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Short to power. Repair or replace harness. See appropriate harness.

NO:Go to Solenoid Check.

( 6 ) Solenoid Check

Action:

Key switch in OFF position.

Disconnect arm 2 flow control solenoid (Y27).

Test arm 2 flow control solenoid (Y27) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)

Is arm 2 flow control solenoid (Y27) within specification?

Result:

YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)

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

<- Go to Section TOC Section 9001 page 137 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

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


360
Arm 2 flow control solenoid (marked SD) (Y27) current above 920 mA.

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

4-Spool Solenoid Valve Unit (SG) Feedback High Input Diagnostic


Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Arm 2 flow control solenoid (Y27) and cab harness-to-machine harness 100-pin connector (X3). See Machine Harness
(W2) Component Location . (Group 9015-10.)
Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate solenoids after check is completed.

Key switch in OFF position.

Disconnect arm 2 flow control solenoid (marked SD) (Y27).

Disconnect arm regenerative solenoid (marked SC) (Y23).

Connect arm 2 flow control solenoid (Y27) to arm regenerative solenoid (Y23).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011428.03—4-Spool Solenoid Valve Unit (SG) Feedback High Input.

Is code active?

<- Go to Section TOC Section 9001 page 138 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Continuity Check.

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

( 3 ) Continuity Check

Action:

Key switch in OFF position.

Disconnect arm 2 flow control solenoid (Y27).

Disconnect cab harness-to-main controller 31-pin connector A (X31).

Check for continuity between:

Pin 1 of arm 2 flow control solenoid (Y27) connector to pin 8 cab of harness-to-main controller 31-pin connector A (X31).
Pin 2 of arm 2 flow control solenoid (Y27) connector to pin 9 cab of harness-to-main controller 31-pin connector A (X31).

Is continuity indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Harness Check.

( 4 ) Harness Check

Action:

Key switch in OFF position.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between pin 27 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.

Is continuity indicated between any pins?

Result:

YES:Short to power. Repair or replace harness. See appropriate harness.

NO:Go to Solenoid Check.

( 5 ) Solenoid Check

Action:

Key switch in OFF position.

Disconnect arm 2 flow control solenoid (Y27).

Test arm 2 flow control solenoid (Y27) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)

Is arm 2 flow control solenoid (Y27) within specification?

Result:

YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group

<- Go to Section TOC Section 9001 page 139 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

9015-20.)

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

<- Go to Section TOC Section 9001 page 140 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

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


185
Arm 2 flow control solenoid (marked SD) (Y27) current below 70 mA.

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

4-Spool Solenoid Valve Unit (SG) Feedback Low Input Diagnostic


Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Arm 2 flow control solenoid (Y27) and cab harness-to-machine harness 100-pin connector (X3). See Machine Harness
(W2) Component Location . (Group 9015-10.)
Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

→NOTE:

Return connectors to appropriate solenoids after check is completed.

Key switch in OFF position.

Disconnect arm 2 flow control solenoid (marked SD) (Y27).

Disconnect arm regenerative solenoid (marked SC) (Y23).

Connect arm 2 flow control solenoid (Y27) to arm regenerative solenoid (Y23).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011428.04—4-Spool Solenoid Valve Unit (SD) Feedback Low Input.

Is code active?

<- Go to Section TOC Section 9001 page 141 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Continuity Check.

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

( 3 ) Continuity Check

Action:

Key switch in OFF position.

Disconnect arm 2 flow control solenoid (Y27).

Disconnect cab harness-to-main controller 31-pin connector A (X31).

Check for continuity between:

Pin 1 of arm 2 flow control solenoid (Y27) connector to pin 8 cab of harness-to-main controller 31-pin connector A (X31).
Pin 2 of arm 2 flow control solenoid (Y27) connector to pin 9 cab of harness-to-main controller 31-pin connector A (X31).

Is continuity indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Short Circuit Check.

( 4 ) Short Circuit Check

Action:

Key switch in OFF position.

Arm 2 flow control solenoid (Y27) disconnected.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between:

Pin 1 of arm 2 flow control solenoid (Y27) connector to machine ground.


Pin 27 of cab harness-to-main controller 31-pin connector A (X31) to machine ground.

Is continuity indicated?

Result:

YES:Go to Solenoid Check.

NO:Short to ground. Repair or replace harness. See appropriate harness.

( 5 ) Solenoid Check

Action:

Key switch in OFF position.

Disconnect arm 2 flow control solenoid (Y27).

Test arm 2 flow control solenoid (Y27) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)

Is arm 2 flow control solenoid (Y27) within specification?

<- Go to Section TOC Section 9001 page 142 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)

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

011434.02- Attachment Relief 1 (Upper) Proportional Solenoid Valve Abnormal Feedback


360

Not applicable to this machine.

011434.03- Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback High Current
360

Not applicable to this machine.

011434.04- Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback Low Current
360

Not applicable to this machine.

011435.02- Attachment Relief 2 (Lower) Proportional Solenoid Valve Abnormal Feedback


360

Not applicable to this machine.

011435.03- Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback High Current
360

Not applicable to this machine.

011435.04- Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback Low Current
360

Not applicable to this machine.

011436.02- Breaker Relief Proportional Solenoid Valve Abnormal Feedback


360

Not applicable to this machine.

011436.03- Breaker Relief Proportional Solenoid Valve Feedback High Current


360

Not applicable to this machine.

011436.04- Breaker Relief Proportional Solenoid Valve Feedback Low Current


360

Not applicable to this machine.

<- Go to Section TOC Section 9001 page 143 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011457.02- 2-Speed Activation Solenoid Disconnected or Not Present


360

→NOTE:

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

2-Speed Activation Solenoid Disconnected or Not Present Diagnostic


Procedure
( 1 ) Fuse Check

Action:

Ignition OFF.

Remove fuse F5 from fuse box F50. See Cab Harness (W1) Component Location and see Cab Harness (W1) Wiring Diagram .
(Group 9015-10.)

Check fuse F5 for continuity.

Is continuity indicated?

Result:

YES:Go to Solenoid Check.

NO:Replace fuse.

( 2 ) Solenoid Check

Action:

Ignition OFF.

Disconnect harness from 2-speed activation solenoid. See 2-Speed Harness (W32) Component Location . (Group 9015-10.) Test
solenoid. See Proportional Solenoid Test . (Group 9015-20.)

Is 2-speed activation solenoid within specification?

Result:

YES:Go to 2-Speed Harness Continuity Check.

NO:Solenoid malfunction. Replace solenoid.

( 3 ) 2-Speed Harness Continuity Check

Action:

Ignition OFF.

Disconnect attachment harness-to-2-speed harness connector (X87). See Attachment Harness (W17) Component Location .
(Group 9015-10.)

Check continuity between 2-speed activation solenoid valve (Y43) connector pin 1 and attachment harness-to-2-speed harness
connector (X87) pin 4.

<- Go to Section TOC Section 9001 page 144 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

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

Is continuity indicated in both circuits?

Result:

YES:Go to Attachment Harness Continuity Check.

NO:Open circuit in 2-speed harness. Repair or replace harness.

( 4 ) Attachment Harness Continuity Check

Action:

Disconnect attachment connector (X46). See Machine Harness (W2) Component Location . (Group 9015-10.)

Check for continuity between attachment harness-to-2-speed harness connector (X87) pin 4 and attachment connector (X46)
pin 10.

Check continuity between attachment harness-to-2-speed harness connector (X87) pin 5 and attachment connector (X46) pin
11. See Attachment Harness (W17) Wiring Diagram . (Group 9015-10.)

Is continuity indicated in both circuits?

Result:

YES:Go to Machine Harness Continuity Check.

NO:Open circuit in attachment harness. Repair or replace harness.

( 5 ) Machine Harness Continuity Check

Action:

Disconnect cab harness-to-machine harness 100-pin connector (X3). See Cab Harness (W1) Component Location . (Group
9015-10.)

Check for continuity between cab harness-to-machine harness 100-pin connector (X3) pin A12 and attachment connector (X46)
pin 10.

Check continuity between cab harness-to-machine harness 100-pin connector (X3) pin C6 and attachment connector (X46) pin
11. See Machine Harness (W2) Wiring Diagram . (Group 9015-10.)

Is continuity indicated in both circuits?

Result:

YES:Go to Cab Harness Continuity Check.

NO:Open circuit in machine harness. Repair or replace harness.

( 6 ) Cab Harness Continuity Check

Action:

Disconnect cab harness-to-main controller 17-pin connector C (X33). See Cab Harness (W1) Component Location . (Group
9015-10.)

Check for continuity between cab harness-to-machine harness 100-pin connector (X3) pin A12 and cab harness-to-main
controller 17-pin connector (X33) pin 3.

<- Go to Section TOC Section 9001 page 145 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

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

Is continuity indicated in both circuits?

Result:

YES:Main controller (MCZ) malfunction. Replace main controller. See Main Controller (MCZ) Remove and Install . (Group
9015-20.)

NO:Open circuit in cab harness. Repair or replace cab harness.

<- Go to Section TOC Section 9001 page 146 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011458.02- Selector Valve Solenoid Valve Disconnected or Not Present


360

→NOTE:

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

Selector Valve Solenoid Valve Disconnected or Not Present Diagnostic


Procedure
( 1 ) Fuse Check

Action:

Ignition OFF.

Remove fuse F5 from fuse box F50. See Cab Harness (W1) Component Location and see Cab Harness (W1) Wiring Diagram .
(Group 9015-10.)

Check fuse F5 for continuity.

Is continuity indicated?

Result:

YES:Go to Solenoid Check.

NO:Replace fuse.

( 2 ) Solenoid Check

Action:

Disconnect connector from selector valve solenoid valve (Y40). See Attachment Harness (W17) Component Location . (Group
9015-10.)

Test solenoid valve. See Proportional Solenoid Test . (Group 9015-20.)

Is selector valve solenoid valve within specification?

Result:

YES:Go to Attachment Harness (W17) Continuity Check.

NO:Solenoid malfunction. Replace selector valve solenoid valve.

( 3 ) Attachment Harness (W17) Continuity Check

Action:

Disconnect attachment connector (X46). See Machine Harness (W2) Component Location . (Group 9015-10.)

Check for continuity between attachment connector (X46) pin 9 and selector valve solenoid valve (Y40) connector pin 2.

Check for continuity between attachment connector (X46) pin 11 and selector valve solenoid valve (Y40) connector pin 1. See
Attachment Harness (W17) Wiring Diagram . (Group 9015-10.)

Is continuity indicated in both circuits?

<- Go to Section TOC Section 9001 page 147 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Machine Harness (W2) Continuity Check.

NO:Open circuit in attachment harness. Repair or replace harness.

( 4 ) Machine Harness (W2) Continuity Check

Action:

Disconnect cab harness-to-machine harness 100-pin connector (X3). See Cab Harness (W1) Component Location . (Group
9015-10.)

Check for continuity between cab harness-to-machine harness 100-pin connector (X3) pin A4 and attachment connector (X46)
pin 9.

Check for continuity between cab harness-to-machine harness 100-pin connector (X3) pin C6 and attachment connector (X46)
pin 11. See Machine Harness (W2) Wiring Diagram . (Group 9015-10.)

Is continuity indicated in both circuits?

Result:

YES:Go to Cab Harness (W1) Continuity Check.

NO:Open circuit in machine harness. Repair or replace harness.

( 5 ) Cab Harness (W1) Continuity Check

Action:

Disconnect cab harness-to-main controller 17-pin connector C (X33). See Cab Harness (W1) Component Location . (Group
9015-10.)

Check for continuity between cab harness-to-machine harness 100-pin connector (X3) pin A4 and cab harness-to-main
controller 17-pin connector C (X33) pin 3.

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

Is continuity indicated in both circuits?

Result:

YES:Main controller (MCZ) malfunction. Replace main controller. See Main Controller (MCZ) Remove and Install . (Group
9015-20.)

NO:Open circuit in cab harness. Repair or replace harness.

<- Go to Section TOC Section 9001 page 148 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011459.02- Idle Stop Relay Circuit Malfunction


360

Idle Stop Relay Circuit Malfunction Diagnostic Procedure


( 1 ) Fuse Check

Action:

Ignition OFF.

Remove fuse F18 from fuse box F50. See Cab Harness (W1) Component Location and see Cab Harness (W1) Wiring Diagram .
(Group 9015-10.)

Check fuse F18 for continuity.

Is continuity indicated?

Result:

YES:Go to Voltage Check.

NO:Replace fuse.

( 2 ) Voltage Check

Action:

Install fuse F18 in fuse box F50.

Ignition ON.

Disconnect connector from idle stop relay (K11).

Check for 24 volts at idle stop relay (K11) connector pin 1.

Are there 24 volts present?

Result:

YES:Go to Relay Check.

NO:Open circuit in cab harness (W1) between idle stop relay (K11) and fuse F18. Repair or replace harness.

( 3 ) Relay Check

Action:

Ignition OFF.

Test idle stop relay. See Relay Test . (Group 9015-20.)

Is relay within specification?

Result:

YES:Go to Cab Harness (W1) Continuity Check.

NO:Replace idle stop relay.

( 4 ) Cab Harness (W1) Continuity Check

<- Go to Section TOC Section 9001 page 149 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Action:

Disconnect cab harness-to-main controller 17-pin connector C (X33). See Cab Harness (W1) Component Location . (Group
9015-10.)

Check for continuity between idle stop relay (K11) connector pin 2 and cab harness-to-main controller 17-pin connector C (X33)
pin 5.

Check for continuity between idle stop relay (K11) connector pin 3 and cab harness-to-main controller 17-pin connector C (X33)
pin 5.

Check for continuity between idle stop relay (K11) connector pin 5 and ground. See Cab Harness (W1) Wiring Diagram . (Group
9015-10.)

Is continuity indicated in all circuits?

Result:

YES:Main controller (MCZ) malfunction. Replace main controller. See Main Controller (MCZ) Remove and Install . (Group
9015-20.)

NO:Open circuit in cab harness. Repair or replace harness.

<- Go to Section TOC Section 9001 page 150 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

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


360
Secondary hydraulic oil temperature sensor (B68) voltage is high (above 4.35 V).

Secondary Hydraulic Oil Temperature Sensor Circuit High Input


Diagnostic Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris:

See Cab Harness (W1) Component Location . (Group 9015-10.)


Cab harness-to-main controller 17-pin connector C (X33).
Cab harness-to-main controller 26-pin connector F (X36).
See Auxiliary Function Lever (AFL) Harness (W75) Component Location . (Group 9015-10.)
Auxiliary function lever (AFL) connector 1 (X574).
See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location . (Group 9015-10.)
Secondary hydraulic oil temperature sensor (B68).
Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577).

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

Key switch in OFF position.

Disconnect secondary hydraulic oil temperature sensor (B68).

Test secondary hydraulic oil temperature sensor and compare to specification. See Electrical Component Checks . (Group
9015-20.)

Is secondary hydraulic oil temperature sensor within specification?

Result:

YES:Go to Voltage Check.

NO:Secondary hydraulic oil temperature sensor (B68) malfunction. Replace sensor.

( 3 ) Voltage Check

Action:

Key switch in OFF position.

Secondary hydraulic oil temperature sensor (B68) disconnected.

Turn key switch to ON position.

Check pin 1 and pin 2 of secondary hydraulic oil temperature sensor (B68) for more than 4.25 V.

Is correct voltage indicated?


<- Go to Section TOC Section 9001 page 151 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Go to Harness Check.

NO:Repair or replace harness. See appropriate harness.

( 4 ) Harness Check

Action:

Key switch in OFF position.

Secondary hydraulic oil temperature sensor (B68) disconnected.

Disconnect cab harness-to-main controller 17-pin connector C (X33).

Disconnect cab harness-to-main controller 26-pin connector F (X36).

Check for continuity between:

Pin 1 of secondary hydraulic oil temperature sensor (B68) and pin 7 of cab harness-to-main controller 17-pin connector C
(X33).
Pin 2 of secondary hydraulic oil temperature sensor (B68) and pins 16 and 17 of cab harness-to-main controller 26-pin
connector F (X36).

Is continuity indicated?

Result:

YES:Checks complete.

NO:Repair or replace harness. See appropriate harness.

<- Go to Section TOC Section 9001 page 152 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

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


360
Secondary hydraulic oil temperature sensor low (below 0.23 V).

Secondary Hydraulic Oil Temperature Sensor Circuit Low Input


Diagnostic Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris:

See Cab Harness (W1) Component Location . (Group 9015-10.)


Cab harness-to-main controller 17-pin connector C (X33).
Cab harness-to-main controller 26-pin connector F (X36).
See Auxiliary Function Lever (AFL) Harness (W75) Component Location . (Group 9015-10.)
Auxiliary function lever (AFL) connector 1 (X574).
See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location . (Group 9015-10.)
Secondary hydraulic oil temperature sensor (B68).
Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577).

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

Key switch in OFF position.

Disconnect secondary hydraulic oil temperature sensor (B68).

Test secondary hydraulic oil temperature sensor and compare to specification. See Electrical Component Checks . (Group
9015-20.)

Is secondary hydraulic oil temperature sensor within specification?

Result:

YES:Go to Voltage Check.

NO:Secondary hydraulic oil temperature sensor (B68) malfunction. Replace sensor.

( 3 ) Voltage Check

Action:

Key switch in OFF position.

Secondary hydraulic oil temperature sensor (B68) disconnected.

Turn key switch to ON position.

Check pin 1 and pin 2 of secondary hydraulic oil temperature sensor (B68) for less than 0.1 V.

Is correct voltage indicated?


<- Go to Section TOC Section 9001 page 153 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Checks complete.

NO:Go to Harness Check.

( 4 ) Harness Check

Action:

Key switch in OFF position.

Secondary hydraulic oil temperature sensor (B68) disconnected.

Disconnect cab harness-to-main controller 17-pin connector C (X33).

Check for continuity between pin 1 of secondary hydraulic oil temperature sensor (B68) and pin 7 of cab harness-to-main
controller 17-pin connector C (X33).

Is continuity indicated?

Result:

YES:Checks complete.

NO:Repair or replace harness. See appropriate harness.

<- Go to Section TOC Section 9001 page 154 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

015016.03- Right Analog Stroke Sensor Circuit High Input


360
Auxiliary function lever (AFL) proportional control switch (S29) voltage is high (above 4.5 V).

Auxiliary Function Lever (AFL) Proportional Control Switch Sensor


Circuit High Input Diagnostic Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris:

See Cab Harness (W1) Component Location . (Group 9015-10.)


Cab harness-to-main controller 17-pin connector C (X33).
Cab harness-to-main controller 26-pin connector F (X36).
See Auxiliary Function Lever (AFL) Harness (W75) Component Location . (Group 9015-10.)
Right auxiliary function lever (AFL) connector (marked R_GRIP) (X536).
Auxiliary function lever (AFL) connector 1 (X574).

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Voltage Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Voltage Check

Action:

Key switch in the OFF position.

Disconnect AFL connector (marked R_GRIP) (X536).

Turn key switch to ON position.

Check between pin 3 of AFL connector (marked R_GRIP) (X536) and machine ground for approximately 0.0 V.

Is correct voltage indicated?

Result:

YES:Go to Harness Check.

NO:Repair or replace harness. See appropriate harness.

( 3 ) Harness Check

Action:

Key switch in the OFF position.

AFL connector (marked R_GRIP) (X536) disconnected.

Disconnect main controller connectors (X31—X36).

Check for continuity between pin 3 of AFL connector (marked R_GRIP) (X536) to all pins on all option controller connectors.

Is continuity indicated between any circuits?

<- Go to Section TOC Section 9001 page 155 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Auxiliary function lever (AFL) proportional control switch (S29) malfunction. Replace switch.

NO:Checks complete.

<- Go to Section TOC Section 9001 page 156 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

015016.04- Right Analog Stroke Sensor Circuit Low Input


360
Auxiliary function lever (AFL) proportional control switch (S29) voltage is low (below 0.1 V).

Auxiliary Function Lever (AFL) Proportional Control Switch Sensor


Circuit Low Input Diagnostic Procedure
( 1 ) Connector Check

Action:

Key switch in the OFF position.

Check the following connectors for damage, corrosion, or debris:

See Cab Harness (W1) Component Location . (Group 9015-10.)


Cab harness-to-main controller 17-pin connector C (X33).
Cab harness-to-main controller 26-pin connector F (X36).
See Auxiliary Function Lever (AFL) Harness (W75) Component Location . (Group 9015-10.)
Right auxiliary function lever (AFL) connector (marked R_GRIP) (X536).
Auxiliary function lever (AFL) connector 1 (X574).

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Voltage Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Voltage Check

Action:

Key switch in the OFF position.

Disconnect AFL connector (marked R_GRIP) (X536).

Turn key switch to ON position.

Check between pin 1 of AFL connector (marked R_GRIP) (X536) and machine ground for approximately 5 V.

Is correct voltage indicated?

Result:

YES:Go to Open Circuit Check.

NO:Repair or replace harness. See appropriate harness.

( 3 ) Open Circuit Check

Action:

Key switch in the OFF position.

AFL connector (marked R_GRIP) (X536) disconnected.

Disconnect cab harness-to-main controller 26-pin connector F (X36).

Check for continuity between:

Pin 1 of AFL connector (marked R_GRIP) (X536) and pins 25 and 26 of cab harness-to-main controller 26-pin connector F
(X36).
<- Go to Section TOC Section 9001 page 157 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

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

Is continuity indicated?

Result:

YES:Go to Harness Check.

NO:Repair or replace harness. See appropriate harness.

( 4 ) Harness Check

Action:

Key switch in the OFF position.

AFL connector (marked R_GRIP) (X536) disconnected.

Check for continuity between pin 1 of AFL connector (marked R_GRIP) (X536) and machine ground.

Is continuity indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Checks complete.

<- Go to Section TOC Section 9001 page 158 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011810.03- Electric Lever Operating Pressure Sensor 1 High Voltage


360
Auxiliary function lever (AFL) solenoid pressure sensor (marked PS1) (B85) signal voltage is high (above 4.5 V).

Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1)


(B85) High Input Diagnostic Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris:

See Cab Harness (W1) Component Location . (Group 9015-10.)


Cab harness-to-main controller 24-pin connector B (X32).
Cab harness-to-main controller 26-pin connector F (X36).
See Auxiliary Function Lever (AFL) Harness (W75) Component Location . (Group 9015-10.)
Auxiliary function lever (AFL) connector 1 (X574).
See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location . (Group 9015-10.)
AFL solenoid pressure sensor (marked PS1) (B85).
Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577).

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connectors. See appropriate harness.

( 2 ) Component Check

Action:

Switch AFL solenoid pressure sensor (marked PS1) (B85) to another properly working pressure sensor.

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011810.03—Electric Lever Operating Pressure Sensor 1 High Voltage.

Is code active?

Return connectors to appropriate sensors after check is complete.

Result:

YES:Go to Voltage Check.

NO:AFL solenoid pressure sensor (marked PS1) (B85) malfunction. Replace sensor.

( 3 ) Voltage Check

Action:

Key switch in OFF position.

Disconnect AFL solenoid pressure sensor (marked PS1) (B85).

Turn key switch to ON position.

<- Go to Section TOC Section 9001 page 159 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

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

Is correct voltage indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Harness Check.

( 4 ) Harness Check

Action:

Key switch in OFF position.

Disconnect AFL solenoid pressure sensor (marked PS1) (B85).

Disconnect main controller connectors (X31—X36).

Check for continuity between pin 2 of cab harness-to-main controller 24-pin connector B (X32) to all pins on all main controller
connectors.

Is continuity indicated between any circuits?

Result:

YES:Circuit is short to power. Repair or replace harness. See appropriate harness.

NO:Checks complete.

<- Go to Section TOC Section 9001 page 160 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011810.04- Electric Lever Operating Pressure Sensor 1 Low Voltage


360
Auxiliary function lever (AFL) solenoid pressure sensor (marked PS1) (B85) signal voltage is low (below 0.1 V).

Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1)


(B85) Low Input Diagnostic Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris:

See Cab Harness (W1) Component Location . (Group 9015-10.)


Cab harness-to-main controller 24-pin connector B (X32).
Cab harness-to-main controller 26-pin connector F (X36).
See Auxiliary Function Lever (AFL) Harness (W75) Component Location . (Group 9015-10.)
Auxiliary function lever (AFL) connector 1 (X574).
See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location . (Group 9015-10.)
AFL solenoid pressure sensor (marked PS1) (B85).
Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577).

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connectors. See appropriate harness.

( 2 ) Component Check

Action:

Switch AFL solenoid pressure sensor (marked PS1) (B85) to another properly working pressure sensor.

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011810.04—Electric Lever Operating Pressure Sensor 1 Low Voltage.

Is code active?

Return connectors to appropriate sensors after check is complete.

Result:

YES:Go to Voltage Check.

NO:AFL solenoid pressure sensor (marked PS1) (B85) malfunction. Replace sensor.

( 3 ) Voltage Check

Action:

Key switch in OFF position.

Disconnect AFL solenoid pressure sensor (marked PS1) (B85).

Turn key switch to ON position.

<- Go to Section TOC Section 9001 page 161 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

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

Is correct voltage indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Open Circuit Check.

( 4 ) Open Circuit Check

Action:

Key switch in OFF position.

AFL solenoid pressure sensor (marked PS1) (B85) disconnected.

Disconnect cab harness-to-main controller 24-pin connector B (X32).

Check for continuity between pin 2 of AFL solenoid pressure sensor (marked PS1) (B85) and pin 2 of cab harness-to-main
controller 24-pin connector B (X32).

Is continuity indicated?

Result:

YES:Go to Short Circuit Check.

NO:Repair or replace harness. See appropriate harness.

( 5 ) Short Circuit Check

Action:

Key switch in OFF position.

AFL solenoid pressure sensor (marked PS1) (B85) disconnected.

Check for continuity between pin 2 of AFL solenoid pressure sensor (marked PS1) (B85) and machine ground.

Is continuity indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Checks complete.

<- Go to Section TOC Section 9001 page 162 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011812.02- OPT Electric Lever 1 Neutral Abnormal


360
Secondary pilot shutoff solenoid (marked PiC) (Y66) signal voltage 0.1 V or less.

OPT Electric Lever 1 Neutral Abnormal Diagnostic Procedure


( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris:

See Cab Harness (W1) Component Location . (Group 9015-10.)


Cab harness-to-main controller 17-pin connector C (X33).
See Auxiliary Function Lever (AFL) Harness (W75) Component Location . (Group 9015-10.)
Optional connector (X26).
Auxiliary function lever (AFL) connector 1 (X574).
See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location . (Group 9015-10.)
Secondary pilot shutoff solenoid (marked PiC) (Y66).
Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577).

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Continuity Check.

NO:Repair or replace connectors. See appropriate harness.

( 2 ) Continuity Check

Action:

Key switch in OFF position.

Disconnect secondary pilot shutoff solenoid (marked PiC) (Y66).

Disconnect cab harness-to-main controller 17-pin connector C (X33).

Check for continuity between:

Pin 1 of secondary pilot shutoff solenoid (marked PiC) (Y66) connector to pin 6 of cab harness-to-main controller 17-pin
connector C (X33).

Is continuity indicated?

Result:

YES:Go to Solenoid Check.

NO:Repair or replace harness. See appropriate harness.

( 3 ) Solenoid Check

Action:

Key switch in OFF position.

Secondary pilot shutoff solenoid (marked PiC) (Y66) disconnected.

Test secondary pilot shutoff solenoid (marked PiC) (Y66) and compare to specification. See Solenoid Test . (Group 9015-20.)

<- Go to Section TOC Section 9001 page 163 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

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

Result:

YES:Checks complete.

NO:Secondary pilot shutoff solenoid (marked PiC) (Y66) malfunction. Replace solenoid.

<- Go to Section TOC Section 9001 page 164 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011813.02- OPT Electric Lever 1 Abnormal Operation


360
Secondary pilot shutoff solenoid (marked PiC) (Y66) current above 920 mA and below 70 mA with slow or no operation.

OPT Electric Lever 1 Abnormal Operation Diagnostic Procedure


( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris:

See Cab Harness (W1) Component Location . (Group 9015-10.)


Cab harness-to-main controller 17-pin connector C (X33).
See Auxiliary Function Lever (AFL) Harness (W75) Component Location . (Group 9015-10.)
Optional connector (X26).
Auxiliary function lever (AFL) connector 1 (X574).
See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location . (Group 9015-10.)
Secondary pilot shutoff solenoid (marked PiC) (Y66).
Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577).

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connectors. See appropriate harness.

( 2 ) Component Check

Action:

Key switch in OFF position.

Disconnect secondary pilot shutoff solenoid (marked PiC) (Y66).

Switch connectors of secondary pilot shutoff solenoid (marked PiC) (Y66) with another solenoid.

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011813.02—OPT Electric Lever 1 Abnormal Operation.

Is code active?

Return connectors to appropriate solenoids after check is complete.

Result:

YES:Go to Continuity Check.

NO:Secondary pilot shutoff solenoid (marked PiC) (Y66) malfunction. Replace solenoid.

( 3 ) Continuity Check

Action:

Key switch in OFF position.

Secondary pilot shutoff solenoid (marked PiC) (Y66) disconnected.

<- Go to Section TOC Section 9001 page 165 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Disconnect cab harness-to-main controller 17-pin connector C (X33).

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

Is continuity indicated?

Result:

YES:Go to Short Circuit Check.

NO:Repair or replace harness. See appropriate harness.

( 4 ) Short Circuit Check

Action:

Key switch in OFF position.

Secondary pilot shutoff solenoid (marked PiC) (Y66) disconnected.

Cab harness-to-main controller 17-pin connector C (X33) disconnected.

Check for continuity between pin 1 of secondary pilot shutoff solenoid (marked PiC) (Y66) to machine ground.

Is continuity indicated?

Result:

YES:Short to ground. Repair or replace harness. See appropriate harness.

NO:Go to Harness Check.

( 5 ) Harness Check

Action:

Key switch in OFF position.

Cab harness-to-main controller 17-pin connector C (X33) disconnected.

Check for continuity between pin 6 of cab harness-to-main controller 17-pin connector C (X33) to all other pins on connector.

Is continuity indicated between any pins?

Result:

YES:Short to power. Repair or replace harness. See appropriate harness.

NO:Go to Solenoid Check.

( 6 ) Solenoid Check

Action:

Key switch in OFF position.

Secondary pilot shutoff solenoid (marked PiC) (Y66) disconnected.

Test secondary pilot shutoff solenoid (marked PiC) (Y66) and compare to specification. See Solenoid Test . (Group 9015-20.)

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

<- Go to Section TOC Section 9001 page 166 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Result:

YES:Checks complete.

NO:Secondary pilot shutoff solenoid (marked PiC) (Y66) malfunction. Replace solenoid.

<- Go to Section TOC Section 9001 page 167 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011816.02- OPT Solenoid 1 Feedback Abnormal


360
Auxiliary function lever (AFL) solenoid A (marked 1A) (Y61) current above 920 mA and below 70 mA.

Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Abnormal


Feedback Diagnostic Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris:

See Cab Harness (W1) Component Location . (Group 9015-10.)


Cab harness-to-main controller 31-pin connector A (X31).
See Auxiliary Function Lever (AFL) Harness (W75) Component Location . (Group 9015-10.)
Auxiliary function lever (AFL) connector 1 (X574).
See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location . (Group 9015-10.)
Auxiliary function lever (AFL) solenoid A (marked 1A) (Y61).
Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577).

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connectors. See appropriate harness.

( 2 ) Component Check

Action:

Key switch in OFF position.

Disconnect AFL solenoid A (marked 1A) (Y61).

Disconnect AFL solenoid B (marked 1B) (Y62).

Connect AFL solenoid A (marked 1A) (Y61) connector to AFL solenoid B (marked 1B) (Y62).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011816.02—OPT Solenoid 1 Feedback Abnormal.

Is code active?

Return connectors to appropriate solenoids after check is complete.

Result:

YES:Go to Continuity Check.

NO:AFL solenoid A (marked 1A) (Y61) malfunction. Replace solenoid.

( 3 ) Continuity Check

Action:

Key switch in OFF position.


<- Go to Section TOC Section 9001 page 168 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Disconnect AFL solenoid A (marked 1A) (Y61).

Disconnect cab harness-to-main controller 31-pin connector A (X31).

Check for continuity between:

Pin 1 of AFL solenoid A (marked 1A) (Y61) connector to pin 22 of cab harness-to-main controller 31-pin connector A (X31).
Pin 2 of AFL solenoid A (marked 1A) (Y61) connector to pin 23 of cab harness-to-main controller 31-pin connector A (X31).

Is continuity indicated?

Result:

YES:Go to Short Circuit Check.

NO:Repair or replace harness. See appropriate harness.

( 4 ) Short Circuit Check

Action:

Key switch in OFF position.

AFL solenoid A (marked 1A) (Y61) disconnected.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between:

Pin 1 of AFL solenoid A (marked 1A) (Y61) connector to machine ground.


Pin 23 of cab harness-to-main controller 31-pin connector A (X31) to machine ground.

Is continuity indicated?

Result:

YES:Short to ground. Repair or replace harness. See appropriate harness.

NO:Go to Harness Check.

( 5 ) Harness Check

Action:

Key switch in OFF position.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between pin 23 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.

Is continuity indicated between any pins?

Result:

YES:Short to power. Repair or replace harness. See appropriate harness.

NO:Go to Solenoid Check.

( 6 ) Solenoid Check

Action:

Key switch in OFF position.


<- Go to Section TOC Section 9001 page 169 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

AFL solenoid A (marked 1A) (Y61) disconnected.

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

Is AFL solenoid A (marked 1A) (Y61) within specification?

Result:

YES:Checks complete.

NO:AFL solenoid A (marked 1A) (Y61) malfunction. Replace solenoid.

<- Go to Section TOC Section 9001 page 170 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011816.03- OPT Solenoid 1 Feedback Current High


360
Auxiliary function lever (AFL) solenoid A (marked 1A) (Y61) current above 920 mA.

Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Feedback


High Current Diagnostic Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris:

See Cab Harness (W1) Component Location . (Group 9015-10.)


Cab harness-to-main controller 31-pin connector A (X31).
See Auxiliary Function Lever (AFL) Harness (W75) Component Location . (Group 9015-10.)
Auxiliary function lever (AFL) connector 1 (X574).
See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location . (Group 9015-10.)
Auxiliary function lever (AFL) solenoid A (marked 1A) (Y61).
Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577).

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connectors. See appropriate harness.

( 2 ) Component Check

Action:

Key switch in OFF position.

Disconnect AFL solenoid A (marked 1A) (Y61).

Disconnect AFL solenoid B (marked 1B) (Y62).

Connect AFL solenoid A (marked 1A) (Y61) connector to AFL solenoid B (marked 1B) (Y62).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011816.03—OPT Solenoid 1 Feedback Current High.

Is code active?

Return connectors to appropriate solenoids after check is complete.

Result:

YES:Go to Continuity Check.

NO:AFL solenoid A (marked 1A) (Y61) malfunction. Replace solenoid.

( 3 ) Continuity Check

Action:

Key switch in OFF position.


<- Go to Section TOC Section 9001 page 171 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Disconnect AFL solenoid A (marked 1A) (Y61).

Disconnect cab harness-to-main controller 31-pin connector A (X31).

Check for continuity between:

Pin 1 of AFL solenoid A (marked 1A) (Y61) connector to pin 22 of cab harness-to-main controller 31-pin connector A (X31).
Pin 2 of AFL solenoid A (marked 1A) (Y61) connector to pin 23 of cab harness-to-main controller 31-pin connector A (X31).

Is continuity indicated?

Result:

YES:Go to Harness Check.

NO:Repair or replace harness. See appropriate harness.

( 4 ) Harness Check

Action:

Key switch in OFF position.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between pin 23 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.

Is continuity indicated between any pins?

Result:

YES:Short to power. Repair or replace harness. See appropriate harness.

NO:Go to Solenoid Check.

( 5 ) Solenoid Check

Action:

Key switch in OFF position.

AFL solenoid A (marked 1A) (Y61) disconnected.

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

Is AFL solenoid A (marked 1A) (Y61) within specification?

Result:

YES:Checks complete.

NO:AFL solenoid A (marked 1A) (Y61) malfunction. Replace solenoid.

<- Go to Section TOC Section 9001 page 172 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011816.04- OPT Solenoid 1 Feedback Current Low


360
Auxiliary function lever (AFL) solenoid A (marked 1A) (Y61) feedback current below 56 mA.

Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Feedback


Low Current Diagnostic Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris:

See Cab Harness (W1) Component Location . (Group 9015-10.)


Cab harness-to-main controller 31-pin connector A (X31).
See Auxiliary Function Lever (AFL) Harness (W75) Component Location . (Group 9015-10.)
Auxiliary function lever (AFL) connector 1 (X574).
See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location . (Group 9015-10.)
Auxiliary function lever (AFL) solenoid A (marked 1A) (Y61).
Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577).

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connectors. See appropriate harness.

( 2 ) Component Check

Action:

Key switch in OFF position.

Disconnect AFL solenoid A (marked 1A) (Y61).

Disconnect AFL solenoid B (marked 1B) (Y62).

Connect AFL solenoid A (marked 1A) (Y61) connector to AFL solenoid B (marked 1B) (Y62).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011816.04—OPT Solenoid 1 Feedback Current Low.

Is code active?

Return connectors to appropriate solenoids after check is complete.

Result:

YES:Go to Continuity Check.

NO:AFL solenoid A (marked 1A) (Y61) malfunction. Replace solenoid.

( 3 ) Continuity Check

Action:

Key switch in OFF position.


<- Go to Section TOC Section 9001 page 173 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Disconnect AFL solenoid A (marked 1A) (Y61).

Disconnect cab harness-to-main controller 31-pin connector A (X31).

Check for continuity between:

Pin 1 of AFL solenoid A (marked 1A) (Y61) connector to pin 22 of cab harness-to-main controller 31-pin connector A (X31).
Pin 2 of AFL solenoid A (marked 1A) (Y61) connector to pin 23 of cab harness-to-main controller 31-pin connector A (X31).

Is continuity indicated?

Result:

YES:Go to Short Circuit Check.

NO:Repair or replace harness. See appropriate harness.

( 4 ) Short Circuit Check

Action:

Key switch in OFF position.

AFL solenoid A (marked 1A) (Y61) disconnected.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between:

Pin 1 of AFL solenoid A (marked 1A) (Y61) connector to machine ground.


Pin 23 of cab harness-to-main controller 31-pin connector A (X31) to machine ground.

Is continuity indicated?

Result:

YES:Short to ground. Repair or replace harness. See appropriate harness.

NO:Go to Solenoid Check.

( 5 ) Solenoid Check

Action:

Key switch in OFF position.

AFL solenoid A (marked 1A) (Y61) disconnected.

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

Is AFL solenoid A (marked 1A) (Y61) within specification?

Result:

YES:Checks complete.

NO:AFL solenoid A (marked 1A) (Y61) malfunction. Replace solenoid.

<- Go to Section TOC Section 9001 page 174 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011817.02- OPT Solenoid 2 Feedback Abnormal


360
Auxiliary function lever (AFL) solenoid B (marked 1B) (Y62) current above 920 mA and below 70 mA.

Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Abnormal


Feedback Diagnostic Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris:

See Cab Harness (W1) Component Location . (Group 9015-10.)


Cab harness-to-main controller 31-pin connector A (X31).
See Auxiliary Function Lever (AFL) Harness (W75) Component Location . (Group 9015-10.)
Auxiliary function lever (AFL) connector 1 (X574).
See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location . (Group 9015-10.)
Auxiliary function lever (AFL) solenoid B (marked 1B) (Y62).
Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577).

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connectors. See appropriate harness.

( 2 ) Component Check

Action:

Key switch in OFF position.

Disconnect AFL solenoid B (marked 1B) (Y62).

Disconnect AFL solenoid A (marked 1A) (Y61).

Connect AFL solenoid B (marked 1B) (Y62) connector to AFL solenoid A (marked 1A) (Y61).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011817.02—OPT Solenoid 2 Feedback Abnormal.

Is code active?

Return connectors to appropriate solenoids after check is complete.

Result:

YES:Go to Continuity Check.

NO:AFL solenoid B (marked 1B) (Y62) malfunction. Replace solenoid.

( 3 ) Continuity Check

Action:

Key switch in OFF position.


<- Go to Section TOC Section 9001 page 175 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Disconnect AFL solenoid B (marked 1B) (Y62).

Disconnect cab harness-to-main controller 31-pin connector A (X31).

Check for continuity between:

Pin 1 of AFL solenoid B (marked 1B) (Y62) connector to pin 25 of cab harness-to-main controller 31-pin connector A (X31).
Pin 2 of AFL solenoid B (marked 1B) (Y62) connector to pin 24 of cab harness-to-main controller 31-pin connector A (X31).

Is continuity indicated?

Result:

YES:Go to Short Circuit Check.

NO:Repair or replace harness. See appropriate harness.

( 4 ) Short Circuit Check

Action:

Key switch in OFF position.

AFL solenoid B (marked 1B) (Y62) disconnected.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between:

Pin 1 of AFL solenoid B (marked 1B) (Y62) connector to machine ground.


Pin 24 of cab harness-to-main controller 31-pin connector A (X31) to machine ground.

Is continuity indicated?

Result:

YES:Short to ground. Repair or replace harness. See appropriate harness.

NO:Go to Harness Check.

( 5 ) Harness Check

Action:

Key switch in OFF position.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between pin 24 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.

Is continuity indicated between any pins?

Result:

YES:Short to power. Repair or replace harness. See appropriate harness.

NO:Go to Solenoid Check.

( 6 ) Solenoid Check

Action:

Key switch in OFF position.


<- Go to Section TOC Section 9001 page 176 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

AFL solenoid B (marked 1B) (Y62) disconnected.

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

Is AFL solenoid B (marked 1B) (Y62) within specification?

Result:

YES:Checks complete.

NO:AFL solenoid B (marked 1B) (Y62) malfunction. Replace solenoid.

<- Go to Section TOC Section 9001 page 177 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011817.03- OPT Solenoid 2 Feedback Current High


360
Auxiliary function lever (AFL) solenoid B (marked 1B) (Y62) current above 920 mA.

Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Feedback


High Current Diagnostic Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris:

See Cab Harness (W1) Component Location . (Group 9015-10.)


Cab harness-to-main controller 31-pin connector A (X31).
See Auxiliary Function Lever (AFL) Harness (W75) Component Location . (Group 9015-10.)
Auxiliary function lever (AFL) connector 1 (X574).
See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location . (Group 9015-10.)
Auxiliary function lever (AFL) solenoid B (marked 1B) (Y62).
Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577).

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connectors. See appropriate harness.

( 2 ) Component Check

Action:

Key switch in OFF position.

Disconnect AFL solenoid B (marked 1B) (Y62).

Disconnect AFL solenoid A (marked 1A) (Y61).

Connect AFL solenoid B (marked 1B) (Y62) connector to AFL solenoid A (marked 1A) (Y61).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011817.03—OPT Solenoid 2 Feedback Current High.

Is code active?

Return connectors to appropriate solenoids after check is complete.

Result:

YES:Go to Continuity Check.

NO:AFL solenoid B (marked 1B) (Y62) malfunction. Replace solenoid.

( 3 ) Continuity Check

Action:

Key switch in OFF position.


<- Go to Section TOC Section 9001 page 178 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Disconnect AFL solenoid B (marked 1B) (Y62).

Disconnect cab harness-to-main controller 31-pin connector A (X31).

Check for continuity between:

Pin 1 of AFL solenoid B (marked 1B) (Y62) connector to pin 25 of cab harness-to-main controller 31-pin connector A (X31).
Pin 2 of AFL solenoid B (marked 1B) (Y62) connector to pin 24 of cab harness-to-main controller 31-pin connector A (X31).

Is continuity indicated?

Result:

YES:Go to Harness Check.

NO:Repair or replace harness. See appropriate harness.

( 4 ) Harness Check

Action:

Key switch in OFF position.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between pin 24 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.

Is continuity indicated between any pins?

Result:

YES:Short to power. Repair or replace harness. See appropriate harness.

NO:Go to Solenoid Check.

( 5 ) Solenoid Check

Action:

Key switch in OFF position.

AFL solenoid B (marked 1B) (Y62) disconnected.

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

Is AFL solenoid B (marked 1B) (Y62) within specification?

Result:

YES:Checks complete.

NO:AFL solenoid B (marked 1B) (Y62) malfunction. Replace solenoid.

<- Go to Section TOC Section 9001 page 179 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011817.04- OPT Solenoid 2 Feedback Current Low


360
Auxiliary function lever (AFL) solenoid B (marked 1B) (Y62) feedback current below 56 mA.

Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Feedback


Low Current Diagnostic Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris:

See Cab Harness (W1) Component Location . (Group 9015-10.)


Cab harness-to-main controller 31-pin connector A (X31).
See Auxiliary Function Lever (AFL) Harness (W75) Component Location . (Group 9015-10.)
Auxiliary function lever (AFL) connector 1 (X574).
See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location . (Group 9015-10.)
Auxiliary function lever (AFL) solenoid B (marked 1B) (Y62).
Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577).

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connectors. See appropriate harness.

( 2 ) Component Check

Action:

Key switch in OFF position.

Disconnect AFL solenoid B (marked 1B) (Y62).

Disconnect AFL solenoid A (marked 1A) (Y61).

Connect AFL solenoid B (marked 1B) (Y62) connector to AFL solenoid A (marked 1A) (Y61).

Clear MCZ diagnostic trouble codes.

Operate machine.

Check for active MCZ diagnostic trouble code 011817.04—OPT Solenoid 2 Feedback Current Low.

Is code active?

Return connectors to appropriate solenoids after check is complete.

Result:

YES:Go to Continuity Check.

NO:AFL solenoid B (marked 1B) (Y62) malfunction. Replace solenoid.

( 3 ) Continuity Check

Action:

Key switch in OFF position.


<- Go to Section TOC Section 9001 page 180 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Disconnect AFL solenoid B (marked 1B) (Y62).

Disconnect cab harness-to-main controller 31-pin connector A (X31).

Check for continuity between:

Pin 1 of AFL solenoid B (marked 1B) (Y62) connector to pin 25 of cab harness-to-main controller 31-pin connector A (X31).
Pin 2 of AFL solenoid B (marked 1B) (Y62) connector to pin 24 of cab harness-to-main controller 31-pin connector A (X31).

Is continuity indicated?

Result:

YES:Go to Short Circuit Check.

NO:Repair or replace harness. See appropriate harness.

( 4 ) Short Circuit Check

Action:

Key switch in OFF position.

AFL solenoid B (marked 1B) (Y62) disconnected.

Cab harness-to-main controller 31-pin connector A (X31) disconnected.

Check for continuity between:

Pin 1 of AFL solenoid B (marked 1B) (Y62) connector to machine ground.


Pin 24 of cab harness-to-main controller 31-pin connector A (X31) to machine ground.

Is continuity indicated?

Result:

YES:Short to ground. Repair or replace harness. See appropriate harness.

NO:Go to Solenoid Check.

( 5 ) Solenoid Check

Action:

Key switch in OFF position.

AFL solenoid B (marked 1B) (Y62) disconnected.

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

Is AFL solenoid B (marked 1B) (Y62) within specification?

Result:

YES:Checks complete.

NO:AFL solenoid B (marked 1B) (Y62) malfunction. Replace solenoid.

<- Go to Section TOC Section 9001 page 181 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011901.03- Hydraulic Oil Temperature Sensor Circuit High Input


360
Hydraulic oil temperature sensor (B40) voltage is high (above 4.35 V).

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Hydraulic Oil Temperature Sensor Circuit High Input Diagnostic


Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Hydraulic oil temperature sensor (B40) and pump harness-to-machine harness connector (X40). See Pump Harness (W8)
Component Location . (Group 9015-10.)
Machine harness splice connector (X98) and cab harness-to-machine harness 100-pin connector (X3). See Machine
Harness (W2) Component Location . (Group 9015-10.)
Cab harness to-main controller 17-pin connector C (X33) and cab harness-to-main controller 26-pin connector F (X36).
See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

Key switch in OFF position.

Disconnect hydraulic oil temperature sensor (B40).

Test hydraulic oil temperature sensor (B40) and compare to specification. See Temperature Sensor Test . (Group 9015-20.)

Is hydraulic oil temperature sensor (B40) within specification?

Result:

YES:Go to Open Circuit Check.

NO:Hydraulic oil temperature sensor (B40) malfunction. Replace sensor.

( 3 ) Open Circuit Check

Action:

Key switch in OFF position.


<- Go to Section TOC Section 9001 page 182 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Hydraulic oil temperature sensor (B40) disconnected.

Disconnect cab harness-to-main controller 17-pin connector C (X33).

Disconnect cab harness-to-main controller 26-pin connector F (X36).

Check for continuity between:

Pin 1 of hydraulic oil temperature sensor (B40) connector and pin 1 of cab harness-to-main controller 17-pin connector C
(X33).
Pin 2 of hydraulic oil temperature sensor (B40) connector and pin 16 of cab harness-to-main controller 26-pin connector F
(X36).

Is continuity indicated?

Result:

YES:Repair or replace harness. See appropriate harness.

NO:Go to Voltage Check.

( 4 ) Voltage Check

Action:

Key switch in OFF position.

Hydraulic oil temperature sensor (B40) disconnected.

Disconnect cab harness-to-main controller 17-pin connector C (X33).

Disconnect cab harness-to-main controller 26-pin connector F (X36).

Turn key switch to ON position.

Check pin 1 of hydraulic oil temperature sensor (B40) connector for voltage.

Is voltage indicated?

Result:

YES:Short circuit to power. Repair or replace harness. See appropriate harness.

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

<- Go to Section TOC Section 9001 page 183 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

011901.04- Hydraulic Oil Temperature Sensor Circuit Low Input


360
Hydraulic oil temperature sensor (B40) voltage is low (below 0.1 V).

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb·in

Hydraulic Oil Temperature Sensor Circuit Low Input Diagnostic


Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Hydraulic oil temperature sensor (B40) and pump harness-to-machine harness connector (X40). See Pump Harness (W8)
Component Location . (Group 9015-10.)
Machine harness splice connector (X98) and cab harness-to-machine harness 100-pin connector (X3). See Machine
Harness (W2) Component Location . (Group 9015-10.)
Cab harness to-main controller 17-pin connector C (X33) and cab harness-to-main controller 26-pin connector F (X36).
See Cab Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Component Check

Action:

Key switch in OFF position.

Disconnect hydraulic oil temperature sensor (B40).

Test hydraulic oil temperature sensor (B40) and compare to specification. See Temperature Sensor Test . (Group 9015-20.)

Is hydraulic oil temperature sensor (B40) within specification?

Result:

YES:Go to Voltage Check.

NO:Hydraulic oil temperature sensor (B40) malfunction. Replace sensor.

( 3 ) Voltage Check

Action:

Key switch in OFF position.


<- Go to Section TOC Section 9001 page 184 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Hydraulic oil temperature sensor (B40) disconnected.

Turn key switch to ON position.

Check between pin 1 and pin 2 on hydraulic oil temperature sensor (B40) connector for voltage.

Is voltage indicated?

Result:

YES:Go to Short Circuit Check.

NO:Open circuit. Repair or replace harness. See appropriate harness.

( 4 ) Short Circuit Check

Action:

Key switch in OFF position.

Hydraulic oil temperature sensor (B40) disconnected.

Check for continuity between pin 1 of hydraulic oil temperature sensor (B40) and machine ground.

Is continuity indicated?

Result:

YES:Short to ground. Repair or replace harness. See appropriate harness.

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

020010.02- Exhaust Filter Alarm


360

Not applicable to this machine.

<- Go to Section TOC Section 9001 page 185 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

020011.02- Electric Lever Alarm


360
Electric control lever system is abnormal.

→NOTE:

There will be other diagnostic trouble codes generated with this code. Correct all diagnostic trouble
codes associated with auxiliary diagnostics before continuing with procedure.

Electric Control Lever Alarm Diagnostic Procedure


( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris:

See Cab Harness (W1) Component Location . (Group 9015-10.)


Cab harness-to-main controller 17-pin connector C (X33).
Cab harness-to-main controller 26-pin connector F (X36).
See Auxiliary Function Lever (AFL) Harness (W75) Component Location . (Group 9015-10.)
Right auxiliary function lever (AFL) connector (marked R_GRIP) (X536).
Left auxiliary function lever (AFL) connector (marked L_GRIP) (X537).
Auxiliary function lever (AFL) connector 1 (X574).
Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577).

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Signal error.

NO:Repair or replace harness. See appropriate harness.

020062.02- Hydraulic Oil Temperature Alarm


360
Hydraulic Oil Temperature Alarm

Diagnose the diagnostic trouble codes (DTC) of main controller (MCZ) diagnostic trouble codes.

See 011901.03 — Hydraulic Oil Temperature Sensor Circuit High and see 011901.04 — Hydraulic Oil Temperature Sensor
Circuit Low . (Group 9001-10.)

<- Go to Section TOC Section 9001 page 186 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes

020303.02- Electric Lever Pilot Cut Alarm


360
Electric control lever abnormal signal in neutral position.

→NOTE:

There will be other diagnostic trouble codes generated with this code. Correct all diagnostic trouble
codes before continuing with procedure.

Attachment Pedal or Blade and Outrigger Control Lever Alarm


Diagnostic Procedure
( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris:

See Cab Harness (W1) Component Location . (Group 9015-10.)


Cab harness-to-main controller 17-pin connector C (X33).
Cab harness-to-main controller 26-pin connector F (X36).
See Auxiliary Function Lever (AFL) Harness (W75) Component Location . (Group 9015-10.)
Right auxiliary function lever (AFL) connector (marked R_GRIP) (X536).
Left auxiliary function lever (AFL) connector (marked L_GRIP) (X537).
Auxiliary function lever (AFL) connector 1 (X574).
Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577).

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Pilot signal error.

NO:Repair or replace harness. See appropriate harness.

<- Go to Section TOC Section 9001 page 187 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes

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


Engine Control Unit (ECU) Diagnostic Trouble Codes
For additional information on the engine control unit circuit, see Engine Control Unit (ECU) Circuit Theory of Operation . (Group
9015-15.)

Engine control unit diagnostic trouble codes (DTCs) can be displayed on the monitor, connection with Service ADVISOR ™ , or
by connection with MPDr.

See Reading Diagnostic Trouble Codes With Monitor Display . (Group 9015-20.)
See Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application . (Group 9015-20.)
See MPDr Application . (Group 9015-20.)

<- Go to Section TOC Section 9001 page 188 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes

000111.07- Coolant Level Low—Moderately Severe Level


346
Loss of coolant detected by engine coolant loss level sensor (S5001) in the surge tank.

Coolant Level Low—Moderately Severe Level Diagnostic Procedure


Alarm Level:

Coolant Level Alarm Illuminated—Highlighted Yellow (warning)

( 1 ) Coolant Level Check

Action:

Check coolant level in surge tank. See Check Engine Coolant Level . (Operator’s Manual.)

Is coolant level low?

Result:

YES:Add coolant to surge tank and check cooling system for leaks.

NO:Go to Connector Check.

( 2 ) Connector Check

Action:

Check harness connection to engine coolant loss level sensor (S5001) and engine control unit (ECU)-to-engine interface
harness connector 3 (X16). See Engine Interface Harness (W5) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector or pins. See Engine Interface Harness (W5) Wiring Diagram . (Group 9015-10.)

( 3 ) Component Check

Action:

Disconnect engine coolant loss level sensor (S5001).

Does monitor indicate low coolant level?

Result:

YES:Engine coolant loss level sensor (S5001) malfunction. Replace sensor.

NO:Go to Short to Ground Check

( 4 ) Short to Ground Check

Action:

Engine coolant loss level sensor (S5001) disconnected.

Check wire Y01 YEL for on engine coolant loss level sensor (S5001) connector pin 1 for continuity to ground.

Is continuity to ground indicated?

<- Go to Section TOC Section 9001 page 189 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes

Result:

YES:Checks complete.

NO:Repair or replace harness as necessary.

<- Go to Section TOC Section 9001 page 190 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes

000111.17- Coolant Level Low—Most Severe Level


346
Loss of coolant detected by engine coolant service level sensor (S5002) in the surge tank.

Coolant Level Low—Most Severe Level Diagnostic Procedure


Alarm Level:

Coolant Level Alarm Illuminated—Highlighted Yellow (warning)

( 1 ) Coolant Level Check

Action:

Check coolant level in surge tank. See Check Engine Coolant Level . (Operator’s Manual.)

Is coolant level low?

Result:

YES:Add coolant to surge tank and check cooling system for leaks.

NO:Go to Connector Check.

( 2 ) Connector Check

Action:

Check harness connection to engine coolant service level sensor (S5002) and engine control unit (ECU)-to-engine interface
harness connector 3 (X16). See Engine Interface Harness (W5) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector or pins. See Engine Interface Harness (W5) Wiring Diagram . (Group 9015-10.)

( 3 ) Component Check

Action:

Disconnect engine coolant service level sensor (S5002).

Does sensor indicate low coolant level?

Result:

YES:Engine coolant service level sensor (S5002) malfunction. Replace sensor.

NO:Go to Short to Ground Check.

( 4 ) Short to Ground Check

Action:

Engine coolant service level sensor (S5002) disconnected.

Check wire Y02 YEL on engine coolant service level sensor (S5002) connector pin 1 for continuity to ground.

Is continuity to ground indicated?

<- Go to Section TOC Section 9001 page 191 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes

Result:

YES:Checks complete.

NO:Repair or replace harness as necessary.

000158.01- Battery Voltage Low


346
Low battery voltage detected by engine control unit (ECU).

Battery Voltage Low Diagnostic Procedure


( 1 ) Voltage Check

Action:

Ignition OFF.

Test battery voltage. See Electrical Component Checks . (Group 9015-20.)

Is battery voltage within specification?

Result:

YES:Checks complete.

NO:Go to Battery Charge.

( 2 ) Battery Charge

Action:

Charge battery. See Using Battery Charger . (Operator’s Manual.)

Test battery voltage. See Electrical Component Checks . (Group 9015-20.)

Is battery voltage within specification?

Result:

YES:Checks complete.

NO:Replace batteries. See Battery Remove and Install . (Group 9015-20.)

<- Go to Section TOC Section 9001 page 192 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes

000647.05- Variable Speed Fan Solenoid Open Circuit


346
Variable speed fan solenoid (Y5005) open circuit.

Variable Speed Fan Solenoid Open Circuit Diagnostic Procedure


Alarm Level:

Warning Alarm Illuminated—Highlighted Yellow (warning)

( 1 ) Connector Check

Action:

Check harness connection to variable speed fan solenoid (Y5005) and engine control unit (ECU)-to-engine interface harness
connector 3 (X16). See Engine Interface Harness (W5) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector or pins. See Engine Interface Harness (W5) Wiring Diagram . (Group 9015-10.)

( 2 ) Component Check

Action:

Disconnect and test variable speed fan solenoid (Y5005). See Proportional Solenoid Test . (Group 9015-20.)

Does variable speed fan solenoid (Y5005) test OK?

Result:

YES:Go to Open Circuit Check.

NO:Variable speed fan solenoid (Y5005) malfunction. Replace solenoid.

( 3 ) Open Circuit Check

Action:

Variable speed fan solenoid (Y5005) disconnected.

Disconnect ECU-to-engine interface harness connector 3 (X16).

Check wire J01 TAN for continuity between variable speed fan solenoid (Y5005) pin 2 and ECU-to-engine interface harness
connector 3 (X16) pin 15.

Disconnect engine interface harness ground (W43).

Check wire G01G BLK for continuity between variable speed fan solenoid (Y5005) pin 1 and engine interface harness ground
connector (W43).

Is continuity indicated?

Result:

YES:Checks complete.

NO:Repair or replace harness as necessary.

<- Go to Section TOC Section 9001 page 193 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes

<- Go to Section TOC Section 9001 page 194 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes

000647.06- Variable Speed Fan Solenoid Short Circuit


346
Variable speed fan solenoid (Y5005) short circuit.

Variable Speed Fan Solenoid Short Circuit Diagnostic Procedure


Alarm Level:

Warning Alarm Illuminated—Highlighted Yellow (warning)

( 1 ) Connector Check

Action:

Check harness connection to variable speed fan solenoid (Y5005) and engine control unit (ECU)-to-engine interface harness
connector 3 (X16). See Engine Interface Harness (W5) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector or pins. See Engine Interface Harness (W5) Wiring Diagram . (Group 9015-10.)

( 2 ) Component Check

Action:

Disconnect and test variable speed fan solenoid (Y5005). See Proportional Solenoid Test . (Group 9015-20.)

Does variable speed fan solenoid (Y5005) test OK?

Result:

YES:Go to Short to Ground Check.

NO:Variable speed fan solenoid (Y5005) malfunction. Replace solenoid.

( 3 ) Short to Ground Check

Action:

Variable speed fan solenoid (Y5005) disconnected.

Disconnect ECU-to-engine interface harness connector 3 (X16).

Check wire J01 TAN between variable speed fan solenoid connector pin 2 (Y5005) and machine ground.

Is continuity indicated?

Result:

YES:Circuit is shorted to ground. Repair or replace harness as necessary.

NO:Checks complete.

<- Go to Section TOC Section 9001 page 195 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes

000647.16- Reversing Fan Switch Active Too Long


346
Reversing fan switch (S15) stuck on.

Reversing Fan Switch Active Too Long Diagnostic Procedure


Alarm Level:

Warning Alarm Illuminated—Highlighted Yellow (warning)

( 1 ) Function Check

Action:

Is operator holding reversing fan switch (S15) too long?

Is reversing fan switch (S15) stuck ON?

Result:

YES:Advise operator of reversing fan function or clean reversing fan switch (S15). See Reversing Fan Switch—If Equipped .
(Operator’s Manual.)

NO:Go to Component Check.

( 2 ) Component Check

Action:

Disconnect reversing fan switch (S15). See Reversing Fan Switch Harness (W23) Component Location and see Cab Harness
(W1) Component Location . (Group 9015-10.)

Place reversing fan switch (S15) in OFF position.

Check reversing fan switch (S15) for continuity between pins 6 and 9. See Reversing Fan Switch Harness (W23) Wiring Diagram
. (Group 9015-10.)

Check for continuity between pins 8 and 9.

Is continuity indicated?

Result:

YES:Reversing fan switch (S15) malfunction. Replace switch.

NO:Go to Short to Power Check.

( 3 ) Short to Power Check

Action:

Reversing fan switch (S15) disconnected.

Turn key switch to ON position.

Is power indicated at pin 9 of reversing fan switch connector (S15)?

Result:

YES:Circuit is shorted to power. Repair or replace harness as necessary.

NO:Checks complete.

<- Go to Section TOC Section 9001 page 196 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes

<- Go to Section TOC Section 9001 page 197 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes

000898.09- Requested Speed/Speed Limit


346
Speed request CAN message is missing from ECU.

Requested Speed/Speed Limit Diagnostic Procedure


Alarm Level:

Warning Alarm Illuminated—Highlighted Yellow (warning)

( 1 ) Connector Check

Action:

Check harness connection at flex load controller (FLC) (A15) and engine control unit (ECU)-to-engine interface harness
connector 3 (X16). See Engine Interface Harness (W5) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to CAN Circuit Check.

NO:Repair or replace connector or pins. See Engine Interface Harness (W5) Wiring Diagram . (Group 9015-10.)

( 2 ) CAN Circuit Check

Action:

Test CAN circuit. See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.)

Does CAN circuit test good?

Result:

YES:Checks complete.

NO:Repair CAN circuit.

<- Go to Section TOC Section 9001 page 198 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes

001638.09- Hydraulic Temperature


346
Hydraulic temperature CAN message is missing from ECU.

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb.-in.

Hydraulic Temperature Diagnostic Procedure


Alarm Level:

Warning Alarm Illuminated—Highlighted Yellow (warning)

( 1 ) Code Check

Action:

Check for the following diagnostic trouble codes.

Is diagnostic trouble codes 011901.03 present?


Is diagnostic trouble codes 011901.04 present?

Result:

YES:See code 011901.03— Hydraulic Oil Temperature Sensor Circuit High Input . (Group 9001-20.)

YES:See code 011901.04— Hydraulic Oil Temperature Sensor Circuit Low Input . (Group 9001-20.)

NO:Go to CAN Circuit Check.

( 2 ) CAN Circuit Check

Action:

Test CAN circuit. See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.)

Does CAN circuit test good?

Result:

YES:Checks complete.

NO:Repair CAN circuit.

<- Go to Section TOC Section 9001 page 199 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes

001639.00- Fan Speed High—Most Severe Level


346
ECU detects higher fan speed than desired.

Fan Speed High—Moderately Severe Level Diagnostic Procedure


Alarm Level:

Warning Alarm Illuminated—Highlighted Yellow (warning)

( 1 ) Connector Check

Action:

Check harness connection at fan speed sensor (B53) and engine control unit (ECU)-to-engine interface harness connector 3
(X16). See Engine Interface Harness (W5) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Code Check.

NO:Repair or replace connector or pins. See Engine Interface Harness (W5) Wiring Diagram . (Group 9015-10.)

( 2 ) Code Check

Action:

Check for active ECU diagnostic trouble codes.

Is ECU diagnostic trouble codes 000647.05 present?

Is ECU diagnostic trouble codes 000647.06 present?

Result:

YES:See ECU code 000647.05— Variable Speed Fan Solenoid Open Circuit . (Group 9001-20.)

YES:See ECU code 000647.06— Variable Speed Fan Solenoid Short Circuit . (Group 9001-20.)

NO:Go to Solenoid Check.

( 3 ) Solenoid Check

Action:

Test variable speed fan solenoid (Y5005). See Proportional Solenoid Test . (Group 9015-20.)

Does variable speed fan solenoid (Y5005) test OK?

Result:

YES:Go to Harness Check.

NO:Variable speed fan solenoid (Y5005) malfunction. Replace solenoid.

( 4 ) Harness Check

Action:

Disconnect fan speed sensor (B53) and ECU-to-engine interface harness connector 3 (X16).

<- Go to Section TOC Section 9001 page 200 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes

Check wire R05 BLK for continuity between fan speed sensor (B53) pin B and ECU-to-engine interface harness connector 3
(X16) pin 33.

Check wire M04 PUR for continuity between fan speed sensor (B53) pin C and ECU-to-engine interface harness connector 3
(X16) pin 18.

Is continuity indicated?

Result:

YES:Go to Fan Speed Check.

NO:Repair or replace harness as necessary.

( 5 ) Fan Speed Check

Action:

Check fan speed. See Fan Speed Test . (Group 9025-25.)

Is fan speed within specification?

Result:

YES:Checks complete.

NO:Diagnose fan speed malfunction. See Fan Drive Hydraulic System Operation . (Group 9025-05.)

<- Go to Section TOC Section 9001 page 201 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes

001639.01- Fan Speed Low—Most Severe Level


346
ECU detects zero fan speed.

Fan Speed Low—Most Severe Level Diagnostic Procedure


Alarm Level:

Warning Alarm Illuminated—Highlighted Yellow (warning)

( 1 ) Connector Check

Action:

Check harness connection at fan speed sensor (B53) and engine control unit (ECU)-to-engine interface harness connector 3
(X16). See Engine Interface Harness (W5) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Voltage Check.

NO:Repair or replace connector or pins. See Engine Interface Harness (W5) Wiring Diagram . (Group 9015-10.)

( 2 ) Voltage Check

Action:

Disconnect fan speed sensor (B53).

Turn key switch to ON position.

Check wire P02 RED of fan speed sensor connector (B53) pin A for voltage.

Is voltage greater than 5.0 V?

Result:

YES:Repair or replace harness as necessary.

NO:Go to Open Circuit Check.

( 3 ) Open Circuit Check

Action:

Fan speed sensor (B53) disconnected.

Disconnect ECU-to-engine interface harness connector 3 (X16).

Check wire R05 BLK for continuity between fan speed sensor (B53) pin B and ECU-to-engine interface harness connector 3
(X16) pin 33.

Check wire M04 PUR for continuity between fan speed sensor (B53) pin C and ECU-to-engine interface harness connector 3
(X16) pin 18.

Is continuity indicated?

Result:

YES:Go to Fan Speed Check.

<- Go to Section TOC Section 9001 page 202 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes

NO:Repair or replace harness as necessary.

( 4 ) Fan Speed Check

Action:

Check fan speed. See Fan Speed Test . (Group 9025-25.)

Is fan speed within specification?

Result:

YES:Fan speed sensor (B53) malfunction. Replace sensor.

NO:Diagnose fan speed malfunction. See Fan Drive Hydraulic System Operation . (Group 9025-05.)

001639.18- Fan Speed Low—Moderately Severe Level


346
For diagnostic procedure, see 001639.01—Fan Speed Low—Most Severe Level . (Group 9001-20.)
003701.14- Exhaust Filter Cleaning Not Required
346
Operator requested a parked exhaust filter cleaning, but an exhaust filter cleaning was not required.

<- Go to Section TOC Section 9001 page 203 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes

005484.05- Reversing Fan Solenoid Open Circuit


346
Reversing fan solenoid (Y9) open circuit.

Reversing Fan Solenoid Open Circuit Diagnostic Procedure


Alarm Level:

Warning Alarm Illuminated—Highlighted Yellow (warning)

( 1 ) Connector Check

Action:

Check harness connection to reversing fan solenoid (Y9) and engine control unit (ECU)-to-engine interface harness connector 3
(X16). See Engine Interface Harness (W5) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector or pins. See Engine Interface Harness (W5) Wiring Diagram . (Group 9015-10.)

( 2 ) Component Check

Action:

Disconnect and test reversing fan solenoid (Y9). See Proportional Solenoid Test . (Group 9015-20.)

Does reversing fan solenoid (Y9) test OK?

Result:

YES:Go to Open Circuit Check.

NO:Reversing fan solenoid (Y9) malfunction. Replace solenoid.

( 3 ) Open Circuit Check

Action:

Reversing fan solenoid (Y9) disconnected.

Disconnect ECU-to-engine interface harness connector 3 (X16).

Check wire J02 TAN for continuity between reversing fan solenoid (Y9) pin 2 and ECU-to-engine interface harness connector 3
(X16) pin 48.

Disconnect engine interface harness ground (W43).

Check wire G01C BLK for continuity between reversing fan solenoid (Y9) pin 1 and engine interface harness ground connector
(W43).

Is continuity indicated?

Result:

YES:Checks complete.

NO:Repair or replace harness as necessary.

<- Go to Section TOC Section 9001 page 204 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes

<- Go to Section TOC Section 9001 page 205 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes

005484.06- Reversing Fan Solenoid Short Circuit


346
Reversing fan solenoid (Y9) short circuit.

Reversing Fan Solenoid Short Circuit Diagnostic Procedure


Alarm Level:

Warning Alarm Illuminated—Highlighted Yellow (warning)

( 1 ) Connector Check

Action:

Check harness connection to reversing fan solenoid (Y9) and engine control unit (ECU)-to-engine interface harness connector 3
(X16). See Engine Interface Harness (W5) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Component Check.

NO:Repair or replace connector or pins. See Engine Interface Harness (W5) Wiring Diagram . (Group 9015-10.)

( 2 ) Component Check

Action:

Disconnect and test reversing fan solenoid (Y9). See Proportional Solenoid Test . (Group 9015-20.)

Does reversing fan solenoid (Y9) test OK?

Result:

YES:Go to Short to Ground Check.

NO:Reversing fan solenoid (Y9) malfunction. Replace solenoid.

( 3 ) Short to Ground Check

Action:

Reversing fan solenoid (Y9) disconnected.

Disconnect ECU-to-engine interface harness connector 3 (X16).

Check wire J01 TAN between reversing fan solenoid connector (Y9) pin 2 and machine ground.

Is continuity indicated?

Result:

YES:Repair or replace harness as necessary.

NO:Checks complete.

<- Go to Section TOC Section 9001 page 206 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes

Group 30 - Monitor Controller (DSZ) Diagnostic Trouble Codes


Monitor Controller (DSZ) Diagnostic Trouble Codes
For additional information on the monitor controller circuit, see Monitor Controller (DSZ) Circuit Theory of Operation . (Group
9015-15.)

Monitor controller diagnostic trouble codes (DTCs) can be displayed on the monitor, connection with Service ADVISOR ™ , or by
connection with MPDr.

See Reading Diagnostic Trouble Codes With Monitor Display . (Group 9015-20.)
See Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application . (Group 9015-20.)
See MPDr Application . (Group 9015-20.)

013002.02- ECU Communication Error


395

Check CAN 0 circuit. See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.)

013003.02- Main Controller (MCZ) Communication Error 1


395

Check CAN 0 circuit. See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.)

013004.02- Main Controller (MCZ) Communication Error 2


395

Check CAN 1 circuit. See Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.)

013005.02- Monitor Controller (DSZ) Communication Error 1


395

Check CAN 0 circuit. See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.)

013006.02- Monitor Controller (DSZ) Communication Error 2


395

Check CAN 1 circuit. See Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.)

013007.02- Machine Controller (BCZ) Communication Error


395

Check CAN 1 circuit. See Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.)

013303.02- Abnormal Monitor Internal Temperature Sensor


395
The monitor screen becomes dark.

Monitor Internal Temperature Sensor Diagnostic Procedure


( 1 ) Temperature Check

Action:

Check temperature in or around monitor controller.

Is temperature above 85°C (185°F)?

Result:

YES:Go to Screen Check.

NO:Monitor controller malfunction. See Monitor Controller (DSZ) Remove and Install . (Group 9015-20.)

( 2 ) Screen Check

<- Go to Section TOC Section 9001 page 207 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes

Action:

Cool monitor controller and observe monitor screen.

Does monitor screen return to normal as monitor cooled?

Result:

YES:Monitor controller is OK.

NO:Monitor controller malfunction. See Monitor Controller (DSZ) Remove and Install . (Group 9015-20.)

013304.02- Alternator Alarm


395
Alternator output above 33.5 volts.

Alternator Alarm Diagnostic Procedure


( 1 ) Alternator Output Check

Action:

Measure alternator output. See Alternator Test . (Group 9015-20.)

Is voltage below 33.5 volts?

Result:

YES:Monitor controller malfunction.Replace monitor controller. See Monitor Controller (DSZ) Remove and Install . (Group
9015-20.)

NO:Alternator malfunction.Repair or replace alternator.

013310.03- Shorted Circuit in Coolant Temperature Sensor


395

Not applicable to this machine.

<- Go to Section TOC Section 9001 page 208 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes

013311.03- Fuel Level Sensor Open Circuit


395
Fuel level sensor (B18) open circuit.

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb.-in.

Fuel Level Sensor Open Circuit Diagnostic Procedure


( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Fuel level sensor connector (B18) and machine harness splice connector (X98). See Machine Harness (W2) Component
Location . (Group 9015-10.)
Cab harness-to-machine harness 100-pin connector (X3) and monitor controller 28-pin connector A (X20). See Cab
Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Resistance Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Resistance Check

Action:

Key switch in OFF position.

Disconnect fuel level sensor connector (B18).

Check resistance between pins 1 and 2 on fuel level sensor connector (B18).

Is sensor within specifications?

Fuel Level Sensor Specifications

Fuel Level Sensor Specifications

Float Position Resistance (ohms)

Upper Limit (full) 6-10

3/4 26

1/2 33-43

1/4 53

Alarm Level 82-88

Lower Limit (empty) 90-100

<- Go to Section TOC Section 9001 page 209 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes

Result:

YES:Go to Continuity Check.

NO:Fuel level sensor malfunction. Replace sensor.

( 3 ) Continuity Check

Action:

Key switch in OFF position.

Disconnect monitor controller 28-pin connector A (X20) and fuel level sensor connector (B18).

Check for continuity between:

Pin 1 on fuel level sensor connector (B18) and pin 23 on machine harness splice connector (X98).
Pin 2 on fuel level sensor connector (B18) and pin 18 on monitor controller 28-pin connector A (X20).

Is continuity indicated?

Result:

YES:Monitor controller malfunction.Replace monitor controller. See Monitor Controller (DSZ) Remove and Install . (Group
9015-20.)

NO:Repair or replace harness. See appropriate harness.

<- Go to Section TOC Section 9001 page 210 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes

013311.04- Fuel Level Sensor Shorted Circuit


395
Fuel level sensor (B18) shorted to ground.

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb.-in.

Fuel Level Sensor Shorted Circuit Diagnostic Procedure


( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Fuel level sensor connector (B18) and machine harness splice connector (X98). See Machine Harness (W2) Component
Location . (Group 9015-10.)
Cab harness-to-machine harness 100-pin connector (X3) and monitor controller 28-pin connector A (X20). See Cab
Harness (W1) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Resistance Check.

NO:Repair or replace connector. See appropriate harness.

( 2 ) Resistance Check

Action:

Key switch in OFF position.

Disconnect fuel level sensor connector (B18).

Check resistance between pins 1 and 2 on fuel level sensor connector (B18).

Is sensor within specifications?

Fuel Level Sensor Specifications

Fuel Level Sensor Specifications

Float Position Resistance (ohms)

Upper Limit (full) 6-10

3/4 26

1/2 33-43

1/4 53

Alarm Level 82-88

Lower Limit (empty) 90-100

<- Go to Section TOC Section 9001 page 211 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes

Result:

YES:Go to Continuity Check.

NO:Fuel level sensor malfunction. Replace sensor.

( 3 ) Continuity Check

Action:

Key switch in OFF position.

Disconnect monitor controller 28-pin connector A (X20) and fuel level sensor connector (B18).

Check for continuity between:

Pin 1 on fuel level sensor connector (B18) and pin 23 on machine harness splice connector (X98).
Pin 2 on fuel level sensor connector (B18) and pin 18 on monitor controller 28-pin connector A (X20).

Is continuity indicated?

Result:

YES:Go to Short Circuit Check.Monitor controller malfunction.Replace monitor controller. See Monitor Controller (DSZ) Remove
and Install . (Group 9015-20.)

NO:Repair or replace harness. See appropriate harness.

( 4 ) Short Circuit Check

Action:

Key switch in OFF position.

Disconnect monitor controller 28-pin connector A (X20).

Check for continuity between pin 18 on monitor controller 28-pin connector A (X20) and machine ground.

Is continuity indicated?

Result:

YES:Short to ground. Repair or replace harness. See appropriate harness.

NO:Monitor controller malfunction.Replace monitor controller. See Monitor Controller (DSZ) Remove and Install . (Group
9015-20.)

013334.02- Radiator Coolant Error


186

Diagnose the diagnostic trouble codes (DTC) in the engine control unit (ECU), then clear codes and re-check DTCs.

See Engine Control Unit (ECU) Diagnostic Trouble Codes . (Group 9001-20.)
See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.)

014001.02- Flash Memory Read/Write Error


395

Flash Memory Read/Write Error Diagnostic Procedure


Flash Memory Read/Write Error in monitor controller.

( 1 ) Diagnostic Trouble Code Check

<- Go to Section TOC Section 9001 page 212 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes

Action:

Clear codes and check for code again.

Is diagnostic trouble code (DTC) 014001.02—Flash Memory Read/Write Error still present?

Result:

YES:Monitor controller malfunction.Replace monitor controller. See Monitor Controller (DSZ) Remove and Install . (Group
9015-20.)

NO:Monitor controller is OK.

014002.02- External RAM Read/Write Error


395

External RAM Read/Write Error Diagnostic Procedure


External RAM Read/Write Error in monitor controller.

( 1 ) Diagnostic Trouble Code Check

Action:

Clear codes and check for code again.

Is diagnostic trouble code (DTC) 014002.02—External RAM Read/Write Error still present?

Result:

YES:Monitor controller malfunction.Replace monitor controller. See Monitor Controller (DSZ) Remove and Install . (Group
9015-20.)

NO:Monitor controller is OK.

014003.02- Abnormal EEPROM


395

Abnormal EEPROM Diagnostics Procedure


Abnormal EEPROM in monitor controller.

( 1 ) Diagnostic Trouble Code Check

Action:

Clear codes and check for code again.

Is diagnostic trouble code (DTC) 014003.02—Abnormal EEPROM still present?

Result:

YES:Monitor controller malfunction.Replace monitor controller. See Monitor Controller (DSZ) Remove and Install . (Group
9015-20.)

NO:Monitor controller is OK.

<- Go to Section TOC Section 9001 page 213 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes

014006.02- Communication Terminal:Communication Error


395

Communication Terminal:Communication Error Diagnostic Procedure


( 1 ) Fuse Check

Action:

Key switch in OFF position.

Remove fuses (F6000—F6002). See Engine Interface Harness (W5) Component Location . (Group 9015-10.)

Check fuses (F6000—F6002) for continuity.

Is continuity indicated?

Result:

YES:Go to Power Check.

NO:Replace defective fuse(s).

( 2 ) Power Check

Action:

Key switch in OFF position.

Disconnect satellite (SAT) module control unit 48-pin connector (X6015). See Satellite (SAT) Harness (W6003) Component
Location . (Group 9015-10.)

Turn key switch to ON position.

Check for voltage between pins M1 and M2 on satellite (SAT) module control unit 48-pin connector (X6015).

Is voltage between 22—25 volts?

Result:

YES:Go to Harness Check.

NO:Repair or replace harness. See appropriate harness.

( 3 ) Harness Check

Action:

Key switch in OFF position.

Disconnect satellite (SAT) module control unit 48-pin connector (X6015).

Disconnect modular telematics gateway (MTG) connector (X6014).

Check continuity between:

Pin A1 on satellite (SAT) module control unit 48-pin connector (X6015) and pin A2 on modular telematics gateway (MTG)
connector (X6014).
Pin A2 on satellite (SAT) module control unit 48-pin connector (X6015) and pin A1 on modular telematics gateway (MTG)
connector (X6014).

Is continuity indicated?

<- Go to Section TOC Section 9001 page 214 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes

Result:

YES:Go to Interface Controller Area Network (N-CAN) Diagnostics . (Group 9001-10.)

NO:Repair or replace harness. See appropriate harness.

014008.02- Abnormal Internal RAM


395

Abnormal Internal RAM Diagnostic Procedure


Abnormal Internal RAM in monitor controller.

( 1 ) Diagnostic Trouble Code Check

Action:

Clear codes and check for code again.

Is diagnostic trouble code (DTC) 014008.02—Abnormal Internal RAM still present?

Result:

YES:Monitor controller malfunction.Replace monitor controller. See Monitor Controller (DSZ) Remove and Install . (Group
9015-20.)

NO:Monitor controller is OK.

014021.02- Communication Terminal Security Error


395
Security malfunction of mobile communication equipment.

For more information:

See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.)


See Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.)
See Interface Controller Area Network (N-CAN) Diagnostics . (Group 9001-10.)
See Engine Controller Area Network (Engine CAN) Diagnostics . (Group 9001-10.)

014022.02- SIM Card Error


395

For more information on JDLink ™ and ZXLink ™ , see TM114519.

014023.02- Security Error


395
Communication error with the main controller (MCZ).

For more information:

See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.)


See Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.)
See Interface Controller Area Network (N-CAN) Diagnostics . (Group 9001-10.)
See Engine Controller Area Network (Engine CAN) Diagnostics . (Group 9001-10.)

020100.02- Overheat Alarm


395

Not applicable to this machine.

020101.02- Engine Warning Alarm


395

Diagnose the Diagnostic Trouble Codes (DTC) in the Engine Control Unit (ECU).

See Engine Control Unit (ECU) Diagnostic Trouble Codes . (Group 9001-20.)

<- Go to Section TOC Section 9001 page 215 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes

020102.02- Engine Oil Pressure Alarm


395

Diagnose the Diagnostic Trouble Codes (DTC) in the Engine Control Unit (ECU).

See Engine Control Unit (ECU) Diagnostic Trouble Codes . (Group 9001-20.)

<- Go to Section TOC Section 9001 page 216 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes

020105.02- Hydraulic Oil Filter Restriction Alarm


395

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb.-in.

Hydraulic Oil Filter Restriction Alarm Diagnostic Procedure


( 1 ) Filter Check

Action:

Replace hydraulic oil filter. See Replace Hydraulic Tank Oil Filter . (Operator’s Manual.)

Is DTC 020105.02 still present?

Result:

YES:Go to Hydraulic Oil Filter Restriction Switch Check.

NO:Checks complete.

( 2 ) Hydraulic Oil Filter Restriction Switch Check

Action:

Key switch in OFF position.

Disconnect hydraulic oil filter restriction switch (B27). See Machine Harness (W2) Component Location . (Group 9015-10.)

Check for continuity between terminals of hydraulic oil filter restriction switch.

Is continuity indicated?

Result:

YES:Hydraulic oil filter restriction switch malfunction. Replace switch.

NO:Go to Circuit Check.

( 3 ) Circuit Check

Action:

Key switch in OFF position.

Disconnect monitor controller 36-pin connector B (X21) and hydraulic oil filter restriction switch (B27).

Check for continuity between pin 13 on monitor controller 36-pin connector B (X21) and machine ground.

Is continuity indicated?

Result:

YES:Short to ground. Repair or replace harness. See appropriate harness.

<- Go to Section TOC Section 9001 page 217 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes

NO:Monitor controller malfunction. Replace monitor controller. See Monitor Controller (DSZ) Remove and Install . (Group
9015-20.)

020106.02- Air Cleaner Restriction Alarm


395

Not applicable to this machine.

020107.02- Water Separator Alarm


395

Not applicable to this machine.

<- Go to Section TOC Section 9001 page 218 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes

020109.02- Pilot Control Shut-Off Lever Alarm


395

Pilot Control Shut-Off Lever Alarm Diagnostic Procedure


( 1 ) Connector Check

Action:

Key switch in OFF position.

Check the following connectors for damage, corrosion, or debris.

Cab harness-to-pilot shutoff switch harness connector (X65). See Pilot Shutoff Switch Harness (W11) Component Location
. (Group 9015-10.)
Cab harness-to-machine harness 100-pin connector (X3). See Cab Harness (W1) Component Location . (Group 9015-10.)

Check cab harness-to-pilot shutoff switch harness connector (X65) for corrosion, loose fit, bent/pressed out pins or crimp
malfunctions.

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Code Check.

NO:Repair or replace connector(s) or pin(s) as needed.

( 2 ) Code Check

Action:

Clear codes and check for code again.

Is diagnostic trouble code (DTC) 020109.02—Pilot Control Shut-Off Lever Alarm?

Result:

YES:Go to Pilot Shutoff Switch 1 (S3) Check.

NO:Monitor controller is OK.

( 3 ) Pilot Shutoff Switch 1 (S3) Check

Action:

Pilot control shutoff lever in locked (UP) position.

Connect positive (+) lead of multimeter to pin 1 and negative (-) lead of multimeter to pin 3 on cab harness-to-pilot shutoff
switch harness connector (X65).

Is continuity indicated?

Result:

YES:Short in pilot shutoff switch harness (W11). Repair or replace harness.

NO:Go to Pilot Shutoff Switch 2 (S4) Check.

( 4 ) Pilot Shutoff Switch 2 (S4) Check

Action:

Pilot control shutoff lever in unlocked (DOWN) position.


<- Go to Section TOC Section 9001 page 219 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes

Connect positive (+) lead of multimeter to pin 1 and negative (-) lead of multimeter to pin 3 on cab harness-to-pilot shutoff
switch harness connector (X65).

Is continuity indicated?

Result:

YES:Short in pilot shutoff switch harness (W11). Repair or replace harness.

NO:Checks complete.

020110.02- Fuel Filter Restriction Alarm


395

Diagnose diagnostic trouble code (DTC) 000094.17 of the engine control unit (ECU).

See 4.5 (4045) and 6.8 L (6068) Engine . (CTM 502.)

020113.02- System Error Alarm


395
Faulty controller area network (CAN) circuit.

For more information:

See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.)


See Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.)
See Interface Controller Area Network (N-CAN) Diagnostics . (Group 9001-10.)
See Engine Controller Area Network (Engine CAN) Diagnostics . (Group 9001-10.)

020114.02- Overheat Alarm


395

Not applicable to this machine.

020133.02- Crane Function Alarm


395

Not applicable to this machine.

020142.02- Intake Air Temperature Alarm


395

Not applicable to this machine.

020145.02- Boost Temperature Increase Alarm


395

Not applicable to this machine.

020146.02- Fuel Temperature Increase Alarm


395

Not applicable to this machine.

020149.02- EGR Gas Temperature Alarm


395

Not applicable to this machine.

<- Go to Section TOC Section 9001 page 220 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes

Group 40 - Air Conditioner Controller (ACF) Diagnostic Trouble Codes


Air Conditioner Controller (ACF) Diagnostic Trouble Codes
Air conditioner controller diagnostic trouble codes (DTCs) can be displayed on the monitor, connection with Service ADVISOR ™
, or by connection with MPDr.

See Reading Diagnostic Trouble Codes With Monitor Display . (Group 9015-20.)
See Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application . (Group 9015-20.)
See MPDr Application . (Group 9015-20.)

<- Go to Section TOC Section 9001 page 221 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes

11- Open Circuit in Air Recirculation Sensor


188

Open Circuit in Air Recirculation Sensor Diagnostic Procedure


( 1 ) Connector Check

Action:

Turn key switch to OFF position.

Check air conditioner controller (A7) and air recirculation sensor (B55) connectors for damage, corrosion, or debris. See Heater
and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Harness Check.

NO:Repair or replace connector or pins. See Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.)

( 2 ) Harness Check

Action:

Turn key switch to OFF position.

Disconnect air conditioner controller (A7) and air recirculation sensor (B55) connectors.

Check heater and air conditioner harness (W41) wires between air conditioner controller (A7) and air recirculation sensor (B55)
connectors for continuity. See Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.)

Is there continuity on the appropriate pins?

Result:

YES:Go to Voltage Check.

NO:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)

( 3 ) Voltage Check

Action:

Turn key switch to OFF position.

Air recirculation sensor (B55) disconnected.

Turn key switch to ON position.

Check air recirculation sensor (B55) circuit voltage to ground.

Is voltage greater than 4.95 V?

Result:

YES:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)

NO:Go to Sensor Check.

( 4 ) Sensor Check

<- Go to Section TOC Section 9001 page 222 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes

Action:

Turn key switch to OFF position.

Air recirculation sensor (B55) disconnected.

Check resistance of sensor to specification. See Temperature Sensor Test . (Group 9015-20.)

Is air recirculation sensor within specification?

Result:

YES:Checks complete.

NO:Air recirculation sensor malfunction. Replace sensor.

<- Go to Section TOC Section 9001 page 223 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes

12- Short-Circuited Air Recirculation Sensor


188

Short-Circuited Air Recirculation Sensor Diagnostic Procedure


( 1 ) Connector Check

Action:

Turn key switch to OFF position.

Check air conditioner controller (A7) and air recirculation sensor (B55) connectors for damage, corrosion, or debris. See Heater
and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Harness Check.

NO:Repair or replace connector or pins. See Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.)

( 2 ) Harness Check

Action:

Turn key switch to OFF position.

Disconnect air conditioner controller (A7) and air recirculation sensor (B55) connectors.

Check heater and air conditioner harness (W41) wires between air conditioner controller (A7) and air recirculation sensor (B55)
connectors for continuity to machine ground. See Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.)

Is continuity to ground indicated?

Result:

YES:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)

NO:Go to Voltage Check.

( 3 ) Voltage Check

Action:

Turn key switch to OFF position.

Air recirculation sensor (B55) disconnected.

Turn key switch to ON position.

Check air recirculation sensor (B55) circuit voltage to ground.

Is voltage less than 0.3 V?

Result:

YES:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)

NO:Go to Sensor Check.

( 4 ) Sensor Check

<- Go to Section TOC Section 9001 page 224 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes

Action:

Turn key switch to OFF position.

Air recirculation sensor (B55) disconnected.

Check resistance of sensor to specification. See Temperature Sensor Test . (Group 9015-20.)

Is air recirculation sensor within specification?

Result:

YES:Checks complete.

NO:Air recirculation sensor malfunction. Replace sensor.

<- Go to Section TOC Section 9001 page 225 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes

13- Open Circuit in Ambient Air Temperature Sensor


188

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb.-in.

Open Circuit in Ambient Air Temperature Sensor Diagnostics Procedure


( 1 ) Connector Check

Action:

Turn key switch to OFF position.

Check the following connectors for damage, corrosion, or debris. See Heater and Air Conditioner Harness (W41) Component
Location . (Group 9015-10.)

Ambient air temperature sensor (B22). See Machine Harness (W2) Component Location . (Group 9015-10.)
Machine harness-to-cab harness 100-pin connector (X3). See Cab Harness (W1) Component Location . (Group 9015-10.)
Cab harness-to-air conditioner 10-pin connector (X52) and air conditioner controller (A7). See Heater and Air Conditioner
Harness (W41) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Harness Check.

NO:Repair or replace connector or pins. See Machine Harness (W2) Wiring Diagram , see Cab Harness (W1) Wiring Diagram , or
see Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.)

( 2 ) Harness Check

Action:

Turn key switch to OFF position.

Disconnect air conditioner controller (A7) and ambient air temperature sensor (B22).

Check wires between air conditioner controller (A7) and ambient air temperature sensor (B22) connectors for continuity.

Is there continuity on the appropriate pins?

Result:

YES:Go to Voltage Check.

NO:Repair or replace wiring harness. See appropriate harness component location or wiring diagram.

( 3 ) Voltage Check

Action:

Turn key switch to OFF position.

Ambient air temperature sensor (B22) disconnected.

<- Go to Section TOC Section 9001 page 226 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes

Turn key switch to ON position.

Check ambient air temperature sensor (B22) circuit voltage to ground.

Is voltage greater than 4.88 V?

Result:

YES:Repair or replace wiring harness. See appropriate harness component location or wiring diagram.

NO:Go to Sensor Check.

( 4 ) Sensor Check

Action:

Turn key switch to OFF position.

Ambient air temperature sensor (B22) disconnected.

Check resistance of sensor to specification. See Temperature Sensor Test . (Group 9015-20.)

Is ambient air temperature sensor within specification?

Result:

YES:Checks complete.

NO:Ambient air temperature sensor malfunction. Replace sensor.

<- Go to Section TOC Section 9001 page 227 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes

14- Short-Circuited Ambient Air Temperature Sensor


188

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb.-in.

Short-Circuited Ambient Air Temperature Sensor Diagnostic Procedure


( 1 ) Connector Check

Action:

Turn key switch to OFF position.

Check the following connectors for damage, corrosion, or debris.

Ambient air temperature sensor (B22). See Machine Harness (W2) Component Location . (Group 9015-10.)
Machine harness-to-cab harness 100-pin connector (X3). See Cab Harness (W1) Component Location . (Group 9015-10.)
Cab harness-to-air conditioner 10-pin connector (X52) and air conditioner controller (A7). See Heater and Air Conditioner
Harness (W41) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Harness Check.

NO:Repair or replace connector or pins. See Machine Harness (W2) Wiring Diagram , see Cab Harness (W1) Wiring Diagram , or
see Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.)

( 2 ) Harness Check

Action:

Turn key switch to OFF position.

Disconnect air conditioner controller (A7) and ambient air temperature sensor (B22) connectors.

Check wires between air conditioner controller (A7) and ambient air temperature sensor (B22) connectors for continuity to
machine ground.

Is continuity to ground indicated?

Result:

YES:Repair or replace wiring harness. See appropriate harness component location or wiring diagram.

NO:Go to Voltage Check.

( 3 ) Voltage Check

Action:

Turn key switch to OFF position.

Ambient air temperature sensor (B22) disconnected.

<- Go to Section TOC Section 9001 page 228 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes

Turn key switch to ON position.

Check ambient air temperature sensor (B22) circuit voltage to ground.

Is voltage less than 0.096 V?

Result:

YES:Repair or replace wiring harness. See appropriate harness component location or wiring diagram.

NO:Go to Sensor Check.

( 4 ) Sensor Check

Action:

Turn key switch to OFF position.

Disconnect ambient air temperature sensor (B22) connector.

Check resistance of sensor to specification. See Temperature Sensor Test . (Group 9015-20.)

Is ambient air temperature sensor within specification?

Result:

YES:Checks complete.

NO:Ambient air temperature sensor malfunction. Replace sensor.

<- Go to Section TOC Section 9001 page 229 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes

18- Short-Circuited Solar Radiation Sensor


188

Short-Circuited Solar Radiation Sensor Diagnostic Procedure


( 1 ) Connector Check

Action:

Turn key switch to OFF position.

Check the following connectors for damage, corrosion, or debris.

Solar sensor (B21). See Monitor Harness (W3) Component Location . (Group 9015-10.)
Monitor harness-to-cab harness (X17). See Cab Harness (W1) Component Location . (Group 9015-10.)
Cab harness-to-air conditioner 10-pin connector (X52) and air conditioner controller (A7). See Heater and Air Conditioner
Harness (W41) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Harness Check.

NO:Repair or replace connector or pins. See Monitor Harness (W3) Wiring Diagram , see Cab Harness (W1) Wiring Diagram , or
see Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.)

( 2 ) Harness Check

Action:

Turn key switch to OFF position.

Disconnect air conditioner controller (A7) and solar sensor (B21) connectors.

Check wires between air conditioner controller (A7) and solar sensor (B21) connectors for continuity.

Is continuity indicated on appropriate pins?

Result:

YES:Go to Voltage Check.

NO:Repair or replace wiring harness. See appropriate harness component location or wiring diagram.

( 3 ) Voltage Check

Action:

Turn key switch to OFF position.

Solar sensor (B21) disconnected.

Turn key switch to ON position.

Check solar sensor (B21) circuit voltage to ground.

Is voltage greater than 5.04 V?

Result:

YES:Repair or replace wiring harness. See appropriate harness component location or wiring diagram.

NO:Solar sensor malfunction. Replace sensor.


<- Go to Section TOC Section 9001 page 230 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes

<- Go to Section TOC Section 9001 page 231 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes

21- Open Circuit in Air Conditioner Freeze Control Switch


188

Open Circuit In Air Conditioner Freeze Control Switch Diagnostic


Procedure
( 1 ) Connector Check

Action:

Turn key switch to OFF position.

Check air conditioner controller (A7) and air conditioner freeze control switch (B41) connectors for damage, corrosion, or
debris. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Harness Check.

NO:Repair or replace connector or pins. See Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.)

( 2 ) Harness Check

Action:

Turn key switch to OFF position.

Disconnect air conditioner controller (A7) and air conditioner freeze control switch (B41) connectors.

Check heater and air conditioner harness (W41) wires between air conditioner controller (A7) and air conditioner freeze control
switch (B41) connectors for continuity. See Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.)

Is there continuity on the appropriate pins?

Result:

YES:Go to Voltage Check.

NO:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)

( 3 ) Voltage Check

Action:

Turn key switch to OFF position.

Air conditioner freeze control switch (B41) disconnected.

Turn key switch to ON position.

Check air conditioner freeze control switch (B41) circuit voltage to ground.

Is voltage greater than 4.79 V?

Result:

YES:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)

NO:Go to Switch Check.

( 4 ) Switch Check

<- Go to Section TOC Section 9001 page 232 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes

Action:

Turn key switch to OFF position.

Air conditioner freeze control switch (B41) disconnected.

Check resistance of switch to specification. See Temperature Sensor Test . (Group 9015-20.)

Is air conditioner freeze control switch within specification?

Result:

YES:Checks complete.

NO:Air conditioner freeze control switch malfunction. Replace switch.

<- Go to Section TOC Section 9001 page 233 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes

22- Short-Circuited Air Conditioner Freeze Control Switch


188

Short-Circuited Air Conditioner Freeze Control Switch Diagnostic


Procedure
( 1 ) Connector Check

Action:

Turn key switch to OFF position.

Check air conditioner controller (A7) and air conditioner freeze control switch (B41) connectors for damage, corrosion, or
debris. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Harness Check.

NO:Repair or replace connector or pins. See Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.)

( 2 ) Harness Check

Action:

Turn key switch to OFF position.

Disconnect air conditioner controller (A7) and air conditioner freeze control switch (B41) connectors.

Check heater and air conditioner harness (W41) wires between air conditioner controller (A7) and air conditioner freeze control
switch (B41) connectors for continuity to machine ground. See Heater and Air Conditioner Harness (W41) Wiring Diagram .
(Group 9015-10.)

Is continuity to ground indicated?

Result:

YES:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)

NO:Go to Voltage Check.

( 3 ) Voltage Check

Action:

Turn key switch to OFF position.

Air conditioner freeze control switch (B41) disconnected.

Turn key switch to ON position.

Check air conditioner freeze control switch (B41) circuit voltage to ground.

Is voltage less than 0.096 V?

Result:

YES:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)

NO:Go to Switch Check.

<- Go to Section TOC Section 9001 page 234 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes

( 4 ) Switch Check

Action:

Turn key switch to OFF position.

Air conditioner freeze control switch (B41) disconnected.

Check resistance of switch to specification. See Temperature Sensor Test . (Group 9015-20.)

Is air conditioner freeze control switch within specification?

Result:

YES:Checks complete.

NO:Air conditioner freeze control switch malfunction. Replace switch.

<- Go to Section TOC Section 9001 page 235 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes

43- Abnormal Air Conditioner and Heater Blower Port Change Servomotor
188

Abnormal Air Conditioner and Heater Blower Port Change Servomotor


Diagnostic Procedure
( 1 ) Connector Check

Action:

Turn key switch to OFF position.

Check air conditioner controller (A7) and air conditioner and heater blower port change servomotor (M10) connectors for
damage, corrosion, or debris. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Harness Check.

NO:Repair or replace connector or pins. See Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.)

( 2 ) Harness Check

Action:

Turn key switch to OFF position.

Disconnect air conditioner controller (A7) and air conditioner and heater blower port change servomotor (M10).

Check heater and air conditioner harness (W41) wires between air conditioner controller (A7) and air conditioner and heater
blower port change servomotor (M10) connectors for continuity. See Heater and Air Conditioner Harness (W41) Wiring Diagram
. (Group 9015-10.)

Is there continuity on the appropriate pins?

Result:

YES:Go to Open Circuit Check.

NO:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)

( 3 ) Open Circuit Check

Action:

Turn key switch to OFF position.

Air conditioner and heater blower port change servomotor (M10) disconnected.

Turn key switch to ON position.

Turn temperature control/mode switch and blower speed switch to ON position.

Check air conditioner and heater blower port change servomotor (M10) circuit voltage to ground.

Is voltage greater than 5 V?

Result:

YES:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)

<- Go to Section TOC Section 9001 page 236 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes

NO:Go to Short Circuit Check.

( 4 ) Short Circuit Check

Action:

Turn key switch to OFF position.

Air conditioner and heater blower port change servomotor (M10) disconnected.

Turn key switch to ON position.

Turn temperature control/mode switch and blower speed switch to ON position.

Check air conditioner and heater blower port change servomotor (M10) circuit voltage to ground.

Is voltage present?

Result:

YES:Air conditioner and heater blower port change servomotor malfunction. Replace servomotor.

NO:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)

<- Go to Section TOC Section 9001 page 237 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes

44- Abnormal Air Conditioner and Heater Mixer Servomotor


188

Abnormal Air Conditioner and Heater Mixer Servomotor Diagnostic


Procedure
( 1 ) Connector Check

Action:

Turn key switch to OFF position.

Check air conditioner controller (A7) and air conditioner and heater mixer servomotor (M11) connectors for damage, corrosion,
or debris. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Harness Check.

NO:Repair or replace connector or pins. See Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.)

( 2 ) Harness Check

Action:

Turn key switch to OFF position.

Disconnect air conditioner controller (A7) and air conditioner and heater mixer servomotor (M11).

Check heater and air conditioner harness (W41) wires between air conditioner controller (A7) and air conditioner and heater
mixer servomotor (M11) connectors for continuity. See Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group
9015-10.)

Is there continuity on the appropriate pins?

Result:

YES:Go to Open Circuit Check.

NO:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)

( 3 ) Open Circuit Check

Action:

Turn key switch to OFF position.

Air conditioner and heater mixer servomotor (M11) disconnected.

Turn key switch to ON position.

Turn temperature control/mode switch and blower speed switch to ON position.

Check air conditioner and heater mixer servomotor (M11) circuit voltage to ground.

Is voltage greater than 4.8V?

Result:

YES:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)

<- Go to Section TOC Section 9001 page 238 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes

NO:Go to Short Circuit Check.

( 4 ) Short Circuit Check

Action:

Turn key switch to OFF position.

Air conditioner and heater mixer servomotor (M11) disconnected.

Turn key switch to ON position.

Turn temperature control/mode switch and blower speed switch to ON position.

Check air conditioner and heater mixer servomotor (M11) circuit voltage to ground.

Is voltage less than 0.2 V?

Result:

YES:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)

NO:Air conditioner and heater mixer servomotor (M11) malfunction. Replace servomotor.

<- Go to Section TOC Section 9001 page 239 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes

91- Communication Error


188

Communication Error Diagnostic Procedure


( 1 ) Connector Check

Action:

Turn key switch to OFF position.

Check harness connection to monitor controller (A4) and air conditioner controller (A7) for damage, corrosion, or debris. See
Heater and Air Conditioner Harness (W41) Component Location and see Monitor Harness (W3) Component Location . (Group
9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Harness Check.

NO:Repair or replace connector or pins. See Heater and Air Conditioner Harness (W41) Wiring Diagram or see Monitor Harness
(W3) Wiring Diagram . (Group 9015-10.)

( 2 ) Harness Check

Action:

Turn key switch to OFF position.

Disconnect monitor controller (A4) and air conditioner controller (A7) connectors.

Check heater and air conditioner harness (W41) wires between monitor controller (A4) and air conditioner controller (A7)
connectors for continuity.

Is there continuity on the appropriate pins?

Result:

YES:Air conditioner controller (A7) malfunction. Replace controller.

NO:Repair or replace wiring harness. See appropriate component location or wiring diagram.

<- Go to Section TOC Section 9001 page 240 130G Excavator Diagnostic
OPERATIONAL CHECKOUT PROCEDURE (g) by Belgreen v2.0

92- CAN Bus Off Error


188

CAN Bus Off Error Diagnostic Procedure


( 1 ) Connector Check

Action:

Turn key switch to OFF position.

Check harness connection to monitor controller (A4) and air conditioner controller (A7) for damage, corrosion, or debris. See
Heater and Air Conditioner Harness (W41) Component Location and see Monitor Harness (W3) Component Location . (Group
9015-10.)

Are connectors in good condition and free of corrosion and debris?

Result:

YES:Go to Harness Check.

NO:Repair or replace connector or pins. See Heater and Air Conditioner Harness (W41) Wiring Diagram or see Monitor Harness
(W3) Wiring Diagram . (Group 9015-10.)

( 2 ) Harness Check

Action:

Turn key switch to OFF position.

Disconnect monitor controller (A4) and air conditioner controller (A7) connectors.

Check heater and air conditioner harness (W41) wires between monitor controller (A4) and air conditioner controller (A7)
connectors for continuity.

Is there continuity on the appropriate pins?

Result:

YES:Air conditioner controller (A7) malfunction. Replace controller.

NO:Repair or replace wiring harness. See appropriate component location or wiring diagram.

<- Go to Section TOC Section 9005 page 241 130G Excavator Diagnostic
130G Excavator Diagnostic (g) by Belgreen v2.1

Section 9005 - OPERATIONAL CHECKOUT PROCEDURE


Table of contents
Group 10 - Operational Checkout Procedure ....................................................................................... 1
Operational Checks—Key Switch On, Engine On Checks ...................................................................... 1

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Group 10 - Operational Checkout Procedure


Operational Checkout
This procedure is used to check operation of machine. It is designed so you can do a walk around inspection, check machine
operation, and perform specific checks from the operator′s seat.

If there is a problem with machine, diagnostic information in this checkout will help pinpoint the probable cause. This
information may allow you to perform a simple adjustment to correct the problem. Use the table of contents to help find
adjustment procedures.

A location will be required which is level and has adequate space to complete checks. No tools or equipment are needed to
perform checkout.

Complete necessary visual checks (oil levels, oil condition, external leaks, loose hardware, linkage, wiring) prior to doing
checkout. The machine must be at operating temperature for many of the checks. See Hydraulic Oil Warm-up Procedure .
(Group 9025-25.)

Read each check completely before performing. If no problem is found, you will be instructed to go to the next check. If a
problem is indicated, you will be referred to a procedure for adjustment, repair, or replacement.

The monitor can be used to perform diagnostic and operational checks. The monitor can display engine speed, pressures, and
diagnostic trouble codes (DTCs).

Diagnostic Trouble Code Check


( 1 ) Display and Clear Trouble Codes

Action:

Always check for diagnostic trouble codes and correct them before performing operational checkout.

Diagnostic trouble codes can be displayed by using one of the following methods:

Monitor
Service ADVISOR ™
MPDr

sss:

Are diagnostic trouble codes present?

Result:

YES:Correct all diagnostic trouble codes before proceeding. See Reading Diagnostic Trouble Codes With Service ADVISOR™
Diagnostic Application . See Reading Diagnostic Trouble Codes With Monitor Display . See MPDr Application . (Group 9015-20.)

NO:Proceed with operational checkout.

Operational Checks—Key Switch Off, Engine Off Checks


( 1 ) Horn Circuit Check

Action:

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Horn Circuit

LEGEND:
1 Horn Button

Key switch in OFF position.

Press horn button (1) on top of left pilot control lever.

sss:

Does horn sound?

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb.-in.

Result:

YES:Go to next check.

NO:Check horn 10 A fuse (F19) (marked HORN). See Fuse and Relay Specifications . (Group 9015-10.)

NO:Check horn wiring harness. See Cab Harness (W1) Wiring Diagram and see Machine Harness (W2) Wiring Diagram . (Group
9015-10.)

( 2 ) Hour Meter and Fuel Gauge Checks

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Action:

Switch Panel

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Hour Meter and Fuel Gauge Screen

LEGEND:
1 Hour Meter
2 Home Button
6 Fuel Gauge

Press and hold home button (2) until default screen appears.

sss:

Does hour meter (1) display machine hours?

sss:

Does fuel gauge (6) display correct fuel level?

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb.-in.

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Result:

YES:Go to next check.

NO:Check power on 5 A fuse (F17) (marked POWER ON). See Fuse and Relay Specifications . (Group 9015-10.)

NO:Check wiring. See Cab Harness (W1) Wiring Diagram or see Monitor Harness (W3) Wiring Diagram . (Group 9015-10.)

Operational Checks—Key Switch On, Engine Off Checks


( 1 ) Monitor Start Up Check

Action:
LEGEND:
1 System Starting Screen
2 Default Screen

System Starting Screen

Default Screen

→NOTE:

The exhaust filter auto cleaning disabled indicator will display on the monitor when the key switch is in
ON position. Once the engine is started, the indicator will disappear unless exhaust filter auto cleaning
has been disabled by the operator through the monitor.

When the key switch is turned to the ON position, the system starting screen (1) displays for about 2 seconds and then the
default screen (2) is displayed.

Turn key switch to ON position.

sss:

Does monitor display system starting screen?

sss:

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Does default screen with hour meter appear after system starting screen disappears?

Result:

YES:Go to next check.

NO:Check controller 5 A fuse (F10) (marked CONTROLLER). See Fuse and Relay Specifications . (Group 9015-10.)

( 2 ) Monitor, Gauges, and Battery Relay Checks

Action:

Default Screen

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Engine Preheat Indicator

LEGEND:
1 Work Mode Indicator
2 Exhaust Filter Auto Cleaning Disabled Indicator
3 Power Mode Indicator
4 Hour Meter
5 Engine Coolant Temperature Gauge
6 Fuel Gauge
7 Travel Mode Indicator
8 Engine Preheat Indicator

IMPORTANT:

This machine is equipped with glow plugs. Glow plugs are automatically controlled by the engine
controller when the key is turned ON. Do not start the engine until the engine preheat indicator (8)
disappears on the monitor. Indicator will not appear if ambient air temperature is above 0°C (32°F).

→NOTE:

The exhaust filter auto cleaning disabled indicator will display on the monitor when the key switch is in
ON position. Once the engine is started, the indicator will disappear unless exhaust filter auto cleaning
has been disabled by the operator through the monitor.

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

→NOTE:

If engine coolant temperature is below 30°C (86°F) engine temperature gauge needle may not move.

Turn key switch to ON.

sss:

Does battery relay click?

sss:

Does engine coolant temperature gauge (5) display correct engine coolant temperature?

sss:

Does fuel gauge (6) display correct fuel level?

sss:

Does hour meter (4) display machine hours?

sss:

Does work mode indicator (1) display correct work mode (dig or attachment)?

sss:

Does travel mode indicator (7) display correct travel mode?

sss:

Does power mode indicator (3) display correct power mode?

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb.-in.

Result:

YES:Go to next check.

NO:Monitor does not turn ON. Check monitor 5 A fuse (F14) (marked MONITOR). See Fuse and Relay Specifications . (Group
9015-10.)

NO:Check wiring. See Cab Harness (W1) Wiring Diagram or see Monitor Harness (W3) Wiring Diagram . (Group 9015-10.)

NO:Check key switch. See Electrical Component Checks . (Group 9015-20.) Check battery relay. See Electrical Component
Checks . (Group 9015-20.) Check wiring. See Machine Harness (W2) Wiring Diagram and see Cab Harness (W1) Wiring Diagram
. (Group 9015-10.)

NO:Neither engine coolant temperature gauge nor fuel gauge moves. Check gauge sensor and wiring. See Machine Harness
(W2) Wiring Diagram and see Cab Harness (W1) Wiring Diagram . (Group 9015-10.)

NO:Other than normal indicator lights remain on. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes With
Monitor Display or see Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application . (Group 9015-20.)

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

( 3 ) Rear Camera Check

Action:
LEGEND:
5 Default Screen

Default Screen

LEGEND:
1 Main Menu Screen

Main Menu Screen

LEGEND:
2 Monitor Dial
3 Back Button
4 Home Button

Switch Panel

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

CAUTION:

To avoid possible injury or death to operator or others. The rear view camera image is designed to
supplement other safety practices and is not intended to be the sole method of collision avoidance.
Always be alert and aware of the surroundings when operating this machine.

Turn key switch to ON position.

When the default screen (5) is displayed, press monitor dial (2) on the switch panel.

sss:

Does main menu (1) display?

Rotate monitor dial to highlight settings menu.

Press monitor dial.

sss:

Does settings menu display?

At settings menu, rotate monitor dial to highlight rear view camera monitor.

Press monitor dial to display rear view camera monitor menu.

sss:

Does rear view camera monitor menu display?

Press monitor dial to turn camera ON (enable).

Press home button (4).

LEGEND:
6 Rear View Image

Rear View Image

sss:

Does rear view image (6) display on default screen?

Repeat above steps.

At rear view camera monitor menu, press monitor dial to turn camera OFF (disable).

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Press home button.

sss:

Does default screen appear without rear view image?

Result:

YES:Go to next check.

NO:Menus do not display. Check monitor 5 A fuse (F14) (marked MONITOR). See Fuse and Relay Specifications . (Group
9015-10.)

NO: See Rear Camera Harness (W19) Component Location and see Rear Camera Harness (W19) Wiring Diagram . (Group
9015-10.)

( 4 ) Travel Lever and Pedal Neutral Checks

Action:

Travel Lever and Pedal

LEGEND:
1 Forward
2 Rearward

Push both travel levers and pedals forward (1), then release.

Pull both travel levers and pedals rearward (2), then release.

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

sss:

Do levers and pedals require equal effort to operate in forward and reverse?

sss:

Do levers and pedals return to neutral at the same time when released?

Result:

YES:Go to next check.

NO:Inspect, repair or replace travel pilot control valve. See Travel Pilot Valve Disassemble and Assemble . (Group 3360.)

( 5 ) Light Circuit Checks

Action:

Switch Panel

LEGEND:
3 Work Light Switch

Turn work light switch (3) to 1st position.

sss:

Is monitor panel back light and base machine work light on?

sss:

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Does switch panel illuminate?

Turn light switch to 2nd position.

sss:

Does base machine work light stay on and switch panel stay illuminated?

sss:

Does boom work light come on and monitor back panel light change to night mode?

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb.-in.

Result:

YES:Go to next check.

NO:Check work and drive lights 20 A fuse (F1) (marked LAMP) and controller 5 A fuses (F10) (marked CONTROLLER). See Fuse
and Relay Specifications . (Group 9015-10.)

NO:Check wiring harness. See System Functional Schematic . (Group 9015-10.) See Cab Harness (W1) Wiring Diagram . (Group
9015-10.)

( 6 ) Windshield Wiper Control Check

Action:

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Switch Panel

LEGEND:
4 Windshield Wiper and Washer Switch

→NOTE:

Front window must be fully closed and latched for windshield wiper to operate.

Turn windshield wiper and washer switch (4) to 1st INT position.

sss:

Does wiper operate intermittently (8 second interval)?

Turn windshield wiper and washer switch to 2nd INT position.

sss:

Does wiper operate intermittently, but faster than when in first position (5 second interval)?

Turn windshield wiper and washer switch to 3rd INT position.

sss:

Does wiper operate intermittently, but faster than when in second position (3 second interval)?

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Turn windshield wiper and washer switch to ON position.

sss:

Does wiper operate continuously?

Turn windshield wiper and washer switch to OFF position.

sss:

Does wiper arm stop and retract to left side of windshield?

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb.-in.

Result:

YES:Go to next check.

NO:Check windshield wiper and washer 10 A fuse (F2) (marked WIPER). See Fuse and Relay Specifications . (Group 9015-10.)
See Cab Harness (W1) Wiring Diagram . (Group 9015-10.) See Windshield Wiper and Washer Circuit Theory of Operation .
(Group 9015-15.)

( 7 ) Windshield Washer Control Check

Action:

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Switch Panel

LEGEND:
4 Windshield Wiper and Washer Switch

IMPORTANT:

Washer motor may be damaged if washer switch is held for more than 20 seconds, or continually
operated with no fluid in the washer fluid tank.

→NOTE:

While wiper is being operated in INT mode, when windshield wiper and washer switch is pressed, wiper
mode is changed to continuous mode.

Press windshield wiper and washer switch (4).

sss:

Is washer fluid supplied to windshield?

Press and hold windshield wiper and washer switch for 3 seconds.

sss:

Does wiper start and continue operating until switch is released?

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Release windshield wiper and washer switch.

sss:

Does wiper stop and retract to left side of windshield?

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb.-in.

Result:

YES:Go to next check.

NO:Check washer fluid level. See Check Windshield Washer Fluid Level . (Operator’s Manual.)

NO:Check windshield wiper and washer 10 A fuse (F2) (marked WIPER). See Fuse and Relay Specifications . (Group 9015-10.)

NO:Check wiring harness. See Cab Harness (W1) Wiring Diagram . (Group 9015-10.)

NO:Check washer pump. See Windshield Wiper and Washer Circuit Theory of Operation . (Group 9015-15.)

( 8 ) Windshield Wiper Circuit Check

Action:

Front Window Release Handle

LEGEND:
1 Lock Pin
2 Lock Release Bar

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

CAUTION:

Prevent possible injury from window closing. Upper front window comes down very forcefully. Close
window only when sitting on operator′s seat. Guide window down slowly.

CAUTION:

Prevent possible injury from window closing. Always lock the pin in cab frame boss hole.

→NOTE:

The wiper cannot operate with the upper front window open. The washer can operate with the upper
front window open. When closing window, check that window upper left corner makes good contact with
the cab.

Slide lock pin (1) inward, then down into notch.

Pull lock release bar (2) toward operator’s seat.

While holding lower handle on window, pull window up and back as far as it can go.

Slide lock pin into cab frame boss hole and rotate downward into the locked position.

Switch Panel

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

LEGEND:
4 Windshield Wiper and Washer Switch

Turn windshield wiper and washer switch (4) to ON position.

sss:

Does wiper circuit click?

sss:

Does wiper remain stationary in park position?

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb.-in.

Result:

YES:Go to next check.

NO:Check windshield wiper and washer 10 A fuse (F2) (marked WIPER). See Fuse and Relay Specifications . (Group 9015-10.)

NO:Check wiper wiring. See Cab Harness (W1) Wiring Diagram . (Group 9015-10.) See Windshield Wiper and Washer Circuit
Theory of Operation . (Group 9015-15.)

( 9 ) Windshield Washer Circuit Check

Action:

IMPORTANT:

Washer motor may be damaged if washer switch is held for more than 20 seconds, or continually
operated with no fluid in the washer fluid tank.

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Switch Panel

LEGEND:
4 Windshield Wiper and Washer Switch

Press windshield wiper and washer switch (4) and hold for 3 seconds.

sss:

Is washer fluid supplied to windshield?

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb.-in.

Result:

YES:Go to next check.

NO:Check washer fluid level. See Check Windshield Washer Fluid Level . (Operator′s Manual.)

NO:Check windshield wiper and washer 10 A fuse (F2) (marked WIPER). See Fuse and Relay Specifications . (Group 9015-10.)

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

NO:Check wiring harness. See Cab Harness (W1) Wiring Diagram . (Group 9015-10.)

NO:Check washer pump. See Windshield Wiper and Washer Circuit Theory of Operation . (Group 9015-15.)

Operational Checks—Key Switch On, Engine On Checks


( 1 ) Monitor and Gauge Circuit Checks

Action:
LEGEND:
1 Power Mode Indicator
2 Hour Meter
3 Engine Coolant Temperature Gauge
4 Fuel Gauge
5 Alarm Indicator

Operating Screen

IMPORTANT:

Engine damage could occur if the alarm indicator (5) or engine oil pressure alarm indicator comes on
after engine starts. Turn off machine immediately.

→NOTE:

The exhaust filter auto cleaning disabled indicator will display on the monitor when the key switch is in
ON position. Once the engine is started, the indicator will disappear unless exhaust filter auto cleaning
has been disabled by the operator through the monitor.

Start engine.

sss:

Do all alarm indicator displays remain off after engine starts?

sss:

Does alarm indicator remain off after engine starts?

sss:

Does engine coolant temperature gauge (3) display correct engine coolant temperature?

sss:

Does fuel gauge (4) display correct fuel level?

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Result:

YES:Go to next check.

NO:Engine oil pressure alarm displayed. Immediately stop engine and check engine oil level. See Check Engine Oil Level .
(Operator’s Manual.)

OK: See Check Engine Oil Pressure . (CTM104.)

NO:Alternator alarm indicator displayed. Check alternator drive belt.

OK:Check alternator. See Alternator Test . (Group 9015-20.)

NO:Other alarm indicators display on monitor. See Monitor Controller (DSZ) Circuit Theory of Operation . (Group 9015-15.)

( 2 ) Pilot Shutoff Circuit Check

Action:
LEGEND:
1 Engine Speed Dial

Engine Speed Dial

Locked

CAUTION:

Avoid possible injury. Machine may move during this check. Make sure area is clear and large enough to
operate all machine functions.

Turn engine speed dial (1) to L (slow idle) position.

Place pilot shutoff lever in locked (UP) position.

Slowly actuate dig and travel functions.

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

sss:

Do dig and travel functions operate?

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb.-in.

Result:

YES:Check wiring. See Cab Harness (W1) Wiring Diagram . (Group 9015-10.) See Pilot Shutoff Switch Harness (W11) Wiring
Diagram . (Group 9015-10.) See Pilot Shutoff Circuit Theory of Operation . (Group 9015-15.) See Pilot Control Valve Operation .
(Group 9025-05.)

NO:Continue check.

Action:

Unlocked

Place pilot shutoff lever in unlocked (DOWN) position.

Slowly actuate dig and travel functions.

sss:

Do dig and travel functions operate?

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb.-in.

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Result:

YES:Go to next check.

NO: See Cab Harness (W1) Wiring Diagram . (Group 9015-10.) See Pilot Shutoff Switch Harness (W11) Wiring Diagram . (Group
9015-10.) See Pilot Shutoff Circuit Theory of Operation . (Group 9015-15.) See Pilot Control Valve Operation . (Group 9025-05.)

( 3 ) Fan Reversing System - If Equipped

Action:

Fan Reversing Switch

Switch Panel

LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Blower Speed Switch
9 Fan Reversing Switch

Place pilot shutoff lever in unlocked (DOWN) position.

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Turn engine speed dial (1) to H (fast idle) position.

Turn auto-idle switch (2) to A/I OFF position.

Press blower speed switch (3) OFF.

Press reversing cooling fan switch to MANUAL position.

sss:

Does fan speed slow down?

sss:

After approximately 20 seconds, does the fan speed increase and rotate in reverse direction for approximately 30 seconds?

sss:

Does the fan speed slow for approximately 20 seconds? Does fan direction return to normal?

sss:

Does fan speed increase?

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb.-in.

Result:

YES:Go to next check.

NO: See Reversing Fan Switch Harness (W23) Wiring Diagram . See Reversing Fan Switch Harness (W23) Component Location .
See Cab Harness (W1) Wiring Diagram . (Group 9015-10.)

( 4 ) Engine Speed Dial Check

Action:

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Switch Panel

LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Mode Switch
4 Power Mode Button

Turn auto-idle switch (2) to A/I OFF position.

Place pilot shutoff lever in locked (UP) position.

Turn engine speed dial (1) clockwise.

sss:

Does engine speed increase?

Turn engine speed dial counterclockwise.

sss:

Does engine speed decrease?

Result:

YES:Go to next check.

NO:Check controller 5 A fuse (F10) (marked CONTROLLER). See Fuse and Relay Specifications . (Group 9015-10.)

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

OK:Check engine speed dial on monitor display. See Service Menu . (Group 9015-16.) See Monitor Controller (DSZ) Circuit
Theory of Operation . (Group 9015-15.) Check wiring harness. See System Functional Schematic . (Group 9015-10.)

( 5 ) ECO (Economy) Mode and PWR (Power) Mode Checks

Action:

Switch Panel

LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch
4 Power Mode Button

Press power mode button (4) until PWR (power) mode is displayed on monitor.

Turn auto-idle switch (2) to A/I OFF position.

Turn engine speed dial (1) to H (fast idle) position.

Press power mode button until ECO (economy) mode is displayed on monitor.

sss:

Does engine speed decrease?

Press power mode button until PWR (power) mode is displayed on monitor.

sss:

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Does engine speed increase?

Result:

YES:Go to next check.

NO: See Engine Speed Control System Operation (Group 9010-05.) for additional information on engine speed and power
mode.

( 6 ) H/P (High Power) Mode Check

Action:

Switch Panel

LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch
4 Power Mode Button

Press power mode button (4) until PWR (power) mode is displayed on monitor.

Turn auto-idle switch (2) to A/I OFF position.

Turn engine speed dial (1) to H (fast idle) position.

Press power mode button until H/P (high power) mode is displayed on monitor.

Actuate arm in function over relief.

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

sss:

Does engine speed increase as function goes over relief?

Result:

YES:Go to next check.

NO:Check controller 5 A fuse (F10) (marked CONTROLLER). See Fuse and Relay Specifications . (Group 9015-10.) See Service
Menu . (Group 9015-16.) See Engine Speed Control System Operation . (Group 9010-05.)

NO:Check main controller (MCZ) pressure sensors. See Pressure Sensor Test . (Group 9015-20.)

NO: See System Functional Schematic . (Group 9015-10.)

NO: See H/P (High Power) Function Does Not Operate, PWR (Power) Mode Is Normal . (Group 9025-15.)

( 7 ) Auto-Idle Circuit Check

Action:

Switch Panel

LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch
4 Power Mode Button

Turn engine speed dial (1) to H (fast idle) position.

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Press power mode button (4) until H/P (high power) mode is displayed on monitor.

Turn auto-idle switch (2) to A/I off position.

Place pilot shutoff lever in unlocked (DOWN) position.

Turn auto-idle switch to A/I on position.

sss:

Does engine speed decrease after 4—6 seconds?

Slowly actuate dig function.

sss:

Does engine speed return to fast idle?

Result:

YES:Go to next check.

NO:Check solenoid 20 A fuse (F4) (marked SOLENOID). See Fuse and Relay Specifications . (Group 9015-10.) See Engine
Control Unit (ECU) Circuit Theory of Operation . (Group 9015-15.) See System Functional Schematic . (Group 9015-10.)

( 8 ) Travel Alarm Check

Action:
LEGEND:
A Pilot Shutoff Lever
B Travel Levers
C Travel Pedals

Travel Alarm

CAUTION:

Avoid possible injury. Machine will move during this check. Make sure area is clear and large enough to
operate machine.

Place pilot shutoff lever (A) in unlocked (DOWN) position.

Push travel pedals or levers forward.

sss:

Does travel alarm sound?

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Push travel pedals or pull levers rearward.

sss:

Does travel alarm sound?

Result:

YES:Go to next check.

NO:Check travel alarm 5 A fuse (F5) (marked OPT 1). See Fuse and Relay Specifications . (Group 9015-10.)

NO:Check wiring. See Travel Alarm Harness (W26) Wiring Diagram . (Group 9015-10.) See Travel Alarm Harness (W26)
Component Location . (Group 9015-10.)

( 9 ) Travel Alarm Cancel Switch Circuit Check

Action:
LEGEND:
1 Reversing Fan Switch
2 Seat Heater Switch
3 Travel Alarm Cancel Switch

Left Console

CAUTION:

Avoid possible injury. Machine will move during this check. Make sure area is clear and large enough to
operate machine.

→NOTE:

Travel alarm must operate for this check.

Place pilot shutoff lever in unlocked (DOWN) position.

Push travel pedals or levers and allow travel alarm to operate for a minimum of 12 seconds.

sss:

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Does travel alarm sound?

While continuing travel, push travel alarm cancel switch (3).

sss:

Does travel alarm stop sounding?

Result:

YES:Go to next check.

NO:Check travel alarm 5 A fuse (F5) (marked OPT 1). See Fuse and Relay Specifications . (Group 9015-10.)

NO:Check wiring. See Travel Alarm Harness (W26) Wiring Diagram . (Group 9015-10.) See Travel Alarm Harness (W26)
Component Location . (Group 9015-10.)

( 10 ) Hydraulic Oil Tank Pressurization Check

Action:
LEGEND:
1 Hydraulic Oil Tank Pressure Release Button
2 Hydraulic Oil Tank Cover

Hydraulic Oil Tank Cover

IMPORTANT:

The pressurized oil tank creates pressure at the inlet to the hydraulic pumps. If tank cover does not seal,
hydraulic pumps could cavitate and be damaged.

Raise boom to full height, then lower boom to ground.

Slowly depress pressure release button (1) on hydraulic oil tank cover.

sss:

Is air heard escaping from the pressure release button on hydraulic oil tank cover?

Result:

YES:Go to next check.

NO:Replace hydraulic oil tank cover.

( 11 ) Control Lever Pattern Check-Excavator Pattern

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Action:

Control Lever Pattern Check - Excavator Pattern

LEGEND:
1 Arm Out
2 Arm In
3 Swing Left
4 Swing Right
5 Boom Down
6 Boom Up
7 Bucket Load
8 Bucket Dump

CAUTION:

Prevent possible injury from unexpected machine movement. Clear all persons from the area before
operating machine.

Turn engine speed dial to L (slow idle) position.

Place pilot shutoff lever in unlocked (DOWN) position.

Slowly move hydraulic levers to all positions.

sss:

Do bucket, boom, arm, and swing move according to pattern?

Result:

YES:Go to next check.

NO: See Control Lever Pattern Operation . (Operator′s Manual.)

NO: See Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern . (Group 9025-15.)

( 12 ) Control Lever Pattern Check- Backhoe Pattern

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Action:

Control Lever Pattern Check - Backhoe Pattern

LEGEND:
1 Arm Out
2 Arm In
3 Swing Left
4 Swing Right
5 Boom Down
6 Boom Up
7 Bucket Load
8 Bucket Dump

CAUTION:

Prevent possible injury from unexpected machine movement. Clear all persons from the area before
operating machine.

Turn engine speed dial to L (slow idle) position.

Place pilot shutoff lever in unlocked (DOWN) position.

Slowly move hydraulic levers to all positions.

sss:

Do bucket, boom, arm, and swing move according to pattern?

Result:

YES:Go to next check.

NO: See Control Lever Pattern Operation . (Operator′s Manual.)

NO: See Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern . (Group 9025-15.)

( 13 ) Swing Dynamic Braking Check

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Action:

Swing Dynamic Braking

Switch Panel

LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch
4 Power Mode Button

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

CAUTION:

Avoid possible injury. Make sure area is clear and large enough to swing extended arm and bucket.
Machine must be on level ground.

Position upperstructure with boom to the front.

Move arm to the extended position, bucket to the retracted position, and bucket-to-arm pivot pin at same level as boom-to-
frame pivot pin.

Turn engine speed dial (1) to H (fast idle) position.

Press power mode button (4) until PWR (power) mode is displayed on monitor.

Fully actuate swing function. Swing clockwise 90 degrees and then release lever.

sss:

Does upperstructure stop within 45 degrees (1/8 turn) or less after releasing lever?

Position upperstructure with boom to the front.

Fully actuate swing function. Swing counterclockwise 90 degrees and then release lever.

sss:

Does upperstructure stop within 45 degrees (1/8 turn) or less after releasing lever?

Result:

YES:Go to next check.

NO: Perform Swing Motor Leakage Test . (Group 9025-25.) Perform Swing Motor Crossover Relief Valve Test and Adjustment .
(Group 9025-25.)

NO:Check swing valve spool and spring. See Control Valve (5-Spool) Disassemble and Assemble . (Group 3360.)

( 14 ) Swing Park Brake and Circuit Drift Checks

Action:

Machine Position

Fill the bucket with dirt.

Position machine on a hillside with a slope of approximately 25%. If a hill is not available, raise one side of machine
<- Go to Section TOC Section 9005 page 36 130G Excavator Diagnostic
Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

approximately 300 mm (1 ft) with the boom and then put a block under the track.

Move arm to the fully extended position.

Raise boom so arm-to-bucket pivot pin are the same height as boom-to-frame pivot pin.

Position upperstructure with cab over travel motors, perpendicular to tracks.

Turn engine speed dial to L (slow idle) position.

Wait approximately 5 minutes with all functions in neutral.

→NOTE:

Function does not need to be fully actuated to disengage the swing park brake.

Slowly actuate bucket load function to disengage the swing park brake. Do not hold the function over relief for more than 10
seconds.

sss:

Does upperstructure hold position when swing park brake is engaged?

sss:

Does upperstructure move only slightly when swing park brake is disengaged?

Swing upperstructure 180 degrees counterclockwise and repeat procedure.

Turn engine speed dial to L (slow idle) position.

Wait approximately 5 minutes with all functions in neutral.

Slowly actuate bucket load function to disengage the swing park brake. Do not hold the function over relief for more than 10
seconds.

sss:

Does upperstructure hold position when swing park brake is engaged?

sss:

Does upperstructure move only slightly when swing park brake is disengaged?

Result:

YES:Go to next check.

NO:Upperstructure moves when all functions are in neutral and park brake is engaged. Check for pilot oil pressure to swing
park brake. See Upperstructure Drift With Swing Valve In Neutral . (Group 9025-15.)

NO:Upperstructure movement is excessive when park brake is disengaged. Perform Swing Motor Leakage Test . (Group
9025-25.)

NO:Check swing spool in the control valve. See Control Valve (5-Spool) Disassemble and Assemble . (Group 3360.)

( 15 ) Swing Power Check

Action:

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Machine Position

Switch Panel

LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch
4 Power Mode Button

Fill the bucket with dirt.

Position machine on a hillside with a slope of approximately 25%. If a hill is not available, raise one side of machine
approximately 300 mm (1 ft) with the boom and then put a block under the track.

Move arm to the fully extended position. Raise boom so arm-to-bucket pivot pin is the same height as boom-to-frame pivot pin.

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Swing upperstructure clockwise so it is 90 degrees to the slope.

Turn engine speed dial (1) to H (fast idle) position.

Press power mode button (4) until H/P (high power) mode is displayed on monitor.

Actuate the swing function to swing uphill.

sss:

Does upperstructure swing uphill?

Swing upperstructure 180 degrees counterclockwise and repeat procedure.

Turn engine speed dial to H (fast idle) position.

Power mode button in H/P (high power) mode.

Actuate the swing function to swing uphill.

sss:

Does upperstructure swing uphill?

Result:

YES:Go to next check.

NO: See Swing Motor Crossover Relief Valve Test and Adjustment . (Group 9025-25.)

NO:Check swing motor leakage. Perform Swing Motor Leakage Test . (Group 9025-25.)

NO:Check swing spool in control valve. See Control Valve (5-Spool) Disassemble and Assemble . (Group 3360.)

( 16 ) Dig Function Drift Check (loaded bucket)

Action:

Machine Position—Loaded Bucket

Fill bucket with material to specification.

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Item Measurement Specification

Loaded Bucket Weight (approximate) 750 kg

1650 lb.

Position bucket at maximum reach with bucket pivot pin at same height as boom pivot pin.

Retract arm cylinder, then extend about 50 mm (2 in.).

Extend bucket cylinder, then retract about 50 mm (2 in.).

Stop engine.

Measure amount cylinders extend or retract in 5 minutes.

Measure distance from bottom of bucket to ground.

Compare measurements to specifications.

Item Measurement Specification

Dig Function Drift Specifications (loaded bucket)


Boom Cylinder Drift 10 mm

0.39 in.

Arm Cylinder Drift 20 mm

0.79 in.

Bucket Cylinder Drift 15 mm

0.59 in.

Bottom of Bucket-to-Ground Drift 110 mm

4.33 in.

Item Measurement Specification

Blade Drift Specifications (if equipped)


Blade Cylinder Drift 5 mm

0.20 in.

Bottom of Blade-to-Ground Drift 20 mm

0.79 in.

sss:

Is cylinder drift within specification?

Result:

YES:Go to next check.

NO: See Load Drifts Down When Control Lever Is In Neutral Position . (Group 9025-15.)

( 17 ) Dig Function Drift Check (empty bucket)

Action:

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Machine Position—Empty Bucket

LEGEND:
1 Arm Tip Position Above Ground

Empty bucket of material.

Extend arm cylinder, then retract about 50 mm (2 in.).

Extend bucket cylinder, then retract about 50 mm (2 in.).

Lower boom until arm tip is 1 m (40 in.) above ground (1).

Stop engine.

Measure amount cylinders extend or retract in 5 minutes.

Measure distance from arm tip to ground.

Compare measurements to specifications.

Item Measurement Specification

Dig Function Drift Specifications (empty bucket)


Boom Cylinder Drift 5 mm

0.20 in.

Arm Cylinder Drift 15 mm

0.59 in.

Bucket Cylinder Drift 10 mm

0.39 in.

Arm Tip-to-Ground Drift 100 mm

3.94 in.

Item Measurement Specification

Blade Drift Specifications (if equipped)


Blade Cylinder Drift 5 mm

0.20 in.

Bottom of Blade-to-Ground Drift 20 mm

0.79 in.

sss:

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Is cylinder drift within specification?

Result:

YES:Go to next check.

NO: See Load Drifts Down When Control Lever Is In Neutral Position . (Group 9025-15.)

( 18 ) Swing Priority Circuit Check

Action:

CAUTION:

Avoid possible injury. Make sure area is clear and large enough to swing extended arm and bucket.
Machine must be on level ground.

Swing Priority Check

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Switch Panel

LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch
4 Power Mode Button

IMPORTANT:

Avoid possible machine damage. Position machine as shown. Operate swing and arm in slowly a few
times before attempting to perform check to ensure bucket does not contact machine or ground.

Position machine as shown.

Turn engine speed dial (1) to H (fast idle) position.

Turn auto-idle switch (2) to A/I OFF position.

Press power mode button (4) until PWR (power) mode is displayed on monitor.

Operate swing function and record time required for three complete revolutions.

Item Measurement Specification

Swing Function Time—Three Revolutions 12.50—14.50 sec.

Position machine as shown, arm extended, bucket curled, and upperstructure 90 degrees to tracks.

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Turn engine speed dial (1) to H (fast idle) position.

Press power mode button (4) until PWR (power) mode is displayed on monitor.

Raise boom high enough so bucket does not contact the machine or ground during arm in and swing combined operation.

Operate swing function and slowly actuate arm in function when upperstructure is in line with tracks. Record time required for
three complete revolutions.

→NOTE:

Swing speed should not slow when actuating arm in.

sss:

Does swing speed remain unchanged when actuating arm in?

Result:

YES:Go to next check.

NO:Check arm 1 flow rate pilot valve. See Pilot Signal Manifold Operation . (Group 9025-05.) See Arm 1 Flow Rate Control
Valve Circuit Operation . (Group 9025-05.)

( 19 ) Control Valve Lift Check Test

Action:

Control Valve Lift

LEGEND:
1 Engine Speed Dial

Engine Speed Dial

Turn engine speed dial (1) to L (slow idle) position.

Position machine as shown.

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Slowly lower boom, extend arm (retract cylinder), and dump bucket (retract cylinder).

sss:

Do functions move in opposite direction as pilot control levers are first moved, then change direction as levers are moved
farther?

Result:

YES: See Load Falls When Control Valve Is Actuated To Raise Load With Engine Running At Slow Idle . (Group 9025-15.)

NO:Go to next check.

( 20 ) Boom Up, Arm In, and Bucket Combined Function Operation Check

Action:

Switch Panel

LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch
4 Power Mode Button

Turn engine speed dial (1) to H (fast idle) position.

Turn auto-idle switch (2) to A/I OFF position.

Press power mode button (4) until PWR (power) mode is displayed on monitor.

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Actuate boom up function, arm in function, and then bucket function in combination.

sss:

Does boom continue to move at approximately the same speed after bucket function is actuated?

Result:

YES:Go to next check.

NO:If boom speed slows excessively, inspect bucket flow rate control valve. See Control Valve (5-Spool) Disassemble and
Assemble . (Group 3360.)

( 21 ) Boom Regenerative Valve Operation Check

Action:

Switch Panel

LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch
4 Power Mode Button

Turn engine speed dial (1) to H (fast idle) position.

Press power mode button (4) until PWR (power) mode is displayed on monitor.

Raise boom and extend the arm to full extension.

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Actuate the boom down, then arm in and boom up functions in combined operation.

sss:

Does the boom move smoothly through the complete cycle down and up and not hesitate when it goes past the vertical
position?

Result:

YES:Go to next check.

NO:Check boom up pressure sensor (B30). See Pressure Sensor Test . (Group 9015-20.)

NO:Check boom regenerative valve. See Boom Regenerative Valve Circuit Operation . (Group 9025-05.) See Control Valve (5-
Spool) Disassemble and Assemble . (Group 3360.)

( 22 ) Arm Regenerative Valve Operation Check

Action:

Switch Panel

LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch
4 Power Mode Button

Turn engine speed dial (1) to H (fast idle) position.

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Press power mode button (4) until PWR (power) mode is displayed on monitor.

Extend the arm to full extension and then lower boom so bucket is on the ground.

Actuate the boom up and arm in functions in combined operation.

sss:

Does the arm move smoothly through the complete cycle and not hesitate when it goes through the vertical position?

Result:

YES:Go to next check.

NO:Check arm in pressure sensor (B31). See Pressure Sensor Test . (Group 9015-20.) Check arm regenerative solenoid valve.
See Arm Regenerative Valve Circuit Operation . (Group 9025-05.)

OK:Check arm regenerative valve. See Control Valve (5-Spool) Disassemble and Assemble . (Group 3360.)

( 23 ) Bucket Regenerative Valve Operation Check

Action:

Switch Panel

LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch
4 Power Mode Button
<- Go to Section TOC Section 9005 page 48 130G Excavator Diagnostic
Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Turn engine speed dial (1) to H (fast idle) position.

Press power mode button (4) until PWR (power) mode is displayed on monitor.

Actuate boom up, arm out and bucket dump functions.

Actuate boom down function, arm in function, and then bucket curl function.

sss:

Does the bucket move smoothly through the complete cycle and not hesitate when it goes to the curl position?

Result:

YES:Go to next check.

NO:Check bucket regenerative valve. See Bucket Regenerative Valve Circuit Operation . (Group 9025-05.)

( 24 ) Travel Speed Selection Check

Action:

Switch Panel

LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch
4 Power Mode Button

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Turn engine speed dial (1) to H (fast idle) position.

Turn travel speed switch (3) to slow speed (turtle) mode.

Actuate travel function to full speed.

Turn travel speed switch to fast speed (rabbit) mode.

sss:

Does machine travel speed increase?

Actuate a dig function and then return to neutral.

sss:

Does machine travel speed decrease and then increase as dig function is actuated and then released?

Turn travel speed switch to slow speed (turtle) mode.

sss:

Does machine travel speed decrease?

Result:

YES:Go to next check.

NO:Check travel pressure sensor (B34) and travel speed switch (S11). See Pressure Sensor Test . (Group 9015-20.) See Travel
Motor Speed Circuit Operation . (Group 9025-05.)

( 25 ) Travel System Tracking Check

Action:

CAUTION:

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.)

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Machine Position

LEGEND:
9 Bucket Height

Fully extend arm cylinder and bucket cylinder.

Position boom so bucket height (9) is approximately 400 mm (16 in.) above ground.

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Switch Panel

LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch
4 Power Mode Button

Turn engine speed dial (1) to H (fast idle) position.

Turn auto-idle switch (2) to A/I OFF position.

Turn travel speed switch (3) to fast speed (rabbit) mode.

Press power mode button (4) until PWR (power) mode is displayed on monitor.

Tracking Check

LEGEND:
5 Distance of Mistrack
6 Acceleration and Deceleration Zone (approximate): 3—5 m (10—16 ft.)
7 Test Line (distance): 20 m (66 ft.)
8 Track Print

Operate machine at full travel forward speed on a flat and level surface approximately 30 m (99 ft.).

→NOTE:

When machine mistracks right, hydraulic pump 1 circuit oil flow may be less than specification. When
machine mistracks left, hydraulic pump 2 circuit oil flow may be less than specification.
<- Go to Section TOC Section 9005 page 52 130G Excavator Diagnostic
Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Observe direction of mistrack.

Create a straight test line 20 m (66 ft.) (7) long between two points on track print (8).

Measure and record greatest distance of mistrack (5) between inside edge of track print and test line.

Repeat procedure in reverse travel.

sss:

Does machine mistrack less than 150 mm (5.91 in.)?

Result:

YES:Go to next check.

NO:Check track sag. See Check and Adjust Track Sag. (Operator’s Manual.)

NO: Perform Travel Motor Leakage Test or perform Pump Flow Test . (Group 9025-25.)

( 26 ) Travel System Tracking Checks While Operating a Dig Function

Action:

Switch Panel

LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

4 Power Mode Button

→NOTE:

Machine will slow down during this test.

Turn engine speed dial (1) to H (fast idle) position.

Turn travel speed switch (3) to fast speed (rabbit) mode.

Operate machine at full speed forward on a flat and level surface.

After machine is moving, actuate arm out from neutral to full actuation and extend the arm.

sss:

Does machine mistrack excessively when the arm is extended?

Result:

YES: See Combined Travel And Dig Functions Slow Or No Power . (Group 9025-15.)

NO:Go to next check.

( 27 ) Travel System Maneuverability Check

Action:

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Switch Panel

LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch
4 Power Mode Button

Turn engine speed dial (1) to H (fast idle) position.

Turn travel speed switch (3) to fast speed (rabbit) mode.

Drive machine at full speed forward down a slope.

Turn in each direction.

sss:

Does each track slow down in response to pedal or lever movement in order to turn?

Repeat the procedure in reverse travel.

Turn travel speed switch to fast speed (rabbit) mode.

Drive machine at full speed in reverse down a slope.

Turn in each direction.

sss:

Does each track slow down in response to pedal or lever movement in order to turn?

Result:

YES:Go to next check.

NO: See Machine Will Not Hold Back and Park Brakes Engage and Disengage When Traveling Down an Incline . (Group
9025-15.)

( 28 ) Cycle Times Check

Action:

CAUTION:

Prevent possible injury from unexpected machine movement. Clear all persons from the area before
operating machine.

→NOTE:

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

→NOTE:

Cycle times are calculated using 2.52 m arm and 0.5 m 3 bucket. Different weight and attachments will
affect cycle times.

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Switch Panel

LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch
4 Power Mode Button
5 Monitor Dial

Turn engine speed dial (1) to H (fast idle) position.

Turn auto-idle switch (2) to A/I OFF position.

Press power mode button (4) until PWR (power) mode is displayed on monitor.

Rotate monitor dial (5) to highlight and select Dig mode from Work Mode menu. See Main Menu—Work Mode . (Operator’s
Manual.)

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Boom

Arm, Bucket, Swing

Move machine to position shown for each test.

Record cycle time for each function.

Item Measurement Specification

Boom Raise (cylinder extend) Cycle Time 2.8—3.4 sec.

Boom Lower (cylinder retract) Cycle Time 2.1—2.7 sec.

Arm In (cylinder extend) Cycle Time 2.9—3.5 sec.

Arm Out (cylinder retract) Cycle Time 2.5—3.1 sec.

Bucket Load (cylinder extend) Cycle Time 3.2—3.8 sec.

Bucket Dump (cylinder retract) Cycle Time 2.1—2.7 sec.

Blade Raise (cylinder retract) Cycle Time 2.0—2.6 sec.

Blade Lower (cylinder extend) Cycle Time 1.8—2.4 sec.

Swing Left or Right, 3 Revolutions Cycle Time 12.5—14.5 sec.

Drive 20 m (65 ft.) (check in forward and reverse with travel speed switch in FAST position) Cycle Time 11.8—14.2 sec.

Drive 20 m (65 ft.) (check in forward and reverse with travel speed switch in SLOW position) Cycle Time 18.6—24.4 sec.

Track Raised for 3 Revolutions (check in forward and reverse with travel mode switch in FAST position) Cycle Time 23.4—27.4 sec.

Track Raised for 3 Revolutions (check in forward and reverse with travel mode switch in SLOW position) Cycle Time 23.4—27.4 sec.

sss:

Does machine perform within specifications?

Result:

YES:Go to next check.

NO: See All Hydraulic Functions Slow or see Some Dig Functions Slow (Not All) . (Group 9025-15.)

( 29 ) Heater and Air Conditioning Circuit Check

Action:

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Switch Panel

LEGEND:
5 Temperature Control/Mode Switch
6 Blower Speed Switch

Start engine and warm to normal operating temperature.

Turn temperature control/mode switch (5) clockwise to maximum heat position.

sss:

Does warm air come from the vents?

Turn temperature control/mode switch counterclockwise to maximum cold position.

sss:

Does air conditioner compressor clutch solenoid “click”?

sss:

Does cool air come from the vents?

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb.-in.

Result:

YES:Go to next check.

NO:Heater does not operate. Check air conditioner and heater 20 A fuse (F3) (marked HEATER). See Fuse and Relay
Specifications . (Group 9015-10.)

NO:Check wiring harness. See System Functional Schematic . See Cab Harness (W1) Wiring Diagram . See Heater and Air
Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.)

NO:Check system operation. See Heater and Air Conditioner Operational Checks . (Group 9031-25.)

( 30 ) Heater and Air Conditioner Controls Check (Automatic Temperature Control)

Action:

Switch Panel

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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

Monitor-Air Conditioner and Heater Display

LEGEND:
5 Temperature Control/Mode Switch
6 Blower Speed Switch
7 Fan Speed
8 AUTO Display
9 Vent Position
10 Temperature Setting

Key ON, press blower speed switch (6).

Start engine and warm to normal operating temperature.

Press blower speed switch.

sss:

Does air conditioner compressor clutch solenoid “click”?

sss:

Does AUTO display (8), display on monitor?

sss:

Does monitor display vent position (9), fan speed (7), and temperature setting (10)?

Turn temperature control/mode switch (5) clockwise to maximum heat position.

<- Go to Section TOC Section 9005 page 60 130G Excavator Diagnostic


Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure

sss:

Does vent position change?

sss:

Does temperature setting increase?

sss:

Does warm air come from the vents?

Turn temperature control/mode switch counterclockwise to maximum cold position.

sss:

Does vent position change?

sss:

Does temperature setting decrease?

sss:

Does cool air come from the vents?

Press blower speed switch.

sss:

Does air conditioner compressor clutch solenoid “click”? (air conditioner and heater are ON in manual mode.)

sss:

Does AUTO display go OFF?

Turn temperature control/mode switch clockwise to maximum heat position.

sss:

Does vent position change?

sss:

Does temperature setting increase?

sss:

Does warm air come from the vents?

Turn temperature control/mode switch counterclockwise to maximum cold position.

sss:

Does vent position change?

sss:

Does temperature setting decrease?

sss:

<- Go to Section TOC Section 9005 page 61 130G Excavator Diagnostic


ENGINE (g) by Belgreen v2.0

Does cool air come from the vents?

Press temperature control/mode switch.

sss:

Does vent position change?

Repeat for all four vent positions.

sss:

Does vent position change each time switch is pressed?

Press blower speed switch.

sss:

Are air conditioner and heater OFF? (press blower speed switch to start air conditioner and heater).

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb.-in.

Result:

YES:Checks complete.

NO:Heater fan does not blow air. Check air conditioner and heater 20 A fuse (F3) (marked HEATER). See Fuse and Relay
Specifications . (Group 9015-10.) Check wiring harness. See System Functional Schematic . See Cab Harness (W1) Wiring
Diagram . See Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.) Check system operation. See
Heater and Air Conditioner Operational Checks . (Group 9031-25.)

<- Go to Section TOC Section 9010 page 62 130G Excavator Diagnostic


130G Excavator Diagnostic (g) by Belgreen v2.1

Section 9010 - ENGINE


Table of contents
Group 05 - Theory of Operation ............................................................................................................. 1
Engine Identification ............................................................................................................................. 1
John Deere Engine ................................................................................................................................ 2
Engine Fuel System Component Location ............................................................................................ 4
Engine Cooling System Component Location ....................................................................................... 6
Cold Weather Starting Aid .................................................................................................................... 7
Engine Speed Control System Operation .............................................................................................. 8
Group 15 - Diagnostic Information ...................................................................................................... 12
John Deere Engine .............................................................................................................................. 12
Group 20 - Adjustments ........................................................................................................................ 13
John Deere Engine .............................................................................................................................. 13
Group 25 - Tests ..................................................................................................................................... 14
John Deere Engine .............................................................................................................................. 14
Radiator Temperature Differential Check ........................................................................................... 15
Engine Power Test Using Turbocharger Boost Pressure ..................................................................... 18

<- Go to Global Table of contents 130G Excavator Diagnostic


Section 9010 - ENGINE Group 05: Theory of Operation

Group 05 - Theory of Operation


Engine Identification
Choosing the Correct Supporting Manuals

John Deere excavators are available in different machine configurations based on the various markets into which they are sold.
Different supporting manuals exist for different machine configurations.

Product identification numbers (PINs) are listed on the front covers of excavator manuals. These numbers are used to identify
the correct supporting manual for your machine.

Product Serial Number Identification

PIN Plate (17 character)

LEGEND:
1 PIN Plate
2 17 Character PIN

The PIN plate (1) is located on front, right corner of the cab. Each machine has a 17 character PIN (2) shown on this plate. The
last 6 characters of the PIN represent the machine′s product serial number.

Engine Model Number Identification

<- Go to Section TOC Section 9010 page 1 130G Excavator Diagnostic


Section 9010 - ENGINE Group 05: Theory of Operation

Engine Serial Number Plate

LEGEND:
3 Engine Serial Number Plate
4 9 Character Engine Model Number

Engine Serial Number Plate Location—4045HT067

The engine serial number plate (3) is located on the right side of the engine. Each engine has a 9 character engine model
number (4) shown on this plate.

Engine Emissions Level Identification

The 9 character engine model number corresponds to a specific engine emissions level.

Engine Model Number Classification

Engine Model Number Engine Emissions Level

4045HT067 Tier 3/Stage IIIA

For machines with a 17 character PIN, where the 11 th character is D, this character also corresponds to a specific engine
emissions level.

PIN Classification

th
17 Character PIN (11 character) Engine Emissions Level

xxxxxxxxxx D xxxxxx Tier 3/Stage IIIA

John Deere Engine

<- Go to Section TOC Section 9010 page 2 130G Excavator Diagnostic


Section 9010 - ENGINE Group 05: Theory of Operation

→NOTE:

For proper engine identification, see Engine Identification . (Group 9010-05.)

For additional information on John Deere PowerTech ™ engines and components for engine model 4045HT067, see the
following component technical manuals (CTMs).

See PowerTech™, PowerTech™ Plus, and PowerTech™ E 4.5L and 6.8L Diesel Engines—Base Engine . (CTM104.)
See PowerTech™ E 4.5 and 6.8L Diesel Engines Level 16 Electronic Fuel Systems with Denso HPCR . (CTM502.)

<- Go to Section TOC Section 9010 page 3 130G Excavator Diagnostic


Section 9010 - ENGINE Group 05: Theory of Operation

Engine Fuel System Component Location

Engine Fuel System Component Location

LEGEND:
1 Primary Fuel Filter and Water Separator
2 Final Fuel Filter and Water Separator
3 Auxiliary Fuel Filter and Water Separator (if equipped)
4 Auxiliary Fuel Filter and Water Separator-to-Primary Fuel Filter and Water Separator Hose
5 Final Fuel Filter-to-High Pressure Fuel Pump Hose
6 Fuel Tank-to-Auxiliary Fuel Filter and Water Separator Hose (supply hose)
7 High Pressure Fuel Pump-to-Fuel Cooler Hose
8 Fuel Cooler-to-Fuel Tank Hose (return hose)
9 Fuel Cooler
10 Fuel Tank
11 Fuel Tank Drain Hose
12 Fuel Transfer Pump-to-Final Fuel Filter and Water Separator Hose
13 Primary Fuel Filter and Water Separator-to-Fuel Transfer Pump Hose
<- Go to Section TOC Section 9010 page 4 130G Excavator Diagnostic
Section 9010 - ENGINE Group 05: Theory of Operation

14 Fuel Transfer Pump


15 High Pressure Fuel Pump

<- Go to Section TOC Section 9010 page 5 130G Excavator Diagnostic


Section 9010 - ENGINE Group 05: Theory of Operation

Engine Cooling System Component Location

Engine Cooling System Component Location

LEGEND:
1 Radiator
2 Radiator-to-Coolant Pump Hose
3 Radiator-to-Thermostat Housing Hose
4 Surge Tank
5 Surge Tank Overflow Hose
6 Surge Tank-to-Radiator Hose
7 Surge Tank-to-Thermostat Housing Hose
8 Surge Tank-to-Coolant Pump Hose
9 Coolant Pump-to-Heater Hose
10 Engine-to-Heater Hose
11 Coolant Pump

<- Go to Section TOC Section 9010 page 6 130G Excavator Diagnostic


Section 9010 - ENGINE Group 05: Theory of Operation

Cold Weather Starting Aid

Auto-Ether Injection System

LEGEND:
2 Ether Canister
Y19 Ether Start Aid Solenoid

The cold start aid system used on this machine is auto-ether injection. Ether injection helps to start the engine in cold weather
by injecting a specific amount of ether into the intake manifold.

When the ignition is ON and the engine control unit (ECU) detects the fuel temperature is below a specified temperature, the
ether start aid solenoid (Y19) energizes, and ether flows from the canister (2) to the intake manifold and mixes with intake air.

When the ether/air mixture reaches the combustion chamber, it mixes with diesel fuel. Ether ignites at a lower temperature
than diesel fuel, therefore, inside the combustion chamber the ether ignites first, heating the diesel fuel and aiding combustion.

The cold start aid system is disabled under the following conditions:

Coolant temperature is above 40°C.


Coolant temperature and fuel temperature are both invalid.

For more information, see Starting and Charging Circuit Theory of Operation . (Group 9015-15.)

<- Go to Section TOC Section 9010 page 7 130G Excavator Diagnostic


Section 9010 - ENGINE Group 05: Theory of Operation

Engine Speed Control System Operation


Specifications

SPECIFICATIONS

Engine Speeds

Slow Idle 750—850 rpm

Fast Idle—PWR Mode 1850—1950 rpm

Fast Idle—ECO Mode (no load) 1700—1800 rpm

Fast Idle—H/P Travel Mode (travel over relief) 1950—2050 rpm

Fast Idle—Relief Operation (boom up over relief) 2050—2130 rpm

Auto-Idle 1150—1250 rpm

1. 1300—1500 rpmHydraulic oil 0°C or lower (32°F or lower)Engine coolant - Not applicable
2. 1350—1450 rpmHydraulic oil 0°C or more (32°F or more)andEngine coolant 0—25°C (32—77°F)
Auto Warm-Up
3. 1150—1250 rpmHydraulic oil 0°C or more (32°F or more)andEngine coolant 25—50°C (77—122°F)
4. 1050—1150 rpmFuel 0°C or less (32°F or less)Engine coolant - Not applicableHydraulic oil - Not applicable

Idle Speed-Up 850—950 rpm

Switch Panel

LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch
4 Power Mode Button
The engine speed is controlled by the following items:

Engine Speed Dial (1)


<- Go to Section TOC Section 9010 page 8 130G Excavator Diagnostic
Section 9010 - ENGINE Group 05: Theory of Operation

Power Mode Button (4)


H/P (high power) Mode
PWR (power) Mode
ECO (economy) Mode
Work Mode Control
Travel HP Mode Control
Auto-Idle Switch (2)
Auto Warm-Up Control
Idle Speed-Up Control

Engine Speed Dial

The purpose of the engine speed dial is to control the engine speed via operator input.

The main controller uses these input signals from the engine speed dial, travel pressure sensor (B34), and the attachment
pressure sensor (B60) to determine appropriate engine speed. The main controller then sends a signal via controller area
network (CAN) to the engine control unit (ECU), and the ECU then sets engine rpm.

H/P (high power) Mode

The purpose of the H/P mode is to increase engine speed using certain hydraulic functions.

The main controller sends a signal to the ECU via CAN to raise engine rpm when the following conditions are met:

Power mode button in H/P mode.


Work mode switch in dig mode.
Engine speed is 1500 rpm or higher.
Arm in, boom up, or a combination of both functions actuated.
Pump delivery pressure high.

PWR (power) Mode

The function of PWR mode is to control the engine speed from slow idle to fast idle in response to the position of the engine
speed dial.

ECO (economy) Mode (no load)

The purpose of ECO mode is to lower engine speed to reduce fuel consumption and noise level.

The main controller receives input signals from the engine speed dial, power mode button, and the pump delivery pressure
sensors, then sends a signal via CAN to the ECU to reduce engine rpm when the following conditions are met:

Engine speed above 1800 rpm.


Power mode button in ECO mode.
Pump control pressure low or pump delivery pressure high.

Engine speed will increase up to 100 rpm over the engine speed dial setting for increased pump flow when the following
conditions are met:

Engine speed above 1800 rpm.


Power mode button in ECO mode.
Pump control pressure high.
Average pump delivery pressure low.

Travel HP (high power) Mode Control

The purpose of travel HP mode is to increase engine speed for faster travel.

The main controller uses these input signals from the travel pressure sensor, engine speed dial, travel speed switch and
delivery pressure sensors to determine appropriate engine speed. The main controller then sends a signal via CAN to the ECU
to increase engine speed when the following conditions are met:

Engine speed dial in the fast idle speed position.


Travel function is operated.
<- Go to Section TOC Section 9010 page 9 130G Excavator Diagnostic
Section 9010 - ENGINE Group 15: Diagnostic Information

Front attachment not operated.


Delivery pressure of either pump is high.

Auto-Idle Control

The purpose of auto-idle control is to lower engine speed to reduce fuel consumption and noise levels while engine is running
and no hydraulic function actuated.

The main controller uses these input signals from the travel pressure sensor, front attachment pressure sensor, engine speed
dial, and power mode button to determine appropriate engine speed. The main controller then sends a signal via CAN to the
ECU to lower engine rpm.

Auto-idle is activated when the following conditions are met:

Auto-idle control switch in the auto-idle position.


No functions activated for approximately 4 seconds.
Engine speed is greater than 1200 rpm.

Auto-idle control is deactivated when the following conditions are met:

Auto-idle control switch turned to OFF.


A hydraulic function is actuated.
Power mode button is pressed from ECO to PWR, PWR to H/P, or H/P to ECO.
Engine speed dial is turned to change engine speed.

When auto-idle is deactivated, the engine rpm increases to the setting of the engine speed dial.

Auto Warm-Up Control

The purpose of auto warm-up control is to increase engine coolant, hydraulic oil, and fuel temperatures to proper operating
temperatures. This is achieved by increasing engine speed. The temperature values read by the main controller determine the
appropriate target engine speed for auto warm-up. The main controller then sends a signal via CAN to the ECU to adjust engine
rpm according to the following conditions.

1. Only when hydraulic oil temperature is below 0°C (32°F), the main controller sends a signal to the ECU to run the engine
between 1300—1500 rpm until the hydraulic oil temperature raises above 0°C (32°F). Engine coolant temperature is not
considered for auto warm-up by the main controller when hydraulic oil temperature is below 0°C.
2. When hydraulic oil temperature is above 0°C (32°F) and engine coolant temperature is 0—25°C (32—77°F), the main
controller sends a signal to the ECU to run the engine between 1350—1450 rpm until the engine coolant temperature
raises above 25°C (77°F).
3. When hydraulic oil temperature is above 0°C (32°F) and engine coolant temperature is 25—50°C (77—122°F), the main
controller sends a signal to the ECU to run the engine between 1150—1250 rpm until the engine coolant temperature
raises above 50°C (122°F).
4. When fuel temperature is 0°C (32°F) or below, the main controller sends a signal to the ECU to run the engine at
1050—1150 rpm until fuel temperature rises above 2°C (36°F). After 12 minutes or when the hydraulic oil temperature is
above 2°C (36°F), the warm-up circuit is deactivated and engine runs at slow idle speed.
5. Only after the engine coolant temperature is raised above 50°C (122°F), the warm-up circuit is deactivated and engine
runs at user-selected idle speed.

Idle Speed-Up Control

The purpose of the idle speed-up control is to increase the engine rpm when a travel or dig function is actuated at slow idle.

The main controller uses these input signals from the travel pressure sensor, front attachment pressure sensor, and engine
speed dial to determine appropriate engine speed. The main controller then sends a signal via CAN to the ECU to increase the
engine rpm.

Idle speed-up is activated when the following conditions are met:

Engine speed below 900 rpm.


Travel or dig function actuated.

<- Go to Section TOC Section 9010 page 10 130G Excavator Diagnostic


Section 9010 - ENGINE Group 15: Diagnostic Information

<- Go to Section TOC Section 9010 page 11 130G Excavator Diagnostic


Section 9010 - ENGINE Group 20: Adjustments

Group 15 - Diagnostic Information


John Deere Engine

→NOTE:

For proper engine identification, see Engine Identification . (Group 9010-05.)

For additional information on John Deere PowerTech ™ engines and components for engine model 4045HT067, see the
following component technical manuals (CTMs).

See PowerTech™, PowerTech™ Plus, and PowerTech™ E 4.5L and 6.8L Diesel Engines—Base Engine . (CTM104.)
See PowerTech™ E 4.5 and 6.8L Diesel Engines Level 16 Electronic Fuel Systems with Denso HPCR . (CTM502.)

<- Go to Section TOC Section 9010 page 12 130G Excavator Diagnostic


Section 9010 - ENGINE Group 25: Tests

Group 20 - Adjustments
John Deere Engine

→NOTE:

For proper engine identification, see Engine Identification . (Group 9010-05.)

For additional information on John Deere PowerTech ™ engines and components for engine model 4045HT067, see the
following component technical manuals (CTMs).

See PowerTech™, PowerTech™ Plus, and PowerTech™ E 4.5L and 6.8L Diesel Engines—Base Engine . (CTM104.)
See PowerTech™ E 4.5 and 6.8L Diesel Engines Level 16 Electronic Fuel Systems with Denso HPCR . (CTM502.)

<- Go to Section TOC Section 9010 page 13 130G Excavator Diagnostic


Section 9010 - ENGINE Group 25: Tests

Group 25 - Tests
John Deere Engine

→NOTE:

For proper engine identification, see Engine Identification . (Group 9010-05.)

For additional information on John Deere PowerTech ™ engines and components for engine model 4045HT067, see the
following component technical manuals (CTMs).

See PowerTech™, PowerTech™ Plus, and PowerTech™ E 4.5L and 6.8L Diesel Engines—Base Engine . (CTM104.)
See PowerTech™ E 4.5 and 6.8L Diesel Engines Level 16 Electronic Fuel Systems with Denso HPCR . (CTM502.)

<- Go to Section TOC Section 9010 page 14 130G Excavator Diagnostic


Section 9010 - ENGINE Group 25: Tests

Radiator Temperature Differential Check


Specifications

SPECIFICATIONS

Radiator Temperature Differential Check

Engine Speed Dial Position Fast Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position H/P (high power)

Auto-Idle Switch Position OFF

4—7°C
Top to Bottom of Radiator Temperature Differential (typical)
7.2—12.6°F

Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JT07253 Non-Contact Temperature Measuring Gun

→NOTE:

Test will be more accurate at higher ambient temperatures.

LEGEND:
1 Top Test Position
2 Bottom Test Position

Radiator Test Positions

[1] - Check the following items before performing this test.

Correct coolant is in engine and at the proper level.


Radiator and any screens are clean of any dirt or debris.
Fan blades are not damaged and fan is installed correctly.
Proportional fan speed solenoid is functioning properly.
All shields, guards, shrouds, baffles, and hoods are in place and properly fastened.
Any foam or seals are in place and in good condition.

[2] -

<- Go to Section TOC Section 9010 page 15 130G Excavator Diagnostic


Section 9010 - ENGINE Group 25: Tests

→NOTE:

Engine must be at or above 93°C (200°F) and readings must be taken when engine is under full load.
Allow heat to transfer throughout engine components.

Warm engine to 93°C (200°F) to allow thermostats to open fully. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)

[3] - Run machine at specifications.

Item Measurement Specification

Radiator Temperature Differential Check


Engine Speed Dial Position Fast Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position H/P (high power)

Auto-Idle Switch Position OFF

[4] -

IMPORTANT:

To avoid hydraulic system damage, do not hold hydraulic functions over relief for more than 30 second
intervals.

Hold arm-in function, at relief, to keep a full load on engine. Temperature readings must be taken with full load on engine.

[5] -

→NOTE:

Coolant enters radiator through upper radiator hose, travels through the radiator, then exits radiator
through lower radiator hose. See Engine Cooling System Component Location . (Group 9010-05.)

Use JT07253 Non-Contact Temperature Measuring Gun to measure the temperature differential between the top test position
(1) and bottom test position (2) of radiator. Repeat test three times.

Non-Contact Temperature Measuring Gun

JT07253

Measure Temperature

[6] - Average readings and compare to specification.

Item Measurement Specification

Top to Bottom of Radiator Temperature Differential (typical) 4—7°C

7.2—12.6°F

[7] -

→NOTE:

A higher temperature differential than specification indicates low coolant flow.

A lower temperature differential than specification indicates low air flow.

<- Go to Section TOC Section 9010 page 16 130G Excavator Diagnostic


Section 9010 - ENGINE Group 25: Tests

For diagnosing problems, see John Deere Engine . (Group 9010-15.)

<- Go to Section TOC Section 9010 page 17 130G Excavator Diagnostic


Section 9010 - ENGINE Group 25: Tests

Engine Power Test Using Turbocharger Boost Pressure


Specifications

SPECIFICATIONS

Power Mode Button Position H/P (high power)

105 kPa
Turbocharger Boost Pressure 1.05 bar
15.2 psi

Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JT07248 Turbo Boost Test Kit

Other Material

OTHER MATERIAL

242 Loctite Thread Lock and Sealer (medium strength)

This procedure should only be used as a guide to determine engine condition.

→NOTE:

Boost specifications are based on use of No. 2 fuel. If using No. 1 fuel, reduce boost specifications by 7%.

[1] -
LEGEND:
1 Adapter
3 Hose
4 Pressure Gauge

Turbo Boost Test Hook-Up

Remove plug from intake manifold and install adapter (1). Install hose (3) and pressure gauge (4) from JT07248 Turbo Boost
Test Kit.

Turbo Boost Test Kit

JT07248

To measure turbocharger boost pressure.

[2] - Warm engine and hydraulic oil to normal operating temperature. Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)

<- Go to Section TOC Section 9010 page 18 130G Excavator Diagnostic


Section 9010 - ENGINE Group 25: Tests

[3] - Turn engine speed dial to fast idle.

[4] - Press power mode button to H/P (high power) position.

Item Measurement Specification

Power Mode Button Position H/P (high power)

[5] - Slowly actuate arm in function over relief and hold until engine rpm stabilizes at highest reading. Repeat this step at least
six times.

Record the highest pressure reading.

[6] -

→NOTE:

If using the JT07248 Turbo Boost Kit, a check valve at the pressure gauge inlet traps the highest reading
for boost pressure and does not decrease as the pressure decreases.

Compare highest reading to specifications.

Item Measurement Specification

Turbocharger Boost Test


Turbocharger Boost Pressure 105 kPa

1.05 bar

15.2 psi

→NOTE:

Pressure gauge accuracy is very critical for this test. Do not make adjustments to injection pump fuel
delivery on the machine to raise or lower boost pressure.

→NOTE:

New engine may not develop specified boost pressure. Check after 50 hours of operation.

[7] - If turbocharger boost pressure is low, check the following:

Wrong fuel.
Restricted air filter elements.
Restricted fuel filter elements.
Restricted muffler, remove muffler and rerun test.
Exhaust manifold leaks. For more information on PowerTech ™ , and PowerTech ™ Plus, PowerTech ™ E, see
PowerTech™, PowerTech™ Plus, and PowerTech™ E 4.5L and 6.8L Diesel Engines—Base Engine . (CTM104.)
Check charge air cooler piping and fittings for leaks.
Faulty fuel injection pump.
Faulty MAP sensor. Replace MAP sensor.
Low compression pressure. For more information on PowerTech ™ , and PowerTech ™ Plus, PowerTech ™ E, see
PowerTech™, PowerTech™ Plus, and PowerTech™ E 4.5L and 6.8L Diesel Engines—Base Engine . (CTM104.)
Cam lobe wear (valve clearance). For more information on PowerTech ™ , and PowerTech ™ Plus, PowerTech ™ E, see
PowerTech™, PowerTech™ Plus, and PowerTech™ E 4.5L and 6.8L Diesel Engines—Base Engine . (CTM104.)
Faulty fuel injectors.
Carbon build-up in turbocharger.
Turbocharger compressor or turbine wheel rubbing housing.
<- Go to Section TOC Section 9010 page 19 130G Excavator Diagnostic
ELECTRICAL SYSTEM (g) by Belgreen v2.0

[8] - Remove gauge and fittings.

[9] - Apply PM37418 Thread Lock and Sealer (medium strength) to plug. Tighten plug.

<- Go to Section TOC Section 9015 page 20 130G Excavator Diagnostic


130G Excavator Diagnostic (g) by Belgreen v2.1

Section 9015 - ELECTRICAL SYSTEM


Table of contents
Group 05 - System Information ............................................................................................................. 1
Electrical Diagram Information ............................................................................................................. 1
Group 10 - System Diagrams ............................................................................................................... 11
Explanation of Wire Markings ............................................................................................................. 11
Fuse and Relay Specifications ............................................................................................................ 12
System Functional Schematic, Component Location, and Wiring Diagram Master Legend ................ 21
System Functional Schematic ............................................................................................................. 29
Cab Harness (W1) Component Location ............................................................................................. 68
Cab Harness (W1) Wiring Diagram ..................................................................................................... 75
Machine Harness (W2) Component Location ...................................................................................... 95
Machine Harness (W2) Wiring Diagram .............................................................................................. 99
Monitor Harness (W3) Component Location ..................................................................................... 104
Monitor Harness (W3) Wiring Diagram ............................................................................................. 105
Engine Harness (W4) Component Location ...................................................................................... 107
Engine Harness (W4) Wiring Diagram .............................................................................................. 111
Engine Interface Harness (W5) Component Location ....................................................................... 116
Engine Interface Harness (W5) Wiring Diagram ............................................................................... 118
Pump Harness (W8) Component Location ........................................................................................ 121
Pump Harness (W8) Wiring Diagram ................................................................................................ 124
Service ADVISOR™ Remote (SAR) Harness (W10) Component Location .......................................... 125
Service ADVISOR™ Remote (SAR) Harness (W10) Wiring Diagram .................................................. 126
Pilot Shutoff Switch Harness (W11) Component Location ................................................................. 127
Pilot Shutoff Switch Harness (W11) Wiring Diagram ......................................................................... 128
Auxiliary Fuse Box Harness (W13) Component Location .................................................................. 129
Auxiliary Fuse Box Harness (W13) Wiring Diagram .......................................................................... 130
Heated Air Seat Harness (W14) Component Location ...................................................................... 132
Heated Air Seat Harness (W14) Wiring Diagram .............................................................................. 134
Multi-Function Pilot Control Lever Harness (W15) Component Location ........................................... 135
Multi-Function Pilot Control Lever Harness (W15) Wiring Diagram ................................................... 137
Travel Alarm Cancel Switch Harness (W16) Component Location .................................................... 138
Travel Alarm Cancel Switch Harness (W16) Wiring Diagram ............................................................ 139
Attachment Harness (W17) Component Location ............................................................................. 140
Attachment Harness (W17) Wiring Diagram ..................................................................................... 142
Rear Camera Harness (W19) Component Location .......................................................................... 144
Rear Camera Harness (W19) Wiring Diagram .................................................................................. 145
Pilot Shutoff Valve Harness (W21) Component Location .................................................................. 146
Pilot Shutoff Valve Harness (W21) Wiring Diagram .......................................................................... 147
Auxiliary 3-Button Cancel Switch Harness (W22) Component Location ............................................ 147
Auxiliary 3-Button Cancel Switch Harness (W22) Wiring Diagram .................................................... 148
Reversing Fan Switch Harness (W23) Component Location ............................................................. 148
Reversing Fan Switch Harness (W23) Wiring Diagram ..................................................................... 149
Seat Heater Switch Harness (W24) Component Location ................................................................. 149
Seat Heater Switch Harness (W24) Wiring Diagram ......................................................................... 150
Travel Alarm Harness (W26) Component Location ........................................................................... 151
Travel Alarm Harness (W26) Wiring Diagram ................................................................................... 152
Starter Harness (W27) Component Location .................................................................................... 153
Starter Harness (W27) Wiring Diagram ............................................................................................ 154
Starter Switch Harness (W29) Component Location ......................................................................... 155
Starter Switch Harness (W29) Wiring Diagram ................................................................................. 156
2-Speed Harness (W32) Component Location .................................................................................. 156

<- Go to Global Table of contents 130G Excavator Diagnostic


130G Excavator Diagnostic (g) by Belgreen v2.1

2-Speed Harness (W32) Wiring Diagram .......................................................................................... 157


Fuel Injector Harness (W38) Component Location ............................................................................ 158
Fuel Injector Harness (W38) Wiring Diagram .................................................................................... 159
Heater and Air Conditioner Harness (W41) Component Location ..................................................... 161
Heater and Air Conditioner Harness (W41) Wiring Diagram ............................................................. 162
Auxiliary Solenoid Harness (W61) Component Location ................................................................... 164
Auxiliary Solenoid Harness (W61) Wiring Diagram ........................................................................... 166
Auxiliary Function Lever (AFL) Harness (W75) Component Location ................................................ 168
Auxiliary Function Lever (AFL) Harness (W75) Wiring Diagram ........................................................ 170
Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location ................................. 172
Auxiliary Function Lever (AFL) Solenoid Harness (W76) Wiring Diagram ......................................... 174
Modular Telematics Gateway (MTG) Harness (W6002) Component Location ................................... 175
Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram ........................................... 176
Satellite (SAT) Harness (W6003) Component Location ..................................................................... 176
Satellite (SAT) Harness (W6003) Wiring Diagram ............................................................................. 177
Group 15 - Sub-System Diagnostics ................................................................................................. 178
Controller Area Network (CAN) Theory of Operation ........................................................................ 178
Starting and Charging Circuit Theory of Operation ........................................................................... 184
Monitor Controller (DSZ) Circuit Theory of Operation ....................................................................... 189
Engine Control Unit (ECU) Circuit Theory of Operation ..................................................................... 197
Main Controller (MCZ) Circuit Theory of Operation ........................................................................... 214
Machine Controller (BCZ) Circuit Theory of Operation ...................................................................... 232
Windshield Wiper and Washer Circuit Theory of Operation .............................................................. 234
Lighting Circuit Theory of Operation ................................................................................................. 237
Travel Alarm Circuit Theory of Operation ......................................................................................... 240
Pilot Shutoff Circuit Theory of Operation .......................................................................................... 243
Attachment Control Circuit Theory of Operation .............................................................................. 246
Group 16 - Monitor Operation ............................................................................................................ 256
Service Menu .................................................................................................................................... 256
Troubleshooting ................................................................................................................................ 256
Monitoring ........................................................................................................................................ 258
Controller Version ............................................................................................................................. 261
Issued Warning Record ..................................................................................................................... 261
Operation ......................................................................................................................................... 262
Machine Setting ................................................................................................................................ 263
Monitor Setting ................................................................................................................................. 266
Group 20 - References ......................................................................................................................... 268
Reading Diagnostic Trouble Codes with Monitor Display .................................................................. 268
Service ADVISOR™ Diagnostic Application ....................................................................................... 268
Service ADVISOR™ Connection Procedure ....................................................................................... 269
Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application ........................ 271
MPDr Application .............................................................................................................................. 273
MPDr Connection Procedure ............................................................................................................. 274
Fuse Test .......................................................................................................................................... 276
Relay Test ......................................................................................................................................... 283
Pressure Sensor Test ........................................................................................................................ 284
Solenoid Test .................................................................................................................................... 285
Proportional Solenoid Test ................................................................................................................ 286
Temperature Sensor Test ................................................................................................................. 287
Alternator Test .................................................................................................................................. 288
Component Checks ........................................................................................................................... 290
Battery Remove and Install .............................................................................................................. 297
Rear Cover Remove and Install ........................................................................................................ 299

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130G Excavator Diagnostic (g) by Belgreen v2.1

Main Controller (MCZ) Remove and Install ....................................................................................... 301


Machine Controller (BCZ) Remove and Install .................................................................................. 304
Engine Control Unit (ECU) Remove and Install ................................................................................. 306
Data Converter Remove and Install .................................................................................................. 306
Monitor Controller (DSZ) Remove and Install ................................................................................... 308
Air Conditioner Controller (ACF) Remove and Install ........................................................................ 310
Key Switch Remove and Install ......................................................................................................... 310
Right Switch Console Remove and Install ......................................................................................... 312
Left Switch Console Remove and Install ........................................................................................... 314
Travel Alarm Remove and Install ...................................................................................................... 315
Disconnect Tab Retainer Connectors ................................................................................................ 315
Disconnecting Spring Wire Clip Connectors ...................................................................................... 316
Replace DEUTSCH™ Connectors ...................................................................................................... 318
Replace DEUTSCH™ Rectangular or Triangular Connectors ............................................................. 320
Install DEUTSCH™ Contact ............................................................................................................... 322
Replace WEATHER PACK™ Connector .............................................................................................. 324
Install WEATHER PACK™ Contact ..................................................................................................... 326
Replace (Pull Type) Metri-Pack™ Connectors ................................................................................... 328
Replace (Push Type) Metri-Pack™ Connectors ................................................................................. 329
Replace CINCH™ Connectors ........................................................................................................... 330
Install CINCH™ Contact .................................................................................................................... 332
Repair 32 and 48 Way CINCH™ Connectors ..................................................................................... 334
Remove Connector Body from Blade Terminals ............................................................................... 338

<- Go to Global Table of contents 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 05: System Information

Group 05 - System Information


Electrical Diagram Information

→NOTE:

All System Functional Schematics, Circuit Schematics, and Wiring Diagrams are shown with key switch in
the OFF position.

Explanation of Wire Markings

System Functional Schematic Diagram

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Section 9015 - ELECTRICAL SYSTEM Group 05: System Information

System Functional Schematic Example

LEGEND:
1 Continuity Chart
2 Power Wires
3 Routing Location Information
4 Wire Identification
5 Ground Wires
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Section 9015 - ELECTRICAL SYSTEM Group 05: System Information

7 Section Number
8 Component Name
9 Component Identification Number
10 Component Schematic Symbol
11 Connector Identification Number
12 Connector
13 Connector Pin Information
F60 Alternator 65 A Fuse
F61 Battery 45 A Fuse
G1 Battery
G2 Battery
K19 Battery Relay
S1 Key Switch
W5 Battery To Frame Ground
W6 Engine To Frame Ground

The System Functional Schematic is made up of equal sections to simplify searching the schematic. Each section of the System
Functional Schematic is assigned a number (7). The System Functional Schematic is formatted with power supply wires (2)
shown near the top of the drawing and ground wires (5) near the bottom. The schematic may contain some harness or
connector information.

When connector information is shown, it will be displayed as a double chevron (12) with a component identification number
(11) corresponding to the connector identification number. Connector pin information (13) will be displayed in a text size
smaller than that of the connector identification number.

Each electrical component is shown by a schematic symbol (10), the component name (8), and a component identification
number (9). A component identification number and name will remain the same throughout the Operation and Test Technical
Manual. This will allow for easy cross-referencing of all electrical drawings (Schematics, Wiring Diagrams, and Component
Location).

Routing location information (3) is presented to let the reader know when a wire is connected to a component in another
section. TO and FROM statements identify when power is going “To” or coming “From” a component in a different location. The
section and component identification number are given in the first line of information and any pin information for the
component is given in parenthesis in the second line. In this example, power is going TO section 23, component B14 on pin C4.

Wiring Diagram

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Section 9015 - ELECTRICAL SYSTEM Group 05: System Information

Wiring Diagram Example

LEGEND:
1 Wire Number
2 Wire End #1 Termination Location
3 Wire Color
4 Wire End #2 Termination Location
5 Wiring Diagram Wire Legend

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Section 9015 - ELECTRICAL SYSTEM Group 05: System Information

6 Component Identification Number


7 Connector End View
8 Wire Number
9 Connector Pin Number
10 Connector Pin Number
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

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Section 9015 - ELECTRICAL SYSTEM Group 05: System Information

Wiring Diagram Example

LEGEND:
1 Component Identification Number
2 Connector
3 Connector End View
4 Wire Harness
5 Wire Number

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Section 9015 - ELECTRICAL SYSTEM Group 05: System Information

6 Wire Splice
7 Wire End #1 Termination Location
8 Wire Number
9 Wire Color
10 Wire End #2 Termination Location

Each harness on the machine is drawn showing connectors, wires, and splices. A “W” component identification number
identifies harnesses. (W6, Etc.) The harness is drawn showing spatial arrangement of components and branches.

A component identification or connector number (1) identifies each component. The harness branch (4) is terminated by a top
or side view of the connector (2). If more than one wire is supplied to the connector, a harness side connector end view (3) is
provided. Each wire number is labeled for the appropriate pin. If only one wire is supplied to the connector, the wire number (5)
is indicated.

An “X” component identification number of 100 or higher identifies splices (6). Each splice lists side A wires and side B wires to
differentiate the side of the harness that the wires come from.

A wire legend is provided for each harness. A component identification number is listed in the “END #1” column (7) to indicate
the termination location of one end of a wire. In the center, the wire number (8) and wire color (9) are listed. A component
identification number in the “END #2” column (10) identifies the opposite end of the wire.

Component Location Diagram

The Component Location Diagram is a pictorial view by harness showing location of all electrical components, connectors,
harness main ground locations and harness band and clamp location. Each component will be identified by the same
identification letter/number and description used in the System Functional Schematic Diagram.

Connector End View Diagram

The Connector End View Diagram is a pictorial end view of the component connectors showing the number of pins in the
connector and the wire color and identifier of the wire in every connector. Each component will be identified by the same
identification letter/number and description used in the System Functional Schematic Diagram.

Electrical Schematic Symbols

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Section 9015 - ELECTRICAL SYSTEM Group 05: System Information

Electrical Schematic Symbols

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Section 9015 - ELECTRICAL SYSTEM Group 05: System Information

LEGEND:
1 Battery
2 Wire Splice
3 Fuse
4 Circuit Breaker
5 Power Outlet
6 Alternator
7 Air Conditioner Compressor
8 Compressor
9 Liquid Pump
10 Antenna
11 Diode
12 Zener Diode
13 Capacitor
14 Magnet
15 Flasher
16 Buzzer
17 Horn
18 Alarm
19 Clock
20 Internal Ground
21 Single Point Ground
22 External Ground
23 Sensor
24 Sensor with Normally Open Switch
25 Speed Sensor
26 Rotary Sensor
27 Single Element Bulb
28 Dual Element Bulb
29 Solenoid Operated Hydraulic Valve With Suppression Diode
30 Solenoid Normally Open
31 Solenoid Normally Closed
32 Starter Motor
33 Starter Motor
34 DC Motor
35 DC Stepping Motor
36 Wiper Motor
37 Blower Motor
38 Servo Motor
39 Speedometer
40 Tachometer
41 Temperature Gauge
42 Liquid Level Gauge
43 Gauge
44 Hourmeter
45 Resistor
46 Variable Resistor
47 Manually Adjusted Variable Resistor
48 Multi-Pin Connector
49 Single Pin Connector
50 Connector
51 4 Pin Relay
52 5 Pin Relay
53 5 Pin Relay With Internal Suppression Diode
54 5 Pin Relay With Internal Suppression Resistor
55 Key Switch
56 Temperature Switch Normally Open
57 Temperature Switch Normally Closed
58 Pressure Switch Normally Open
59 Pressure Switch Normally Closed
60 Liquid Level Switch Normally Open
61 Liquid Level Switch Normally Closed
62 Momentary Switch Normally Open
63 Momentary Switch Normally Closed
64 Toggle Switch Normally Open
65 Toggle Switch Normally Closed
66 2 Way Toggle Switch Normally Open

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Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

67 2 Way Toggle Switch Normally Closed


68 Manual Switch Operation
69 Push Switch Operation
70 Pull Switch Operation
71 Turn Switch Operation
72 Toggle Switch Operation
73 Pedal Switch Operation
74 Key Switch Operation
75 Detent Switch Operation
76 Temperature Sensor
77 Solar Sensor
78 Pressure Sensor
79 Liquid Level Sensor

<- Go to Section TOC Section 9015 page 10 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Group 10 - System Diagrams


Explanation of Wire Markings
Electrical harness wires are identified by color, with no number stamped on wire. Wire numbers are used on some connector
drawings simply as reference numbers, useful in tracing wires through the harness.

Some wires are solid wire colors. These would be identified by one color name such as RED or BLK or GRN.

Other wire colors are identified with two color names. These are solid wires with a narrow stripe. For example, a wire identified
as RED/WHT would be a primarily RED wire, with a WHT stripe. A wire identified as WHT/RED would be a primarily WHT wire
with a RED stripe.

Following is a listing of wire color abbreviations used on drawings.

BLK—Black
BLU—Blue
BRN—Brown
CABLE—Bare Wire
DK GRN—Dark Green
GRN—Green
GRY—Grey
LT BLU—Light Blue
LT GRN—Light Green
ORG—Orange
PNK—Pink
PUR—Purple
RED—Red
SK BLU—Sky Blue
TAN—Tan
VLT—Violet
WHT—White
YEL—Yellow

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Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Fuse and Relay Specifications


Fuse and Relay Specifications (S.N. —040754)

Relay and Fuse Block Component Location

LEGEND:
1 Relay Block
2 Fuse Block 1
3 Fuse Block 2

Fuse Block 1

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Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Fuse Block 1

LEGEND:
F1 Work and Boom Lights 20 A Fuse (marked LAMP)
F2 Windshield Wiper and Washer 10 A Fuse (marked WIPER)
F3 Air Conditioner and Heater 20 A Fuse (marked HEATER)
F4 Solenoid 20 A Fuse (marked SOLENOID)
F5 Travel Alarm 5 A Fuse (marked OPT. 1 ALT)
F6 12-Volt Power Outlet 20 A Fuse (marked OPT. 2 ALT)
F7 Start Position Signal 5 A Fuse (marked START)
F8 Engine Control Unit (ECU) 30 A Fuse (marked ECU)
F9 Radio Backup 10 A Fuse (marked BACK UP)
F10 Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)
F11 Not Used
F12 Radio and Dome 5 A Fuse (marked RADIO)
F13 Lighter 10 A Fuse (marked LIGHTER)
F14 Monitor 5 A Fuse (marked MONITOR)
F15 Cab Auxiliary Power Connector 1 10 A Fuse (marked AUX)
F16 Start Aid 20 A Fuse (marked START AID)
F17 Power On 5 A Fuse (marked POWER ON)
F18 Idle Stop 5 A Fuse (marked IDLE STOP)
F19 Horn 10 A Fuse (marked HORN)
F20 Optional Equipment 5 A Fuse (marked OPT. 3 BATT)

Fuse Block 2

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Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Fuse Block 2

LEGEND:
F21 Heated Air Seat 10 A Fuse (marked SEAT HEATER)
F22 Front Cab Light 1 10 A Fuse (marked CAB LAMP FRONT)
F23 Rear Cab Light 10 A Fuse (marked CAB LAMP REAR)
F24 12-Volt Power Unit 10 A Fuse (marked 12V UNIT)
F25 IMOBI 5 A Fuse (marked IMOBI)
F26 Quick Hitch 5 A Fuse (marked QUICK HITCH)
F27 Cab Auxiliary Power Connector 3 5 A Fuse (marked AUX. 3)
F28 Not Used
F29 Not Used
F30 Not Used
F31 Seat Compressor 10 A Fuse (marked SEAT COMPR)
F32 Front Cab Light 2 10 A Fuse (marked CAB LAMP FRONT +2)
F33 Warning Lamp 10 A Fuse (marked WARNING LAMP)
F34 Cab Auxiliary Power Connector 2 10 A Fuse (marked AUX. 2)
F35 Not Used
F36 Not Used
F37 Not Used
F38 Not Used
F39 Not Used
F40 Not Used

Additional fuses located near the engine control unit (ECU):

F6000— JDLink ™ Unswitched Power 7.5 A Fuse


F6001— JDLink ™ Ground 7.5 A Fuse
F6002— JDLink ™ Switched Power 7.5 A Fuse

Additional fuses located in the engine compartment:

F63—Glow Plug 50 A Fuse

Additional fuses located under cover behind radiator door:

<- Go to Section TOC Section 9015 page 14 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

F45—Starter In-line 30 A Fuse


F60—Alternator 65 A Fuse
F61—Battery 45 A Fuse

Relay Block

Relay Block

LEGEND:
K1 Load Dump Relay
K2 Pilot Shutoff Relay
K3 Security Alarm Relay
K4 Starter Cut Relay
K5 Security Relay
K6 Windshield Wiper Relay
K7 Work Light Relay
K8 Boom Light Relay
K9 Windshield Washer Relay
K10 Horn Relay
K11 Idle Stop Relay
K12 Accessory Cut Relay
K13 Key Cut Relay
K14 (not used)

Additional relays located in the engine compartment:

K16—Glow Plug Relay

Additional relays are located by the air conditioning unit:

K15—Air Conditioner Blower Motor Relay


K17—Max Hi Relay
K18—Air Conditioner Compressor Clutch Relay

Additional relays located under cover behind cooling package door:

K19—Battery Relay
K34—Starter Relay

<- Go to Section TOC Section 9015 page 15 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

K35—Starter Protection Relay

Additional relays located behind cab seat:

K20—Seat Heater Relay


K30—Right Solenoid Relay B
K31—Right Solenoid Relay A
K32—Left Solenoid Relay B
K33—Left Solenoid Relay A

Fuse and Relay Specifications (S.N. 040755— )

Relay and Fuse Block Component Location

LEGEND:
1 Relay Block
2 Fuse Block 1
3 Fuse Block 2

Fuse Block 1

<- Go to Section TOC Section 9015 page 16 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Fuse Block 1

LEGEND:
F1 Work and Boom Lights 20 A Fuse (marked LAMP)
F2 Windshield Wiper and Washer 10 A Fuse (marked WIPER)
F3 Air Conditioner and Heater 20 A Fuse (marked HEATER)
F4 Solenoid 20 A Fuse (marked SOLENOID)
F5 Optional and Attachment Connector 20 A Fuse (marked OPT. 1 ALT)
F6 Optional Connector and Reversing Fan 20 A Fuse (marked OPT. 2 ALT)
F7 Start Position Signal 5 A Fuse (marked START)
F8 Engine Control Unit (ECU) 20 A Fuse (marked ECU P1)
F9 Radio Backup 10 A Fuse (marked BACK UP)
F10 Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)
F11 Travel Alarm 5 A Fuse (marked TRAVEL ALARM)
F12 Radio and Dome 5 A Fuse (marked RADIO)
F13 Lighter 10 A Fuse (marked LIGHTER)
F14 Monitor 5 A Fuse (marked MONITOR)
F15 Cab Auxiliary Power Connector 1 10 A Fuse (marked AUX)
F16 12-Volt Power Unit 10 A Fuse (marked 12V UNIT)
F17 Power On 5 A Fuse (marked POWER ON)
F18 Idle Stop 5 A Fuse (marked IDLE STOP)
F19 Horn 10 A Fuse (marked HORN)
F20 Optional Equipment 5 A Fuse (marked OPT. 3 BATT)

Fuse Block 2

<- Go to Section TOC Section 9015 page 17 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Fuse Block 2

LEGEND:
F21 Heated Air Seat 10 A Fuse (marked SEAT HEATER)
F22 Front Cab Light 1 10 A Fuse (marked CAB LAMP FRONT)
F23 Rear Cab Light 10 A Fuse (marked CAB LAMP REAR)
F24 IMOBI 5 A Fuse (marked IMOBI)
F25 Quick Hitch 5 A Fuse (marked QUICK HITCH)
F26 Cab Auxiliary Power Connector 3 5 A Fuse (marked AUX. 3)
F27 Not Used
F28 Not Used
F29 Not Used
F30 Not Used
F31 Seat Compressor 10 A Fuse (marked SEAT COMPR)
F32 Front Cab Light 2 10 A Fuse (marked CAB LAMP FRONT +2)
F33 Warning Lamp 10 A Fuse (marked WARNING LAMP)
F34 Cab Auxiliary Power Connector 2 10 A Fuse (marked AUX. 2)
F35 Service Advisor Diagnostic Connector 5 A Fuse (marked DIAG)
F36 Engine Control Unit (ECU) 20 A Fuse (marked ECU P2, not used)
F37 Engine Control Unit (ECU) 20 A Fuse (marked ECU P3, not used)
F38 Fuel Transfer Pump/Controllers 20 A Fuse (marked ECU P4, not used)
F39 Not Used
F40 Not Used

Additional fuses located near the engine control unit (ECU):

F6000— JDLink ™ Unswitched Power 7.5 A Fuse


F6001— JDLink ™ Ground 7.5 A Fuse
F6002— JDLink ™ Switched Power 7.5 A Fuse

Additional fuses located in the engine compartment:

F5002—Fuel Transfer Pump 15 A Fuse

Additional fuses located under cover behind radiator door:

<- Go to Section TOC Section 9015 page 18 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

F45—Starter In-line 30 A Fuse


F60—Alternator 65 A Fuse
F61—Battery 45 A Fuse

Relay Block

Relay Block

LEGEND:
K1 Load Dump Relay
K2 Pilot Shutoff Relay
K3 Security Alarm Relay
K4 Starter Cut Relay
K5 Security Relay
K6 Windshield Wiper Relay
K7 Work Light Relay
K8 Boom Light Relay
K9 Windshield Washer Relay
K10 Horn Relay
K11 Idle Stop Relay
K12 Accessory Cut Relay
K13 Key Cut Relay

Additional relays located in the engine compartment:

K16—Glow Plug Relay

Additional relays are located by the air conditioning unit:

K15—Air Conditioner Blower Motor Relay


K17—Max Hi Relay
K18—Air Conditioner Compressor Clutch Relay

Additional relays located under cover behind cooling package door:

K19—Battery Relay
K34—Starter Relay
K35—Starter Protection Relay

<- Go to Section TOC Section 9015 page 19 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Additional relays located behind cab seat:

K20—Seat Heater Relay


K30—Right Solenoid Relay B
K31—Right Solenoid Relay A
K32—Left Solenoid Relay B
K33—Left Solenoid Relay A

<- Go to Section TOC Section 9015 page 20 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

System Functional Schematic, Component Location, and Wiring Diagram


Master Legend
A1—Engine Control Unit (ECU) ( SE10 , SE11 , SE12 , SE13 , SE14 , SE15 ) ( W5 )
A2—Variable Geometry Turbocharger (VGT) ( W5 )
A3—Main Controller (MCZ) ( SE7 , SE8 , SE9 , SE10 ) ( W1 )
A4—Monitor Controller (DSZ) ( SE4 , SE5 , SE6 ) ( W1 ) ( W3 )
A5—Data Converter ( SE20 ) ( W1 )
A6—Radio ( SE18 ) ( W1 )
A7—Air Conditioner Controller (ACF) ( SE23 ) ( W41 )
A8—12-Volt Power Converter ( SE17 ) ( W1 )
A10—Monitor ( SE6 ) ( W3 )
A11—Machine Controller (BCZ) ( SE19 ) ( W1 )
A12—Rear Camera ( SE6 ) ( W19 )
A6000—Modular Telematics Gateway (MTG) Controller ( SE21 ) ( W5 )
A6001—GPS/Cellular Antenna ( SE21 )
B16—Air Filter Restriction Switch ( SE14 ) ( W5 )
A6002—Satellite (SAT) Module Control Unit ( SE21 ) ( W6003 )
B18—Fuel Level Sensor ( SE4 ) ( W2 )
B20—Air Conditioner High/Low Pressure Switch ( SE22 ) ( W2 )
B21—Solar Sensor ( SE24 ) ( W3 )
B22—Ambient Air Temperature Sensor ( SE23 ) ( W2 )
B23—High Note Horn ( SE22 ) ( W2 )
B24—Low Note Horn ( SE22 ) ( W2 )
B25—Right Speaker ( SE18 ) ( W1 )
B26—Left Speaker ( SE18 ) ( W1 )
B27—Hydraulic Oil Filter Restriction Switch (if equipped) ( SE4 ) ( W2 )
B30—Boom Up Pressure Sensor ( SE7 ) ( W2 )
B31—Arm In Pressure Sensor ( SE8 ) ( W2 )
B32—Front Attachment Pressure Sensor ( SE8 ) ( W2 )
B33—Swing Pressure Sensor ( SE8 ) ( W2 )
B34—Travel Pressure Sensor ( SE8 ) ( W2 )
B35—Pump 1 Delivery Pressure Sensor ( SE8 ) ( W8 )
B36—Pump 1 Control Pressure Sensor ( SE8 ) ( W8 )
B37—Pump 2 Delivery Pressure Sensor ( SE9 ) ( W8 )
B38—Pump 2 Control Pressure Sensor ( SE9 ) ( W8 )
B40—Hydraulic Oil Temperature Sensor ( SE9 ) ( W2 )
B41—Air Conditioner Freeze Control Switch ( SE24 ) ( W41 )
B53—Fan Speed Sensor ( SE13 , SE15 ) ( W5 )
B55—Air Recirculation Sensor ( SE24 ) ( W41 )
B60—Attachment Pressure Sensor ( SE9 ) ( W17 )
B61—Arm Out Pressure Sensor ( SE9 ) ( W17 )
B68—Secondary Hydraulic Oil Temperature Sensor ( SE30 ) ( W76 )
B80—Seat Temperature Switch 1 ( SE26 ) ( W17 )
B81—Seat Temperature Switch 2 ( SE26 )
B82—Ambient Air Temperature Sensor 2 ( SE10 ) ( W5 )
B85—Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1) ( SE30 ) ( W76 )
B5100—Fuel Rail Pressure Sensor ( SE13 ) ( W4 )
B5101—Engine Oil Pressure Sensor ( SE11 ) ( W4 )
B5107—Inlet Fuel Pressure Sensor ( SE14 ) ( W4 )
B5206—Manifold Air Temperature (MAT) Sensor ( SE11 ) ( W4 )
B5208—Engine Coolant Temperature Sensor ( SE11 ) ( W4 )
B5209—Fuel Temperature Sensor ( SE10 ) ( W4 )
B5300—Turbocharger Speed Sensor ( SE15 ) ( W4 )
B5301—Crankshaft Position Sensor ( SE11 ) ( W4 )
B5302—Camshaft Position Sensor ( SE11 ) ( W4 )
B5500—Intake Air Sensor ( SE12 ) ( W4 )
B5600—Water-in-Fuel Sensor ( SE10 ) ( W5 )
E1—Work Light ( SE17 ) ( W2 )
E2—Boom Light ( SE17 ) ( W2 )

<- Go to Section TOC Section 9015 page 21 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

E3—Cab Dome Light ( SE19 )


E5—Switch Panel Back Light 1 ( SE6 )
E6—Switch Panel Back Light 2 ( SE5 )
E7—Switch Panel Back Light 3 ( SE6 )
E8—Switch Panel Back Light 4 ( SE6 )
E9—Key Switch Light ( SE20 )
E10—Switch Panel Back Light 5 ( SE20 )
F1—Work and Boom Lights 20 A Fuse (marked LAMP) ( SE17 ) ( W1 )
F2—Windshield Wiper and Washer 10 A Fuse (marked WIPER) ( SE16 ) ( W1 )
F3—Air Conditioner and Heater 20 A Fuse (marked HEATER) ( SE22 ) ( W1 )
F4—Solenoid 20 A Fuse (marked SOLENOID) ( SE3 ) ( W1 )
F5—Travel Alarm 5 A Fuse (marked OPT. 1 ALT) ( SE9 ) ( W1 )
F6—12-Volt Power Outlet 20 A Fuse (marked OPT. 2 ALT) ( SE17 ) ( W1 )
F7—Start Position Signal 5 A Fuse (marked START) ( W1 )
F8—Engine Control Unit (ECU) 30 A Fuse (marked ECU) ( SE14 ) ( W1 )
F9—Radio Backup 10 A Fuse (marked BACK UP) ( SE4 ) ( W1 )
F10—Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER) ( SE7 ) ( W1 )
F11—Not Used ( W1 )
F12—Radio and Dome 5 A Fuse (marked RADIO) ( SE18 ) ( W1 )
F13—Lighter 10 A Fuse (marked LIGHTER) ( SE18 ) ( W1 )
F14—Monitor 5 A Fuse (marked MONITOR) ( SE4 ) ( W1 )
F15—Cab Auxiliary Power Connector 1 10 A Fuse (marked AUX) ( SE18 ) ( W1 )
F17—Power On 5 A Fuse (marked POWER ON) ( SE4 ) ( W1 )
F18—Idle Stop 5 A Fuse (marked IDLE STOP) ( SE1 ) ( W1 )
F19—Horn 10 A Fuse (marked HORN) ( SE22 ) ( W1 )
F20—Optional Equipment 5 A Fuse (marked OPT. 3 BATT) ( SE17 ) ( W1 )
F21—Heated Air Seat 10 A Fuse (marked SEAT HEATER) ( SE26 ) ( W13 )
F22—Front Cab Light 1 10 A Fuse (marked CAB LAMP FRONT) ( SE25 ) ( W13 )
F23—Rear Cab Light 10 A Fuse (marked CAB LAMP REAR) ( SE25 ) ( W13 )
F24—12-Volt Power Unit 10 A Fuse (marked 12V UNIT) ( SE25 ) ( W13 )
F25—IMMOBI 5 A Fuse (marked IMOBI) ( SE25 ) ( W13 )
F26—Quick Hitch 5 A Fuse (marked QUICK HITCH) ( SE25 ) ( W13 )
F27—Cab Auxiliary Power Connector 3 5 A Fuse (marked AUX_3) ( SE25 ) ( W13 )
F31—Seat Compressor 10 A Fuse (marked SEAT COMPR) ( SE26 ) ( W13 )
F32—Front Cab Light 2 10 A Fuse (marked CAB LAMP FRONT +2) ( SE25 ) ( W13 )
F33—Warning Lamp 10 A Fuse (marked WARNING LAMP) ( SE25 ) ( W13 )
F34—Cab Auxiliary Power Connector 2 10 A Fuse (marked AUX_2) ( SE25 ) ( W13 )
F45—Starter In-line 30 A Fuse ( SE2 ) ( W27 )
F50—Fuse Box ( W1 )
F51—Auxiliary Fuse Box ( W13 )
F60—Alternator 65 A Fuse ( SE1 ) ( W2 )
F61—Battery 45 A Fuse ( SE1 ) ( W2 )
F62—Wiper Motor Assembly Circuit Breaker ( SE16 )
F6000— JDLink ™ Unswitched Power 7.5 A Fuse ( SE21 ) ( W5 )
F6001—JDLink™ Ground 7.5 A Fuse ( SE21 ) ( W5 )
F6002—JDLink™ Switched Power 7.5 A Fuse ( SE21 ) ( W5 )
G1—Battery ( SE1 ) ( W2 )
G2—Battery ( SE1 ) ( W2 )
G3—Alternator ( SE3 ) ( W2 )
G5—12-Volt Power Outlet ( SE17 ) ( W1 )
H2—Security Alarm ( SE4 ) ( W1 )
H3—Monitor Warning Alarm ( SE4 ) ( W3 )
H4—Travel Alarm ( SE9 ) ( W26 )
K1—Load Dump Relay ( SE3 ) ( W1 )
K2—Pilot Shutoff Solenoid Relay ( SE3 ) ( W1 )
K3—Security Alarm Relay ( SE4 ) ( W1 )
K4—Starter Cut Relay ( SE2 ) ( W1 )
K5—Security Relay ( SE2 ) ( W1 )
K6—Windshield Wiper Relay ( SE16 ) ( W1 )
K7—Work Light Relay ( SE17 ) ( W1 )
K8—Boom Light Relay ( SE17 ) ( W1 )
<- Go to Section TOC Section 9015 page 22 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

K9—Windshield Washer Relay ( SE16 ) ( W1 )


K10—Horn Relay ( SE22 ) ( W1 )
K11—Idle Stop Relay ( SE1 ) ( W1 )
K12—Accessory Cut Relay ( SE1 ) ( W1 )
K13—Key Cut Relay ( SE1 ) ( W1 )
K15—Air Conditioner Blower Motor Relay ( SE23 ) ( W41 )
K17—Max Hi Relay ( SE23 ) ( W41 )
K18—Air Conditioner Compressor Clutch Relay ( SE22 ) ( W41 )
K19—Battery Relay ( SE1 ) ( W2 )
K20—Seat Heater Relay ( SE26 )
K30—Right Solenoid Relay B ( SE27 ) ( W15 )
K31—Right Solenoid Relay A ( SE27 ) ( W15 )
K31—Right Solenoid Relay (marked RSW1) ( SE28 ) ( W75 )
K32—Left Solenoid Relay B ( SE27 ) ( W15 )
K32—Left Solenoid Relay B (marked LSW1) ( SE28 ) ( W75 )
K33—Left Solenoid Relay A ( SE27 ) ( W15 )
K33—Left Solenoid Relay A (marked LSW3) ( SE29 ) ( W75 )
K34—Starter Relay ( SE2 ) ( W2 ) ( W27 )
K35—Starter Protection Relay ( SE2 ) ( W27
M1—Starter Motor ( SE2 ) ( W2 ) ( W5 ) ( W27 )
M5—Windshield Wiper Motor ( SE16 )
M6—Windshield Washer Motor ( SE16 ) ( W2 )
M7—Air Conditioner and Heater Blower Motor ( SE23 ) ( W41 )
M9—Air Conditioner and Heater Internal and External Servo Motor ( SE24 ) ( W41 )
M10—Air Conditioner and Heater Blower Port Change Servo Motor ( SE24 ) ( W41 )
M11—Air Conditioner and Heater Mixer Servo Motor ( SE24 ) ( W41 )
M12—Seat Air Compressor Motor ( SE26 ) ( W14 )
M13—High Pressure Fuel Pump ( SE11 ) ( W4 )
R9—Lighter ( SE18 ) ( W1 )
R10—Interface CAN Resistor 1 ( SE20 ) ( W1 )
R11—Interface CAN Resistor 2 (later models) ( SE21 ) ( W5 )
R12—CAN 0 Termination Resistor ( SE11 ) ( W2 )
R13—Alternator Resistor ( SE3 ) ( W2 )
R15—Engine Speed Dial ( SE7 ) ( W1 )
R16—Blower Motor Transistor ( SE23 ) ( W41 )
R17—Blower Motor Resistor ( SE23 ) ( W41 )
R18—Seat Heater ( SE26 ) ( W14 )
S1—Key Switch ( SE1 ) ( W29 )
S2—Cab Dome Light Switch ( SE19 )
S3—Pilot Shutoff Switch 1 ( SE3 ) ( W17 )
S4—Pilot Shutoff Switch 2 ( SE3 ) ( W17 )
S5—Horn Switch ( SE22 ) ( W1 ), ( W75 )
S7—Power Dig Switch ( SE10 , SE28 ) ( W1 ) or ( W75 )
S8—Auto-Idle Switch ( SE7 ) ( W1 )
S9—Windshield Wiper and Washer Switch ( SE20 ) ( W1 )
S10—Work Light Switch ( SE6 ) ( W1 )
S11—Travel Speed Switch ( SE7 ) ( W1 )
S12—Power Mode Button ( SE7 ) ( W1 )
S13—Travel Alarm Cancel Switch ( SE9 ) ( W16 )
S14—Door Switch ( SE20 ) ( W1 )
S15—Reversing Fan Switch ( SE13 ) ( W23 )
S18— Service ADVISOR ™ Remote (SAR) Switch ( SE11 ) ( W1 )
S20—Seat Belt Switch ( SE6 ) ( W1 )
S21—Blower Motor Speed Switch ( SE5 ) ( W1 )
S22—Temperature Control/Mode Switch ( SE5 ) ( W1 )
S23—Radio Volume and Power Switch ( SE6 ) ( W1 )
S24—Radio Tuning Switch ( SE5 ) ( W1 )
S25—Monitor Dial ( SE5 ) ( W1 )
S26—Back Button ( SE5 ) ( W1 )
S27—Home Button ( SE5 ) ( W1 )
S28—Window Switch ( SE16 )
<- Go to Section TOC Section 9015 page 23 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

S29—Auxiliary Function Lever (AFL) Proportional Control Switch ( SE28 ) ( W75 )


S30—Right Pilot Control Lever Switch B (marked B) ( SE27 ) ( W15 )
S31—Right Pilot Control Lever Switch A (marked C) ( SE27 ) ( W15 )
S31—Right Pilot Control Lever Switch ( SE28 ) ( W75 )
S32—Left Pilot Control Lever Switch B (marked B) ( SE27 ) ( W15 ) or ( W75 )
S33—Left Pilot Control Lever Switch A (marked C) ( SE27 ) ( W15 ) or ( W75 )
S34—Right Enable Switch ( SE27 ) ( W15 ), ( W22 )
S34—Right Enable Switch (marked ON/OFF) ( SE28 ) ( W75 )
S35—Left Enable Switch ( SE27 ) ( W15 ), ( W22 )
S35—Left Enable Switch (marked ON/OFF) ( SE28 ) ( W75 )
S40—Hydraulic Oil Temperature Switch (if equipped) ( SE4 ) ( W2 )
S50—0 Key ( SE5 ) ( W1 )
S51—1 Key ( SE5 ) ( W1 )
S52—2 Key ( SE5 ) ( W1 )
S53—3 Key ( SE5 ) ( W1 )
S54—4 Key ( SE5 ) ( W1 )
S55—5 Key ( SE5 ) ( W1 )
S56—6 Key ( SE5 ) ( W1 )
S57—7 Key ( SE5 ) ( W1 )
S58—8 Key ( SE5 ) ( W1 )
S59—9 Key ( SE5 ) ( W1 )
S60—Keypad ( SE5 , SE6 ) ( W1 )
S61—Seat Compressor Switch ( SE26 )
S62—Seat Heater Switch ( SE26 ) ( W24 )
S5001—Engine Coolant Loss Level Sensor ( SE13 ) ( W5 )
S5002—Engine Coolant Service Level Sensor ( SE13 ) ( W5 )
V1—Battery Relay Diode ( SE1 ) ( W1 )
V2—Alternator Excitation Diode ( SE3 ) ( W1 )
V3—Load Dump Relay Diode ( SE3 , SE22 ) ( W1 )
V4—Security Diode ( SE2 ) ( W1 )
V5—Starter Cut Relay Diode ( SE3 ) ( W1 )
V6—Auxiliary Power Connector Diode ( SE18 ) ( W1 )
V7—Start Relay Diode ( SE2 ) ( W1 )
V8—Air Conditioner Clutch Diode ( SE22 ) ( W1 )
V9—Pilot Shutoff Diode ( SE3 ) ( W1 )
V10—Starter Protection Diode ( SE1 ) ( W1 )
V11—Accessory Cut Diode ( SE1 ) ( W1 )
V12—Starter Cut Diode ( SE2 ) ( W1 )
V13—Work Light 1 Diode ( SE19 ) ( W1 )
V14—Work Light 2 Diode ( SE19 ) ( W1 )
V20—Pilot Shutoff Switch Diode ( SE3 ) ( W11 )
V22—Pilot Shutoff Solenoid Diode ( SE29 ) ( W75 )
V30—Right Solenoid Diode B ( SE27 ) ( W61 )
V31—Right Solenoid Diode A ( SE27 ) ( W61 )
V32—Left Solenoid Diode B ( SE27 ) ( W61 )
V33—Left Solenoid Diode A ( SE27 ) ( W61 )
V40—Selector Valve Solenoid Valve Diode ( SE8 ) ( W17 )
V41—Secondary Relief Solenoid Valve Diode ( SE9 ) ( W17 )
V43—2-Speed Activation Solenoid Valve Diode ( SE9 ) ( W17 )
V44—Starter Relay Diode ( W27 ) ( SE2 )
W1—Cab Harness ( W1 )
W2—Machine Harness ( W2 )
W3—Monitor Harness ( W3 )
W4—Engine Harness ( W4 )
W5—Engine Interface Harness ( W5 )
W8—Pump Harness ( W8 )
W10—Service ADVISOR™ Remote (SAR) Switch Harness ( W10 )
W11—Pilot Shutoff Switch Harness ( W11 )
W13—Auxiliary Fuse Box ( W13 )
W14—Heated Air Seat Harness ( W14 )
W15—Multi-Function Pilot Control Lever Harness ( W15 )
<- Go to Section TOC Section 9015 page 24 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

W16—Travel Alarm Cancel Switch Harness ( W16 )


W17—Attachment Harness ( W17 )
W19—Rear Camera Harness ( W19 )
W21—Pilot Shutoff Valve Harness ( W21 )
W22—Auxiliary 3-Button Cancel Switch Harness ( W22 )
W23—Reversing Fan Switch Harness ( W23 )
W24—Seat Heater Switch Harness ( W24 )
W26—Travel Alarm Harness ( W26 )
W27—Starter Harness ( W27 )
W29—Starter Switch Harness ( W29 )
W35—Cab Harness Ground 1 ( W1 )
W36—Cab Harness Ground 2 ( W1 )
W37—Cab Harness Ground 3 ( W1 )
W38—Fuel Injector Harness ( W38 )
W41—Heater and Air Conditioner Harness ( W41 )
W43—Engine Interface Harness Ground ( W5 )
W60—Radio Antenna ( SE18 )
W61—Auxiliary Solenoid Harness ( W61 )
W75—Auxiliary Function Lever (AFL) Harness ( W75 )
W76—Auxiliary Function Lever (AFL) Solenoid Harness ( W76 )
W6002—Modular Telematices Gateway (MTG) Harness ( W6002 )
W6003—Satellite (SAT) Harness ( W6003 )
X1—Service ADVISOR™ Diagnostic Connector ( SE12 ) ( W2 )
X2—MPDr 6-Pin Connector ( SE6 ) ( W1 )
X3—Cab Harness-to-Machine Harness 100-Pin Connector ( SE3 , SE4 , SE6 , SE16 , SE17 ) ( W1 ) ( W2 )
X5—Machine Harness-to-Engine Interface Harness 8-Pin Connector 1 ( SE4 , SE11 ) ( W2 )
X6—Machine Harness-to-Engine Interface Harness 1-Pin Connector ( SE10 ) ( W2 )
X7—Machine Harness-to-Engine Interface Harness 8-Pin Connector 2 ( W2 )
X8—Machine Harness-to-Engine Interface Harness 8-Pin Connector 3 ( SE21 ) ( W2 )
X10—Machine Controller 8-Pin Connector A ( SE19 ) ( W1 )
X11—Machine Controller 20-Pin Connector B ( SE19 ) ( W1 )
X14—Engine Control Unit (ECU)-to-Engine Harness Connector 1 ( SE10 , SE11 , SE12 , SE13 , SE14 , SE15 ) ( W5 )
X15—Engine Control Unit (ECU)-to-Engine Harness Connector 2 ( SE10 , SE11 , SE12 , SE13 , SE14 , SE15 ) ( W5 )
X17—Cab Harness-to-Monitor Harness Connector ( W1 ) ( W3 )
X18—Monitor 12-Pin Connector C ( SE6 ) ( W3 )
X19—Monitor 2-Pin Connector G ( SE6 ) ( W3 )
X20—Monitor Controller 28-Pin Connector A ( SE4 , SE5 , SE6 ) ( W1 )
X21—Monitor Controller 36-Pin Connector B ( SE4 , SE5 , SE6 ) ( W1 )
X22—Monitor Controller 16-Pin Connector D ( SE4 , SE5 , SE6 ) ( W1 )
X23—Monitor Controller 12-Pin Connector C ( SE4 , SE5 , SE6 ) ( W3 )
X24—Monitor Controller 2-Pin Connector G ( SE4 , SE5 , SE6 ) ( W3 )
X25—Cab Harness Auxiliary Power Connector 1 ( SE18 ) ( W1 )
X26—Optional Connector ( SE17 , SE26 , SE28 , SE30 ) ( W1 ) ( W15 ) or ( W75 )
X27—Cab Harness-to-Switch Panel Connector 1 ( SE20 ) ( W1 )
X28—Cab Harness-to-Switch Panel Connector 2 ( SE5 , SE6 ) ( W1 )
X29—Cab Harness-to-Switch Panel Connector 3 ( SE6 , SE7 ) ( W1 )
X30—Cab Harness-to-Switch Panel Connector 4 ( SE5 ) ( W1 )
X31—Cab Harness-to-Main Controller 31-Pin Connector A ( SE7 , SE8 , SE9 , SE10 ) ( W1 )
X32—Cab Harness-to-Main Controller 24-Pin Connector B ( SE7 , SE8 , SE9 , SE10 ) ( W1 )
X33—Cab Harness-to-Main Controller 17-Pin Connector C ( SE7 , SE8 , SE9 , SE10 ) ( W1 )
X34—Cab Harness-to-Main Controller 30-Pin Connector D ( SE7 , SE8 , SE9 , SE10 ) ( W1 )
X35—Cab Harness-to-Main Controller 24-Pin Connector E ( SE7 , SE8 , SE9 , SE10 ) ( W1 )
X36—Cab Harness-to-Main Controller 26-Pin Connector F ( SE7 , SE8 , SE9 , SE10 ) ( W1 )
X37—Cab Harness-to-Exhaust Filter Switch Harness Connector (not used) ( W1 )
X39—Cab Harness-to-Window Switch Connector ( SE16 ) ( W1 )
X40—Pump Harness-to-Machine Harness Connector ( SE7 , SE8 , SE9 ) ( W2 ) ( W8 )
X43—Optional Fuse Connector ( W1 ) ( W13 )
X44—Optional Light Connector ( SE17 , SE26 ) ( W1 ) ( W13 )
X45—Option 2 12-Pin Connector (not used) ( W1 )
X46—Attachment Connector ( W2 ) ( W17 )
X47—Cab Harness-to-Key Switch Harness Connector ( W1 ) ( W29 )
<- Go to Section TOC Section 9015 page 25 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

X50—Cab Harness-to-Travel Alarm Cancel Switch Harness Connector ( W1 ) ( W16 )


X51—Air Conditioner 4-Pin Connector ( W1 ) ( W41 )
X52—Air Conditioner 10-Pin Connector ( SE23 ) ( W1 ) ( W41 )
X53—Heated Air Seat Harness-to-Heated Seat Switch Harness 3-Pin Connector (marked SEAT HEATER) ( W14 ) ( W24 )
X54—Auxiliary Fuse Box Harness-to-Heated Air Seat Harness 3-Pin Connector (marked SEAT HEATER) ( SE26 ) ( W13 )
X55—Front Cab Light 1 Connector (marked CAB LAMP FRONT) ( SE26 ) ( W13 )
X56—Front Cab Light 2 Connector (marked CAB LAMP FRONT +2) ( SE25 ) ( W13 )
X57—Rear Cab Light Connector (marked CAB LAMP REAR) ( SE25 ) ( W13 )
X58—Warning Light Connector (marked WARNING LAMP) ( SE25 ) ( W13 )
X59—Satellite Communication Connector (marked IMOBI) ( SE25 ) ( W13 )
X60—12-Volt Power Supply Connector (marked 12V UNIT) ( SE25 ) ( W13 )
X61—Quick Hitch Connector (marked QUICK HITCH) ( SE25 ) ( W13 )
X62—Cab Auxiliary Power Connector 2 (marked AUX_2) ( SE25 ) ( W13 )
X63—Cab Auxiliary Power Connector 3 (marked AUX_3) ( SE25 ) ( W13 )
X64—Machine Harness-to-Rear Camera Harness Connector ( SE6 ) ( W2 ) ( W19 )
X65—Cab Harness-to-Pilot Shutoff Switch Harness Connector ( SE6 ) ( W1 ) ( W21 )
X67—Machine Harness Auxiliary Power Connector ( W2 )
X73—Cab Harness-to-Speakers Connector ( SE18 ) ( W1 )
X74—Cab Harness-to-Remote Service ADVISOR™ Remote (SAR) Switch Harness Connector ( W1 ) ( W10 )
X75—Cab Harness-to-Pilot Shutoff Valve Harness Connector ( W1 ) ( W21 )
X76—Cab Harness Connector 1 (not used) ( SE4 ) ( W1 )
X77—Radio Auxiliary Connector ( SE18 ) ( W1 )
X78—Optional Switch ( W1 )
X79—Engine Interface-to-Engine Harness Connector 1 ( W4 ) ( W5 )
X80—Engine Interface-to-Engine Harness Connector 2 ( W4 ) ( W5 )
X81—Multi-Function Pilot Control Lever Harness-to-Auxiliary 3-Button Cancel Switch Harness Connector ( W15 ) ( W22 )
X82—Multi-Function Pilot Control Lever Harness-to-Auxiliary 3-Button Cancel Switch Harness Connector ( W15 ) ( W22 )
X83—Cab Harness-to-Reversing Fan Switch Harness Connector ( W1 ) ( W23 )
X86—Machine Harness-to-Travel Alarm Harness Connector ( W2 ) ( W26 )
X91—Not Used ( SE7 ) ( W8 )
X90—Machine Harness-to-Hydraulic Oil Temperature Switch Connector ( SE4 ) ( W2 )
X97—Pump Harness Splice Connector ( SE8 , SE9 ) ( W8 )
X98—Machine Harness Splice Connector ( W2 )
X99—Cab Ground Splice ( W1 )
X100—Air Conditioner Controller 32-Pin Connector ( W41 )
X135—Pilot Shutoff Harness Splice 1 ( W11 )
X136—Pilot Shutoff Harness Splice 2 ( W11 )
X137—Pilot Shutoff Harness Splice 3 ( W11 )
X160—1356 YEL Splice (later models) ( W5 )
X161—1357 GRN Splice (later models) ( W5 )
X174—Engine Harness-to-Engine Interface Harness Connector ( W4 ) ( W5 )
X175—Machine Harness-to-Starter Harness Connector ( SE2 ) ( W27 )
X200—G01 BLK Splice 1 ( W5 )
X201—P01 RED Splice 1 ( W5 )
X202—R02 BLK Splice 1 ( W5 )
X203—M13 LT GRN Splice 1 ( W5 )
X204—M12 YEL Splice 1 ( W5 )
X205—M12 YEL Splice 2 ( W5 )
X206—M13 LT GRN Splice 2 ( W5 )
X207—R02 BLK Splice 2 ( W5 )
X208—M12 YEL Splice 3 ( W5 )
X209—5491 BLK Splice 1 ( W38 )
X210—5496 BLK Splice 2 ( W38
X240—5804 YEL Splice 1 ( W4 )
X241—5805 GRN Splice 1 ( W4 )
X242—5804 YEL Splice 2 ( W4 )
X243—5805 GRN Splice 2 ( W4 )
X244—5804 YEL Splice 3 ( W4 )
X245—5805 GRN Splice 3 ( W4 )
X246—5774 YEL Splice ( W4 )
X247—5441 BRN Splice ( W4 )
<- Go to Section TOC Section 9015 page 26 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

X248—5446 LT BLU Splice ( W4 )


X296—8A PUR Splice ( W38 )
X297—7A BRN Splice ( W38 )
X300—7 RED/BLK Splice ( W41 )
X301—17 RED/BLU Splice ( W41 )
X302—25 BRN/RED Splice ( W41 )
X303—26 BLK Splice ( W41 )
X335—BRN Splice ( W38 )
X336—PUR Splice ( W38 )
X350—5479 WHT Splice ( W4 )
X351—5410 BLK Splice (SHIELD) ( W4 )
X352—5437 PUR Splice ( W4 )
X353—5474 YEL Splice ( W4 )
X354—5414 YEL Splice ( W4 )
X357—5466 LT BLU Splice ( W4 )
X358—5774 YEL Splice ( W4 )
X359—5441 BRN Splice ( W4 )
X360—5446 LT BLU Splice ( W4 )
X361—5804 YEL Splice 1 ( W4 )
X362—5805 DK GRN Splice 3 ( W4 )
X365—5804 YEL Splice 1 ( W4 )
X366—5805 DK GRN Splice 1 ( W4 )
X400—E03 WHT Splice ( W27 )
X401—P21 RED Splice ( W27 )
X534—Right Auxiliary Solenoid Connector (marked SR/H) ( SE27 , SE29 ) ( W61 ) ( W15 ) or ( W75 )
X535—Left Auxiliary Solenoid Connector (marked SL/H) ( SE27 , SE29 ) ( W61 ) ( W15 ) or ( W75 )
X536—Right Auxiliary Function Lever (AFL) Connector (marked R_GRIP) ( SE28 ) ( W75 )
X537—Left Auxiliary Function Lever (AFL) Connector (marked L_GRIP) ( SE28 ) ( W75 )
X574—Auxiliary Function Lever (AFL) Connector 1 ( SE10 , SE29 ) ( W1 ), ( W75 )
X575—Auxiliary Function Lever (AFL) Connector 2 ( SE10 ) ( W1 )
X577—Auxiliary Function Lever (AFL) Harness-to-Auxiliary Function Lever (AFL) Solenoid Harness Connector ( SE29 ) (
W75 ), ( W76 )
X5000—Engine Harness-to-Fuel Injector Harness 8-Pin Connector ( W38 )
X5001—Static Ground ( W4 )
X5010—Engine Harness-to-Front Engine Harness 8-Pin Connector ( W4 )
X5014—Engine Harness-to-Air Sensor Harness 6-Pin Connector (dual turbo) (not used) ( W4 )
X5015—Engine Interface Harness-to-Engine Harness 40-Pin Connector 1 ( W4 ) ( W5 )
X5016—Engine Interface Harness-to-Engine Harness 40-Pin Connector 2 ( W4 ) ( W5 )
X5030A—DRAIN ( W5 )
X5808—P01-2 RED Splice ( W5 )
X5809—G01-3 BLK Splice ( W5 )
X5810—PM13-3 LT GRN Splice ( W5 )
X5811—PM12-3 YEL Splice ( W5 )
X5812—PR02-3 BLK Splice ( W5 )
X5813—M13-2 LT GRN Splice ( W5 )
X5814—M12-2 YEL Splice ( W5 )
X5815—R02-2 BLK Splice ( W5 )
X5816—P307 RED Splice ( W5 )
X5817—P01 RED Splice ( W5 )
X5818—G01 BLK Splice 1 ( W5 )
X5819—R02 BLK Splice ( W5 )
X5820—M12 YEL Splice ( W5 )
X5821—M13 LT GRN Splice ( W5 )
X5822—G01 BLK Splice 2 ( W5 )
X5823—5437 PUR Splice ( W5 )
X5824—5474 YEL Splice ( W5 )
X6007—JDLink™ Harness Ground 1 ( SE21 ) ( W4 )
X6014—Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector ( SE21 ) ( W4 ) ( W6002 )
X6015—Satellite (SAT) Module Control Unit 48-Pin Connector ( SE21 ) ( W5 )
X6016—Engine Interface Harness-to-Satellite (SAT) Harness Connector ( SE21 ) ( W5 ) ( W6003 )
X6019— Modular Telematics Gateway (MTG) Connector ( SE21 ) ( W5 ) ( W6002 )
<- Go to Section TOC Section 9015 page 27 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

X6022—Cab Harness-to-Exhaust Filter Solenoid Harness Connector (not used) ( W2 )


Y1—Electronic Injector 1 (cylinder 1) ( SE12 ) ( W38 )
Y2—Electronic Injector 2 (cylinder 2) ( SE12 ) ( W38 )
Y3—Electronic Injector 3 (cylinder 3) ( SE12 ) ( W38 )
Y4—Electronic Injector 4 (cylinder 4) ( SE12 ) ( W38 )
Y9—Reversing Fan Solenoid ( SE13 ) ( W5 )
Y10—Pilot Shutoff Solenoid ( SE2 ) ( W1 )
Y11—Air Conditioner Compressor Clutch ( SE22 ) ( W2 )
Y19—Ether Start Aid ( SE14 ) ( W5 )
Y20—Pump 2 Flow Rate Limit Solenoid (marked SB) ( SE7 ) ( W8 )
Y21—Torque Control Solenoid (marked ST) ( SE7 ) ( W8 )
Y22—Dig Regenerative Solenoid (marked SF) ( SE7 ) ( W2 )
Y23—Arm Regenerative Solenoid (marked SC) ( SE8 ) ( W2 )
Y24—Power Dig Solenoid (marked SG) ( SE8 ) ( W2 )
Y24—Power Dig/Travel Speed Solenoid (marked SG) ( SE8 ) ( W2 )
Y25—Travel Speed Solenoid (marked SI) ( SE8 ) ( W2 )
Y27—Arm 2 Flow Control Solenoid (marked SD) ( SE8 ) ( W2 )
Y34—Right Solenoid (marked SR/H) ( SE27 ) ( W61 )
Y35—Left Solenoid (marked SL/H) ( SE27 ) ( W61 )
Y40—Selector Valve Solenoid Valve ( SE8 ) ( W17 )
Y41—Secondary Relief Solenoid Valve ( SE9 ) ( W17 )
Y44—Flow Rate Adjustment Solenoid Valve ( SE8 ) ( W17 )
Y61—Auxiliary Function Lever (AFL) Solenoid A (marked 1A) ( SE30 ) ( W76 )
Y62—Auxiliary Function Lever (AFL) Solenoid B (marked 1B) ( SE30 ) ( W76 )
Y66—Secondary Pilot Shutoff Solenoid Valve (marked PiC) ( SE30 ) ( W76 )
Y5005—Variable Speed Fan Solenoid ( SE13 ) ( W5 )
Y5401—Intake Air Throttle ( SE11 , SE12 ) ( W4 )

<- Go to Section TOC Section 9015 page 28 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

System Functional Schematic


System Functional Schematic (S.N. —040754)

<- Go to Section TOC Section 9015 page 29 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

130G System Functional Schematic (SE1—SE3) (1 of 9) (S.N. —040754)

<- Go to Section TOC Section 9015 page 30 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
F4 Solenoid 20 A Fuse (marked SOLENOID)
F7 Start Position Signal 5 A Fuse (marked START)
F18 Idle Stop 5 A Fuse (marked IDLE STOP)
F45 Starter In-Line 30 A Fuse
F60 Alternator 65 A Fuse
F61 Battery 45 A Fuse
G1 Battery
G2 Battery
G3 Alternator
K1 Load Dump Relay
K2 Pilot Shutoff Solenoid Relay
K4 Starter Cut Relay
K5 Security Relay
K11 Idle Stop Relay
K12 Accessory Cut Relay
K13 Key Cut Relay
K19 Battery Relay
K34 Starter Relay
K35 Starter Protection Relay
M1 Starter Motor
R13 Alternator Resistor
S1 Key Switch
S3 Pilot Shutoff Switch 1
S4 Pilot Shutoff Switch 2
V1 Battery Relay Diode
V2 Alternator Excitation Diode
V3 Load Dump Relay Diode
V4 Security Diode
V5 Starter Cut Relay Diode
V7 Start Relay Diode
V9 Pilot Shutoff Diode
V10 Starter Protection Diode
V11 Accessory Cut Diode
V12 Starter Cut Diode
V44 Starter Relay Diode
V20 Pilot Shutoff Switch Diode
X175 Machine Harness-to-Starter Harness Connector
Y10 Pilot Shutoff Solenoid

<- Go to Section TOC Section 9015 page 31 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

130G System Functional Schematic (SE4—SE6) (2 of 9) (S.N. —040754)

<- Go to Section TOC Section 9015 page 32 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
A4 Monitor Controller (DSZ)
A10 Monitor
A12 Rear Camera
B18 Fuel Level Sensor
B27 Hydraulic Oil Filter Restriction Switch (if equipped)
E5 Switch Panel Back Light 1
E6 Switch Panel Back Light 2
E7 Switch Panel Back Light 3
E8 Switch Panel Back Light 4
F9 Radio Backup 10 A Fuse (marked BACK UP)
F14 Monitor 5 A Fuse (marked MONITOR)
F17 Power On 5 A Fuse (marked POWER ON)
H2 Security Alarm
H3 Monitor Warning Alarm
K3 Security Alarm Relay
S10 Work Light Switch
S20 Seat Belt Switch
S21 Blower Motor Speed Switch
S22 Temperature Control/Mode Switch
S23 Radio Volume and Power Switch
S24 Radio Tuning Switch
S25 Monitor Dial
S26 Back Button
S27 Home Button
S40 Hydraulic Oil Temperature Switch (if equipped)
S50 0 Key
S51 1 Key
S52 2 Key
S53 3 Key
S54 4 Key
S55 5 Key
S56 6 Key
S57 7 Key
S58 8 Key
S59 9 Key
S60 Keypad
X2 MPDr 6-Pin Connector
X3 Cab Harness-to-Machine Harness 100-Pin Connector
X18 Monitor 12-Pin Connector C
X19 Monitor 2-Pin Connector G
X20 Monitor Controller 28-Pin Connector A
X21 Monitor Controller 36-Pin Connector B
X22 Monitor Controller 16-Pin Connector D
X23 Monitor Controller 12-Pin Connector C
X24 Monitor Controller 2-Pin Connector G
X28 Cab Harness-to-Switch Panel Connector 2
X29 Cab Harness-to-Switch Panel Connector 3
X30 Cab Harness-to-Switch Panel Connector 4
X64 Machine Harness-to-Rear Camera Harness Connector
X76 Cab Harness Connector 1 (not used)
X90 Machine Harness-to-Hydraulic Oil Temperature Switch Connector

<- Go to Section TOC Section 9015 page 33 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

130G System Functional Schematic (SE7—SE9) (3 of 9) (S.N. —040754)

<- Go to Section TOC Section 9015 page 34 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
A3 Main Controller (MCZ)
B30 Boom Up Pressure Sensor
B31 Arm In Pressure Sensor
B32 Front Attachment Pressure Sensor
B33 Swing Pressure Sensor
B34 Travel Pressure Sensor
B35 Pump 1 Delivery Pressure Sensor
B36 Pump 1 Control Pressure Sensor
B37 Pump 2 Delivery Pressure Sensor
B38 Pump 2 Control Pressure Sensor
B40 Hydraulic Oil Temperature Sensor
B60 Attachment Pressure Sensor
B61 Arm Out Pressure Sensor
F5 Travel Alarm 5 A Fuse (marked OPT. 1 ALT)
F10 Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)
H4 Travel Alarm
R15 Engine Speed Dial
S8 Auto-Idle Switch
S11 Travel Speed Switch
S12 Power Mode Button
S13 Travel Alarm Cancel Switch
V40 Selector Valve Solenoid Valve Diode
V41 Secondary Relief Solenoid Valve Diode
V43 2-Speed Activation Solenoid Valve Diode
X29 Cab Harness-to-Switch Panel Connector 3
X31 Cab Harness-to-Main Controller 31-Pin Connector A
X32 Cab Harness-to-Main Controller 24-Pin Connector B
X33 Cab Harness-to-Main Controller 17-Pin Connector C
X34 Cab Harness-to-Main Controller 30-Pin Connector D
X35 Cab Harness-to-Main Controller 24-Pin Connector D
X36 Cab Harness-to-Main Controller 26-Pin Connector E
X40 Pump Harness-to-Machine Harness Connector
X90 Not Used
X91 Not Used
X97 Pump Harness Splice Connector
Y20 Pump 2 Flow Rate Limit Solenoid (marked SB)
Y21 Torque Control Solenoid (marked ST)
Y22 Dig Regenerative Solenoid (marked SF)
Y23 Arm Regenerative Solenoid (marked SC)
Y24 Power Dig Solenoid (marked SG)
Y27 Arm 2 Flow Control Solenoid (marked SD)
Y40 Selector Valve Solenoid Valve
Y41 Secondary Relief Solenoid Valve
Y43 2-Speed Activation Solenoid Valve
Y44 Flow Rate Adjustment Solenoid Valve

<- Go to Section TOC Section 9015 page 35 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

130G System Functional Schematic (SE10—SE12) (4 of 9 (S.N. —040754)

<- Go to Section TOC Section 9015 page 36 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
A1 Engine Control Unit (ECU)
A3 Main Controller (MCZ)
B82 Ambient Air Temperature Sensor 2
B5100 Fuel Rail Pressure Sensor
B5101 Engine Oil Pressure Sensor
B5107 Inlet Fuel Pressure Sensor
B5206 Manifold Air Temperature (MAT) Sensor
B5208 Engine Coolant Temperature Sensor
B5209 Fuel Temperature Sensor
B5301 Crankshaft Position Sensor
B5302 Camshaft Position Sensor
B5600 Water-in-Fuel Sensor
M13 High Pressure Fuel Pump
R12 CAN 0 Termination Resistor
S7 Power Dig Switch
X1 Service ADVISOR ™ Diagnostic Connector
X14 Engine Control Unit (ECU)-to-Engine Harness Connector 1
X15 Engine Control Unit (ECU)-to-Engine Harness Connector 2
X31 Cab Harness-to-Main Controller 31-Pin Connector A
X32 Cab Harness-to-Main Controller 24-Pin Connector B
X33 Cab Harness-to-Main Controller 17-Pin Connector C
X34 Cab Harness-to-Main Controller 30-Pin Connector D
X35 Cab Harness-to-Main Controller 24-Pin Connector E
X36 Cab Harness-to-Main Controller 26-Pin Connector F
Y1 Electronic Injector 1 (cylinder 1)
Y2 Electronic Injector 2 (cylinder 2)
Y3 Electronic Injector 3 (cylinder 3)
Y4 Electronic Injector 4 (cylinder 4)

<- Go to Section TOC Section 9015 page 37 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

130G System Functional Schematic (SE13—SE15) (5 of 9) (S.N. —040754)

<- Go to Section TOC Section 9015 page 38 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
A1 Engine Control Unit (ECU)
B16 Air Filter Restriction Switch
B53 Fan Speed Sensor
F8 Engine Control Unit (ECU) 30 A Fuse (marked ECU)
S15 Reversing Fan Switch
S5001 Engine Coolant Loss Level Sensor
S5002 Engine Coolant Service Level Sensor
X14 Engine Control Unit (ECU)-to-Engine Harness Connector 1
X15 Engine Control Unit (ECU)-to-Engine Harness Connector 2
Y9 Reversing Fan Solenoid
Y19 Ether Start Aid
Y5005 Variable Speed Fan Solenoid

<- Go to Section TOC Section 9015 page 39 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

130G Functional Schematic (SE16—SE18) (6 of 9) (S.N. —040754)

<- Go to Section TOC Section 9015 page 40 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
A6 Radio
A8 12-Volt Power Converter
B25 Right Speaker
B26 Left Speaker
E1 Work Light
E2 Boom Light
F1 Work and Boom Lights 20 A Fuse (marked LAMP)
F2 Windshield Wiper and Washer 10 A Fuse (marked WIPER)
F6 12-Volt Power Outlet 10 A Fuse (marked OPT. 2 ALT)
F12 Radio and Dome 5 A Fuse (marked RADIO)
F13 Lighter 10 A Fuse (marked LIGHTER)
F15 Cab Auxiliary Power Connector One 10 A Fuse (marked AUX)
F20 Optional Equipment 5 A Fuse (marked OPT. 3 BATT)
F62 Wiper Motor Assembly Circuit Breaker
G5 12-Volt Power Outlet
K6 Windshield Wiper Relay
K7 Work Light Relay
K8 Boom Light Relay
K9 Windshield Washer Relay
M5 Windshield Wiper Motor
M6 Windshield Washer Motor
R9 Lighter
S28 Window Switch
V6 Auxiliary Power Connector Diode
W60 Radio Antenna
X3 Cab Harness-to-Machine Harness 100-Pin Connector
X25 Cab Harness Auxiliary Power Connector 1
X26 Optional Connector
X39 Cab Harness-to-Window Switch Connector
X44 Optional Light Connector
X73 Cab Harness-to-Speakers Connector
X77 Radio Auxiliary Connector

<- Go to Section TOC Section 9015 page 41 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

130G Functional Schematic (SE19—SE21) (7 of 9) (S.N. —040754)

<- Go to Section TOC Section 9015 page 42 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
A5 Data Converter
A11 Machine Controller (BCZ)
A6000 Modular Telematics Gateway (MTG) Controller (if equipped)
A6001 GPS/Cellular Antenna
A6002 Satellite (SAT) Module Control Unit (if equipped)
A6003 Satellite (SAT) Antenna
E3 Cab Dome Light
E9 Key Switch Light
E10 Switch Panel Back Light 5
F6000 JDLink ™ Unswitched Power 7.5 A Fuse
F6001 JDLink™ Ground 7.5 A Fuse
F6002 JDLink™ Switched Power 7.5 A Fuse
R10 Interface CAN Resistor 1
R11 Interface CAN Resistor 2 (later models)
S2 Cab Dome Light Switch
S9 Windshield Wiper and Washer Switch
S14 Door Switch
V13 Work Light 1 Diode
V14 Work Light 2 Diode
X8 Machine Harness-to-Engine Interface Harness 8-Pin Connector 3
X10 Machine Controller 8-Pin Connector A
X11 Machine Controller 20-Pin Connector B
X27 Cab Harness-to-Switch Panel Connector 1
X6007 JDLink™ Harness Ground 1
X6014 Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector
X6015 Satellite (SAT) Module Control Unit 48-Pin Connector
X6016 Engine Interface Harness-to-Satellite (SAT) Harness
X6019 Modular Telematics Gateway (MTG) Connector

<- Go to Section TOC Section 9015 page 43 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

130G System Functional Schematic (SE22—SE24) (8 of 9) (S.N. —040754)

<- Go to Section TOC Section 9015 page 44 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
A7 Air Conditioner Controller (ACF)
B20 Air Conditioner High/Low Pressure Switch
B21 Solar Sensor
B22 Ambient Air Temperature Sensor
B23 High Note Horn
B24 Low Note Horn
B41 Air Conditioner Freeze Control Switch
B55 Air Recirculation Sensor
F3 Air Conditioner and Heater 20 A Fuse (marked HEATER)
F19 Horn 10 A Fuse (marked HORN)
K10 Horn Relay
K15 Air Conditioner Blower Motor Relay
K17 Max Hi Relay
K18 Air Conditioner Compressor Clutch Relay
M7 Air Conditioner and Heater Blower Motor
M9 Air Conditioner and Heater Internal and External Servomotor
M10 Air Conditioner and Heater Blower Port Change Servomotor
M11 Air Conditioner and Heater Mixer Servomotor
R16 Blower Motor Transistor
R17 Blower Motor Resistor
S5 Horn Switch
V8 Air Conditioner Clutch Diode
X52 Air Conditioner 10-Pin Connector
Y11 Air Conditioner Compressor Clutch

<- Go to Section TOC Section 9015 page 45 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

130G System Functional Schematic (SE25—SE27) (9 of 9) (S.N. —040754)

<- Go to Section TOC Section 9015 page 46 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
B80 Seat Temperature Switch 1
B81 Seat Temperature Switch 2
F21 Heated Air Seat 10 A Fuse (marked SEAT HEATER)
F22 Front Cab Light 1 10 A Fuse (marked CAB LAMP FRONT)
F23 Rear Cab Light 10 A Fuse (marked CAB LAMP REAR)
F24 12-Volt Power Unit 10 A Fuse (marked 12V UNIT)
F25 IMOBI 5 A Fuse (marked IMOBI)
F26 Quick Hitch 5 A Fuse (marked QUICK HITCH)
F27 Cab Auxiliary Power Connector 3 5 A Fuse (marked AUX. 3)
F31 Seat Compressor 10 A Fuse (marked SEAT COMPR)
F32 Front Cab Light 2 10 A Fuse (marked CAB LAMP FRONT +2)
F33 Warning Lamp 10 A Fuse (marked WARNING LAMP)
F34 Cab Auxiliary Power Connector 2 10 A Fuse (marked AUX. 2)
K20 Seat Heater Relay
K30 Right Solenoid Relay B
K31 Right Solenoid Relay A
K32 Left Solenoid Relay B
K33 Left Solenoid Relay A
M12 Seat Air Compressor Motor
R18 Seat Heater (marked SEAT HEATER)
S30 Right Pilot Control Lever Switch B (marked B)
S31 Right Pilot Control Lever Switch A (marked A)
S32 Left Pilot Control Lever Switch B (marked B)
S33 Left Pilot Control Lever Switch A (marked A)
S34 Right Enable Switch
S35 Left Enable Switch
S61 Seat Compressor Switch
S62 Seat Heater Switch
V30 Right Solenoid Diode B
V31 Right Solenoid Diode A
V32 Left Solenoid Diode B
V33 Left Solenoid Diode A
X26 Optional Connector
X44 Optional Light Connector
X54 Auxiliary Fuse Box Harness-to-Heated Air Seat Harness 3-Pin Connector (marked SEAT HEATER)
X55 Front Cab Light 1 Connector (marked CAB LAMP FRONT)
X56 Front Cab Light 2 Connector (marked CAB LAMP FRONT+2)
X57 Rear Cab Light Connector (marked CAB LAMP REAR)
X58 Warning Light Connector (marked WARNING LAMP)
X59 Satellite Communication Connector (marked IMOBI)
X60 12-Volt Power Supply Connector (marked 12V UNIT)
X61 Quick Hitch Connector (marked QUICK HITCH)
X62 Cab Auxiliary Power Connector 2 (marked AUX_2)
X63 Cab Auxiliary Power Connector 3 (marked AUX_3)
X534 Right Auxiliary Solenoid Connector (marked SR/H)
X535 Left Auxiliary Solenoid Connector (marked SL/H)
Y34 Right Solenoid (marked SR/H)
Y35 Left Solenoid (marked SL/H)

System Functional Schematic (S.N. 040755— )

<- Go to Section TOC Section 9015 page 47 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

System Functional Schematic (SE1—SE3) (1 of 10) (S.N. 040755— )

<- Go to Section TOC Section 9015 page 48 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
F4 Solenoid 20 A Fuse (marked SOLENOID)
F7 Start Position Signal 5 A Fuse (marked START)
F18 Idle Stop 5 A Fuse (marked IDLE STOP)
F45 Starter In-Line 30 A Fuse
F60 Alternator 65 A Fuse
F61 Battery 45 A Fuse
G1 Battery
G2 Battery
G3 Alternator
K1 Load Dump Relay
K2 Pilot Shutoff Solenoid Relay
K4 Starter Cut Relay
K5 Security Relay
K11 Idle Stop Relay
K12 Accessory Cut Relay
K13 Key Cut Relay
K19 Battery Relay
K34 Starter Relay
K35 Starter Protection Relay
M1 Starter Motor
R13 Alternator Resistor
S1 Key Switch
S3 Pilot Shutoff Switch 1
S4 Pilot Shutoff Switch 2
V1 Battery Relay Diode
V2 Alternator Excitation Diode
V3 Load Dump Relay Diode
V4 Security Diode
V5 Starter Cut Relay Diode
V7 Start Relay Diode
V9 Pilot Shutoff Diode
V10 Starter Protection Diode
V11 Accessory Cut Diode
V12 Starter Cut Diode
V44 Starter Relay Diode
V20 Pilot Shutoff Switch Diode
X65 Cab Harness-to-Pilot Shutoff Switch Harness Connector
X175 Machine Harness-to-Starter Harness Connector
Y10 Pilot Shutoff Solenoid

<- Go to Section TOC Section 9015 page 49 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

System Functional Schematic (SE4—SE6) (2 of 10) (S.N. 040755— )

<- Go to Section TOC Section 9015 page 50 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
A4 Monitor Controller (DSZ)
A10 Monitor
A12 Rear Camera
B18 Fuel Level Sensor
B27 Hydraulic Oil Filter Restriction Switch (if equipped)
E5 Switch Panel Back Light 1
E6 Switch Panel Back Light 2
E7 Switch Panel Back Light 3
E8 Switch Panel Back Light 4
F9 Radio Backup 10 A Fuse (marked BACK UP)
F14 Monitor 5 A Fuse (marked MONITOR)
F17 Power On 5 A Fuse (marked POWER ON)
H2 Security Alarm
H3 Monitor Warning Alarm
K3 Security Alarm Relay
S10 Work Light Switch
S20 Seat Belt Switch
S21 Blower Motor Speed Switch
S22 Temperature Control/Mode Switch
S23 Radio Volume and Power Switch
S24 Radio Tuning Switch
S25 Monitor Dial
S26 Back Button
S27 Home Button
S40 Hydraulic Oil Temperature Switch (if equipped)
S50 0 Key
S51 1 Key
S52 2 Key
S53 3 Key
S54 4 Key
S55 5 Key
S56 6 Key
S57 7 Key
S58 8 Key
S59 9 Key
S60 Keypad
X2 MPDr 6-Pin Connector
X3 Cab Harness-to-Machine Harness 100-Pin Connector
X18 Monitor 12-Pin Connector C
X19 Monitor 2-Pin Connector G
X20 Monitor Controller 28-Pin Connector A
X21 Monitor Controller 36-Pin Connector B
X22 Monitor Controller 16-Pin Connector D
X23 Monitor Controller 12-Pin Connector C
X24 Monitor Controller 2-Pin Connector G
X28 Cab Harness-to-Switch Panel Connector 2
X29 Cab Harness-to-Switch Panel Connector 3
X30 Cab Harness-to-Switch Panel Connector 4
X64 Machine Harness-to-Rear Camera Harness Connector
X76 Cab Harness Connector 1 (not used)
X90 Machine Harness-to-Hydraulic Oil Temperature Switch Connector

<- Go to Section TOC Section 9015 page 51 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

System Functional Schematic (SE7—SE9) (3 of 10) (S.N. 040755— )

<- Go to Section TOC Section 9015 page 52 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
A3 Main Controller (MCZ)
B30 Boom Up Pressure Sensor
B31 Arm In Pressure Sensor
B32 Front Attachment Pressure Sensor
B33 Swing Pressure Sensor
B34 Travel Pressure Sensor
B35 Pump 1 Delivery Pressure Sensor
B36 Pump 1 Control Pressure Sensor
B37 Pump 2 Delivery Pressure Sensor
B38 Pump 2 Control Pressure Sensor
B40 Hydraulic Oil Temperature Sensor
B60 Attachment Pressure Sensor
B61 Arm Out Pressure Sensor
F5 Optional and Attachment Connector 5 A Fuse (marked OPT. 1 ALT)
F10 Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)
F11 Travel Alarm 5 A Fuse (marked TRAVEL ALARM)
H4 Travel Alarm
R15 Engine Speed Dial
S8 Auto-Idle Switch
S11 Travel Speed Switch
S12 Power Mode Button
S13 Travel Alarm Cancel Switch
V40 Selector Valve Solenoid Valve Diode
V41 Secondary Relief Solenoid Valve Diode
V43 2-Speed Activation Solenoid Valve Diode
X29 Cab Harness-to-Switch Panel Connector 3
X31 Cab Harness-to-Main Controller 31-Pin Connector A
X32 Cab Harness-to-Main Controller 24-Pin Connector B
X33 Cab Harness-to-Main Controller 17-Pin Connector C
X34 Cab Harness-to-Main Controller 30-Pin Connector D
X35 Cab Harness-to-Main Controller 24-Pin Connector E
X36 Cab Harness-to-Main Controller 26-Pin Connector F
X40 Pump Harness-to-Machine Harness Connector
X90 Not Used
X91 Not Used
X97 Pump Harness Splice Connector
Y20 Pump 2 Flow Rate Limit Solenoid (marked SB)
Y21 Torque Control Solenoid (marked ST)
Y22 Dig Regenerative Solenoid (marked SF)
Y23 Arm Regenerative Solenoid (marked SC)
Y24 Power Dig/Travel Speed Solenoid (marked SG)
Y27 Arm 2 Flow Control Solenoid (marked SD)
Y40 Selector Valve Solenoid Valve
Y41 Secondary Relief Solenoid Valve
Y43 2-Speed Activation Solenoid Valve
Y44 Flow Rate Adjustment Solenoid Valve

<- Go to Section TOC Section 9015 page 53 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

System Functional Schematic (SE10—SE12) (4 of 10) (S.N. 040755— )

<- Go to Section TOC Section 9015 page 54 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
A1 Engine Control Unit (ECU)
A3 Main Controller (MCZ)
B82 Ambient Air Temperature Sensor 2
B5100 Fuel Rail Pressure Sensor
B5101 Engine Oil Pressure Sensor
B5107 Inlet Fuel Pressure Sensor
B5206 Manifold Air Temperature (MAT) Sensor
B5208 Engine Coolant Temperature Sensor
B5209 Fuel Temperature Sensor
B5301 Crankshaft Position Sensor
B5302 Camshaft Position Sensor
B5600 Water-in-Fuel Sensor
M13 High Pressure Fuel Pump
R12 CAN 0 Termination Resistor
S7 Power Dig Switch
X1 Service ADVISOR ™ Diagnostic Connector
X14 Engine Control Unit (ECU)-to-Engine Harness Connector 1
X15 Engine Control Unit (ECU)-to-Engine Harness Connector 2
X31 Cab Harness-to-Main Controller 31-Pin Connector A
X32 Cab Harness-to-Main Controller 24-Pin Connector B
X33 Cab Harness-to-Main Controller 17-Pin Connector C
X34 Cab Harness-to-Main Controller 30-Pin Connector D
X35 Cab Harness-to-Main Controller 24-Pin Connector E
X36 Cab Harness-to-Main Controller 26-Pin Connector F
X574 Auxiliary Function Lever (AFL) Connector 1
X575 Auxiliary Function Lever (AFL) Connector 2
Y1 Electronic Injector 1 (cylinder 1)
Y2 Electronic Injector 2 (cylinder 2)
Y3 Electronic Injector 3 (cylinder 3)
Y4 Electronic Injector 4 (cylinder 4)

<- Go to Section TOC Section 9015 page 55 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

System Functional Schematic (SE13—SE15) (5 of 10) (S.N. 040755— )

<- Go to Section TOC Section 9015 page 56 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
A1 Engine Control Unit (ECU)
B16 Air Filter Restriction Switch
B53 Fan Speed Sensor
F8 Engine Control Unit (ECU) 20 A Fuse (marked ECU)
S15 Reversing Fan Switch
S5001 Engine Coolant Loss Level Sensor
S5002 Engine Coolant Service Level Sensor
X14 Engine Control Unit (ECU)-to-Engine Harness Connector 1
X15 Engine Control Unit (ECU)-to-Engine Harness Connector 2
Y9 Reversing Fan Solenoid
Y19 Ether Start Aid
Y5005 Variable Speed Fan Solenoid

<- Go to Section TOC Section 9015 page 57 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

System Functional Schematic (SE16—SE18) (6 of 10) (S.N. 040755— )

<- Go to Section TOC Section 9015 page 58 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
A6 Radio
A8 12-Volt Power Converter
B25 Right Speaker
B26 Left Speaker
E1 Work Light
E2 Boom Light
F1 Work and Boom Lights 20 A Fuse (marked LAMP)
F2 Windshield Wiper and Washer 10 A Fuse (marked WIPER)
F6 12-Volt Power Outlet 20 A Fuse (marked OPT. 2 ALT)
F12 Radio and Dome 5 A Fuse (marked RADIO)
F13 Lighter 10 A Fuse (marked LIGHTER)
F15 Cab Auxiliary Power Connector One 10 A Fuse (marked AUX)
F20 Optional Equipment 5 A Fuse (marked OPT. 3 BATT)
F62 Wiper Motor Assembly Circuit Breaker
G5 12-Volt Power Outlet
K6 Windshield Wiper Relay
K7 Work Light Relay
K8 Boom Light Relay
K9 Windshield Washer Relay
M5 Windshield Wiper Motor
M6 Windshield Washer Motor
R9 Lighter
S28 Window Switch
V6 Auxiliary Power Connector Diode
W60 Radio Antenna
X3 Cab Harness-to-Machine Harness 100-Pin Connector
X25 Cab Harness Auxiliary Power Connector 1
X26 Optional Connector
X39 Cab Harness-to-Window Switch Connector
X73 Cab Harness-to-Speakers Connector
X77 Radio Auxiliary Connector

<- Go to Section TOC Section 9015 page 59 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

System Functional Schematic (SE19—SE21) (7 of 10) (S.N. 040755— )

<- Go to Section TOC Section 9015 page 60 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
A5 Data Converter
A11 Machine Controller (BCZ)
A6000 Modular Telematics Gateway (MTG) Controller (if equipped)
A6001 GPS/Cellular Antenna
A6002 Satellite (SAT) Module Control Unit (if equipped)
A6003 Satellite (SAT) Antenna
E3 Cab Dome Light
E9 Key Switch Light
E10 Switch Panel Back Light 5
F6000 JDLink ™ Unswitched Power 7.5 A Fuse
F6001 JDLink™ Ground 7.5 A Fuse
F6002 JDLink™ Switched Power 7.5 A Fuse
R10 Interface CAN Resistor 1
R11 Interface CAN Resistor 2 (later models)
S2 Cab Dome Light Switch
S9 Windshield Wiper and Washer Switch
S14 Door Switch
V13 Work Light 1 Diode
V14 Work Light 2 Diode
X8 Machine Harness-to-Engine Interface Harness 8-Pin Connector 3
X10 Machine Controller 8-Pin Connector A
X11 Machine Controller 20-Pin Connector B
X27 Cab Harness-to-Switch Panel Connector 1
X6007 JDLink™ Harness Ground 1
X6014 Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector
X6015 Satellite (SAT) Module Control Unit 48-Pin Connector
X6016 Engine Interface Harness-to-Satellite (SAT) Harness
X6019 Modular Telematics Gateway (MTG) Connector

<- Go to Section TOC Section 9015 page 61 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

System Functional Schematic (SE22—SE24) (8 of 10) (S.N. 040755— )

<- Go to Section TOC Section 9015 page 62 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
A7 Air Conditioner Controller (ACF)
B20 Air Conditioner High/Low Pressure Switch
B21 Solar Sensor
B22 Ambient Air Temperature Sensor
B23 High Note Horn
B24 Low Note Horn
B41 Air Conditioner Freeze Control Switch
B55 Air Recirculation Sensor
F3 Air Conditioner and Heater 20 A Fuse (marked HEATER)
F19 Horn 10 A Fuse (marked HORN)
K10 Horn Relay
K15 Air Conditioner Blower Motor Relay
K17 Max-Hi Relay
K18 Air Conditioner Compressor Clutch Relay
M7 Air Conditioner and Heater Blower Motor
M9 Air Conditioner and Heater Internal and External Servo Motor
M10 Air Conditioner and Heater Blower Port Change Servo Motor
M11 Air Conditioner and Heater Mixer Servo Motor
R16 Blower Motor Transistor
R17 Blower Motor Resistor
S5 Horn Switch
V8 Air Conditioner Clutch Diode
X52 Air Conditioner 10-Pin Connector
Y11 Air Conditioner Compressor Clutch

<- Go to Section TOC Section 9015 page 63 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

System Functional Schematic (SE25—SE27) (9 of 10) (S.N. 040755— )

<- Go to Section TOC Section 9015 page 64 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
B80 Seat Temperature Switch 1
B81 Seat Temperature Switch 2
F21 Heated Air Seat 10 A Fuse (marked SEAT HEATER)
F22 Front Cab Light 1 10 A Fuse (marked CAB LAMP FRONT)
F23 Rear Cab Light 10 A Fuse (marked CAB LAMP REAR)
F24 IMMOBI 5 A Fuse (marked IMOBI)
F25 Quick Hitch 5 A Fuse (marked QUICK HITCH)
F26 Cab Auxiliary Power Connector 3 5 A Fuse (marked AUX_3)
F31 Seat Compressor 10 A Fuse (marked SEAT COMPR)
F32 Front Cab Light 2 10 A Fuse (marked CAB LAMP FRONT +2)
F33 Warning Lamp 10 A Fuse (marked WARNING LAMP)
F34 Cab Auxiliary Power Connector 2 10 A Fuse (marked AUX_2)
K20 Seat Heater Relay
K30 Right Solenoid Relay B
K31 Right Solenoid Relay A
K32 Left Solenoid Relay B
K33 Left Solenoid Relay A
M12 Seat Air Compressor Motor
R18 Seat Heater (marked SEAT HEATER)
S30 Right Pilot Control Lever Switch B (marked B)
S31 Right Pilot Control Lever Switch A (marked C)
S32 Left Pilot Control Lever Switch B (marked B)
S33 Left Pilot Control Lever Switch A (marked C)
S34 Right Enable Switch
S35 Left Enable Switch
S61 Seat Compressor Switch
S62 Seat Heater Switch
V30 Right Solenoid Diode B
V31 Right Solenoid Diode A
V32 Left Solenoid Diode B
V33 Left Solenoid Diode A
X26 Optional Connector
X44 Optional Light Connector
X54 Auxiliary Fuse Box Harness-to-Heated Air Seat Harness 3-Pin Connector (marked SEAT HEATER)
X55 Front Cab Light 1 Connector (marked CAB LAMP FRONT)
X56 Front Cab Light 2 Connector (marked CAB LAMP FRONT +2)
X57 Rear Cab Light Connector (marked CAB LAMP REAR)
X58 Warning Light Connector (marked WARNING LAMP)
X59 Satellite Communication Connector (marked IMOBI)
X61 Quick Hitch Connector (marked QUICK HITCH)
X62 Cab Auxiliary Power Connector 2 (marked AUX_2)
X63 Cab Auxiliary Power Connector 3 (marked AUX_3)
X534 Right Auxiliary Solenoid Connector (marked SR/H)
X535 Left Auxiliary Solenoid Connector (marked SL/H)
Y34 Right Solenoid (marked SR/H)
Y35 Left Solenoid (marked SL/H)

<- Go to Section TOC Section 9015 page 65 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

System Functional Schematic (SE28—SE30) (10 of 10) (S.N. 040755— )

<- Go to Section TOC Section 9015 page 66 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
B68 Secondary Hydraulic Oil Temperature Sensor
B85 Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1)
K31 Right Solenoid Relay A
K32 Left Solenoid Relay B
K33 Left Solenoid Relay A
S7 Power Dig Switch
S29 Auxiliary Function Lever (AFL) Proportional Control Switch
S31 Right Pilot Control Lever Switch
S34 Right Enable Switch
S35 Left Enable Switch
S45 Auxiliary Function Enable Switch (marked AFL_SW)
V22 Pilot Shutoff Solenoid Diode
X26 Optional Connector
X534 Right Auxiliary Solenoid Connector (marked SR/H)
X535 Left Auxiliary Solenoid Connector (marked SL/H)
X536 Right Auxiliary Function Lever (AFL) Connector (marked R_GRIP)
X537 Left Auxiliary Function Lever (AFL) Connector (marked L_GRIP)
X574 Auxiliary Function Lever (AFL) Connector 1
X577 Auxiliary Function Lever (AFL) Harness-to-Auxiliary Function Lever (AFL) Solenoid Harness Connector
Y61 Auxiliary Function Lever (AFL) Solenoid A (marked 1A)
Y62 Auxiliary Function Lever (AFL) Solenoid B (marked 1B)
Y66 Secondary Pilot Shutoff Solenoid Valve (marked PiC)

<- Go to Section TOC Section 9015 page 67 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Cab Harness (W1) Component Location

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb.-in.

Cab Harness (W1) Component Location (S.N. —040754)

<- Go to Section TOC Section 9015 page 68 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Cab Harness (W1) Component Location (S.N. —040754)

<- Go to Section TOC Section 9015 page 69 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
A3 Main Controller (MCZ)
A4 Monitor Controller (DSZ)
A5 Data Converter
A6 Radio
A7 Air Conditioner Controller (ACF)
A8 12-Volt Power Converter
A11 Machine Controller (BCZ)
E3 Cab Dome Light
F50 Fuse Box
F51 Auxiliary Fuse Box
G5 12-Volt Power Outlet
H2 Security Alarm
K1 Load Dump Relay
K2 Pilot Shutoff Solenoid Relay
K3 Security Alarm Relay
K4 Starter Cut Relay
K5 Security Relay
K6 Windshield Wiper Relay
K7 Work Light Relay
K8 Boom Light Relay
K9 Windshield Washer Relay
K10 Horn Relay
K11 Idle Stop Relay
K12 Accessory Cut Relay
K13 Key Cut Relay
K15 Air Conditioner Blower Motor Relay
K17 Max Hi Relay
K18 Air Conditioner Compressor Clutch Relay
R9 Lighter
R10 Interface CAN Resistor 1
R15 Engine Speed Dial
S1 Key Switch
S5 Horn Switch
S7 Power Dig Switch
S8 Auto-Idle Switch
S9 Windshield Wiper and Washer Switch
S10 Work Light Switch
S11 Travel Speed Switch
S12 Power Mode Button
S13 Travel Alarm Cancel Switch
S14 Door Switch
S15 Reversing Fan Switch
S16 Exhaust Filter Parked Cleaning Switch
S18 Service ADVISOR ™ Remote (SAR) Switch
S20 Seat Belt Switch
S21 Blower Motor Speed Switch
S22 Temperature Control/Mode Switch
S23 Radio Volume and Power Switch
S24 Radio Tuning Switch
S25 Monitor Dial
S26 Back Button
S27 Home Button
S34 Right Enable Switch
S60 Keypad
S62 Seat Heater Switch
V1 Battery Relay Diode
V2 Alternator Excitation Diode
V3 Load Dump Relay Diode
V4 Security Diode
V5 Starter Cut Relay Diode
V6 Auxiliary Power Connector Diode
V7 Start Relay Diode
V8 Air Conditioner Clutch Diode
V9 Pilot Shutoff Diode
V10 Starter Protection Diode
V11 Accessory Cut Diode

<- Go to Section TOC Section 9015 page 70 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

V12 Starter Cut Diode


V13 Work Light 1 Diode
V14 Work Light 2 Diode
W1 Cab Harness
W9 Exhaust Filter Parked Cleaning Switch Harness
W10 Service ADVISOR™ Remote (SAR) Switch Harness
W16 Travel Alarm Cancel Switch Harness
W22 Auxiliary 3-Button Cancel Switch Harness
W23 Reversing Fan Switch Harness
W24 Seat Heater Switch Harness
W29 Starter Switch Harness
W35 Cab Harness Ground 1
W36 Cab Harness Ground 2
W37 Cab Harness Ground 3
X2 MPDr 6-Pin Connector
X3 Cab Harness-to-Machine Harness 100-Pin Connector
X10 Machine Controller 8-Pin Connector A
X11 Machine Controller 20-Pin Connector B
X17 Cab Harness-to-Monitor Harness Connector
X20 Monitor Controller 28-Pin Connector A
X21 Monitor Controller 36-Pin Connector B
X22 Monitor Controller 16-Pin Connector D
X25 Cab Harness Auxiliary Power Connector
X26 Optional Connector
X27 Cab Harness-to-Switch Panel Connector 1
X28 Cab Harness-to-Switch Panel Connector 2
X29 Cab Harness-to-Switch Panel Connector 3
X30 Cab Harness-to-Switch Panel Connector 4
X31 Cab Harness-to-Main Controller 31-Pin Connector A
X32 Cab Harness-to-Main Controller 24-Pin Connector B
X33 Cab Harness-to-Main Controller 17-Pin Connector C
X35 Cab Harness-to-Main Controller 24-Pin Connector D
X36 Cab Harness-to-Main Controller 26-Pin Connector E
X39 Cab Harness-to-Window Switch
X43 Optional Fuse Connector
X44 Optional Light Connector
X45 Option 2 12-Pin Connector (not used)
X47 Cab Harness-to-Key Switch Harness Connector
X50 Cab Harness-to-Travel Alarm Cancel Switch Harness Connector
X51 Air Conditioner 4-Pin Connector
X52 Air Conditioner 10-Pin Connector
X53 Heated Air Seat Harness-to-Heated Seat Switch Harness 3-Pin Connector (marked SEAT HEATER)
X65 Cab Harness-to-Pilot Shutoff Switch Harness Connector
X73 Cab Harness-to-Speakers
X74 Cab Harness-to-Remote Service ADVISOR™ Remote (SAR) Switch Harness
X75 Cab Harness-to-Pilot Shutoff Valve Harness Connector
X76 Cab Harness Connector 1 (not used)
X77 Radio Auxiliary Connector
X78 Optional Switch
X83 Cab Harness-to-Reversing Fan Switch Harness
X99 Cab Ground Splice

Cab Harness (W1) Component Location (S.N. 040755— )

<- Go to Section TOC Section 9015 page 71 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Cab Harness (W1) Component Location (S.N. 040755— )

<- Go to Section TOC Section 9015 page 72 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
A3 Main Controller (MCZ)
A4 Monitor Controller (DSZ)
A5 Data Converter
A6 Radio
A8 12-Volt Power Converter
A11 Machine Controller (BCZ)
E3 Cab Dome Light
F50 Fuse Box
F51 Fuse Box 2
G5 12-Volt Power Outlet
H2 Security Alarm
K1 Load Dump Relay
K2 Pilot Shutoff Solenoid Relay
K3 Security Alarm Relay
K4 Starter Cut Relay
K5 Security Relay
K6 Windshield Wiper Relay
K7 Work Light Relay
K8 Boom Light Relay
K9 Windshield Washer Relay
K10 Horn Relay
K11 Idle Stop Relay
K12 Accessory Cut Relay
K13 Key Cut Relay
R9 Lighter
R10 Interface CAN Resistor 1
R15 Engine Speed Dial
S1 Key Switch
S5 Horn Switch
S7 Power Dig Switch
S8 Auto-Idle Switch
S9 Windshield Wiper and Washer Switch
S10 Work Light Switch
S11 Travel Speed Switch
S12 Power Mode Button
S13 Travel Alarm Cancel Switch
S14 Door Switch
S15 Reversing Fan Switch
S16 Exhaust Filter Parked Cleaning Switch
S18 Service ADVISOR™ Remote (SAR) Switch
S21 Blower Motor Speed Switch
S22 Temperature Control/Mode Switch
S23 Radio Volume and Power Switch
S24 Radio Tuning Switch
S25 Monitor Dial
S26 Back Button
S27 Home Button
S34 Right Enable Switch
S60 Keypad
S62 Seat Heater Switch
V1 Battery Relay Diode
V2 Alternator Excitation Diode
V3 Load Dump Relay Diode
V4 Security Diode
V5 Starter Cut Relay Diode
V6 Auxiliary Power Connector Diode
V7 Start Relay Diode
V8 Air Conditioner Clutch Diode
V9 Pilot Shutoff Diode
V10 Starter Protection Diode
V11 Accessory Cut Diode
V12 Starter Cut Diode
V13 Work Light 1 Diode
V14 Work Light 2 Diode
W1 Cab Harness
W3 Monitor Harness

<- Go to Section TOC Section 9015 page 73 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

W9 Exhaust Filter Parked Cleaning Switch Harness


W10 Service ADVISOR™ Remote (SAR) Switch Harness
W16 Travel Alarm Cancel Switch Harness
W22 Auxiliary 3-Button Cancel Switch Harness
W23 Reversing Fan Switch Harness
W24 Seat Heater Switch Harness
W29 Starter Switch Harness
W35 Cab Harness Ground 1
W36 Cab Harness Ground 2
W37 Cab Harness Ground 3
X1 Service ADVISOR ™ Diagnostic Connector
X2 WinDr 6-Pin Connector
X3 Cab Harness-to-Machine Harness 100-Pin Connector
X10 Machine Controller 8-Pin Connector A
X11 Machine Controller 20-Pin Connector B
X17 Cab Harness-to-Machine Harness Connector
X20 Monitor Controller 28-Pin Connector A
X21 Monitor Controller 36-Pin Connector B
X22 Monitor Controller 16-Pin Connector D
X23 Monitor Controller 12-Pin Connector C
X24 Monitor Controller 2-Pin Connector G
X25 Cab Harness Auxiliary Power Connector 1 (marked AUX+/-)
X26 Optional Connector
X27 Cab Harness-to-Switch Panel Connector 1
X28 Cab Harness-to-Switch Panel Connector 2
X29 Cab Harness-to-Switch Panel Connector 3
X30 Cab Harness-to-Switch Panel Connector 4
X31 Cab Harness-to-Main Controller 31-Pin Connector A
X32 Cab Harness-to-Main Controller 24-Pin Connector B
X33 Cab Harness-to-Main Controller 17-Pin Connector C
X34 Cab Harness-to-Main Controller 30-Pin Connector D
X35 Cab Harness-to-Main Controller 24-Pin Connector E
X36 Cab Harness-to-Main Controller 26-Pin Connector F
X37 Cab Harness-to-Exhaust Filter Switch Harness Connector
X39 Cab Harness-to-Window Switch
X42 CAN 1 Connector
X45 Option 2 12-Pin Connector (not used)
X47 Cab Harness-to-Key Switch Harness Connector
X50 Cab Harness-to-Travel Alarm Cancel Switch Harness Connector
X51 Air Conditioner 4-Pin Connector
X52 Air Conditioner 10-Pin Connector
X54 Heated Air Seat Harness 3-Pin Connector (marked SEAT HEATER)
X55 Front Cab Light 1 Connector (marked CAB LAMP FRONT)
X56 Front Cab Light 2 Connector (marked CAB LAMP FRONT+2)
X57 Rear Cab Light Connector (marked CAB LAMP REAR)
X58 Warning Light Connector (marked WARNING LAMP)
X59 Satellite Communication Connector (marked IMMOBI)
X61 Quick Hitch Connector (marked QUICK HITCH)
X62 Cab Auxiliary Power Connector 2 (marked AUX. 2)
X63 Cab Auxiliary Power Connector 3 (marked AUX. 3)
X65 Cab Harness-to-Pilot Shutoff Switch Harness Connector
X73 Cab Harness-to-Speakers Connector
X74 Cab Harness-to-Service ADVISOR™ Remote (SAR) Switch Harness (marked SDV-SW)
X75 Cab Harness-to-Pilot Shutoff Valve Harness Connector
X76 Cab Harness Connector 1 (marked HMST, not used)
X77 Radio Auxiliary Connector
X78 Optional Switch
X81 Multi-Function Pilot Control Lever Harness-to-Auxiliary 3-Button Cancel Switch Harness Connector
X83 Cab Harness-to-Reversing Fan Switch Harness (marked VSF-SW)
X99 Cab Ground Splice
X573 Exhaust Solenoid Harness Connector (not used)
X574 Auxiliary Function Lever (AFL) Connector 1
X575 Auxiliary Function Lever (AFL) Connector 2

<- Go to Section TOC Section 9015 page 74 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Cab Harness (W1) Wiring Diagram

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb.-in.

Cab Harness (W1) Wiring Diagram (S.N. —040754)

<- Go to Section TOC Section 9015 page 75 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Cab Harness (W1) Wiring Diagram (1 of 4) (S.N. —040754)

<- Go to Section TOC Section 9015 page 76 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

<- Go to Section TOC Section 9015 page 77 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Cab Harness (W1) Wiring Diagram (2 of 4) (S.N. —040754)

<- Go to Section TOC Section 9015 page 78 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
1 Continued on Sheet 2
K1 Load Dump Relay
K2 Pilot Shutoff Solenoid Relay
K3 Security Alarm Relay
K4 Starter Cut Relay
K5 Security Relay
K6 Windshield Wiper Relay
K7 Work Light Relay
K8 Boom Light Relay
K9 Windshield Washer Relay
K10 Horn Relay
K11 Idle Stop Relay
K12 Accessory Cut Relay
K13 Key Cut Relay
S7 Power Dig Switch
V1 Battery Relay Diode
V4 Security Diode
V7 Start Relay Diode
V8 Air Conditioner Clutch Diode
V10 Starter Protection Diode
V13 Work Light 1 Diode
V14 Work Light 2 Diode
W35 Cab Harness Ground 1
W36 Cab Harness Ground 2
X10 Machine Controller 8-Pin Connector A
X11 Machine Controller 20-Pin Connector B
X17 Cab Harness-to-Monitor Harness Connector
X20 Monitor Controller 28-Pin Connector A
X21 Monitor Controller 36-Pin Connector B
X22 Monitor Controller 16-Pin Connector D
X27 Cab Harness-to-Switch Panel Connector 1
X28 Cab Harness-to-Switch Panel Connector 2
X29 Cab Harness-to-Switch Panel Connector 3
X30 Cab Harness-to-Switch Panel Connector 4
X37 Cab Harness-to-Exhaust Filter Switch Harness Connector
X47 Cab Harness-to-Key Switch Harness Connector
X74 Cab Harness-to- Service ADVISOR ™ Remote (SAR) Switch Harness Connector
X76 Cab Harness Connector (not used)
X78 Optional Switch

<- Go to Section TOC Section 9015 page 79 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Cab Harness (W1) Wiring Diagram (3 of 4) (S.N. —040754)

<- Go to Section TOC Section 9015 page 80 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
1 Continued on Sheet 1
2 Continued on Sheet 3
A5 Data Converter
E3 Cab Dome Light
H2 Security Alarm
K15 Air Conditioner Blower Motor Relay
K17 Max Hi Relay
K18 Air Conditioner Compressor Clutch Relay
R10 Interface CAN Resistor 1
V2 Alternator Excitation Diode
V3 Load Dump Relay Diode
V5 Starter Cut Relay Diode
V9 Pilot Shutoff Diode
V11 Accessory Cut Diode
V12 Starter Cut Diode
X3 Cab Harness-to-Machine Harness 100-Pin Connector
X31 Cab Harness-to-Main Controller 31-Pin Connector A
X32 Cab Harness-to-Main Controller 24-Pin Connector B
X33 Cab Harness-to-Main Controller 17-Pin Connector C
X35 Cab Harness-to-Main Controller 24-Pin Connector D
X36 Cab Harness-to-Main Controller 26-Pin Connector E
X51 Air Conditioner 4-Pin Connector
X52 Air Conditioner 10-Pin Connector
X73 Cab Harness-to-Speakers Connector
X99 Cab Ground Splice

<- Go to Section TOC Section 9015 page 81 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Cab Harness (W1) Wiring Diagram (4 of 4) (S.N. —040754)

<- Go to Section TOC Section 9015 page 82 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
2 Continued on Sheet 2
A6 Radio
A8 12-Volt Power Converter
F1 Work and Boom Lights 20 A Fuse (marked LAMP)
F2 Windshield Wiper and Washer 10 A Fuse (marked WIPER)
F3 Air Conditioner and Heater 20 A Fuse (marked HEATER)
F4 Solenoid 20 A Fuse (marked SOLENOID)
F5 Travel Alarm 5 A Fuse (marked OPT. 1 ALT)
F6 12-Volt Power Outlet 20 A Fuse (marked OPT. 2 ALT)
F7 Start Position Signal 5 A Fuse (marked START)
F8 Engine Control Unit (ECU) 30 A Fuse (marked ECU)
F9 Radio Backup 10 A Fuse (marked BACK UP)
F10 Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)
F11 Not Used
F12 Radio and Dome 5 A Fuse (marked RADIO)
F13 Lighter 10 A Fuse (marked LIGHTER)
F14 Monitor 5 A Fuse (marked MONITOR)
F15 Cab Auxiliary Power Connector 1 10 A Fuse (marked AUX)
F16 Start Aid 20 A Fuse (marked START AID)
F17 Power On 5 A Fuse (marked POWER ON)
F18 Idle Stop 5 A Fuse (marked IDLE STOP)
F19 Horn 10 A Fuse (marked HORN)
F20 Optional Equipment 5 A Fuse (marked OPT. 3 BATT)
F50 Fuse Box
G5 12-Volt Power Outlet
R9 Lighter
S5 Horn Switch
S14 Door Switch
V6 Auxiliary Power Connector Diode
W37 Cab Harness Ground 3
X2 MPDr 6-Pin Connector
X25 Cab Harness Auxiliary Power Connector 1
X26 Optional Connector
X39 Cab Harness-to-Window Switch Connector
X43 Optional Fuse Connector
X44 Optional Light Connector
X45 Option 2 12-Pin Connector (not used)
X50 Cab Harness-to-Travel Alarm Cancel Switch Harness Connector
X65 Cab Harness-to-Pilot Shutoff Switch Harness Connector
X75 Cab Harness-to-Pilot Shutoff Valve Harness Connector
X77 Radio Auxiliary Connector
X83 Cab Harness-to-Reversing Fan Switch Harness Connector

Cab Harness (W1) Wiring Diagram (S.N. 040755— )

<- Go to Section TOC Section 9015 page 83 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Cab Harness (W1) Wiring Diagram (1 of 5) (S.N. 040755— )

<- Go to Section TOC Section 9015 page 84 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

<- Go to Section TOC Section 9015 page 85 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Cab Harness (W1) Wiring Diagram (2 of 5) (S.N. 040755— )

<- Go to Section TOC Section 9015 page 86 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
1 Continued on sheet 3
A6 Radio
A8 12-Volt Power Converter
F1 Work and Boom Lights 20 A Fuse (marked LAMP)
F2 Windshield Wiper and Washer 10 A Fuse (marked WIPER)
F3 Air Conditioner and Heater 20 A Fuse (marked HEATER)
F4 Solenoid 20 A Fuse (marked SOLENOID)
F5 Optional and Attachment Connector 20 A Fuse (marked OPT. 1 ALT)
F6 Optional Connector and Reversing Fan 20 A Fuse (marked OPT. 2 ALT)
F7 Start Position Signal 5 A Fuse (marked START)
F8 Engine Control Unit (ECU) 20 A Fuse (marked ECU P1)
F9 Radio Backup 10 A Fuse (marked BACK UP)
F10 Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)
F11 Travel Alarm 5 A Fuse (marked TRAVEL ALARM)
F12 Radio and Dome 5 A Fuse (marked RADIO)
F13 Lighter 10 A Fuse (marked LIGHTER)
F14 Monitor 5 A Fuse (marked MONITOR)
F15 Cab Auxiliary Power Connector 1 10 A Fuse (marked AUX)
F16 12-Volt Power Unit 10 A Fuse (marked 12V UNIT)
F17 Power On 5 A Fuse (marked POWER ON)
F18 Idle Stop 5 A Fuse (marked IDLE STOP)
F19 Horn 10 A Fuse (marked HORN)
F20 Optional Equipment 5 A Fuse (marked OPT. 3 BATT)
F21 Heated Air Seat 10 A Fuse (marked SEAT HEATER)
F22 Front Cab Light 1 10 A Fuse (marked CAB LAMP FRONT)
F23 Rear Cab Light 10 A Fuse (marked CAB LAMP REAR)
F24 IMOBI 5 A Fuse (marked IMOBI)
F25 Quick Hitch 5 A Fuse (marked QUICK HITCH)
F26 Cab Auxiliary Power Connector 3 5 A Fuse (marked AUX. 3)
F27 Not Used
F28 Not Used
F29 Not Used
F30 Not Used
F31 Seat Compressor 10 A Fuse (marked SEAT COMPR)
F32 Front Cab Light 2 10 A Fuse (marked CAB LAMP FRONT +2)
F33 Warning Lamp 10 A Fuse (marked WARNING LAMP)
F34 Cab Auxiliary Power Connector 2 10 A Fuse (marked AUX. 2)
F35 Service Advisor Diagnostic Connector 5 A Fuse (marked DIAG)
F36 Engine Control Unit (ECU) 20 A Fuse (marked ECU P2, not used)
F37 Engine Control Unit (ECU) 20 A Fuse (marked ECU P3, not used)
F38 Fuel Transfer Pump/Controllers 20 A Fuse (marked ECU P4, not used)
F39 Not Used
F40 Not Used
F50 Fuse Box
F51 Fuse Box 2
G5 12-Volt Power Outlet
R9 Lighter
S5 Horn Switch
S14 Door Switch
V6 Auxiliary Power Connector Diode
W37 Cab Harness Ground 3
X1 Service ADVISOR ™ Diagnostic Connector
X2 WinDr. 6-Pin Connector
X25 Cab Harness Auxiliary Power Connector 1 (marked AUX+/-)
X26 Optional Connector
X34 Cab Harness-to-Main Controller 30-Pin Connector D
X35 Cab Harness-to-Main Controller 24-Pin Connector E
X36 Cab Harness-to-Main Controller 26-Pin Connector F
X39 Cab Harness-to-Window Switch Connector
X45 Option 2 12-Pin Connector (not used)
X50 Cab Harness-to-Travel Alarm Cancel Switch Harness Connector
X54 Auxiliary Fuse Box Harness-to-Heated Air Seat Harness 3-Pin Connector (marked SEAT HEATER)
X55 Front Cab Light 1 Connector (marked CAB LAMP FRONT)
X56 Front Cab Light 2 Connector (marked CAB LAMP FRONT+2)
X57 Rear Cab Light Connector (marked CAB LAMP REAR)
X58 Warning Light Connector (marked WARNING LAMP)

<- Go to Section TOC Section 9015 page 87 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

X59 Satellite Communication Connector (marked IMMOBI)


X61 Quick Hitch Connector (marked QUICK HITCH)
X62 Cab Auxiliary Power Connector 2 (marked AUX 2)
X63 Cab Auxiliary Power Connector 3 (marked AUX 3)
X65 Cab Harness-to-Pilot Shutoff Switch Harness Connector
X75 Cab Harness-to-Pilot Shutoff Valve Harness Connector
X77 Radio Auxiliary Connector
X83 Cab Harness-to-Reversing Fan Switch Harness Connector (marked VSF-SW)

<- Go to Section TOC Section 9015 page 88 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Cab Harness (W1) Wiring Diagram (3 of 5) (S.N. 040755— )

<- Go to Section TOC Section 9015 page 89 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
1 Continued on sheet 2
2 Continued on sheet 4
A5 Information Controller (ICF)
E3 Cab Dome Light
H2 Security Alarm
R10 Interface CAN Resistor 1
V2 Alternator Excitation Diode
V3 Load Dump Relay Diode
V5 Starter Cut Relay Diode
V9 Pilot Shutoff Diode
V11 Accessory Cut Diode
V12 Starter Cut Diode
X3 Cab Harness-to-Machine Harness 100-Pin Connector
X31 Cab Harness-to-Main Controller 31-Pin Connector A
X32 Cab Harness-to-Main Controller 24-Pin Connector B
X33 Cab Harness-to-Main Controller 17-Pin Connector C
X51 Air Conditioner 4-Pin Connector
X52 Air Conditioner 10-Pin Connector
X73 Cab Harness-to-Speakers Connector
X99 Cab Ground Splice
X573 Exhaust Solenoid Harness Connector (not used)

<- Go to Section TOC Section 9015 page 90 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Cab Harness (W1) Wiring Diagram (4 of 5) (S.N. 040755— )

<- Go to Section TOC Section 9015 page 91 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
2 Continued on sheet 3
3 Continued on sheet 5
K1 Load Dump Relay
K2 Pilot Shutoff Solenoid Relay
K3 Security Alarm Relay
K4 Starter Cut Relay
K5 Security Relay
K6 Windshield Wiper Relay
K7 Work Light Relay
K8 Boom Light Relay
K9 Windshield Washer Relay
K10 Horn Relay
K11 Idle Stop Relay
K12 Accessory Cut Relay
K13 Key Cut Relay
V1 Battery Relay Diode
V4 Security Diode
V7 Start Relay Diode
V8 Air Conditioner Clutch Diode
V10 Starter Protection Diode
V13 Work Light 1 Diode
V14 Work Light 2 Diode
W36 Cab Harness Ground 2
X10 Machine Controller 8-Pin Connector A
X11 Machine Controller 20-Pin Connector B
X17 Cab Harness-to-Monitor Harness Connector
X42 CAN 1 Connector
X78 Optional Switch
X574 Auxiliary Function Lever (AFL) Connector 1
X575 Auxiliary Function Lever (AFL) Connector 2

<- Go to Section TOC Section 9015 page 92 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Cab Harness (W1) Wiring Diagram (5 of 5) (S.N. 040755— )

<- Go to Section TOC Section 9015 page 93 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
3 Continued on sheet 4
S7 Power Dig Switch
W35 Cab Harness Ground 1
X20 Monitor Controller 28-Pin Connector A
X21 Monitor Controller 36-Pin Connector B
X22 Monitor Controller 16-Pin Connector D
X27 Cab Harness-to-Switch Panel Connector 1
X28 Cab Harness-to-Switch Panel Connector 2
X29 Cab Harness-to-Switch Panel Connector 3
X30 Cab Harness-to-Switch Panel Connector 4
X37 Cab Harness-to-Exhaust Filter Switch Harness Connector
X47 Cab Harness-to-Key Switch Harness Connector
X74 Cab Harness-to- Service ADVISOR ™ Remote (SAR) Switch Harness Connector (marked SDV-SW)
X76 Cab Harness Connector 1 (marked HMST, not used)

<- Go to Section TOC Section 9015 page 94 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Machine Harness (W2) Component Location

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb.-in.

Machine Harness (W2) Component Location (1 of 2)

LEGEND:
B18 Fuel Level Sensor
B20 Air Conditioner High/Low Pressure Switch
<- Go to Section TOC Section 9015 page 95 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

B22 Ambient Air Temperature Sensor


B23 High Note Horn
B24 Low Note Horn
B27 Hydraulic Oil Filter Restriction Switch (if equipped)
B30 Boom Up Pressure Sensor
B31 Arm In Pressure Sensor
B32 Front Attachment Pressure Sensor
B33 Swing Pressure Sensor
B34 Travel Pressure Sensor
B40 Hydraulic Oil Temperature Sensor
E1 Work Light
E2 Boom Light
F45 Starter In-Line 30 A Fuse
F60 Alternator 65 A Fuse
F61 Battery 45 A Fuse
G3 Alternator
K19 Battery Relay
K34 Starter Relay
M1 Starter Motor
S40 Hydraulic Oil Temperature Switch (if equipped)
V44 Starter Relay Diode
W2 Machine Harness
W27 Starter Harness
X1 Service ADVISOR ™ Diagnostic Connector
X5 Machine Harness-to-Engine Interface Harness 8-Pin Connector 1
X6 Machine Harness-to-Engine Interface Harness 1-Pin Connector
X7 Machine Harness-to-Engine Interface Harness 8-Pin Connector 2
X8 Machine Harness-to-Engine Interface Harness 8-Pin Connector 3
X40 Pump Harness-to-Machine Harness Connector
X46 Attachment Connector
X64 Machine Harness-to-Rear Camera Harness Connector
X67 Machine Harness Auxiliary Power Connector
X86 Machine Harness-to-Travel Alarm Harness Connector
X90 Machine Harness-to-Hydraulic Oil Temperature Switch Connector
X98 Machine Harness Splice Connector
X175 Machine Harness-to-Starter Harness Connector
X6022 Cab Harness-to-Exhaust Filter Solenoid Harness
Y11 Air Conditioner Compressor Clutch
Y22 Dig Regenerative Solenoid (marked SF)
Y23 Arm Regenerative Solenoid (marked SC)
Y24 Power Dig Solenoid (marked SG)
Y27 Arm 2 Flow Control Solenoid (marked SD)

<- Go to Section TOC Section 9015 page 96 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Machine Harness (W2) Component Location (2 of 2)

LEGEND:
B18 Fuel Level Sensor
B20 Air Conditioner High/Low Pressure Switch
B22 Ambient Air Temperature Sensor
B30 Boom Up Pressure Sensor
B31 Arm In Pressure Sensor
B32 Front Attachment Pressure Sensor
B33 Swing Pressure Sensor
B34 Travel Pressure Sensor
F45 Starter In-Line 30 A Fuse
F60 Alternator 65 A Fuse
F61 Battery 45 A Fuse
G3 Alternator
K34 Starter Relay
M1 Starter Motor
M6 Windshield Washer Motor
R13 Alternator Resistor
W2 Machine Harness
<- Go to Section TOC Section 9015 page 97 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

W27 Starter Harness


X1 Service ADVISOR ™ Diagnostic Connector
X3 Cab Harness-to-Machine Harness 100-Pin Connector
X5 Machine Harness-to-Engine Interface Harness 8-Pin Connector 1
X6 Machine Harness-to-Engine Interface Harness 1-Pin Connector
X7 Machine Harness-to-Engine Interface Harness 8-Pin Connector 2
X8 Machine Harness-to-Engine Interface Harness 8-Pin Connector 3
X19 Monitor 2-Pin Connector G
X40 Pump Harness-to-Machine Harness Connector
X46 Attachment Connector
X64 Machine Harness-to-Rear Camera Harness Connector
X86 Machine Harness-to-Travel Alarm Harness Connector
X90 Machine Harness-to-Hydraulic Oil Temperature Switch Connector
X98 Machine Harness Splice Connector
X175 Machine Harness-to-Starter Harness Connector
X6022 Cab Harness-to-Exhaust Filter Solenoid Harness
Y11 Air Conditioner Compressor Clutch

<- Go to Section TOC Section 9015 page 98 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Machine Harness (W2) Wiring Diagram

<- Go to Section TOC Section 9015 page 99 130G Excavator Diagnostic


Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Machine Harness (W2) Wiring Diagram (1 of 2)

<- Go to Section TOC Section 9015 page 100 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
1 Continued on Sheet 2
B18 Fuel Level Sensor
B23 High Note Horn
B24 Low Note Horn
B30 Boom Up Pressure Sensor
B31 Arm In Pressure Sensor
B32 Front Attachment Pressure Sensor
B33 Swing Pressure Sensor
B34 Travel Pressure Sensor
B40 Hydraulic Oil Temperature Sensor
E1 Work Light
E2 Boom Light
X46 Attachment Connector
X67 Machine Harness Auxiliary Power Connector
X90 Machine Harness-to-Hydraulic Oil Temperature Switch Connector
X98 Machine Harness Splice Connector
Y22 Dig Regenerative Solenoid (marked SF)
Y23 Arm Regenerative Solenoid (marked SC)
Y24 Power Dig Solenoid (marked SG)
Y27 Arm 2 Flow Control Solenoid (marked SD)

<- Go to Section TOC Section 9015 page 101 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Machine Harness (W2) Wiring Diagram (2 of 2)

<- Go to Section TOC Section 9015 page 102 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
1 Continued on Sheet 1
B20 Air Conditioner High/Low Pressure Switch
B22 Ambient Air Temperature Sensor
F60 Alternator 65 A Fuse
F61 Battery 45 A Fuse
G3 Alternator
K19 Battery Relay
M6 Windshield Washer Motor
R13 Alternator Resistor
X1 Service ADVISOR ™ Diagnostic Connector
X3 Cab Harness-to-Machine Harness 100-Pin Connector
X5 Machine Harness-to-Engine Interface Harness 8-Pin Connector 1
X6 Machine Harness-to-Engine Interface Harness 1-Pin Connector
X7 Machine Harness-to-Engine Interface Harness 8-Pin Connector 2
X8 Machine Harness-to-Engine Interface Harness 8-Pin Connector 3
X40 Pump Harness-to-Machine Harness Connector
X64 Machine Harness-to-Rear Camera Harness Connector
X86 Machine Harness-to-Travel Alarm Harness
X175 Machine Harness-to-Starter Harness Connector
X6022 Cab Harness-to-Exhaust Filter Solenoid Harness (not used)
Y11 Air Conditioner Compressor Clutch

<- Go to Section TOC Section 9015 page 103 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Monitor Harness (W3) Component Location

Monitor Harness (W3) Component Location

LEGEND:
A4 Monitor Controller (DSZ)
A10 Monitor
B21 Solar Sensor
H3 Monitor Warning Alarm
W1 Cab Harness
W3 Monitor Harness
X17 Cab Harness-to-Monitor Harness
X18 Monitor 12-Pin Connector C
X19 Monitor 2-Pin Connector G
X23 Monitor Controller 12-Pin Connector C
X24 Monitor Controller 2-Pin Connector G

<- Go to Section TOC Section 9015 page 104 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Monitor Harness (W3) Wiring Diagram

Monitor Harness (W3) Wiring Diagram

LEGEND:
B21 Solar Sensor
H3 Monitor Warning Alarm
X17 Cab Harness-to-Monitor Harness

<- Go to Section TOC Section 9015 page 105 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

X18 Monitor 12-Pin Connector C


X19 Monitor 2-Pin Connector G
X23 Monitor Controller 12-Pin Connector C
X24 Monitor Controller 2-Pin Connector G

<- Go to Section TOC Section 9015 page 106 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Engine Harness (W4) Component Location

Engine Harness (W4) Component Location (right side)

LEGEND:
A1 Engine Control Unit (ECU)
B5206 Manifold Air Temperature (MAT) Sensor
M1 Starter Motor

<- Go to Section TOC Section 9015 page 107 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

R12 CAN 0 Termination Resistor


W4 Engine Harness
W30 Static Ground
W38 Fuel Injector Harness
X14 Engine Control Unit (ECU)-to-Engine Harness Connector 1
X15 Engine Control Unit (ECU)-to-Engine Harness Connector 2
X174 Engine Harness-to-Engine Interface Harness Connector
X5000 Engine Harness-to-Fuel Injector Harness 8-Pin Connector
Y1 Electronic Injector 1 (cylinder 1)
Y2 Electronic Injector 2 (cylinder 2)
Y3 Electronic Injector 3 (cylinder 3)
Y4 Electronic Injector 4 (cylinder 4)

<- Go to Section TOC Section 9015 page 108 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Engine Harness (W4) Component Location (left side)

LEGEND:
B5100 Fuel Rail Pressure Sensor
B5101 Engine Oil Pressure Sensor
B5208 Engine Coolant Temperature Sensor
B5209 Fuel Temperature Sensor
B5301 Crankshaft Position Sensor

<- Go to Section TOC Section 9015 page 109 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

B5302 Camshaft Position Sensor


M13 High Pressure Fuel Pump
W4 Engine Harness

<- Go to Section TOC Section 9015 page 110 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Engine Harness (W4) Wiring Diagram

<- Go to Section TOC Section 9015 page 111 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Engine Harness (W4) Wiring Diagram (1 of 2)

<- Go to Section TOC Section 9015 page 112 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
1 Continued on Sheet 2
M1 Starter Motor
R12 CAN 0 Termination Resistor
W30 Static Ground
X14 Engine Control Unit (ECU)-to-Engine Harness Connector 1
X15 Engine Control Unit (ECU)-to-Engine Harness Connector 2
X174 Engine Harness-to-Engine Interface Harness Connector
X240 G01 BLK Splice 1
X241 G04 BLK Splice 2
X242 P99 RED Splice 1
X243 P01 RED Splice 2
X244 R02 BLK Splice 3
X245 M13 GRN Splice 1
X246 M12 YEL Splice 1
X247 R92 BLK Splice 4
X248 5446 LT BLU Splice

<- Go to Section TOC Section 9015 page 113 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Engine Harness (W4) Wiring Diagram (2 of 2)

<- Go to Section TOC Section 9015 page 114 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
1 Continued on Sheet 1
B5100 Fuel Rail Pressure Sensor
B5101 Engine Oil Pressure Sensor
B5206 Manifold Air Temperature (MAT) Sensor
B5208 Engine Coolant Temperature Sensor
B5209 Fuel Temperature Sensor
B5301 Crankshaft Position Sensor
B5302 Camshaft Position Sensor
M13 High Pressure Fuel Pump
X5000 Engine Harness-to-Fuel Injector Harness 8-Pin Connector

<- Go to Section TOC Section 9015 page 115 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Engine Interface Harness (W5) Component Location

Engine Interface Harness (W5) Component Location

LEGEND:
B16 Air Filter Restriction Switch
B53 Fan Speed Sensor
B82 Ambient Air Temperature Sensor 2
B5107 Inlet Fuel Pressure Sensor
B5600 Water-in-Fuel Sensor
F6000 JDLink ™ Unswitched Power 7.5 A Fuse
F6001 JDLink™ Ground 7.5 A Fuse
F6002 JDLink™ Switched Power 7.5 A Fuse
R11 Interface CAN Resistor 2 (later models)
S5001 Engine Coolant Loss Level Sensor
S5002 Engine Coolant Service Level Sensor
W5 Engine Interface Harness
W43 Engine Interface Harness Ground
<- Go to Section TOC Section 9015 page 116 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

X5 Machine Harness-to-Engine Interface Harness 8-Pin Connector 1


X6 Machine Harness-to-Engine Interface Harness 1-Pin Connector 2
X7 Machine Harness-to-Engine Interface Harness 8-Pin Connector
X8 Machine Harness-to-Engine Interface Harness 8-Pin Connector 3
X174 Engine Harness to Engine Interface Harness Connector
X6016 Engine Interface Harness-to-Satellite (SAT) Harness
X6019 Modular Telematics Gateway (MTG) Connector
Y9 Reversing Fan Solenoid
Y19 Ether Start Aid
Y5005 Variable Speed Fan

<- Go to Section TOC Section 9015 page 117 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Engine Interface Harness (W5) Wiring Diagram

Engine Interface Harness (W5) Wiring Diagram (1 of 2)

<- Go to Section TOC Section 9015 page 118 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Engine Interface Harness (W5) Wiring Diagram (2 of 2)

<- Go to Section TOC Section 9015 page 119 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
B16 Air Filter Restriction Switch
B53 Fan Speed Sensor
B82 Ambient Air Temperature Sensor 2
B5107 Inlet Fuel Pressure Sensor
B5600 Water-in-Fuel Sensor
F6000 JDLink™ Unswitched Power 7.5 A Fuse
F6001 JDLink ™ Ground 7.5 A Fuse
F6002 JDLink™ Switched Power 7.5 A Fuse
R11 Interface CAN Resistor 2 (later models)
S5001 Engine Coolant Loss Level Sensor
S5002 Engine Coolant Service Level Sensor
X5 Machine Harness-to-Engine Interface Harness 8-Pin Connector 1
X6 Machine Harness-to-Engine Interface Harness 1-Pin Connector
X7 Machine Harness-to-Engine Interface Harness 8-Pin Connector 2
X8 Machine Harness-to-Engine Interface Harness 8-Pin Connector 3
X160 1356 YEL Splice
X161 1357 GRN Splice
X174 Engine Harness-to-Engine Interface Harness Connector
X200 M12A YEL Splice
X201 M13A GRN Splice
X202 R02A BLK Splice 1
X203 P01A RED Splice 1
X204 G01A BLK Splice 2
X205 P01B RED Splice 2
X206 P307 RED Splice 3
X207 G01B BLK Splice 3
X208 R99A BLK Splice 4
X6016 Engine Interface Harness-to-Satellite (SAT) Connector
X6019 Modular Telematics Gateway (MTG) Connector
Y9 Reversing Fan Solenoid
Y19 Ether Start Aid
Y5005 Variable Speed Fan Solenoid

<- Go to Section TOC Section 9015 page 120 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Pump Harness (W8) Component Location

Pump Harness (W8) Component Location (1 of 2)

LEGEND:
B36 Pump 1 Control Pressure Sensor
B38 Pump 2 Control Pressure Sensor
W8 Pump Harness

<- Go to Section TOC Section 9015 page 121 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

X40 Pump Harness-to-Machine Harness Connector


X97 Pump Harness Splice Connector
Y20 Pump 2 Flow Rate Limit Solenoid (marked SB)
Y21 Torque Control Solenoid (marked ST)

Pump Harness (W8) Component Location (2 of 2)

LEGEND:
B35 Pump 1 Delivery Pressure Sensor

<- Go to Section TOC Section 9015 page 122 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

B36 Pump 1 Control Pressure Sensor


B37 Pump 2 Delivery Pressure Sensor
B38 Pump 2 Control Pressure Sensor
W8 Pump Harness
Y20 Pump 2 Flow Rate Limit Solenoid (marked SB)
Y21 Torque Control Solenoid (marked ST)

<- Go to Section TOC Section 9015 page 123 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Pump Harness (W8) Wiring Diagram

Pump Harness (W8) Wiring Diagram

LEGEND:
B35 Pump 1 Delivery Pressure Sensor
B36 Pump 1 Control Pressure Sensor
B37 Pump 2 Delivery Pressure Sensor

<- Go to Section TOC Section 9015 page 124 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

B38 Pump 2 Control Pressure Sensor


X40 Pump Harness-to-Machine Harness Connector
X97 Pump Harness Splice Connector
Y20 Pump 2 Flow Rate Limit Solenoid (marked SB)
Y21 Torque Control Solenoid (marked ST)
Service ADVISOR™ Remote (SAR) Harness (W10) Component Location
See Cab Harness (W1) Component Location . (Group 9015.)

<- Go to Section TOC Section 9015 page 125 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Service ADVISOR™ Remote (SAR) Harness (W10) Wiring Diagram

Service ADVISOR ™ Remote (SAR) Harness (W10) Wiring Diagram

LEGEND:
S18 Service Advisor™ Remote (SAR) Switch
X74 Cab Harness-to-Service ADVISOR™ Remote (SAR) Switch Harness

<- Go to Section TOC Section 9015 page 126 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Pilot Shutoff Switch Harness (W11) Component Location

Pilot Shutoff Switch Harness (W11) Component Location

LEGEND:
S3 Pilot Shutoff Switch 1
S4 Pilot Shutoff Switch 2
V20 Pilot Shutoff Switch Diode
W11 Pilot Shutoff Switch Harness
X65 Cab Harness-to-Pilot Shutoff Switch Harness Connector

<- Go to Section TOC Section 9015 page 127 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Pilot Shutoff Switch Harness (W11) Wiring Diagram

Pilot Shutoff Switch Harness (W11) Wiring Diagram

<- Go to Section TOC Section 9015 page 128 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
S3 Pilot Shutoff Switch 1
S4 Pilot Shutoff Switch 2
V20 Pilot Shutoff Switch Diode
X65 Cab Harness-to-Pilot Shutoff Switch Harness Connector
X135 Pilot Shutoff Harness Splice 1
X136 Pilot Shutoff Harness Splice 2
X137 Machine Harness-to-Starter Harness Connector
Auxiliary Fuse Box Harness (W13) Component Location
See Cab Harness (W1) Component Location . (Group 9015.)

<- Go to Section TOC Section 9015 page 129 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Auxiliary Fuse Box Harness (W13) Wiring Diagram


Auxiliary Fuse Box Harness (W13) Wiring Diagram (S.N. —040754)

Auxiliary Fuse Box Harness (W13) Wiring Diagram

<- Go to Section TOC Section 9015 page 130 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
F21 Heated Air Seat 10 A Fuse (marked SEAT HEATER)
F22 Front Cab Light One 10 A Fuse (marked CAB LAMP FRONT)
F23 Rear Cab Light 10 A Fuse (marked CAB LAMP REAR)
F24 12 Volt Power Unit 10 A Fuse (marked 12V UNIT)
F25 IMOBI 5 A Fuse (marked IMOBI)
F26 Quick Hitch 5 A Fuse (marked QUICK HITCH)
F27 Cab Auxiliary Power Connector Three 5 A Fuse (marked AUX. 3)
F31 Seat Compressor 10 A Fuse (marked SEAT COMPR)
F32 Front Cab Light Two 10 A Fuse (marked CAB LAMP FRONT +2)
F33 Warning Lamp 10 A Fuse (marked WARNING LAMP)
F34 Cab Auxiliary Power Connector Two 10 A Fuse (marked AUX. 2)
F51 Auxiliary Fuse Box
X43 Optional Fuse Connector
X44 Optional Light Connector
X54 Auxiliary Fuse Box Harness-to-Heated Air Sear Harness 3-Pin Connector (marked SEAT HEATER)
X55 Front Cab Light 1 Connector (marked CAB LAMP FRONT)
X56 Front Cab Light 2 Connector (marked CAB LAMP FRONT+2)
X57 Rear Cab Light Connector (marked CAB LAMP REAR)
X58 Warning Light (marked WARNING LAMP)
X59 Satellite Communication Connector (marked IMOBI)
X60 12 Volt Power Supply (marked 12V UNIT)
X61 Quick Hitch Connector (marked QUICK HITCH)
X62 Cab Auxiliary Power Connector 2 (marked AUX_2)
X63 Cab Auxiliary Power Connector 3 (marked AUX_3)

Auxiliary Fuse Box Harness (W13) Wiring Diagram (S.N. 040755— )

See Cab Harness (W1) Wiring Diagram . (Group 9015-15.)

<- Go to Section TOC Section 9015 page 131 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Heated Air Seat Harness (W14) Component Location

Heated Air Seat Harness (W14) Component Location

LEGEND:
K20 Seat Heater Relay
M12 Seat Air Compressor
R18 Seat Heater (marked SEAT HEATER)

<- Go to Section TOC Section 9015 page 132 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

S62 Seat Heater Switch


W14 Heated Air Seat Harness
W24 Seat Heater Switch Harness
X53 Heated Air Seat Harness-to-Heated Seat Switch Harness 3-Pin Connector (marked SEAT HEATER)
X54 Auxiliary Fuse Box Harness-to-Heated Air Sear Harness 3-Pin Connector (marked SEAT HEATER)

<- Go to Section TOC Section 9015 page 133 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Heated Air Seat Harness (W14) Wiring Diagram

Seat Heater Switch Harness (W14) Wiring Diagram

LEGEND:
K20 Seat Heater Relay
M12 Seat Air Compressor Motor
R18 Seat Heater (marked SEAT HEATER)
X53 Heated Air Seat Harness-to-Heated Seat Switch Harness 3-Pin Connector (marked SEAT HEATER)
X54 Auxiliary Fuse Box Harness-to-Heated Air Seat Harness 3-Pin Connector (marked SEAT HEATER)

<- Go to Section TOC Section 9015 page 134 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Multi-Function Pilot Control Lever Harness (W15) Component Location

Multi-Function Pilot Control Lever Harness (W15) Component Location

LEGEND:
K30 Right Solenoid Relay B
K31 Right Solenoid Relay A
K32 Left Solenoid Relay B

<- Go to Section TOC Section 9015 page 135 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

K33 Left Solenoid Relay A


S30 Right Pilot Control Lever Switch B (marked B)
S31 Right Pilot Control Lever Switch A (marked C)
S32 Left Pilot Control Lever Switch B (marked B)
S33 Left Pilot Control Lever Switch A (marked C)
S34 Right Enable Switch
S35 Left Enable Switch
W15 Multi-Function Pilot Control Lever Harness
W22 Auxiliary 3-Button Cancel Switch Harness
X26 Optional Connector (2 used)
X81 Multi-Function Pilot Control Lever Harness-to-Auxiliary 3-Button Cancel Switch Harness
X82 Multi-Function Pilot Control Lever Harness-to-Auxiliary 3-Button Cancel Switch Harness
X534 Right Auxiliary Solenoid Connector (marked SR/H)
X535 Left Auxiliary Solenoid Connector (marked SL/H)

<- Go to Section TOC Section 9015 page 136 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Multi-Function Pilot Control Lever Harness (W15) Wiring Diagram

Multi-Function Pilot Control Lever Harness (W15) Wiring Diagram

<- Go to Section TOC Section 9015 page 137 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
K30 Right Solenoid Relay B
K31 Right Solenoid Relay A
K32 Left Solenoid Relay B
K33 Left Solenoid Relay A
S30 Right Pilot Control Lever Switch B (marked B)
S31 Right Pilot Control Lever Switch A (marked A)
S32 Left Pilot Control Lever Switch B (marked B)
S33 Left Pilot Control Lever Switch A (marked A)
X26 Optional Connector
X81 Multi-Function Pilot Control Lever Harness-to-Auxiliary 3-Button Cancel Switch Harness
X82 Multi-Function Pilot Control Lever Harness-to-Auxiliary 3-Button Cancel Switch Harness
X534 Right Auxiliary Solenoid (marked SR/H) Connector
X535 Left Auxiliary Solenoid (marked SL/H) Connector
Travel Alarm Cancel Switch Harness (W16) Component Location
See Cab Harness (W1) Component Location . (Group 9015-10.)

<- Go to Section TOC Section 9015 page 138 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Travel Alarm Cancel Switch Harness (W16) Wiring Diagram

Travel Alarm Cancel Switch Harness (W16) Wiring Diagram

LEGEND:
S13 Travel Alarm Cancel Switch
X50 Cab Harness-to-Travel Alarm Cancel Switch Harness Connector

<- Go to Section TOC Section 9015 page 139 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Attachment Harness (W17) Component Location

Attachment Harness (W17) Component Location

LEGEND:
B60 Attachment Pressure Sensor
B61 Arm Out Pressure Sensor
V40 Selector Valve Solenoid Valve Diode

<- Go to Section TOC Section 9015 page 140 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

V41 Secondary Relief Solenoid Valve Diode


V43 2-Speed Activation Solenoid Valve Diode
W17 Attachment Harness
W32 2-Speed Harness
X46 Attachment Connector
X87 Attachment Harness-to-Two Speed Harness Connector
Y40 Selector Valve Solenoid Valve
Y41 Secondary Relief Solenoid Valve
Y43 2-Speed Activation Solenoid Valve
Y44 Flow Rate Adjustment Solenoid Valve

<- Go to Section TOC Section 9015 page 141 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Attachment Harness (W17) Wiring Diagram

Attachment Harness (W17) Wiring Diagram

<- Go to Section TOC Section 9015 page 142 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
B60 Attachment Pressure Sensor
V40 Selector Valve Solenoid Valve Diode
V41 Secondary Relief Solenoid Valve Diode
X46 Attachment Connector
X87 Attachment Harness-to-Two Speed Harness Connector
Y40 Selector Valve Solenoid Valve
Y41 Secondary Relief Solenoid Valve

<- Go to Section TOC Section 9015 page 143 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Rear Camera Harness (W19) Component Location

Rear Camera Harness (W19)

LEGEND:
A12 Rear Camera
W19 Camera Harness
X64 Machine Harness-to-Rear Camera Harness Connector

<- Go to Section TOC Section 9015 page 144 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Rear Camera Harness (W19) Wiring Diagram

Rear Camera Harness (W19) Wiring Diagram

LEGEND:
A12 Rear Camera
X64 Machine Harness-to-Rear Camera Harness Connector

<- Go to Section TOC Section 9015 page 145 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Pilot Shutoff Valve Harness (W21) Component Location

Pilot Shutoff Valve Harness (W21) Component Location

LEGEND:
W21 Pilot Shutoff Valve Harness
X75 Cab Harness-to-Pilot Shutoff Valve Harness Connector
Y10 Pilot Shutoff Solenoid

<- Go to Section TOC Section 9015 page 146 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Pilot Shutoff Valve Harness (W21) Wiring Diagram

Pilot Shutoff Valve Harness (W21) Wiring Diagram

LEGEND:
X75 Cab Harness-to-Pilot Shutoff Valve Harness Connector
Y10 Pilot Shutoff Solenoid
Auxiliary 3-Button Cancel Switch Harness (W22) Component Location
See Multi-Function Pilot Control Lever Harness (W15) Component Location . (Group 9015-10.)

<- Go to Section TOC Section 9015 page 147 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Auxiliary 3-Button Cancel Switch Harness (W22) Wiring Diagram

Auxiliary 3-Button Cancel Switch Harness (W22) Wiring Diagram

LEGEND:
S34 Right Enable Switch
S35 Left Enable Switch
X81 Multi-Function Pilot Control Lever Harness-to-Auxiliary 3-Button Cancel Switch Harness
X82 Multi-Function Pilot Control Lever Harness-to-Auxiliary 3-Button Cancel Switch Harness
Reversing Fan Switch Harness (W23) Component Location
See Cab Harness (W1) Component Location . (Group 9015.)

<- Go to Section TOC Section 9015 page 148 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Reversing Fan Switch Harness (W23) Wiring Diagram

Reversing Fan Switch Harness (W23) Wiring Diagram

LEGEND:
S15 Reversing Fan Switch
X83 Cab Harness-to-Reversing Fan Switch Harness
Seat Heater Switch Harness (W24) Component Location
See Heated Air Seat Harness (W14) Component Location . (Group 9015-10.)

<- Go to Section TOC Section 9015 page 149 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Seat Heater Switch Harness (W24) Wiring Diagram

Seat Heater Switch Harness (W24) Wiring Diagram

LEGEND:
S62 Seat Heater Switch
X53 Heated Air Seat Harness-to-Heated Seat Switch Harness 3-Pin Connector (marked SEAT HEATER)

<- Go to Section TOC Section 9015 page 150 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Travel Alarm Harness (W26) Component Location

Travel Alarm Harness (W26) Component Location

LEGEND:
H4 Travel Alarm
W2 Machine Harness
W26 Travel Alarm Harness
X86 Machine Harness-to-Travel Alarm Harness

<- Go to Section TOC Section 9015 page 151 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Travel Alarm Harness (W26) Wiring Diagram

Travel Alarm Harness (W26) Wiring Diagram

LEGEND:
H4 Travel Alarm
X86 Machine Harness-to-Travel Alarm Harness

<- Go to Section TOC Section 9015 page 152 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Starter Harness (W27) Component Location

Starter Harness (W27) Component Location

LEGEND:
F45 Starter In-Line 30 A Fuse
K34 Starter Relay
K35 Starter Protection Relay
M1 Starter Motor
V44 Starter Relay Diode
W27 Starter Harness
X175 Machine Harness-to-Starter Harness Connector

<- Go to Section TOC Section 9015 page 153 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Starter Harness (W27) Wiring Diagram

Starter Harness (W27) Wiring Diagram

LEGEND:
F45 Starter In-Line 30 A Fuse
K34 Starter Relay
K35 Starter Protection Relay
M1 Starter Motor
<- Go to Section TOC Section 9015 page 154 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

V44 Starter Relay Diode


X175 Machine Harness-to-Starter Harness Connector
X400 E03 WHT Splice
X401 P21 RED Splice
Starter Switch Harness (W29) Component Location
See Cab Harness (W1) Component Location . (Group 9015.)

<- Go to Section TOC Section 9015 page 155 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Starter Switch Harness (W29) Wiring Diagram

Starter Switch Harness (W29) Wiring Diagram

LEGEND:
S1 Key Switch
X47 Cab Harness-to-Key Switch Harness Connector
2-Speed Harness (W32) Component Location
See Attachment Harness (W17) Component Location . (Group 9015-10.)

<- Go to Section TOC Section 9015 page 156 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

2-Speed Harness (W32) Wiring Diagram

2-Speed Harness (W32) Wiring Diagram

LEGEND:
B61 Arm Out Pressure Sensor
V43 2-Speed Activation Solenoid Valve Diode
X87 Attachment Harness-to-Two Speed Harness Connector

<- Go to Section TOC Section 9015 page 157 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Y43 2-Speed Activation Solenoid Valve


Y44 Flow Rate Adjustment Solenoid Valve
Fuel Injector Harness (W38) Component Location
See Engine Harness (W4) Component Location . (Group 9015.)

<- Go to Section TOC Section 9015 page 158 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Fuel Injector Harness (W38) Wiring Diagram

Fuel Injector Harness (W38) Wiring Diagram

LEGEND:
X209 5491 BLK Splice 1
X210 5496 BLK Splice 2
X5000 Engine Harness-to-Fuel Injector Harness 8-Pin Connector

<- Go to Section TOC Section 9015 page 159 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Y1 Electronic Injector 1 (cylinder 1)


Y2 Electronic Injector 2 (cylinder 2)
Y3 Electronic Injector 3 (cylinder 3)
Y4 Electronic Injector 4 (cylinder 4)

<- Go to Section TOC Section 9015 page 160 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Heater and Air Conditioner Harness (W41) Component Location

Heater and Air Conditioner Harness (W41) Component Location

LEGEND:
A7 Air Conditioner Controller (ACF)
B41 Air Conditioner Freeze Control Switch
B55 Air Recirculation Sensor
M7 Air Conditioner and Heater Blower Motor
M9 Air Conditioner and Heater Internal and External Servomotor
M10 Air Conditioner and Heater Blower Port Change Servomotor
M11 Air Conditioner and Heater Mixer Servomotor
R16 Blower Motor Transistor
R17 Blower Motor Resistor
W41 Heater and Air Conditioner Harness
X51 Air Conditioner 4-Pin Connector
X52 Air Conditioner 10-Pin Connector

<- Go to Section TOC Section 9015 page 161 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Heater and Air Conditioner Harness (W41) Wiring Diagram

Heater and Air Conditioner Harness (W41) Wiring Diagram

<- Go to Section TOC Section 9015 page 162 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
A7 Air Conditioner Controller (ACF)
B41 Air Conditioner Freeze Control Switch
B55 Air Recirculation Sensor
M7 Air Conditioner and Heater Blower Motor
M9 Air Conditioner and Heater Internal and External Servomotor
M10 Air Conditioner and Heater Blower Port Change Servomotor
M11 Air Conditioner and Heater Mixer Servomotor
R16 Blower Motor Transistor
R17 Blower Motor Resistor
X51 Air Conditioner 4-Pin Connector
X52 Air Conditioner 10-Pin Connector
X418 978 BLK Splice
X419 BLK/RED Splice
X420 BLK/YEL Splice
X421 979 RED Splice
X422 RED/BLK Splice

<- Go to Section TOC Section 9015 page 163 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Auxiliary Solenoid Harness (W61) Component Location

Auxiliary Solenoid Harness (W61) Component Location

LEGEND:
V30 Right Solenoid Diode B
V31 Right Solenoid Diode A
V32 Left Solenoid Diode B
V33 Left Solenoid Diode A
W15 Multi-Function Pilot Control Lever Harness
W61 Auxiliary Solenoid Harness
W75 Auxiliary Function Lever (AFL) Harness
X534 Right Auxiliary Solenoid Connector (marked SR/H)
X535 Left Auxiliary Solenoid Connector (marked SL/H)
Y34 Right Solenoid (marked SR/H)
Y34A Right Solenoid Connector A (marked SR/H)
Y34B Right Solenoid Connector B (marked SR/H)
Y35 Left Solenoid (marked SR/H)

<- Go to Section TOC Section 9015 page 164 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Y35A Left Solenoid Connector A (marked SR/H)


Y35B Left Solenoid Connector B (marked SR/H)

<- Go to Section TOC Section 9015 page 165 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Auxiliary Solenoid Harness (W61) Wiring Diagram

Auxiliary Solenoid Harness (W61) Wiring Diagram

LEGEND:
V30 Right Solenoid Diode B
V31 Right Solenoid Diode A
V32 Left Solenoid Diode B

<- Go to Section TOC Section 9015 page 166 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

V33 Leftt Solenoid Diode A


X450 GO5 BLK Splice
X451 HO1 GRN Splice
X452 HO2 GRN Splice
X534 Right Auxiliary Solenoid Connector (marked SR/H)
X535 Left Auxiliary Solenoid Connector (marked SL/H)
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)

<- Go to Section TOC Section 9015 page 167 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Auxiliary Function Lever (AFL) Harness (W75) Component Location

Auxiliary Function Lever (AFL) Harness (W75) Component Location

LEGEND:
K31 Right Solenoid Relay A (marked RSW1)
K32 Left Solenoid Relay B (marked LSW1)
K33 Left Solenoid Relay A (marked LSW3)

<- Go to Section TOC Section 9015 page 168 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

S5 Horn Switch
S7 Power Dig Switch
S29 Auxiliary Function Lever (AFL) Proportional Control Switch
S31 Right Pilot Control Lever Switch
S32 Left Pilot Control Lever Switch B (marked B)
S33 Left Pilot Control Lever Switch A (marked C)
S34 Right Enable Switch (marked ON/OFF)
S35 Left Enable Switch (marked ON/OFF)
S45 Auxiliary Function Enable Switch (marked AFL_SW)
V22 Pilot Shutoff Solenoid Diode
W75 Auxiliary Function Lever (AFL) Harness
X26 Optional Connector (2 used)
X534 Right Auxiliary Solenoid Connector (marked SR/H)
X535 Left Auxiliary Solenoid Connector (marked SL/H)
X536 Right Auxiliary Function Lever (AFL) Connector (marked R_GRIP)
X537 Left Auxiliary Function Lever (AFL) Connector (marked L_GRIP)
X574 Auxiliary Function Lever (AFL) Connector 1
X577 Auxiliary Function Lever (AFL) Harness-to-Auxiliary Function Lever (AFL) Solenoid Harness Connector

<- Go to Section TOC Section 9015 page 169 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Auxiliary Function Lever (AFL) Harness (W75) Wiring Diagram

Auxiliary Function Lever (AFL) Harness (W75) Wiring Diagram

<- Go to Section TOC Section 9015 page 170 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

LEGEND:
K31 Right Solenoid Relay A (marked RSW1)
K32 Left Solenoid Relay B (marked LSW1)
K33 Left Solenoid Relay A (marked LSW3)
S5 Horn Switch
S7 Power Dig Switch
S34 Right Enable Switch (marked ON/OFF)
S35 Left Enable Switch (marked ON/OFF)
S45 Auxiliary Function Enable Switch (marked AFL_SW)
V22 Pilot Shutoff Solenoid Diode
X26 Optional Connector
X534 Right Auxiliary Solenoid Connector (marked SR/H)
X535 Left Auxiliary Solenoid Connector (marked SL/H)
X536 Right Auxiliary Function Lever (AFL) Connector (marked R_GRIP)
X537 Left Auxiliary Function Lever (AFL) Connector (marked L_GRIP)
X574 Auxiliary Function Lever (AFL) Connector 1
X577 Auxiliary Function Lever (AFL) Harness-to-Auxiliary Function Lever (AFL) Solenoid Harness Connector

<- Go to Section TOC Section 9015 page 171 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component


Location

Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location

LEGEND:
B68 Secondary Hydraulic Oil Temperature Sensor

<- Go to Section TOC Section 9015 page 172 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

B85 Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1)
W75 Auxiliary Function Lever (AFL) Harness
W76 Auxiliary Function Lever (AFL) Solenoid Harness
X577 Auxiliary Function Lever (AFL) Harness-to-Auxiliary Function Lever (AFL) Solenoid Harness Connector
Y61 Auxiliary Function Lever (AFL) Solenoid A (marked 1A)
Y62 Auxiliary Function Lever (AFL) Solenoid B (marked 1B)
Y66 Secondary Pilot Shutoff Solenoid Valve (marked PiC)

<- Go to Section TOC Section 9015 page 173 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Auxiliary Function Lever (AFL) Solenoid Harness (W76) Wiring Diagram

Auxiliary Function Lever (AFL) Solenoid Harness (W76) Wiring Diagram

LEGEND:
B68 Secondary Hydraulic Oil Temperature Sensor
B85 Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1)
X577 Auxiliary Function Lever (AFL) Harness-to-Auxiliary Function Lever (AFL) Solenoid Harness Connector

<- Go to Section TOC Section 9015 page 174 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Y61 Auxiliary Function Lever (AFL) Solenoid A (marked 1A)


Y62 Auxiliary Function Lever (AFL) Solenoid B (marked 1B)
Y66 Secondary Pilot Shutoff Solenoid Valve (marked PiC)
Modular Telematics Gateway (MTG) Harness (W6002) Component
Location
See Engine Interface Harness (W5) Component Location . (Group 9015-10.)

<- Go to Section TOC Section 9015 page 175 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams

Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram

Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram

LEGEND:
X6014 Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector
X6019 Modular Telematics Gateway (MTG) Connector
Satellite (SAT) Harness (W6003) Component Location
See Engine Interface Harness (W5) Component Location . (Group 9015-10.)

<- Go to Section TOC Section 9015 page 176 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

Satellite (SAT) Harness (W6003) Wiring Diagram

Satellite (SAT) Harness (W6003) Wiring Diagram

LEGEND:
X6015 Satellite (SAT) Module Control Unit 48-Pin Connector
X6016 JDLink ™ Harness-to-Satellite (SAT) Harness

<- Go to Section TOC Section 9015 page 177 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

Group 15 - Sub-System Diagnostics


Controller Area Network (CAN) Theory of Operation

<- Go to Section TOC Section 9015 page 178 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

Controller Area Network (CAN) Circuit Theory of Operation Schematic (S.N. —040754)

<- Go to Section TOC Section 9015 page 179 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

LEGEND:
A1 Engine Control Unit (ECU)
A3 Main Controller (MCZ)
A4 Monitor Controller (DSZ)
A5 Data Converter
A6 Radio
A7 Air Conditioner Controller (ACF)
A11 Machine Controller (BCZ)
A6000 Modular Telematics Gateway Controller (MTG)
R10 Interface CAN Resistor 1
R11 Interface CAN Resistor 2 (later models)
R12 CAN 0 Termination Resistor
X1 Service ADVISOR™ Diagnostic Connector
X3 Cab Harness-to-Machine Harness 100-Pin Connector
X5 Machine Harness-to-Engine Interface Harness 8-Pin Connector 1
X8 Machine Harness-to-Engine Interface Harness 8-Pin Connector 3
X11 Machine Controller 20-Pin Connector B
X15 Engine Control Unit (ECU)-to-Engine Harness Connector 2
X20 Monitor Controller 28-Pin Connector A
X31 Cab Harness-to-Main Controller 31-Pin Connector A
X36 Cab Harness-to-Main Controller 26-Pin Connector F
X52 Air Conditioner 10-Pin Connector
X174 Engine Harness-to-Engine Interface Harness Connector
X6014 Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector
X6019 Modular Telematics Gateway (MTG) Connector

<- Go to Section TOC Section 9015 page 180 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

Controller Area Network (CAN) Circuit Theory of Operation Schematic (S.N. 040755— )

<- Go to Section TOC Section 9015 page 181 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

LEGEND:
A1 Engine Control Unit (ECU)
A3 Main Controller (MCZ)
A4 Monitor Controller (DSZ)
A5 Data Converter
A6 Radio
A7 Air Conditioner Controller (ACF)
A11 Machine Controller (BCZ)
A6000 Modular Telematics Gateway Controller (MTG)
R10 Interface CAN Resistor 1
R11 Interface CAN Resistor 2
R12 CAN 0 Termination Resistor
X1 Service ADVISOR™ Diagnostic Connector
X3 Cab Harness-to-Machine Harness 100-Pin Connector
X5 Machine Harness-to-Engine Interface Harness 8-Pin Connector 1
X8 Machine Harness-to-Engine Interface Harness 8-Pin Connector 3
X11 Machine Controller 20-Pin Connector B
X15 Engine Control Unit (ECU)-to-Engine Harness Connector 2
X20 Monitor Controller 28-Pin Connector A
X34 Cab Harness-to-Main Controller 30-Pin Connector D
X52 Air Conditioner 10-Pin Connector
X174 Engine Harness-to-Engine Interface Harness Connector
X6014 Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector
X6019 Modular Telematics Gateway (MTG) Connector

Controller Area Network (CAN) Overview— The controller area network (CAN) provides a standardized means for
electronic controllers and other devices to communicate with each other.

The CAN consists of two buses (wires): CAN high and CAN low. These two wires carry signals opposite to each other to
overcome noise interference and minimize communication errors. The high and low wires, and sometimes a ground wire, are
woven together which provides an additional method of reducing interference and thus helps the devices communicate with
minimal errors. When woven together with a ground wire the three wires are commonly referred to as a twisted triple.

The 120 ohm termination resistors, usually located at opposite ends of the CAN bus, also help prevent signal errors.

The CAN is an arbitration-based system. This means a low priority message always allows a high priority message to go first.
Each CAN device checks to see if the bus is idle before it transmits a signal. Whichever device gets on the bus first is able to
transmit its signal.

When collision occurs, that is, when two or more devices are transmitting at the same time, the device with the lowest ID has
higher priority to access the bus. The device that loses arbitration immediately retransmits its signal when the device with the
higher priority has completed its transmission.

This machine contains four CAN circuits: CAN 0, CAN 1, interface CAN, and engine CAN.

CAN 0— The CAN 0 circuit provides the communication link for the following devices:

Engine Control Unit (ECU) (A1)


Main Controller (MCZ) (A3)
Monitor Controller (DSZ) (A4)
Modular Telematics Gateway (MTG) Controller (A6000)

Operations and functions of the individual devices on CAN 0 are covered separately.

For the ECU, see Engine Control Unit (ECU) Circuit Theory of Operation . (Group 9015-15.)
For the MCZ, see Main Controller (MCZ) Circuit Theory of Operation . (Group 9015-15.)
For the DSZ, see Monitor Controller (DSZ) Circuit Theory of Operation . (Group 9015-15.)

CAN 0 also includes the following components:

Service ADVISOR ™ Diagnostic Connector (X1)


CAN 0 Termination Resistor (R12)

CAN 0 utilizes two terminating resistors; CAN 0 termination resistor (R12) and one located inside monitor controller (DSZ) (A4),
which is not accessible.

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

The Service ADVISOR diagnostic connector provides an interface for connecting diagnostic equipment such as a laptop. See
Service ADVISOR™ Diagnostic Application . (Group 9015-20.)

CAN 1— The CAN 1 circuit provides the communication link for the following devices:

Main Controller (MCZ) (A3)


Monitor Controller (DSZ) (A4)
Data Converter (A5)
Radio (A6)
Air Conditioner Controller (ACF) (A7)
Machine Controller (BCZ) (A11)

Operations and functions of the individual devices on CAN 1 are covered separately.

For the MCZ, see Main Controller (MCZ) Circuit Theory of Operation . (Group 9015-15.)
For the DSZ, see Monitor Controller (DSZ) Circuit Theory of Operation . (Group 9015-15.)
For the BCZ, see Machine Controller (BCZ) Circuit Theory of Operation . (Group 9015-15.)

CAN 1 utilizes two terminating resistors; one is located inside monitor controller (DSZ) (A4), and one is located inside machine
controller (BCZ) (A11). These resistors are not accessible.

Interface CAN— The interface CAN circuit provides the communication link for the following devices:

Data Converter (A5)


Modular Telematics Gateway (MTG) Controller (A6000)
Service ADVISOR Diagnostic Connector (X1)

The interface CAN allows the data converter (A5) to relay information from CAN 1 to the modular telematics gateway (MTG)
and the Service ADVISOR ™ diagnostic connector (X1).

The Service ADVISOR diagnostic connector provides an interface for connecting diagnostic equipment such as a laptop. See
Service ADVISOR™ Diagnostic Application . (Group 9015-20.)

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

Starting and Charging Circuit Theory of Operation

Starting and Charging Circuit Theory of Operation Schematic

<- Go to Section TOC Section 9015 page 184 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

LEGEND:
A1 Engine Control Unit (ECU)
A3 Main Controller (MCZ)
A4 Monitor Controller (DSZ)
A5 Data Converter
F7 Start Position Signal 5 A Fuse (marked START)
F8 Engine Control Unit (ECU) 30 A Fuse (marked ECU)
F9 Radio Backup 10 A Fuse (marked BACK UP)
F10 Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)
F14 Monitor 5 A Fuse (marked MONITOR)
F17 Power On 5 A Fuse (marked POWER ON)
F18 Idle Stop 5 A Fuse (marked IDLE STOP)
F45 Starter In-Line 30 A Fuse
F60 Alternator 65 A Fuse
F61 Battery 45 A Fuse
G1 Battery
G2 Battery
G3 Alternator
K1 Load Dump Relay
K4 Starter Cut Relay
K11 Idle Stop Relay
K12 Accessory Cut Relay
K13 Key Cut Relay
K19 Battery Relay
K34 Starter Relay
K35 Starter Protection Relay
M1 Starter Motor
R13 Alternator Resistor
S1 Key Switch
S3 Pilot Shutoff Switch 1
S4 Pilot Shutoff Switch 2
V1 Battery Relay Diode
V2 Alternator Excitation Diode
V3 Load Dump Relay Diode
V4 Security Diode
V5 Starter Cut Relay Diode
V7 Start Relay Diode
V9 Pilot Shutoff Diode
V10 Starter Protection Diode
V11 Accessory Cut Diode
V12 Starter Cut Diode
V44 Starter Relay Diode
V20 Pilot Shutoff Switch Diode
W37 Cab Harness Ground 3
X14 Engine Control Unit (ECU)-to-Engine Harness Connector 1
X15 Engine Control Unit (ECU)-to-Engine Harness Connector 2
X20 Monitor Controller 28-Pin Connector A
X21 Monitor Controller 36-Pin Connector B
X22 Monitor Controller 16-Pin Connector D
X33 Cab Harness-to-Main Controller 17-Pin Connector C
X35 Cab Harness-to-Main Controller 24-Pin Connector E
X36 Cab Harness-to-Main Controller 26-Pin Connector F
X175 Machine Harness-to-Starter Harness Connector
Y19 Ether Start Aid

Unswitched power is supplied to the following components:

Battery Relay (K19)


Key Switch (S1) [from Battery 45 A Fuse (F61)]
Main Controller (MCZ) (A3) [from Data Converter and Main Controller Battery Power 5 A Fuse (marked
CONTROLLER)(F10)]
Data Converter (A5) [from Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER) (F10)]
Engine Control Unit (ECU) (A1) [from Engine Control Unit (ECU) 30 A Fuse (marked ECU) (F8)]
Monitor Controller (DSZ) (A4) [from Radio Backup 10 A Fuse (marked BACK UP) (F9)]
Load Dump Relay (K1)

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

Ignition ON

When key switch (S1) is placed in the ON position, current is applied from key switch pin ACC to pin 3 of accessory cut relay
(K12). Utilizing the normally closed contacts of accessory cut relay, power is supplied through accessory cut diode (V11), next
through monitor 5 A Fuse (F14) to pin 17 of the monitor controller (DSZ) (A4), powering up the DSZ.

Key switch pin M also receives power, supplying idle stop relay (K11), accessory cut relay (K12), and key cut relay (K13)
through idle stop 5 A fuse (F18). Utilizing the normally closed contacts of key cut relay, power is passed through pin 3 of key
cut relay, next through load dump relay diode (V3), then to pin S of battery relay (K19), energizing the battery relay. Ground is
provided to pin E of battery relay from cab harness ground 3 (W37). When energized, the battery relay allows current to pass
through to pin B of starter motor (M1) and pin 3 of starter relay (K34). Power is also passed through to alternator 65 A fuse
(F60) providing a path from pin B of alternator (G3) to the batteries (G1 and G2).

Power through pin 3 of key cut relay is also provided through power on 5 A fuse (F17) at pin 7 of data converter (A5) 17-pin
connector, pin 4 of cab harness-to-main controller 24-pin connector E (X35), and pin 16 of monitor controller 28-pin connector
A (X20), indicating the key switch is in the ON/START position. Pin D+ of alternator (G3) also receives power from power on 5 A
fuse through alternator excitation diode (V2), and alternator resistor (R13). The alternator excitation diode (V2) allows current
to flow in only one direction and the alternator resistor (R13) limits excitation current to the alternator to protect the excitation
circuit.

Engine Start

When key switch (S1) is moved to the START position, power is applied from key switch pin ST to pins 1 and 3 of starter cut
relay (K4) and through start position signal 5 A fuse (F7) to pin 17 of monitor controller 28-pin connector A (X20), indicating the
key switch is in the START position. Utilizing the normally closed contacts of starter cut relay, power is passed to pin 3 of
starter protection relay (K35). With battery relay (K19) energized from the ignition ON position, power is supplied to pin B of
starter motor (M1) through starter in-line 30 A fuse (F45), pin 5 of the starter protection relay (K35), and pin 3 of starter relay
(K34).

Starter relay (K34) is a normally open relay which closes when power is present on relay pin 1 and ground is present on relay
pin 2. The energized starter relay provides power from battery relay (K19) to pin S of starter motor (M1) through starter relay
diode (V44). When power is present on starter motor pins B and S, the starter rotates thus cranking the engine. When the
starter relay is de-energized, starter relay contacts are opened, removing power from starter pin S, stopping the starter motor
from turning.

Utilizing the normally closed contacts of the starter cut relay (K4), power is passed to pin 3 of the starter protection relay (K35).
Applied power is then transferred through the normally closed contacts of the starter protection relay (K35) (pin 1) and
energizes the starter relay (K34) (pin 1). Starter cut relay is energized when power from the key switch is present at pin 1 and
ground on pin 2, thus preventing the start motor from cranking the engine.

The starter can be disabled based on the following components:

Monitor controller (DSZ) (A4).


Pilot shutoff switches (S3 and S4).
Main controller (MCZ) (A3).
Engine control unit (ECU) (A1).

A ground from the monitor controller (DSZ) (A4) is the result of a security code violation or machine warning alarm. When a
warning alarm or security code error is detected, pin 16 of monitor controller 16-pin connector D (X22) is connected to ground.
When a fault in the pilot shutoff circuit is detected, pin 10 of monitor controller 36-pin connector B (X21) is connected to
ground. With either pin 16 or pin 10 of the monitor controller connected to ground the starter cut relay (K4) is energized
through security diode (V4), removing the start signal from the starter protection relay (K35) and starter relay (K34). With no
start signal at starter relay, the relay remains de-energized, removing power from pin S of starter motor (M1), preventing
engine from starting.

A ground pin C2 (X15) from the engine control unit (ECU) (A1) is based on engine run status. This prevents the starter from
engaging while the engine is running. Ground is removed from pin 2 of the starter protection relay (K35) by the engine control
unit, opening the relay and not allowing current to .

A ground from pilot shutoff switches or the main controller is the result of the pilot shutoff lever in the unlocked (DOWN)
position or an error in the pilot shutoff circuit. When pilot shutoff switches 1 and 2 (S3 and S4) are closed, pilot shutoff lever in
the unlocked (DOWN) position, pin 2 of starter cut relay is connected to ground through starter cut relay diode (V5), removing
the start signal from the starter relay. With no start signal at starter relay, the relay remains de-energized, removing power
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

from pin S of starter motor. This prevents activation of starter motor when pilot shutoff lever is in the unlocked (DOWN)
position. For more information, see Pilot Shutoff Circuit Theory of Operation . (Group 9015-15.)

When the engine is running, the main controller (MCZ) (A3) will ground pin 2 of starter cut relay (K4). This opens the normally
closed contacts of the starter cut relay, removing the start signal from starter protection relay (K35) and starter relay (K34).
This prevents the starter from engaging while the engine is running. When the engine is not running, the main controller will
not ground starter cut relay.

A ground from the engine control unit (ECU) (A1) is based on engine run status. This prevents the starter from engaging while
the engine is running. Ground is removed from pin 2 of the starter protection relay (K35) by the engine control unit, opening
the relay.

Security diode (V4), starter cut relay diode (V5), pilot shutoff diode (V9), starter protection diode (V10), accessory cut diode
(V11), starter cut diode (V12), starter relay diode (V44), and pilot shutoff switch diode (V20) work as logic gates to allow more
than one device to control one circuit without backfeeding other circuits.

Auto-Ether Cold Start

If the engine control unit (ECU) determines the fuel temperature is below a specified temperature, the ECU sends current from
pin H4 of engine control unit (ECU)-to-engine harness connector (X14) energizing the ether start aid (Y19). Ether flows from the
canister to the intake manifold and mixes with intake air. When the ether/air mixture reaches the combustion chamber it mixes
with diesel fuel. Ether ignites at a lower temperature than diesel fuel, therefore, inside the combustion chamber the ether
ignites first, heating the diesel fuel and aiding in combustion. Ether shall be deactivated if 750 rpm engine speed has been
exceeded. For more information on the electrical control of auto-ether injection, see Cold Weather Starting Aid . (Group
9010-05.)

Ether Start Time

Starting Time Fuel Temperature

10 Seconds -3°C (27°F)

0 Seconds -2.9°C (26°F)

Charging Circuit

Alternator (G3) provides power to all machine circuits and charges the batteries when the engine is running.

Pin B of the alternator is connected to battery positive (+) through alternator 65 A fuse (F60) when the battery relay (K19) is
energized.

When key switch (S1) is in the ON position, key cut relay (K13) is de-energized allowing current to flow from pin M of key switch
to power on 5 A fuse (F17). The current then flows through alternator excitation diode (V2) and alternator resistor (R13) to pin
D+ of the alternator. Current from pin D+ of the alternator flows through the alternator field windings, causing excitation of the
windings. The engine control unit (ECU) monitors battery and alternator system voltage. When low voltage is indicated, the
ECU sends a message via the controller area network (CAN) to the monitor controller (DSZ) (A4) to activate the alternator or
battery indicator light. For more information, see Controller Area Network (CAN) Theory of Operation . (Group 9015-15.)

Auto Shutdown Circuit

The auto shutdown feature allows the main controller (MCZ) to automatically turn off ignition power and stop the engine if the
machine has been operating in auto-idle for 1, 2, 3, 4, 5, 10, 15, 20, 25, or 30 minutes (depending on setting).

The time duration is selectable by accessing the SETTINGS MENU/AUTO SHUTDOWN menu in the monitor service menu. See
Main Menu—Setting Menu—Auto Shutdown . (Operators Manual.)

When key switch (S1) is in the ON position, current from pin M of key switch flows through idle stop 5 A fuse (F18) to pin 1 of
idle stop relay (K11). Ground is available at pin 5 of idle stop relay.

When engine has been operating in auto-idle for a set amount of time (1, 2, 3, 4, 5, 10, 15, 20, 25, or 30 minutes), the main
controller (MCZ) connects pin 5 of cab harness-to-main controller 17-pin connector C (X33) to ground, energizing idle stop relay
(K11). Providing ground to pin 3 of idle stop relay (K11).

When all of the following conditions have been met:

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

Engine operating in auto-idle for set amount of time.


Pilot shutoff switch in the LOCKED down position.
Auto shutdown enabled.
Engine coolant temperature less than 100°C (212°F).

With idle stop relay (K11) energized, ground is provided to accessory cut relay (K12) and key cut relay (K13), energizing the
relays, removing power from the ignition ON and accessory (ACC) circuits. With no power on the ignition circuit, the controllers
are powered down, including the engine control unit (ECU), stopping the engine.

Load Dump Circuit

The load dump circuit consists of load dump relay (K1) and load dump relay diode (V3).

When the alternator (G3) is generating electricity, this causes the monitor controller to put pin 8 of monitor controller 16-pin
connector D (X22) to ground, energizing load dump relay (K1). With load dump relay (K1) energized, battery power is applied
through pins 3 and 5 to battery relay (K19). Monitor controller (DSZ) (A4) pin 8 retains a ground path for load dump relay (K1)
until alternator (G3) stops producing output voltage, keeping the battery relay (K19) energized, providing a path to the
batteries (G1 and G2) for any power produced by the alternator (G3) as the engine slows to a stop. Then the ground path is
removed from load dump relay, and battery relay (K19) is de-energized. For more information, see Controller Area Network
(CAN) Theory of Operation . (Group 9015-15.)

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

Monitor Controller (DSZ) Circuit Theory of Operation

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

Monitor Controller (DSZ) Circuit Schematic (1 of 2)

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

LEGEND:
A1 Engine Control Unit (ECU)
A3 Main Controller (MCZ)
A4 Monitor Controller (DSZ)
A5 Data Converter
A6 Radio
A7 Air Conditioner Controller (ACF)
A11 Machine Controller (BCZ)
F7 Start Position Signal 5 A Fuse (marked START)
F9 Radio Backup 10 A Fuse (marked BACK UP)
F14 Monitor 5 A Fuse (marked MONITOR)
F17 Power On 5 A Fuse (marked POWER ON)
F18 Idle Stop 5 A Fuse (marked IDLE STOP)
F45 Starter In-Line 30 A Fuse
F60 Alternator 65 A Fuse
F61 Battery 45 A Fuse
G1 Battery
G2 Battery
G3 Alternator
H2 Security Alarm
H3 Monitor Warning Alarm
K1 Load Dump Relay
K3 Security Alarm Relay
K4 Starter Cut Relay
K12 Accessory Cut Relay
K13 Key Cut Relay
K19 Battery Relay
K34 Starter Relay
K35 Starter Protection Relay
M1 Starter Motor
R13 Alternator Resistor
S1 Key Switch
V1 Battery Relay Diode
V2 Alternator Excitation Diode
V3 Load Dump Relay Diode
V7 Start Relay Diode
V10 Starter Protection Diode
V11 Accessory Cut Diode
V44 Starter Relay Diode
W37 Cab Harness Ground 3
X11 Machine Controller 20-Pin Connector B
X15 Engine Control Unit (ECU)-to-Engine Harness Connector 2
X20 Monitor Controller 28-Pin Connector A
X21 Monitor Controller 36-Pin Connector B
X22 Monitor Controller 16-Pin Connector D
X31 Cab Harness-to-Main Controller 31-Pin Connector A
X36 Cab Harness-to-Main Controller 26-Pin Connector F
X52 Air Conditioner 10-Pin Connector
X175 Machine Harness-to-Starter Harness Connector

Monitor Controller (DSZ) (A4)— The monitor controller (DSZ) contains the monitor software and interprets inputs from
various sensors, buttons, and switches. Information sent over the controller area network (CAN) from other controllers is sent
to the DSZ where it is then displayed on the monitor.

The DSZ uses the CAN 1 to communicate with the data converter (A5), radio (A6), air conditioner controller (ACF) (A7), and
machine controller (BCZ) (A11) through pins A25 and A26 of DSZ. The DSZ also communicates on CAN 0 with the engine
control unit (ECU) (A1), and the main controller (MCZ) (A3) through pins A23 and A24 of DSZ.

For more information on CAN communication, see Controller Area Network (CAN) Theory of Operation . (Group 9015-15.)

Monitor Controller (DSZ) (power and ground)— Unswitched battery power is available through battery 45 A fuse (F61)
and radio backup 10 A fuse (F9) to pin B18 of the monitor controller (DSZ). Battery power from battery 45 A fuse is also
provided to pins 1 and 3 of load dump relay (K1). Ground is provided to pins A22, B11, B35, and B36 of the DSZ.

When key switch (S1) is in the accessory (ACC) position, current flows from pin ACC of key switch, to accessory cut relay (K12).
Utilizing the normally closed contacts of accessory cut relay, current flows through accessory cut diode (V11), through monitor

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

5 A fuse (F14) to pin B17 of the DSZ. Accessory power enables the radio and air conditioning and heating electronic features to
operate without powering up the other vehicle controllers.

When the key switch is in the ignition ON position, current flows to pin M in addition to pin ACC. Current from pin M flows to key
cut relay (K13) directly to pin 3 and through idle stop 5 A fuse (F18) to pin 1 of key cut relay and pin 1 of accessory cut relay.
Utilizing the normally closed contacts of the key cut relay, current flows through load dump relay diode (V3), to pin 5 of load
dump relay and to battery relay (K19), energizing the battery relay. Current from key cut relay also flows through power on 5 A
fuse (F17) to pin A16 of the DSZ, powering up the DSZ.

When the key switch is in the START position, current flows to pin ST in addition to pin M. Current from key switch pin ST flows
to pins 1 and 3 of starter cut relay (K4), and through start position signal 5 A fuse (F7) to pin A17 of the DSZ, indicating the key
switch is in the START position.

Anti-Theft Security— The anti-theft security circuit consists of security alarm relay (K3) and security alarm (H2). Battery
power is provided to pin 1 of security alarm relay and to pin 1 of the security alarm through radio backup 10 A fuse (F9). When
an invalid code has been entered, ground is provided to pin 2 of security alarm relay from pin D15 of the monitor controller
(DSZ), energizing the security alarm relay, and activating the security alarm. When the anti-theft security circuit is active,
ground is provided to starter cut relay (K4), disabling the starter motor (M1), preventing the machine from starting.

For more information, see Starting and Charging Circuit Theory of Operation . (Group 9015-15.)

Monitor Warning Alarm— The monitor warning alarm (H3) sounds when certain diagnostic trouble codes (DTCs) or machine
conditions exist which could damage the machine. The monitor warning alarm receives switched power from power on 5 A fuse
(F17). Ground is provided from pin D7 of monitor controller (DSZ), activating the alarm.

Alternator Voltage Indicator— The alternator alarm indicator is monitored by the engine control unit (ECU). When the
alternator excitation field voltage is below charging level, the ECU sends a message over the controller area network (CAN) to
the monitor controller (DSZ). The DSZ then illuminates the alternator warning indicator.

For more information on the ECU, see Engine Control Unit (ECU) Circuit Theory of Operation . (Group 9015-15.)

The monitor controller also uses this signal from the ECU to activate the load dump circuit. When a voltage decrease is
monitored by the ECU, and the key switch is in the OFF position, pin D8 of the DSZ is placed to ground, energizing load dump
relay (K1). With the load dump relay energized and the key switch in the OFF position, voltage from the alternator is allowed to
return to the batteries (G1 and G2) as the engine slows to a stop.

For more information on the load dump circuit, see Starting and Charging Circuit Theory of Operation . (Group 9015-15.)

Check Engine Indicator— The check engine indicator will come ON if there is an engine problem.

The engine may run at reduced power to protect the engine but still allow the machine to be moved. For more information on
the engine control unit (ECU) and sensors, see Engine Control Unit (ECU) Circuit Theory of Operation . (Group 9015-15.)

For more information on ECU diagnostic trouble codes, see Engine Control Unit (ECU) Diagnostic Trouble Codes . (Group
9001-20.)

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

Monitor Controller (DSZ) Circuit Schematic (2 of 2)

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

LEGEND:
A4 Monitor Controller (DSZ)
A10 Monitor
A12 Rear Camera
B18 Fuel Level Sensor
B27 Hydraulic Oil Filter Restriction Switch (if equipped)
E5 Switch Panel Back Light 1
E6 Switch Panel Back Light 2
E8 Switch Panel Back Light 4
S20 Seat Belt Switch
S21 Blower Motor Speed Switch
S22 Temperature Control/Mode Switch
S23 Radio Volume and Power Switch
S24 Radio Tuning Switch
S25 Monitor Dial
S26 Back Button
S27 Home Button
S40 Hydraulic Oil Temperature Switch (if equipped)
S50 0 Key
S51 1 Key
S52 2 Key
S53 3 Key
S54 4 Key
S55 5 Key
S56 6 Key
S57 7 Key
S58 8 Key
S59 9 Key
S60 Keypad
X2 MPDr 6-Pin Connector
X3 Cab Harness-to-Machine Harness 100-Pin Connector
X18 Monitor 12-Pin Connector C
X19 Monitor 2-Pin Connector G
X20 Monitor Controller 28-Pin Connector A
X21 Monitor Controller 36-Pin Connector B
X22 Monitor Controller 16-Pin Connector D
X23 Monitor Controller 12-Pin Connector C
X24 Monitor Controller 2-Pin Connector G
X28 Cab Harness-to-Switch Panel Connector 2
X29 Cab Harness-to-Switch Panel Connector 3
X30 Cab Harness-to-Switch Panel Connector 4
X65 Cab Harness-to-Pilot Shutoff Switch Harness Connector
X90 Machine Harness-to-Hydraulic Oil Temperature Switch Connector

Monitor (A10)— The monitor (A10) communicates directly with the monitor controller (DSZ) (A4). The monitor receives power
from pin C3 and ground from pin C5 of the DSZ. The DSZ sends voltage from pin C2 of the DSZ, to the monitor, indicating how
dark or bright to set the backlight on the monitor depending on operator setting. The monitor has a built-in temperature sensor
which is not accessible. The monitor temperature sensor provides an indication to pin C6 of the DSZ, if the monitor
temperature is too high. Pin C1 of the DSZ illuminates the alert light when an alert or diagnostic trouble code (DTC) is present.

The monitor controller outputs video signal from the rear camera (A12) on pins G1 and G2 of the DSZ to the monitor when the
rear camera is active.

Rear Camera (A12)— The rear camera (A12) communicates directly with the monitor controller (DSZ). Power is provided to
the rear camera from pin D2 and ground is provided from pin D3 of the DSZ. The rear camera sends the video signal to pins D1
and D9 of the DSZ. The DSZ then outputs the video signal to the monitor.

MPDr Application— The MPDr application communicates directly with the monitor controller (DSZ). The monitor controller
communicates via the controller area network (CAN) with the other electronic controllers to provide information to MPDr.

The DSZ provides MPDr with 5 V power from pin A1 and serial communication from pins A13 and A28.

For more information on MPDr, see MPDr Application . (Group 9015-20.)

Fuel Level Indicator— The fuel level sensor (B18) provides a variable resistance to the fuel gauge as fuel level changes in the
tank. Once the sensor is at a high enough resistance at pin A18 of monitor controller (DSZ), the fuel level indicator notification

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

will activate, indicating a low level of fuel.

Item Measurement Specification

Fuel Level Indicator Light Resistance Illuminates Above 82—88 ohms

Hydraulic Oil Filter Restriction Indicator— Ground is passed to pin B13 of monitor controller (DSZ) (A4) when hydraulic oil
temperature switch (if equipped) (S40) and hydraulic oil filter restriction switch (if equipped) (B27) are closed (hydraulic oil
temperature is above 24°C [75°F] and a plugged hydraulic oil filter is sensed). When this condition exists for a minimum of
5—10 seconds, the hydraulic oil filter restriction indicator will illuminate.

Blower Motor Speed Switch (S21)— The blower motor speed switch (S21) is a hall effect sensor which offers infinite 360
degree rotation. Pressing the blower motor speed switch grounds pin B29 of monitor controller (DSZ) turning the blower motor
ON and OFF. Rotating the blower motor speed switch left or right adjusts blower motor speed by sending a pulse width
modulated (PWM) signal to pins A3 and A4 of the DSZ.

The monitor controller communicates these inputs to the air conditioner controller (ACF) via the controller area network (CAN).

For more information, see Cab Heater and Air Conditioner . (Operator’s Manual.)

Temperature Control/Mode Switch (S22)— The temperature control/mode switch (S22) is a hall effect sensor which offers
infinite 360 degree rotation. Pressing the temperature control/mode switch grounds pin B28 of monitor controller (DSZ), cycling
through the different air vent modes. Rotating the temperature control/mode switch left or right adjusts air temperature by
sending a pulse width modulated (PWM) signal to pins A5 and A6 of the DSZ.

The monitor controller communicates these inputs to the air conditioner controller (ACF) via the controller area network (CAN).

For more information, see Cab Heater and Air Conditioner . (Operator’s Manual.)

Radio Volume and Power Switch (S23)— The radio volume and power switch (S23) is a hall effect sensor which offers
infinite 360 degree rotation. Pressing the radio volume and power switch grounds pin B31 of monitor controller (DSZ), turning
the radio ON and OFF. Rotating the radio volume and power switch left or right adjusts radio volume by sending a pulse width
modulated (PWM) signal to pins A11 and A12 of the DSZ.

The monitor controller communicates these inputs to the radio (A6) via the controller area network (CAN).

For more information, see Operating the AM/FM Radio . (Operator’s Manual.)

Radio Tuning Switch (S24)— The radio tuning switch (S24) is a hall effect sensor which offers infinite 360 degree rotation.
Pressing the radio tuning switch grounds pin B30 of monitor controller (DSZ), cycling through the AM and FM radio frequencies.
Rotating the radio tuning switch left or right adjusts radio frequency to the desired station by sending a pulse width modulated
(PWM) signal to pins A7 and A9 of the DSZ.

The monitor controller communicates these inputs to the radio (A6) via the controller area network (CAN).

For more information, see Operating the AM/FM Radio . (Operator’s Manual.)

Monitor Dial (S25)— The monitor dial (S25) is a hall effect sensor which offers infinite 360 degree rotation. Pressing the
monitor dial grounds pin B27 of monitor controller (DSZ), selecting the highlighted option on the monitor (A10). Rotating the
monitor dial left or right moves the current selection on the monitor UP and DOWN by sending a pulse width modulated (PWM)
signal to pins A8 and A10 of the DSZ.

For more information, see Switch Panel Functions . (Operator’s Manual.)

Back Button (S26)— The back button (S26) grounds pin B25 of monitor controller (DSZ), returning the monitor to the
previous menu.

For more information, see Switch Panel Functions . (Operator’s Manual.)

Home Button (S27)— The home button (S27) grounds pin B26 of monitor controller (DSZ), returning the monitor to the
default screen.

For more information, see Switch Panel Functions . (Operator’s Manual.)

Keypad (S60)— Keypad (S60) contains numerical keys 0—9 (S50—S59, respectively). Keypad also contains switch panel back
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

light 1 (E5) which provides backlighting for the individual keys.

The keypad is used to input the anti-theft security code and other various parameters into the monitor controller (DSZ).

For more information, see Switch Panel Functions . (Operator’s Manual.)

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

Engine Control Unit (ECU) Circuit Theory of Operation

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

Engine Control Unit (ECU) Circuit Schematic (1 of 2) (S.N. —040754)

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

LEGEND:
A1 Engine Control Unit (ECU)
A3 Main Controller (MCZ)
A4 Monitor Controller (DSZ)
A6000 Modular Telematics Gateway (MTG) Controller
F6 12-Volt Power Outlet 20 A Fuse (marked OPT. 2 ALT)
F8 Engine Control Unit (ECU) 30 A Fuse (marked ECU)
F18 Idle Stop 5 A Fuse (marked IDLE STOP)
F20 Optional Equipment 5 A Fuse (marked OPT. 3 BATT)
F45 Starter In-Line 30 A Fuse
F60 Alternator 65 A Fuse
F61 Battery 45 A Fuse
G1 Battery
G2 Battery
G3 Alternator
K1 Load Dump Relay
K4 Starter Cut Relay
K13 Key Cut Relay
K19 Battery Relay
K34 Starter Relay
K35 Starter Protection Relay
M1 Starter Motor
R12 CAN 0 Termination Resistor
S1 Key Switch
S15 Reversing Fan Switch
V1 Battery Relay Diode
V3 Load Dump Relay Diode
V7 Start Relay Diode
V10 Starter Protection Diode
V44 Starter Relay Diode
W37 Cab Harness Ground 3
X1 Service ADVISOR™ Diagnostic Connector
X14 Engine Control Unit (ECU)-to-Engine Harness Connector 1
X15 Engine Control Unit (ECU)-to-Engine Harness Connector 2
X20 Monitor Controller 28-Pin Connector A
X22 Monitor Controller 16-Pin Connector D
X31 Cab Harness-to-Main Controller 31-Pin Connector A
X33 Cab Harness-to-Main Controller 17-Pin Connector C
X36 Cab Harness-to-Main Controller 30-Pin Connector D
X175 Machine Harness-to-Starter Harness Connector

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

Engine Control Unit (ECU) Circuit Schematic (1 of 2) (S.N. 040755— )

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

LEGEND:
A1 Engine Control Unit (ECU)
A3 Main Controller (MCZ)
A4 Monitor Controller (DSZ)
A6000 Modular Telematics Gateway (MTG) Controller
F6 Optional Connector and Reversing Fan 20 A Fuse (marked OPT. 2 ALT)
F8 Engine Control Unit (ECU) 20 A Fuse (marked ECU P1)
F18 Idle Stop 5 A Fuse (marked IDLE STOP)
F20 Optional Equipment 5 A Fuse (marked OPT. 3 BATT)
F45 Starter In-Line 30 A Fuse
F60 Alternator 65 A Fuse
F61 Battery 45 A Fuse
G1 Battery
G2 Battery
G3 Alternator
K1 Load Dump Relay
K4 Starter Cut Relay
K13 Key Cut Relay
K19 Battery Relay
K34 Starter Relay
K35 Starter Protection Relay
M1 Starter Motor
R12 CAN 0 Termination Resistor
S1 Key Switch
S15 Reversing Fan Switch
V1 Battery Relay Diode
V3 Load Dump Relay Diode
V7 Start Relay Diode
V10 Starter Protection Diode
V44 Starter Relay Diode
W37 Cab Harness Ground 3
X1 Service ADVISOR™ Diagnostic Connector
X14 Engine Control Unit (ECU)-to-Engine Harness Connector 1
X15 Engine Control Unit (ECU)-to-Engine Harness Connector 2
X20 Monitor Controller 28-Pin Connector A
X22 Monitor Controller 16-Pin Connector D
X33 Cab Harness-to-Main Controller 17-Pin Connector C
X34 Cab Harness-to-Main Controller 30-Pin Connector D
X36 Cab Harness-to-Main Controller 26-Pin Connector F
X175 Machine Harness-to-Starter Harness Connector

Engine Control Unit (ECU) (A1)— The engine control unit (ECU) uses information received from various sensors to determine
the correct amount of fuel and injection timing based on load, temperatures, and operator input. Some of the data calculated
by the ECU is transmitted across the controller area network (CAN) to the main controller (MCZ) (A3), monitor controller (DSZ)
(A4), and modular telematics gateway (MTG) controller (A6000). The DSZ forwards much of the information across the CAN
data line to the monitor where it is displayed on the appropriate screen.

→NOTE:

For component location, see Engine Harness (W4) Component Location . (Group 9015-10.)

For information concerning the MCZ, see Main Controller (MCZ) Circuit Theory of Operation . (Group 9015-15.)
For information concerning the DSZ, see Monitor Controller (DSZ) Circuit Theory of Operation . (Group 9015-15.)
For information concerning the CAN, see Controller Area Network (CAN) Theory of Operation . (Group 9015-15.)

The ECU also detects malfunctions in the sensors and sensor circuits, or abnormal operating conditions. When this happens,
the ECU generates a diagnostic trouble code (DTC). For a complete list of engine diagnostic trouble codes, see Engine Control
Unit (ECU) Diagnostic Trouble Codes . (Group 9001-20.)

For additional information on John Deere PowerTech ™ engines and components for engine model 6068HT069 or
6068HT085 see the following component technical manual (CTM).

See PowerTech™, PowerTech™ Plus, and PowerTech™ E 4.5L and 6.8L Diesel Engines—Base Engine . (CTM104.)

<- Go to Section TOC Section 9015 page 201 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

See PowerTech™ E 4.5 and 6.8L Diesel Engines Level 16 Electronic Fuel Systems with Denso HPCR . (CTM502.)

Whenever an engine DTC occurs, the information is captured or recorded. The information generated is called a Snapshot. The
Snapshot information is categorized in two types: Snapshot Capture and Snapshot Recording. For more information, see
Snapshot Instructions . (CTM104.) or (CTM502.)

The following data is captured automatically for storing each code in the fault buffer:

MAP
Engine Speed
Percent Load at Current Speed
Coolant Temperature
Vehicle Speed
Engine Hours (first and last occurrence)
Engine Mode

The ECU contains a barometric air pressure (BAP) sensor that is located inside the ECU. This sensor is used to determine the
pressure of the ambient air at the mounting location of the ECU. The BAP sensor helps the ECU determine the air density for
calculating the correct air-fuel ratio. This sensor cannot be repaired or replaced without replacing the entire ECU.

The ECU also contains a temperature sensor that is located inside the ECU. This sensor is used to determine the internal
temperature of the ECU. If the ECU temperature exceeds specification, the ECU limits the speed of the engine in an attempt to
protect the ECU from permanent damage. This sensor cannot be repaired or replaced without replacing the entire ECU.

The ECU allows for programming and diagnostic tests using Service ADVISOR ™ as follows:

Programming—The ECU can be programmed by downloading the latest programs from the software delivery system
(SDS).
Compression Test—This test is used to determine the relative compression of each cylinder. The engine is cranked while
being provided with no fuel. The angular period of the crankshaft is measured near TDC, and again past TDC. The periods
can be converted to velocities, and the relative decelerations can be calculated from the difference in the velocities. The
deceleration is a function of the pressure in the cylinder. By comparing the result from each cylinder, cylinders with
relatively low compression can be identified.
Cylinder Cutout-Misfire Test—This test provides the capability to cut out fuel to individual cylinders and provide a
programmable fuel command to the other cylinders for a programmable number of cylinder firing events. The total time
for the number of firing events is determined and made available to Service ADVISOR for analysis.

ECU Power Up (Power and Ground) (S.N. —040754)— Unswitched battery power is available at pins M1, M4, L1, and L4 of
engine control unit (ECU)-to-engine harness connector 2 (X15), through engine control unit (ECU) 30 A fuse (F8). Ground is
provided at pins M3, L3, L2, and M2 of engine control unit (ECU)-to-engine interface harness connector 2.

When key switch (S1) is in the ON position, current flows from pin M of key switch through idle stop 5 A fuse (F18) to pins 1 and
3 of key cut relay (K13). Utilizing the normally closed contacts of the key cut relay, current is passed to pin B2 of engine control
unit (ECU)-to-engine harness connector 2 (X15) through power on 5 A fuse (F17), causing the ECU to power up.

When key switch (S1) is in the START position, current flows from pin ST through the normally closed contacts of starter cut
relay (K4) then through pin 3 and 1 of starter protection relay (K35) and onto pin 1 of starter relay (K34) to energize the relay.
With the starter relay pins 3 and 4 energized, power is supplied to pin S of starter motor (M1), thus cranking the engine. Once
the ECU has determined the engine has started, pin C2 of engine control unit (ECU)-to-engine harness connector 2 (X15) is
grounded, providing ground to starter protection relay (K35), de-energizing the starter relay (K34). With the starter relay de-
energized, the start signal is removed from pin 4 on the starter relay, thus disengaging the starter motor. For more
information, see Starting and Charging Circuit Theory of Operation . (Group 9015-15.)

ECU Power Up (Power and Ground) (S.N. 040755— )— Unswitched battery power is available at pins M1, M4, L1, and L4
of engine control unit (ECU)-to-engine harness connector 2 (X15), through engine control unit (ECU) 20 A fuse (F8). Ground is
provided at pins M3, L3, L2, and M2 of engine control unit (ECU)-to-engine interface harness connector 2.

When key switch (S1) is in the ON position, current flows from pin M of key switch through idle stop 5 A fuse (F18) to pins 1 and
3 of key cut relay (K13). Utilizing the normally closed contacts of the key cut relay, current is passed to pin B2 of engine control
unit (ECU)-to-engine harness connector 2 (X15) through power on 5 A fuse (F17), causing the ECU to power up.

When key switch (S1) is in the START position, current flows from pin ST through the normally closed contacts of starter cut
relay (K4) then through pin 3 and 1 of starter protection relay (K35) and onto pin 1 of starter relay (K34) to energize the relay.
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

With the starter relay pins 3 and 4 energized, power is supplied to pin S of starter motor (M1), thus cranking the engine. Once
the ECU has determined the engine has started, pin C2 of engine control unit (ECU)-to-engine harness connector 2 (X15) is
grounded, providing ground to starter protection relay (K35), de-energizing the starter relay (K34). With the starter relay de-
energized, the start signal is removed from pin 4 on the starter relay, thus disengaging the starter motor. For more
information, see Starting and Charging Circuit Theory of Operation . (Group 9015-15.)

Hydraulic Variable Speed Fan with Reversing Function (S.N. —040754)— The hydraulic variable speed fan with
reversing function controls the cooling capacity of the cooling package by varying the speed of the fan. The engine control unit
(ECU) automatically controls the speed of the fan by monitoring the following:

Engine Coolant Temperature


Charge Air Cooler Outlet Temperature
Hydraulic Oil Temperature
Ambient Air Temperature
Air Conditioning State (On-Off)
Fuel Temperature

The engine coolant temperature sensor (B5208) and charge air cooler outlet temperature sensor (B5204) are hard-wired to the
engine control unit (ECU).

The hydraulic oil temperature (B40) is hard-wired to the main controller (MCZ) (A3), and continuously transmits information
across the controller area network (CAN) to communicate with the ECU. For more information on the hydraulic oil temperature
sensor, see Main Controller (MCZ) Circuit Theory of Operation . (Group 9015-15.)

The air conditioner compressor clutch (Y11) is hard-wired to the air conditioner controller (ACF) (A7), and continuously
transmits information via CAN to communicate with the monitor controller (DSZ) (A4), which then forwards the information via
CAN to the ECU. For more information on the DSZ, see Monitor Controller (DSZ) Circuit Theory of Operation . (Group 9015-15.)

→NOTE:

If a fault condition exists for any of the previously mentioned temperature sensors, the fan speed will go
to full speed.

The engine control unit (ECU) uses certain reference values in the form of look-up tables for each of the temperatures and the
air conditioning state to determine the fan speed for each input. The ECU then selects the highest fan speed required and
sends current out pin J4 of engine control unit (ECU)-to-engine harness connector 2 (X15) to variable speed fan solenoid
(Y5005). Static ground is provided to variable speed fan solenoid at all times.

The amount of current the ECU provides the variable speed fan solenoid is inversely dependent on the calculated fan speed
and compared to a predefined look-up table. Zero current commands maximum fan speed. For hydraulic operation of the fan,
see Fan Drive Hydraulic System Operation . (Group 9025-05.)

The reversing fan function reverses the fan direction to purge the cooling system of debris. The reversing fan function can be
operated in manual or automatic mode via reversing fan switch (S15). Switched power is passed from the alternator (G3) to the
reversing fan switch through power outlet 20 A fuse (F6). When the reversing fan switch is pressed to the AUTOMATIC position,
current flows to pin K4 of engine control unit (ECU)-to-engine harness connector 2 (X15). The ECU then automatically reverses
fan direction every 30 minutes unless the cycle time is changed. If the engine has been running for 60 minutes and the
hydraulic oil temperature has exceeded 12°C (53.6°F), the ECU will begin the reversing sequence.

When the reversing fan timer in the ECU reaches full count, the ECU begins the reversing sequence as follows:

1. The ECU ramps up the current to variable speed fan solenoid (Y5005) to slow the fan to minimum fan speed
(approximately 300 rpm).
2. When fan speed is at minimum, the ECU sends current out pin K4 of engine control unit (ECU)-to-engine harness
connector 2 (X15) to the reversing fan solenoid (Y9), energizing the solenoid. This causes the fan to reverse direction.
3. With the fan now operating in the reverse direction, the ECU ramps down the current applied to the variable speed fan
solenoid (Y5005) until maximum fan speed (approximately 1800 rpm) is reached.
4. The ECU operates the fan at maximum speed in reverse direction for 15 seconds, then ramps up the variable speed fan
solenoid current until the fan is at minimum speed.
5. When the fan slows to minimum speed, the ECU stops sending current to the reversing fan solenoid (Y9), causing the fan
to change back to forward direction.
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

6. With the fan operating in the forward direction, the ECU ramps down the variable speed fan solenoid current until the
normal operating fan speed is obtained.

When the reversing fan has completed a cycle, the reversing sequence cannot be activated again for 1 minute. If the reversing
fan is in the automatic mode when the manual mode is activated, the reversing fan timer is stopped and then started again
after the reversing fan sequence is completed.

When a manual reverse cycle is complete, the function returns to the automatic mode.

Optional Connector and Reversing Fan

Hydraulic Variable Speed Fan with Reversing Function (S.N. 040755— )— The hydraulic variable speed fan with
reversing function controls the cooling capacity of the cooling package by varying the speed of the fan. The engine control unit
(ECU) automatically controls the speed of the fan by monitoring the following:

Engine Coolant Temperature


Charge Air Cooler Outlet Temperature
Hydraulic Oil Temperature
Ambient Air Temperature
Air Conditioning State (On-Off)
Fuel Temperature

The engine coolant temperature sensor (B5208) and charge air cooler outlet temperature sensor (B5204) are hard-wired to the
engine control unit (ECU).

The hydraulic oil temperature (B40) is hard-wired to the main controller (MCZ) (A3), and continuously transmits information
across the controller area network (CAN) to communicate with the ECU. For more information on the hydraulic oil temperature
sensor, see Main Controller (MCZ) Circuit Theory of Operation . (Group 9015-15.)

The air conditioner compressor clutch (Y11) is hard-wired to the air conditioner controller (ACF) (A7), and continuously
transmits information via CAN to communicate with the monitor controller (DSZ) (A4), which then forwards the information via
CAN to the ECU. For more information on the DSZ, see Monitor Controller (DSZ) Circuit Theory of Operation . (Group 9015-15.)

→NOTE:

If a fault condition exists for any of the previously mentioned temperature sensors, the fan speed will go
to full speed.

The engine control unit (ECU) uses certain reference values in the form of look-up tables for each of the temperatures and the
air conditioning state to determine the fan speed for each input. The ECU then selects the highest fan speed required and
sends current out pin J4 of engine control unit (ECU)-to-engine harness connector 2 (X15) to variable speed fan solenoid
(Y5005). Static ground is provided to variable speed fan solenoid at all times.

The amount of current the ECU provides the variable speed fan solenoid is inversely dependent on the calculated fan speed
and compared to a predefined look-up table. Zero current commands maximum fan speed. For hydraulic operation of the fan,
see Fan Drive Hydraulic System Operation . (Group 9025-05.)

The reversing fan function reverses the fan direction to purge the cooling system of debris. The reversing fan function can be
operated in manual or automatic mode via reversing fan switch (S15). Switched power is passed from the alternator (G3) to the
reversing fan switch through optional connector and reversing fan 20 A fuse (F6). When the reversing fan switch is pressed to
the AUTOMATIC position, current flows to pin K4 of engine control unit (ECU)-to-engine harness connector 2 (X15). The ECU
then automatically reverses fan direction every 30 minutes unless the cycle time is changed. If the engine has been running for
60 minutes and the hydraulic oil temperature has exceeded 12°C (53.6°F), the ECU will begin the reversing sequence.

When the reversing fan timer in the ECU reaches full count, the ECU begins the reversing sequence as follows:

1. The ECU ramps up the current to variable speed fan solenoid (Y5005) to slow the fan to minimum fan speed
(approximately 300 rpm).
2. When fan speed is at minimum, the ECU sends current out pin K4 of engine control unit (ECU)-to-engine harness
connector 2 (X15) to the reversing fan solenoid (Y9), energizing the solenoid. This causes the fan to reverse direction.
3. With the fan now operating in the reverse direction, the ECU ramps down the current applied to the variable speed fan

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

solenoid (Y5005) until maximum fan speed (approximately 1800 rpm) is reached.
4. The ECU operates the fan at maximum speed in reverse direction for 15 seconds, then ramps up the variable speed fan
solenoid current until the fan is at minimum speed.
5. When the fan slows to minimum speed, the ECU stops sending current to the reversing fan solenoid (Y9), causing the fan
to change back to forward direction.
6. With the fan operating in the forward direction, the ECU ramps down the variable speed fan solenoid current until the
normal operating fan speed is obtained.

When the reversing fan has completed a cycle, the reversing sequence cannot be activated again for 1 minute. If the reversing
fan is in the automatic mode when the manual mode is activated, the reversing fan timer is stopped and then started again
after the reversing fan sequence is completed.

When a manual reverse cycle is complete, the function returns to the automatic mode.

<- Go to Section TOC Section 9015 page 205 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

Engine Control Unit (ECU) Circuit Schematic (2 of 2)

<- Go to Section TOC Section 9015 page 206 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

LEGEND:
A1 Engine Control Unit (ECU)
B16 Air Filter Restriction Switch
B53 Fan Speed Sensor
B82 Ambient Air Temperature Sensor
B5100 Fuel Rail Pressure Sensor
B5101 Engine Oil Pressure Sensor
B5107 Inlet Fuel Pressure Sensor
B5206 Manifold Air Temperature (MAT) Sensor
B5208 Engine Coolant Temperature Sensor
B5209 Fuel Temperature Sensor
B5301 Crankshaft Position Sensor
B5302 Camshaft Position Sensor
B5600 Water-in-Fuel Sensor
M13 High Pressure Fuel Pump
S5001 Engine Coolant Loss Level Sensor
S5002 Engine Coolant Service Level Sensor
X14 Engine Control Unit (ECU)-to-Engine Harness Connector 1
X15 Engine Control Unit (ECU)-to-Engine Harness Connector 2
X5000 Engine Harness-to-Fuel Injector Harness 8-Pin Connector
Y1 Electronic Injector 1 (cylinder 1)
Y2 Electronic Injector 2 (cylinder 2)
Y3 Electronic Injector 3 (cylinder 3)
Y4 Electronic Injector 4 (cylinder 4)
Y9 Reversing Fan Solenoid
Y19 Ether Start Aid
Y5005 Variable Speed Fan Solenoid

Fuel Rail Pressure Sensor (B5100)— The fuel rail pressure sensor (B5100) sends a pressure equivalent signal to the engine
control unit (ECU). The ECU monitors fuel pressure to control the amount and timing of fuel being transferred from the high
pressure fuel pump to the high pressure common rail (HPCR). The ECU uses this signal input to determine if fuel rail pressure is
adequate for the current operating condition. The ECU will command more or less fuel from the high pressure fuel pump by
altering the signal to the suction control valve (Y5002). The ECU also uses this sensor to determine if there is an electronic
injector problem by measuring the drop of pressure in the HPCR during each injection. The fuel rail pressure sensor is used for
engine protection.

The fuel rail pressure sensor uses pin D3 for supply voltage, pin E2 for ground, and pin E3 for signal on engine control unit
(ECU)-to-engine harness connector 1 (X14).

→NOTE:

For component location, see Engine Harness (W4) Component Location . (Group 9015-10.)

For information on how pressure sensors operate, see Measuring Pressure . (CTM104.) or (CTM502.)

For information on engine protection and derate programs, see Engine Derate and Shutdown Protection . (CTM104) or
(CTM502.)

Engine Oil Pressure Sensor (B5101)— The engine oil pressure sensor (B5101) sends an oil pressure equivalent signal to the
engine control unit (ECU). The ECU uses this signal to determine if engine oil pressure is adequate for the current operating
conditions. The ECU monitors oil pressure for engine protection purposes.

The engine oil pressure sensor uses pin F3 for supply voltage on engine control unit (ECU)-to-engine harness connector 1 (X14).

The engine oil pressure sensor uses pin A3 for signal on engine control unit (ECU)-to-engine harness connector 1 (X14).

→NOTE:

For component location, see Engine Harness (W4) Component Location . (Group 9015-10.)

For information on how pressure sensors operate, see Measuring Pressure . (CTM104) or (CTM502.)

<- Go to Section TOC Section 9015 page 207 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

For information on engine protection and derate programs, see Engine Derate and Shutdown Protection . (CTM104) or
(CTM502.)

Intake Manifold Pressure Senor (B5104)— Intake manifold pressure sensor (B5104) is used to help calculate the amount of
airflow into the engine. The intake manifold pressure sensor also supplies the engine control unit (ECU) with a direct
measurement of turbo boost.

The intake manifold pressure sensor uses pin G4 for supply voltage, pin L2 for ground, and pin D2 for signal on engine control
unit (ECU)-to-engine harness connector 2 (X15).

→NOTE:

For component location, see Engine Harness (W4) Component Location . (Group 9015-10.)

For information on how pressure sensors operate, see Measuring Pressure . (CTM104) or (CTM502.)

Crankshaft Position Sensor (B5301)— The crankshaft position sensor (B5301) is an inductive type pickup sensor that
detects teeth on the crankshaft timing gear. The crankshaft timing gear is composed of 78 evenly-spaced teeth. Two of the
teeth are ground back 1/2 the width of the teeth from the front of the gear. These partially ground-off teeth help the engine
control unit (ECU) determine when cylinder number one or six is at top dead center (TDC) of its compression stroke.

The ECU uses the crankshaft position input to determine engine speed and the angular position of the crankshaft in its 360
degree field of rotation. The ECU also uses this signal to calculate engine (crankshaft) speed and sends this information across
the controller area network (CAN) to the monitor controller (DSZ) (A4), where it appears on the monitor display as engine rpm.

Based on information from the crankshaft position and camshaft position sensors, the ECU calculates precisely to control the
timing and duration of fuel injection. If there is a problem with the crankshaft position sensor, the ECU will use the camshaft
position sensor to determine engine timing. This may require prolonged engine cranking to start the engine.

The crankshaft position sensor uses pin B4 for signal and pin D4 for ground on engine control unit (ECU)-to-engine harness
connector 1 (X14).

→NOTE:

For component location, see Engine Harness (W4) Component Location . (Group 9015-10.)

For information on how speed sensors operate, see Measuring Speed . (CTM104) or (CTM502.)

Camshaft Position Sensor (B5302)— The camshaft position sensor (B5302) is used to determine engine speed and when
each cylinder is at top dead center (TDC) of the compression stroke. The ECU uses this information to determine injection
timing.

Camshaft position sensor consists of a permanent magnet, coil, and yoke. It is mounted near the inner camshaft gear which
contains seven webs. During engine rotation, an AC voltage pulse is induced in the coil as each web passes by the sensor.
There are seven pulses per camshaft revolution. The circular distance between two of the webs is smaller, by detecting this
difference the ECU determines when cylinder number one is at TDC of its compression stroke.

The camshaft speed signal circuit is shielded from electro-magnetic interference (EMI). If there is a problem with the camshaft
position sensor, the ECU will use the crankshaft position sensor to determine engine timing. This may require prolonged engine
cranking to start the engine

The camshaft position sensor uses pin E4 for signal and pin A4 for ground on engine control unit (ECU)-to-engine harness
connector 1 (X14).

→NOTE:

For component location, see Engine Harness (W4) Component Location . (Group 9015-10.)

<- Go to Section TOC Section 9015 page 208 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

For information on how speed sensors operate, see Measuring Speed . (CTM104) or (CTM502.)

Water-in-Fuel Sensor (B5600)— The water-in-fuel sensor (B5600) is located on the bottom of the primary fuel filter in the
water separator bowl. When water is detected in the fuel, a signal is sent to the engine control unit (ECU). The water-in-fuel
sensor uses the resistance of fuel and water in the fuel system along with the principle that water is a better conductor than
fuel. If water is present, the voltage will be lower. The ECU monitors water-in-fuel for engine protection.

The water-in-fuel sensor uses pin B2 signal and pin D2 for power on engine control unit (ECU)-to-engine harness connector 1
(X14).

→NOTE:

For component location, see Engine Interface Harness (W5) Component Location . (Group 9015-10.)

For information on engine protection and derate programs, see Engine Derate and Shutdown Protection . (CTM104) or
(CTM502.)

Water-in-Fuel Alarm— The engine control unit (ECU) (A1) monitors the water-in-fuel sensor (B5600) for water in the fuel.
When water is present, the engine control unit will ground connector X14 pin B2, grounding monitor controller (A4) pin C12.
When monitor controller (A4) pin C12 is grounded, the monitor will display the water-in-fuel indicator to notify the operator of
the water-in-fuel condition.

Engine Coolant Loss Level Sensor (S5001)— The engine coolant loss level sensor (S5001) is a reed switch that extends
from the bottom of the surge tank. A float in the tank changes position with coolant level. When the coolant level falls, the ring
magnet on the bottom of the float moves to the bottom of the tank, below the switch position. The magnetic field is removed,
the switch will open, a diagnostic trouble code (DTC) will be set, and the engine will be derated.

The engine coolant loss level sensor uses pin J1 for signal on engine control unit (ECU)-to-engine harness connector 2 (X15).

→NOTE:

For component location, see Engine Interface Harness (W5) Component Location . (Group 9015-10.)
(Group 1915-10.)

For information on engine protection and derate programs, see Engine Derate and Shutdown Protection . (CTM104) or
(CTM502.)

Engine Coolant Service Level Sensor (S5002)— The engine coolant service level sensor (S5002) is a reed switch that
extends from the bottom of the surge tank. A float in the tank changes position with coolant level. When the coolant level falls,
the ring magnet on the bottom of the float moves to the bottom of the tank, below the switch position. A diagnostic trouble
code (DTC) will be set. The purpose of the sensor is to inform of a moderately low coolant level when the ignition is turned on.
Once the engine is running, the sensor is only used for mismatch detection with engine coolant loss level sensor (S5001).

The associated float in the surge tank is longer than the float associated with the coolant loss level sensor (S5001). The magnet
for the engine coolant service level sensor will fall to the bottom of the surge tank sooner if engine coolant level decreases.

The engine coolant service level sensor uses pin E3 for signal on engine control unit (ECU)-to-engine harness connector 2
(X15).

→NOTE:

For component location, see Engine Interface Harness (W5) Component Location . (Group 9015-10.)

For information on engine protection and derate programs, see Engine Derate and Shutdown Protection . (CTM104) or
(CTM502.)

Fan Speed Sensor (B53)— The fan speed sensor (B53) sends the engine control unit (ECU) with the fan speed in revolutions

<- Go to Section TOC Section 9015 page 209 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

per minute (RPM). The ECU uses the fan speed sensor for more precise control of the fan speed.

The fan speed sensor uses pin A3 for supply voltage, pin C3 for ground, and pin H1 for signal on engine control unit (ECU)-to-
engine harness connector 2 (X15).

Inlet Fuel Pressure Sensor (B5107)— The inlet fuel pressure sensor (B5107) sends a pressure equivalent signal to the
engine control unit (ECU). The ECU monitors fuel pressure to determine if fuel is continuously passing through the low pressure
side of the fuel system, or if there is a leak or blockage in it. Based on inlet fuel pressure sensor inputs, the ECU controls the
low pressure fuel pump speed to maintain the desired pressure.

The inlet fuel pressure sensor uses pin D2 for supply voltage, pin C2 for ground, and pin B3 for signal on engine control unit
(ECU)-to-engine harness connector 1 (X14).

→NOTE:

For component location, see Engine Harness (W4) Component Location . (Group 9015-10.)

For information on how pressure sensors operate, see Measuring Pressure . (CTM104) or (CTM502.)

For information on engine protection and derate programs, see Engine Derate and Shutdown Protection . (CTM104) or
(CTM502.)

Manifold Air Temperature (MAT) Sensor (B5206)— The manifold air temperature (MAT) sensor (B5206) is used to
measure the temperature of the air in the intake manifold. The MAT sensor helps the ECU calculate the correct fueling for the
engine. The ECU also uses this sensor for engine protection purposes.

The MAT sensor uses pin D2 for signal and pin C2 for ground on engine control unit (ECU)-to-engine harness connector 1 (X14).

→NOTE:

For component location, see Engine Harness (W4) Component Location . (Group 9015-10.)

For information on how temperature sensors operate, see Measuring Temperature . (CTM104) or (CTM502.)

For information on engine protection and derate programs, see Engine Derate and Shutdown Protection . (CTM104) or
(CTM502.)

Engine Coolant Temperature Sensor (B5208)— The engine coolant temperature sensor (B5208) monitors the coolant
temperature for engine protection. Depending on the severity of the temperature increase, the engine control unit (ECU)
transmits a diagnostic trouble code (DTC) for either moderate or extreme temperature levels. The engine is derated for each
level of temperature severity. When the ECU determines the coolant temperature is too low for the current operating
conditions, it will set a DTC. This normally indicates a thermostat that is stuck open.

The engine coolant temperature sensor uses pin C4 for signal and pin C2 for ground on engine control unit (ECU)-to-engine
harness connector 1 (X14).

→NOTE:

For component location, see Engine Harness (W4) Component Location . (Group 9015-10.)

For information on how temperature sensors operate, see Measuring Temperature . (CTM104) or (CTM502.)

For information on engine protection and derate programs, see Engine Derate and Shutdown Protection . (CTM104.) or
(CTM502.)

Fuel Temperature Sensor (B5209)— The fuel temperature sensor (B5209) input is used by the engine control unit (ECU) to
calculate fuel density and adjust fuel delivery.

<- Go to Section TOC Section 9015 page 210 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

The fuel temperature sensor uses pin F4 for signal and pin C2 for ground on engine control unit (ECU)-to-engine harness
connector 1 (X14).

→NOTE:

For component location, see Engine Harness (W4) Component Location . (Group 9015-10.)

For information on how temperature sensors operate, see Measuring Temperature . (CTM104) or (CTM502.)

For information on engine protection and derate programs, see Engine Derate and Shutdown Protection . (CTM104) or
(CTM502.)

Electronic Injectors (Y1—Y4)— The electronic injectors (Y1—Y4) are controlled by the engine control unit (ECU) for injection
timing and amount of fuel, by energizing and de-energizing the electronic injectors. For more information on the electronic
injectors, see Electronic Injector (EI) Operation . (CTM104) or (CTM502.)

→NOTE:

For component location, see Engine Harness (W4) Component Location . (Group 9015-10.)

Engine Control Unit (S.N. —040754)— The engine control unit (ECU) (A1) manages the engine with input from main
controller (MCZ) and sensors located on the engine. The ECU is supplied with unswitched power through connector X15 and
engine control unit 30 amp fuse (F8). The ECU is turned on by a power on 5 amp fuse (F17) through pin B2 of connector X15.
The ECU communicates with the MCZ through a CAN (controller area network). The CAN connects to ECU through pins A1, B1,
and K2 of connector X15. If there is a malfunction with the ECU or one of the sensor circuits it is connected to the ECU, it will
illuminate an indicator on the monitor controller (A4) to notify the operator of the problem. See Reading Diagnostic Trouble
Codes With Monitor Display . (Group 9015-20.) See Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic
Application . (Group 9015-20.)

Engine Control Unit (S.N. 040755— )— The engine control unit (ECU) (A1) manages the engine with input from main
controller (MCZ) and sensors located on the engine. The ECU is supplied with unswitched power through connector X15 and
engine control unit 20 amp fuse (F8). The ECU is turned on by a power on 5 amp fuse (F17) through pin B2 of connector X15.
The ECU communicates with the MCZ through a CAN (controller area network). The CAN connects to ECU through pins A1, B1,
and K2 of connector X15. If there is a malfunction with the ECU or one of the sensor circuits it is connected to the ECU, it will
illuminate an indicator on the monitor controller (A4) to notify the operator of the problem. See Reading Diagnostic Trouble
Codes With Monitor Display . (Group 9015-20.) See Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic
Application . (Group 9015-20.)

Engine Speed Control— The engine speed dial allows for manual adjustment of the engine speed through the main controller
(MCZ) to the engine control unit (ECU) (A1). A variable voltage of 0 to 5 volts is sent from the engine speed dial to the MCZ.
The MCZ uses this information along with the status of the power mode button, work mode switch, auto-idle switch and
information from the pressure sensors to create an engine speed output signal. The engine speed output signal from the MCZ
is used by the ECU to set the engine speed. The engine speed dial uses terminals 2, 3, and 4 in connector X27. Terminal 2 in
connector X27 is the power wire which goes to MCZ connector X31 pin D1. Terminal 3 in connector X27 is a signal wire which
goes to MCZ connector X30 pin C1, and to monitor controller connector X21 pin C4. Terminal 4 in connector X27 is a ground
wire which goes to MCZ connector X31 pin D6, and monitor controller (A4) connector X21 pin C10. For information on auto-idle
and power modes ECO, PWR, and H/P, see Engine Speed Control System Operation . (Group 9010-05.)

Variable Speed Fan— The variable speed fan cools the machine′s systems by a hydraulic pump and motor controlled by a
proportional solenoid. This provides machine efficiency and reduced fan noise levels by only operating the fan at the minimum
speed necessary to cool the machine systems. The engine control unit (ECU) uses inputs from the engine coolant temperature
sensor (B5208) at terminal C4 of ECU-to-engine harness connector 1 (X14), turbocharger boost temperature sensor (B7) at
terminals D2 and G4 of ECU-to-engine harness connector 2 (X15), hydraulic oil temperature sensor via controller area network
(CAN), and ambient air temperature sensor, if air conditioner is ON, via CAN to determine the proper fan speed. The input that
requires the most cooling takes precedence over the other inputs and the fan is run at a speed sufficient to cool the warmest
input. If any of the three temperature sensor inputs are invalid, the fan will run at maximum speed to ensure proper cooling.
Temperature thresholds and proportional solenoid duty cycles (fan speeds) are preprogrammed into the ECU and cannot be
changed. The proportional fan solenoid is driven from engine control unit (ECU) terminals C1, D2, and J4 of connector X15.

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
Fan Speed Temperature Thresholds

Engine Control Unit (ECU) Sensor Input Temperature

Coolant Temperature 90°C (194°F)

Hydraulic Oil Temperature 80°C (176°F)

Ambient Air Temperature (when A/C is ON) 15°C (60°F)*

Intake Air Temperature 52°C at 25°C ambient (126°F at 77°F ambient)**

*When the air conditioner is ON and the ambient air temperature is over 15°C (60°F) the engine fan will increase to 1200 rpm.
**The engine control unit measures the intake air temperature and adds a constant value to it at ambient temperatures above 25°C (77°F). In this application, the
constant value is 27°C (49°F) above ambient air temperature when ambient air temperature is above 25°C (77°F). At temperatures below 25°C (77°F), the engine
control unit uses the constant of 52°C (126°F) for the fan speed calculations. For example:
• at 20°C (68°F) ambient temperature, the ECU calculated temperature would be 52°C (126°F)
• at 26°C (79°F) ambient temperature, the ECU calculated temperature would be 53°C (128°F)
• at 30°C (86°F) ambient temperature, the ECU calculated temperature would be 57°C (135°F)

Variable Speed Fan Reversing Function (if equipped) (S.N. —040754)— The variable speed fan reversing option
switches the direction of the cooling fan to help clear the cooling package of debris buildup. A complete reversing cycle takes
approximately 2 minutes with the fan running for 60 seconds at full speed in reverse during that time.

The variable speed fan reversing operation can be activated in two ways, manual or automatic mode. The fan reversing switch
(S15) applies power from power outlet 20 amp fuse (F6) to engine control unit (ECU) terminal F2 of connector X15 for manual
mode or engine control unit (ECU) terminal E1 of connector X15 for automatic mode. The manual mode position on the switch
is a momentary position and the automatic position on the switch is a detent position. The reversing fan solenoid (Y9) is
powered by engine control unit (ECU) terminal K4 on connector X15.

In manual mode, the fan may be reversed by pressing the fan reversing switch (S15) momentarily to the manual position. If the
engine is running and hydraulic oil temperature is above 12°C (53°F), the fan will reverse.

In automatic reverse mode, the fan will reverse every 60 minutes when the fan reversing switch (S15) is in the automatic
position. The hydraulic oil temperature must be above 12°C (53°F), and the engine speed must be greater than 1000 rpm for
60 minutes.

Once a reversing cycle has been started, it cannot be stopped unless the engine control unit (ECU) is powered down. After a
reversing cycle completes, the ECU prevents reactivation of the reversing circuit for 1 minute and the automatic reversing
mode timer is reset to 60 minutes. If the fan reversing switch (S15) is held in the manual position for 160 seconds or more, a
diagnostic trouble code (DTC) will occur and the manual reversing mode is deactivated. Continuously holding the fan reversing
switch in the manual position will not trigger a second cycle. The switch must be cycled to trigger a new reverse cycle.

Variable Speed Fan Reversing Function (if equipped) (S.N. 040755— )— The variable speed fan reversing option
switches the direction of the cooling fan to help clear the cooling package of debris buildup. A complete reversing cycle takes
approximately 2 minutes with the fan running for 60 seconds at full speed in reverse during that time.

The variable speed fan reversing operation can be activated in two ways, manual or automatic mode. The fan reversing switch
(S15) applies power from optional connector and reversing fan 20 amp fuse (F6) to engine control unit (ECU) terminal F2 of
connector X15 for manual mode or engine control unit (ECU) terminal E1 of connector X15 for automatic mode. The manual
mode position on the switch is a momentary position and the automatic position on the switch is a detent position. The
reversing fan solenoid (Y9) is powered by engine control unit (ECU) terminal K4 on connector X15.

In manual mode, the fan may be reversed by pressing the fan reversing switch (S15) momentarily to the manual position. If the
engine is running and hydraulic oil temperature is above 12°C (53°F), the fan will reverse.

In automatic reverse mode, the fan will reverse every 60 minutes when the fan reversing switch (S15) is in the automatic
position. The hydraulic oil temperature must be above 12°C (53°F), and the engine speed must be greater than 1000 rpm for
60 minutes.

Once a reversing cycle has been started, it cannot be stopped unless the engine control unit (ECU) is powered down. After a
reversing cycle completes, the ECU prevents reactivation of the reversing circuit for 1 minute and the automatic reversing
mode timer is reset to 60 minutes. If the fan reversing switch (S15) is held in the manual position for 160 seconds or more, a
diagnostic trouble code (DTC) will occur and the manual reversing mode is deactivated. Continuously holding the fan reversing
switch in the manual position will not trigger a second cycle. The switch must be cycled to trigger a new reverse cycle.

Engine Warm-Up— When the coolant temperature is below 0°C (32°F), the engine control unit (ECU) (A1) will run the engine
at 1200 rpm for 12 minutes to warm up the engine. After the 12 minute warm-up period, the engine will return to slow idle

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

unless the main controller (MCZ) is requesting the warm-up routine for the hydraulic oil. When the hydraulic oil temperature is
below 0°C (32°F), the MCZ sends a signal to ECU to increase engine speed to 1400 rpm for 15 minutes. See Engine Speed
Control System Operation for more information on Auto Warm-Up Control. (Group 9010-05.)

Power Limiting— The engine control unit (ECU) (A1) has a built-in engine protection program. The ECU will derate the amount
of fuel that is delivered to the engine when sensor inputs exceed normal operating ranges. For a list of these fault codes and
derate percentages, see Engine Control Unit (ECU) Diagnostic Trouble Codes . (Group 9001-20.)

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

Main Controller (MCZ) Circuit Theory of Operation


Main Controller (MCZ) Circuit Theory of Operation (S.N. —040754)

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

Main Controller (MCZ) Circuit Schematic (1 of 2) (S.N. —040754)

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

LEGEND:
A1 Engine Control Unit (ECU)
A3 Main Controller (MCZ)
A4 Monitor Controller (DSZ)
F4 Solenoid 20 A Fuse (marked SOLENOID)
F10 Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)
F17 Power On 5 A Fuse (marked POWER ON)
F18 Idle Stop 5 A Fuse (marked IDLE STOP)
F45 Starter In-Line 30 A Fuse
F60 Alternator 65 A Fuse
F61 Battery 45 A Fuse
G1 Battery
G2 Battery
G3 Alternator
K1 Load Dump Relay
K4 Starter Cut Relay
K13 Key Cut Relay
K19 Battery Relay
K34 Starter Relay
K35 Starter Protection Relay
M1 Starter Motor
S1 Key Switch
V1 Battery Relay Diode
V3 Load Dump Relay Diode
V7 Start Relay Diode
V10 Starter Protection Diode
V44 Starter Motor Diode
W37 Cab Harness Ground 3
X15 Engine Control Unit (ECU)-to-Engine Harness Connector 2
X20 Monitor Controller 28-Pin Connector A
X22 Monitor Controller 16-Pin Connector D
X31 Cab Harness-to-Main Controller 31-Pin Connector A
X33 Cab Harness-to-Main Controller 17-Pin Connector C
X35 Cab Harness-to-Main Controller 24-Pin Connector D
X36 Cab Harness-to-Main Controller 26-Pin Connector E
X175 Machine Harness-to-Starter Harness Connector

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

Main Controller (MCZ) Circuit Schematic (2 of 2) (S.N. —040754)

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

LEGEND:
A3 Main Controller (MCZ)
B30 Boom Up Pressure Sensor
B31 Arm In Pressure Sensor
B32 Front Attachment Pressure Sensor
B33 Swing Pressure Sensor
B34 Travel Pressure Sensor
B35 Pump 1 Delivery Pressure Sensor
B36 Pump 1 Control Pressure Sensor
B37 Pump 2 Delivery Pressure Sensor
B38 Pump 2 Control Pressure Sensor
B40 Hydraulic Oil Temperature Sensor
B60 Attachment Pressure Sensor
B61 Arm Out Pressure Sensor
H4 Travel Alarm
R15 Engine Speed Dial
S7 Power Dig Switch
S8 Auto-Idle Switch
S11 Travel Speed Switch
S12 Power Mode Button
S13 Travel Alarm Cancel Switch
X29 Cab Harness-to-Switch Panel Connector 3
X31 Cab Harness-to-Main Controller 31-Pin Connector A
X32 Cab Harness-to-Main Controller 24-Pin Connector B
X33 Cab Harness-to-Main Controller 17-Pin Connector C
X35 Cab Harness-to-Main Controller 24-Pin Connector D
X36 Cab Harness-to-Main Controller 26-Pin Connector E
X40 Pump Harness-to-Machine Harness Connector
X90 Not Used
X91 Not Used
X97 Pump Harness Splice Connector
Y20 Pump 2 Flow Rate Limit Solenoid (marked SB)
Y21 Torque Control Solenoid (marked ST)
Y22 Dig Regenerative Solenoid (marked SF)
Y23 Arm Regenerative Solenoid (marked SC)
Y24 Power Dig Solenoid (marked SG)
Y27 Arm 2 Flow Control Solenoid (marked SD)

Main Controller (MCZ) (A3)— The main controller (MCZ) uses inputs from the following sensors on the machine:

Boom Up Pressure Sensor (B30)


Arm In Pressure Sensor (B31)
Front Attachment Pressure Sensor (B32)
Swing Pressure Sensor (B33)
Travel Pressure Sensor (B34)
Pump 1 Delivery Pressure Sensor (B35)
Pump 1 Control Pressure Sensor (B36)
Pump 2 Delivery Pressure Sensor (B37)
Pump 2 Control Pressure Sensor (B38)
Hydraulic Oil Temperature Sensor (B40)
Engine Speed Dial (R15)
Auto-Idle Switch (S8)
Travel Speed Switch (S11)
Power Mode Button (S12)

The MCZ controls the following solenoids:

Pump 2 Flow Rate Limit Solenoid (SB) (Y20)


Torque Control Solenoid (ST) (Y21)
Dig Regenerative Solenoid (SF) (Y22)
Arm Regenerative Solenoid (SC) (Y23)
Power Dig Solenoid (SG/SI) (Y24)
Arm 2 Flow Control Solenoid (SD) (Y27)

Main Controller Power Up (Power and Ground)— Unswitched battery power is available at pins 3 and 4 of the main

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

controller (MCZ) through controller 5 A fuse (F10). Ground is provided to pins 1, 2, 5, and 6 of the MCZ.

When key switch (S1) is in the ON position, current flows from pin M of key switch to pin 3 of key cut relay (K13) and through
idle stop 5 A fuse (F18) to pin 1 of key cut relay. Utilizing the normally closed contacts of the key cut relay, current is passed to
pin 10 of the MCZ through power on 5 A fuse (F17), causing the MCZ to power up.

With the battery relay (K19) energized, current flows through alternator 65 A fuse (F60), to pin B of alternator (G3). From pin B
of alternator, current flows through solenoid 20 A fuse (F4) to pins 2, 5, and 6 of the MCZ.

Engine Speed Dial (R15)— The engine speed dial (R15) controls the engine speed according to the rotation angle of the dial.
The main controller (MCZ) sends the equivalent to target engine speed to the engine control unit (ECU) via the controller area
network (CAN).

For more information on CAN communication, see Controller Area Network (CAN) Theory of Operation . (Group 9015-15.)
For more information on the ECU, see Engine Control Unit (ECU) Circuit Theory of Operation . (Group 9015-15.)
For more information on engine speed control, see Engine Speed Control System Operation . (Group 9010-05.)

Power Mode Button (S12)— The power mode button (S12) allows the operator to cycle through three power modes: ECO
(economy), PWR (power) or H/P (high power).

ECO power mode reduces engine speed to 1630 rpm to reduce fuel consumption versus PWR mode. H/P mode delivers more
power to boom up and arm in functions when hydraulic pump delivery pressure is high. The main controller (MCZ) sends an
engine speed request to the engine control unit (ECU) via the controller area network (CAN). The engine control unit monitors
several sensors in the engine and makes adjustments to maintain the engine speed requested by the MCZ. For more
information on CAN communication, see Controller Area Network (CAN) Theory of Operation . (Group 9015-15.) For more
information on the ECU, see Engine Control Unit (ECU) Circuit Theory of Operation . (Group 9015-15.)

Travel Mode (HP)— When the travel speed switch (S11) is set to fast travel speed, the switch grounds the main controller
(MCZ) at pin 13. The MCZ then activates the power dig solenoid (SG/SI) (Y24), depending on the status of the travel pressure
sensor (B34), the front attachment pressure sensor (B32), the pump control pressure sensors (B36 and B38), and the pump
delivery pressure sensors (B35 and B37). The power dig solenoid is a proportional solenoid that is controlled by pins 5 and 15
of the MCZ.

The power dig solenoid is activated when:

Engine speed dial (R15) is in fast idle position


Travel pressure sensor is sensing pressure (travel function actuated)
Front attachment pressure sensor not sensing pressure (no swing or dig functions actuated)
Either pump 1 or pump 2 delivery pressure low
Either pump 1 or pump 2 control pressure high

Activation of the power dig solenoid sends pilot pressure to the travel speed change switch in the travel motors. When the
travel speed switch (S11) is in the slow (turtle) speed (2) position, the power dig solenoid valve (SG) (Y24) is de-energized.
Pressure at the travel speed change valve changes the displacement of the travel motors allowing for fast travel speed. Since
both delivery pressure must be low and both control pressure must be high, the travel motor will not shift to fast speed when
one track is lifted off the ground. If the machine is traveling in fast travel speed and a dig or swing function is operated, the
machine will remain in fast travel speed, but will slow travel speed as hydraulic oil is routed to other functions. For more
information, see Travel Motor Speed Circuit Operation . (Group 9025-05.)

A/I (Auto-Idle) Mode— A/I (Auto-Idle) is a feature that reduces engine speed when hydraulic functions are not operated for
more than 4 seconds. When the auto-idle switch (S8) is turned to A/I (auto-idle), the switch sends a ground to the main
controller (MCZ) to pin 14 of the MCZ. The MCZ communicates the selected mode through the controller area network (CAN) to
the DSZ, updating the monitor with the current mode. When the engine speed dial is set to an engine speed above auto-idle
speed, the MCZ will reduce the engine speed to auto-idle speed if hydraulic functions are not operated for more than 4
seconds. If engine speed dial is set to an engine speed below auto-idle speed, the engine speed will not increase or decrease
after 4 seconds. The MCZ receives the pressure signal from the front attachment pressure sensor (B32) in the swing park brake
circuit or the travel pressure sensor (B34) to sense if a hydraulic function has been operated. For more information on CAN
communication, see Controller Area Network (CAN) Theory of Operation . (Group 9015-15.)

Hydraulic Oil Warm-Up Circuit— When hydraulic oil temperature is below 0°C (32°F), the main controller (MCZ) activates a
warm-up circuit, which raises the engine speed slightly above slow idle to help warm up the hydraulic oil. The MCZ receives oil
temperature from the hydraulic oil temperature sensor (B40), located in the hydraulic oil tank. The MCZ will activate the warm-
up circuit for 12 minutes or until the hydraulic oil temperature rises above 2°C (36°F).
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

For more information on engine speed control, see Engine Speed Control System Operation . (Group 9010-05.)

Engine Coolant Warm-Up Circuit— When engine coolant temperature is below predefined point, the main controller (MCZ)
activates a warm-up circuit, which raises the engine speed slightly above slow idle to help warm up the engine coolant. The
MCZ receives coolant temperature via the controller area network (CAN) from the ECU. The MCZ will activate the warm-up
circuit for 12 minutes or until the coolant temperature rises to 25°C (77°F).

Idle Speed-Up Circuit— The idle speed-up circuit prevents the engine from hunting when travel or front attachment
operation is performed while the engine is running at a speed between slow idle and idle speed-up speed. When the travel or
front attachment operation is performed while the engine is between slow idle and idle speed-up speed, the main controller
(MCZ) sends the equivalent to target engine speed to the engine control unit (ECU) via the controller area network (CAN). The
ECU then increases the engine speed to the idle speed-up speed.

Pilot Shut-Off Idle Speed-Up Circuit— When engine speed dial (R15) is in the slow idle position and the pilot shut-off lever
is in the unlocked (DOWN) position, the main controller (MCZ) activates the pilot shut-off idle speed up circuit. The MCZ sends
the equivalent to target engine speed to the ECU via the controller area network (CAN), which increases the engine speed by
100 rpm from the slow idle speed in order to prevent engine stall during a control lever operation.

Engine Starting Idle Speed-Up Circuit— The engine starting idle speed-up circuit increases the engine speed and increases
the engine oil pressure when the engine starts. The engine starting idle speed-up circuit will not activate if the engine speed
dial (R15) is set above 1150 rpm. When active, the engine starting idle speed-up circuit sends the signals equivalent to the
target engine speed to the engine control unit (ECU) via the controller area network (CAN). The idle speed-up circuit will remain
active for 15 seconds. Engine speed will then return to the engine speed set by the engine speed dial.

Travel Torque Up— The torque control solenoid valve may also be activated during a travel function. At slow engine speeds,
the torque control solenoid valve is activated and both pumps are moved to maximum displacement. This reduces the oil flow
difference between the two hydraulic pumps and therefore reduces machine mistracking at low engine speeds. At fast engine
speeds, the torque control solenoid may also be activated to slightly increase pump oil flow to improve the travel function. The
torque control solenoid (Y21) is a proportional solenoid and is controlled by a pulse width modulated signal from pins 3 and 16
of the main controller (MCZ).

Auto Shutdown Circuit— The auto shutdown circuit automatically stops the engine in order to reduce fuel consumption when
the operation is not carried out in a fixed time.

The main controller (MCZ) sends the auto shutdown signal to the monitor controller (DSZ) via the controller area network (CAN)
when the following conditions have been met:

Pilot shutoff switch in the LOCKED position


Auto shutdown enabled
Engine coolant temperature less than 100°C (212°F)

The MCZ then reduces engine speed to slow idle, and provides ground to the idle stop relay, accessory cut relay, and key cut
relay, thus de-energizing the battery relay (K19), turning the machine off.

For more information on the auto shutdown circuit, see Starting and Charging Circuit Theory of Operation . (Group 9015-15.)

Work Modes— The monitor controller (DSZ) contains several work modes that are communicated by the controller area
network (CAN) to the main controller (MCZ). The MCZ can adjust pump delivery and engine speed depending on the work mode
or attachment selected. Pump flow and engine speeds can be adjusted with the monitor controller or by using MPDr.

Hydraulic Oil Overheat Alarm Circuit— The hydraulic oil overheat alarm circuit sounds the monitor alarm when the
hydraulic oil temperature increases beyond the specified value. The main controller (MCZ) monitors hydraulic oil temperature
utilizing hydraulic oil temperature sensor (B40). When hydraulic oil temperature increases, and remains past a predefined
point, the MCZ sends the signal to the monitor controller (DSZ) via the controller area network (CAN).

The monitor controller sounds the alarm and displays the hydraulic oil overheat alarm on the monitor. For more information,
see Monitor Controller (DSZ) Circuit Theory of Operation . (Group 9015-15.)

Travel Alarm Circuit— The travel alarm sounds during travel operation. When the main controller (MCZ) receives the signal
from travel pressure sensor (B34), it sends power to travel alarm (H4), activating the alarm. After traveling continuously for
more than 13 seconds, the alarm can be deactivated using travel alarm cancel switch (S13).

Pump 2 Flow Rate Limit Solenoid (SB) (Y20)— The pump 2 flow rate limit solenoid valve (SB) (Y20) limits the pump 2

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

displacement when an auxiliary (attachment) function is used. The pump 2 flow rate limit solenoid is a proportional solenoid
and is controlled by a pulse width modulated (PWM) signal from pins 8 and 15 of the main controller (MCZ). The MCZ activates
the pump 2 flow rate limit solenoid valve when pilot pressure is present at the attachment pressure sensor (optional) and a
work mode other than dig mode is selected in the monitor. The flow rate for each attachment mode can be adjusted using
MPDr.

Fine adjustments to the pump 2 flow rate can be made through the monitor.

→NOTE:

Flow rates and adjustments in MPDr and the monitor are approximate. Actual flow rates may vary.

The auxiliary flow combiner may greatly affect MPDr flow adjustments if activated.

Torque Control Solenoid (ST) (Y21)— The torque control solenoid (ST) (Y21) valve helps control pump displacement in
response to changes in engine load. As engine load increases, the torque control solenoid valve is deactivated reducing the
pump displacement and therefore reducing engine load and prevents engine stall. As engine load decreases, the torque control
solenoid is activated increasing pump displacement therefore increasing the efficiency of the machine. The main controller
(MCZ) monitors the difference between target engine speed as set by the MCZ and the actual engine speed as read by the ECU
and communicated to the MCZ over controller area network (CAN). As engine speed varies above or below target speed, the
MCZ adjusts the signal to the torque control solenoid valve to change the pump displacement to utilize the maximum efficiency
of the engine without allowing the engine to stall.

The torque control solenoid is a proportional solenoid and is controlled by a pulse width modulated (PWM) signal from pins 3
and 16 of the MCZ. Under most conditions, the torque control solenoid is activated to some degree. For more information, see
Engine Speed Sensing Control Circuit Operation . (Group 9025-05.)

Dig Regenerative Solenoid (SF) (Y22)— The dig regenerative solenoid valve (SF) (Y22) redirects oil from the boom cylinder
rod end to the arm cylinder head end during a boom up and arm in function. This helps improve arm control and prevents arm
cylinder cavitation during the combined function. The dig regenerative solenoid is a proportional solenoid that is controlled by a
pulse width modulated signal from pins 4 and 13 of the main controller (MCZ).

The MCZ activates the dig regenerative solenoid valve (SF) when the following conditions have been met:

Pump 1 and pump 2 delivery pressure high


Pressure at arm in pressure sensor
Pressure at boom up pressure sensor

When the dig regenerative solenoid valve is activated, pilot oil from the dig regenerative solenoid valve shifts the dig
regenerative valve in the control valve. This allows oil from the boom cylinder rod end to combine with oil in the arm cylinder
head end. For more information, see Dig Regenerative Valve Circuit Operation . (Group 9025-05.)

Arm Regenerative Solenoid (SC) (Y23)— The arm regenerative solenoid valve (SC) (Y23) combines the return oil from the
arm cylinder rod end with the supply oil to the arm cylinder head end. This helps prevent arm hesitation or cavitation in the
arm in circuit during a combined arm in and swing or boom up function. The arm regenerative solenoid is a proportional
solenoid that is controlled by a pulse width modulated signal from pins 5 and 14 of the main controller (MCZ).

The MCZ activates the arm regenerative solenoid valve (SC) when the following conditions have been met:

Either pump 1 or pump 2 delivery pressure low


Arm in pressure sensor sensing high pressure (arm in function fully actuated)
Swing or boom up pressure sensor sensing pressure (swing or boom up function actuated)

When the arm regenerative solenoid valve is activated, pilot oil from the arm regenerative solenoid valve shifts the arm
regenerative valve in the control valve. This blocks the return oil from the arm cylinder rod end from returning to the hydraulic
oil tank and combines it with the oil to the arm cylinder head end. Pilot oil from the arm regenerative solenoid valve also shifts
the arm flow control valve, limiting the oil to the second arm spool to preserve oil flow to other functions in the control valve.
For more information, see Arm Regenerative Valve Circuit Operation . (Group 9025-05.)

Power Dig Solenoid (SG) (Y24)— The power dig solenoid (SG) (Y24) increases digging force by temporarily increasing the
main hydraulic system relief pressure. The power dig switch (S7) grounds pin 27 of the main controller (MCZ). The MCZ then

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

energizes dig solenoid (SG) for a maximum of 8 seconds. The power dig solenoid (SG) is a proportional solenoid and is
controlled by a pulse width modulated signal from pins 5 and 15 of the MCZ.

When the power dig solenoid is activated, pilot oil from the power dig solenoid flows to the top of the main relief and power dig
valve. The pilot oil pressure pushes the piston in the main relief and power dig valve down, increasing the pressure setting. The
main hydraulic system now operates at the power dig higher operating pressure. For more information, see Main Relief Valve
Circuit Operation . (Group 9025-05.)

Arm 2 Flow Control Solenoid (SD) (Y27)— The arm 2 flow control solenoid (SD) (Y27) maintains boom raise operating
speed when operating digging (boom raise and arm roll in). The arm 2 flow control solenoid is a proportional solenoid that is
controlled by a pulse width modulated signal from pins 6 and 16 of the main controller (MCZ).

The MCZ activates the arm 2 flow control solenoid (SD) when the following conditions have been met:

Pump 1 and pump 2 delivery pressure high


Arm in pressure sensor sensing pressure
Boom up pressure sensor sensing pressure

When arm 2 flow control solenoid valve is activated, pilot oil is delivered, shifting arm 2 flow control valve. Arm 2 flow control
valve reduces pressure oil from pump 1 to arm 2 spool, maintaining boom raise operating speed.

Main Controller (MCZ) Circuit Theory of Operation (S.N. 040755— )

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

Main Controller (MCZ) Circuit Schematic (1 of 2) (S.N. 040755— )

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

LEGEND:
A1 Engine Control Unit (ECU)
A3 Main Controller (MCZ)
A4 Monitor Controller (DSZ)
F4 Solenoid 20 A Fuse (marked SOLENOID)
F10 Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)
F17 Power On 5 A Fuse (marked POWER ON)
F18 Idle Stop 5 A Fuse (marked IDLE STOP)
F45 Starter In-Line 30 A Fuse
F60 Alternator 65 A Fuse
F61 Battery 45 A Fuse
G1 Battery
G2 Battery
G3 Alternator
K1 Load Dump Relay
K4 Starter Cut Relay
K13 Key Cut Relay
K19 Battery Relay
K34 Starter Relay
K35 Starter Protection Relay
M1 Starter Motor
S1 Key Switch
V1 Battery Relay Diode
V3 Load Dump Relay Diode
V7 Start Relay Diode
V10 Starter Protection Diode
V44 Starter Motor Diode
W37 Cab Harness Ground 3
X15 Engine Control Unit (ECU)-to-Engine Harness Connector 2
X20 Monitor Controller 28-Pin Connector A
X22 Monitor Controller 16-Pin Connector D
X31 Cab Harness-to-Main Controller 31-Pin Connector A
X33 Cab Harness-to-Main Controller 17-Pin Connector C
X35 Cab Harness-to-Main Controller 24-Pin Connector E
X36 Cab Harness-to-Main Controller 26-Pin Connector F
X175 Machine Harness-to-Starter Harness Connector

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

Main Controller (MCZ) Circuit Schematic (2 of 2) (S.N. 040755— )

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

LEGEND:
A3 Main Controller (MCZ)
B30 Boom Up Pressure Sensor
B31 Arm In Pressure Sensor
B32 Front Attachment Pressure Sensor
B33 Swing Pressure Sensor
B34 Travel Pressure Sensor
B35 Pump 1 Delivery Pressure Sensor
B36 Pump 1 Control Pressure Sensor
B37 Pump 2 Delivery Pressure Sensor
B38 Pump 2 Control Pressure Sensor
B40 Hydraulic Oil Temperature Sensor
B60 Attachment Pressure Sensor
B61 Arm Out Pressure Sensor
H4 Travel Alarm
R15 Engine Speed Dial
S7 Power Dig Switch
S8 Auto-Idle Switch
S11 Travel Speed Switch
S12 Power Mode Button
S13 Travel Alarm Cancel Switch
X29 Cab Harness-to-Switch Panel Connector 3
X31 Cab Harness-to-Main Controller 31-Pin Connector A
X32 Cab Harness-to-Main Controller 24-Pin Connector B
X33 Cab Harness-to-Main Controller 17-Pin Connector C
X34 Cab Harness-to-Main Controller 30-Pin Connector D
X35 Cab Harness-to-Main Controller 24-Pin Connector E
X36 Cab Harness-to-Main Controller 26-Pin Connector F
X40 Pump Harness-to-Machine Harness Connector
X97 Pump Harness Splice Connector
Y20 Pump 2 Flow Rate Limit Solenoid (marked SB)
Y21 Torque Control Solenoid (marked ST)
Y22 Dig Regenerative Solenoid (marked SF)
Y23 Arm Regenerative Solenoid (marked SC)
Y24 Power Dig/Travel Speed Solenoid (marked SG)
Y27 Arm 2 Flow Control Solenoid (marked SD)

Main Controller (MCZ) (A3)— The main controller (MCZ) uses inputs from the following sensors on the machine:

Boom Up Pressure Sensor (B30)


Arm In Pressure Sensor (B31)
Front Attachment Pressure Sensor (B32)
Swing Pressure Sensor (B33)
Travel Pressure Sensor (B34)
Pump 1 Delivery Pressure Sensor (B35)
Pump 1 Control Pressure Sensor (B36)
Pump 2 Delivery Pressure Sensor (B37)
Pump 2 Control Pressure Sensor (B38)
Hydraulic Oil Temperature Sensor (B40)
Engine Speed Dial (R15)
Auto-Idle Switch (S8)
Travel Speed Switch (S11)
Power Mode Button (S12)

The MCZ controls the following solenoids:

Pump 2 Flow Rate Limit Solenoid (SB) (Y20)


Torque Control Solenoid (ST) (Y21)
Dig Regenerative Solenoid (SF) (Y22)
Arm Regenerative Solenoid (SC) (Y23)
Power Dig/Travel Speed Solenoid (SG) (Y24)
Arm 2 Flow Control Solenoid (SD) (Y27)

Main Controller Power Up (Power and Ground)— Unswitched battery power is available at pins E5 and E6 of the main
controller (MCZ) through data converter and main controller battery power 5 A fuse (F10). Ground is provided to pins E1, E2,

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

F4, F5, and F6 of the MCZ.

When key switch (S1) is in the ON position, current flows from pin M of key switch to pin 3 of key cut relay (K13) and through
idle stop 5 A fuse (F18) to pin 1 of key cut relay. Utilizing the normally closed contacts of the key cut relay current is passed to
pin E4 of the MCZ through power on 5 A fuse (F17), causing the MCZ to power up.

With the battery relay (K19) energized, current flows through alternator 65 A fuse (F60), to pin B of alternator (G3). From pin B
of alternator, current flows through solenoid 20 A fuse (F4) to pins F1, F2, and F3 of the MCZ.

Engine Speed Dial (R15)— The engine speed dial (R15) controls the engine speed according to the rotation angle of the dial.
The main controller (MCZ) sends the equivalent to target engine speed to the engine control unit (ECU) via the controller area
network (CAN).

For more information on CAN communication, see Controller Area Network (CAN) Theory of Operation . (Group 9015-15.)
For more information on the ECU, see Engine Control Unit (ECU) Circuit Theory of Operation . (Group 9015-15.)
For more information on engine speed control, see Engine Speed Control System Operation . (Group 9010-05.)

Power Mode Button (S12)— The power mode button (S12) allows the operator to cycle through three power modes: ECO
(economy), PWR (power) or H/P (high power).

ECO power mode reduces engine speed to 1630 rpm to reduce fuel consumption versus PWR mode. H/P mode delivers more
power to boom up and arm in functions when hydraulic pump delivery pressure is high. The main controller (MCZ) sends an
engine speed request to the engine control unit (ECU) via the controller area network (CAN). The engine control unit monitors
several sensors in the engine and makes adjustments to maintain the engine speed requested by the MCZ. For more
information on CAN communication, see Controller Area Network (CAN) Theory of Operation . (Group 9015-15.) For more
information on the ECU, see Engine Control Unit (ECU) Circuit Theory of Operation . (Group 9015-15.)

Travel Mode (HP)— When the travel speed switch (S11) is set to fast travel speed, the switch grounds the main controller
(MCZ) at pin F11. The MCZ then activates the power dig/travel speed solenoid (SG) (Y24), depending on the status of the travel
pressure sensor (B34), the front attachment pressure sensor (B32), the pump control pressure sensors (B36 and B38), and the
pump delivery pressure sensors (B35 and B37). The power dig/travel speed solenoid (SG) (Y24) is a proportional solenoid that
is controlled by pins E15 and E21 of the MCZ.

The power dig/travel speed solenoid (SG) (Y24) is activated when:

Engine speed dial (R15) is in fast idle position


Travel pressure sensor is sensing pressure (travel function actuated)
Front attachment pressure sensor not sensing pressure (no swing or dig functions actuated)
Either pump 1 or pump 2 delivery pressure low
Either pump 1 or pump 2 control pressure high

Activation of the power dig/travel speed solenoid (SG) (Y24) sends pilot pressure to the travel speed change switch in the travel
motors. When the travel speed switch (S11) is in the slow (turtle) speed (2) position, the power dig/travel speed solenoid (SG)
(Y24) is de-energized. Pressure at the travel speed change valve changes the displacement of the travel motors allowing for
fast travel speed. Since both delivery pressures must be low and both control pressures must be high, the travel motor will not
shift to fast speed when one track is lifted off the ground. If the machine is traveling in fast travel speed and a dig or swing
function is operated, the machine will remain in fast travel speed, but will slow travel speed as hydraulic oil is routed to other
functions. For more information, see Travel Motor Speed Circuit Operation . (Group 9025-05.)

A/I (Auto-Idle) Mode— A/I (Auto-Idle) is a feature that reduces engine speed when hydraulic functions are not operated for
more than 4 seconds. When the auto-idle switch (S8) is turned to A/I (auto-idle), the switch sends a ground to the main
controller (MCZ) to pin F7 of the MCZ. The MCZ communicates the selected mode through the controller area network (CAN) to
the DSZ, updating the monitor with the current mode. When the engine speed dial is set to an engine speed above auto-idle
speed, the MCZ will reduce the engine speed to auto-idle speed if hydraulic functions are not operated for more than 4
seconds. If engine speed dial is set to an engine speed below auto-idle speed, the engine speed will not increase or decrease
after 4 seconds. The MCZ receives the pressure signal from the front attachment pressure sensor (B32) in the swing park brake
circuit or the travel pressure sensor (B34) to sense if a hydraulic function has been operated. For more information on CAN
communication, see Controller Area Network (CAN) Theory of Operation . (Group 9015-15.)

Hydraulic Oil Warm-Up Circuit— When hydraulic oil temperature is below 0°C (32°F), the main controller (MCZ) activates a
warm-up circuit, which raises the engine speed slightly above slow idle to help warm up the hydraulic oil. The MCZ receives oil
temperature from the hydraulic oil temperature sensor (B40), located in the hydraulic oil tank. The MCZ will activate the warm-
up circuit for 12 minutes or until the hydraulic oil temperature rises above 2°C (36°F).
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

For more information on engine speed control, see Engine Speed Control System Operation . (Group 9010-05.)

Engine Coolant Warm-Up Circuit— When engine coolant temperature is below predefined point, the main controller (MCZ)
activates a warm-up circuit, which raises the engine speed slightly above slow idle to help warm up the engine coolant. The
MCZ receives coolant temperature via the controller area network (CAN) from the ECU. The MCZ will activate the warm-up
circuit for 12 minutes or until the coolant temperature rises to 25°C (77°F).

Idle Speed-Up Circuit— The idle speed-up circuit prevents the engine from hunting when travel or front attachment
operation is performed while the engine is running at a speed between slow idle and idle speed-up speed. When the travel or
front attachment operation is performed while the engine is between slow idle and idle speed-up speed, the main controller
(MCZ) sends the equivalent to target engine speed to the engine control unit (ECU) via the controller area network (CAN). The
ECU then increases the engine speed to the idle speed-up speed.

Pilot Shut-Off Idle Speed-Up Circuit— When engine speed dial (R15) is in the slow idle position and the pilot shut-off lever
is in the unlocked (DOWN) position, the main controller (MCZ) activates the pilot shut-off idle speed up circuit. The MCZ sends
the equivalent to target engine speed to the ECU via the controller area network (CAN), which increases the engine speed by
100 rpm from the slow idle speed in order to prevent engine stall during a control lever operation.

Engine Starting Idle Speed-Up Circuit— The engine starting idle speed-up circuit increases the engine speed and increases
the engine oil pressure when the engine starts. The engine starting idle speed-up circuit will not activate if the engine speed
dial (R15) is set above 1150 rpm. When active, the engine starting idle speed-up circuit sends the signals equivalent to the
target engine speed to the engine control unit (ECU) via the controller area network (CAN). The idle speed-up circuit will remain
active for 15 seconds. Engine speed will then return to the engine speed set by the engine speed dial.

Travel Torque Up— The torque control solenoid (ST) (Y21) valve may also be activated during a travel function. At slow
engine speeds, the torque control solenoid (ST) (Y21) valve is activated and both pumps are moved to maximum displacement.
This reduces the oil flow difference between the two hydraulic pumps and therefore reduces machine mistracking at low engine
speeds. At fast engine speeds, the torque control solenoid (ST) (Y21) may also be activated to slightly increase pump oil flow to
improve the travel function. The torque control solenoid (ST) (Y21) is a proportional solenoid and is controlled by a pulse width
modulated (PWM) signal from pins B1 and B2 of the main controller (MCZ).

Auto Shutdown Circuit— The auto shutdown circuit automatically stops the engine in order to reduce fuel consumption when
the operation is not carried out in a fixed time.

The main controller (MCZ) sends the auto shutdown signal to the monitor controller (DSZ) via the controller area network (CAN)
when the following conditions have been met:

Pilot shutoff switch in the LOCKED position


Auto shutdown enabled
Engine coolant temperature less than 100°C (212°F)

The MCZ then reduces engine speed to slow idle, and provides ground to the idle stop relay, accessory cut relay, and key cut
relay thus de-energizing the battery relay (K19), turning the machine off.

For more information on the auto shutdown circuit, see Starting and Charging Circuit Theory of Operation . (Group 9015-15.)

Work Modes— The monitor controller (DSZ) contains several work modes that are communicated by the controller area
network (CAN) to the main controller (MCZ). The MCZ can adjust pump delivery and engine speed depending on the work mode
or attachment selected. Pump flow and engine speeds can be adjusted with the monitor controller or by using MPDr.

Hydraulic Oil Overheat Alarm Circuit— The hydraulic oil overheat alarm circuit sounds the monitor alarm when the
hydraulic oil temperature increases beyond the specified value. The main controller (MCZ) monitors hydraulic oil temperature
utilizing hydraulic oil temperature sensor (B40). When hydraulic oil temperature increases, and remains past a predefined
point, the MCZ sends the signal to the monitor controller (DSZ) via the controller area network (CAN).

The monitor controller sounds the alarm and displays the hydraulic oil overheat alarm on the monitor. For more information,
see Monitor Controller (DSZ) Circuit Theory of Operation . (Group 9015-15.)

Travel Alarm Circuit— The travel alarm sounds during travel operation. When the main controller (MCZ) receives the signal
from travel pressure sensor (B34), it sends power to travel alarm (H4), activating the alarm. After traveling continuously for
more than 13 seconds, the alarm can be deactivated using travel alarm cancel switch (S13).

Pump 2 Flow Rate Limit Solenoid (SB) (Y20)— The pump 2 flow rate limit solenoid (SB) (Y20) valve limits the pump 2

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

displacement when an auxiliary (attachment) function is used. The pump 2 flow rate limit solenoid (SB) (Y20) is a proportional
solenoid and is controlled by a pulse width modulated (PWM) signal from pins A6 and A7 of the main controller (MCZ). The MCZ
activates the pump 2 flow rate limit solenoid (SB) (Y20) valve when pilot pressure is present at the attachment pressure sensor
(optional) and a work mode other than bucket mode is selected in the monitor. The flow rate for each attachment mode can be
adjusted using MPDr.

Fine adjustments to the pump 2 flow rate can be made through the monitor.

→NOTE:

Flow rates and adjustments in MPDr and the monitor are approximate. Actual flow rates may vary.

The auxiliary flow combiner may greatly affect MPDr flow adjustments if activated.

Torque Control Solenoid (ST) (Y21)— The torque control solenoid (ST) (Y21) valve helps control pump displacement in
response to changes in engine load. As engine load increases, the torque control solenoid (ST) (Y21) valve is deactivated
reducing the pump displacement and therefore reducing engine load and prevents engine stall. As engine load decreases, the
torque control solenoid (ST) (Y21) is activated increasing pump displacement therefore increasing the efficiency of the
machine. The main controller (MCZ) monitors the difference between target engine speed as set by the MCZ and the actual
engine speed as read by the ECU and communicated to the MCZ over controller area network (CAN). As engine speed varies
above or below target speed, the MCZ adjusts the signal to the torque control solenoid (ST) (Y21) valve to change the pump
displacement to utilize the maximum efficiency of the engine without allowing the engine to stall.

The torque control solenoid (ST) (Y21) is a proportional solenoid and is controlled by a pulse width modulated (PWM) signal
from pins A2 and A3 of the MCZ. Under most conditions, the torque control solenoid (ST) (Y21) is activated to some degree. For
more information, see Engine Speed Sensing Control Circuit Operation . (Group 9025-05.)

Dig Regenerative Solenoid (SF) (Y22)— The dig regenerative solenoid (SF) (Y22) valve redirects oil from the boom cylinder
rod end to the arm cylinder head end during a boom up and arm in function. This helps improve arm control and prevents arm
cylinder cavitation during the combined function. The dig regenerative solenoid (SF) (Y22) is a proportional solenoid that is
controlled by a pulse width modulated (PWM) signal from pins A14 and A15 of the main controller (MCZ).

The MCZ activates the dig regenerative solenoid (SF) (Y22) valve when the following conditions have been met:

Pump 1 and pump 2 delivery pressure high


Pressure at arm in pressure sensor
Pressure at boom up pressure sensor

When the dig regenerative solenoid (SF) (Y22) valve is activated, pilot oil from the dig regenerative solenoid (SF) (Y22) valve
shifts the dig regenerative valve in the control valve. This allows oil from the boom cylinder rod end to combine with oil in the
arm cylinder head end. For more information, see Dig Regenerative Valve Circuit Operation . (Group 9025-05.)

Arm Regenerative Solenoid (SC) (Y23)— The arm regenerative solenoid (SC) (Y23) valve combines the return oil from the
arm cylinder rod end with the supply oil to the arm cylinder head end. This helps prevent arm hesitation or cavitation in the
arm in circuit during a combined arm in and swing or boom up function. The arm regenerative solenoid (SC) (Y23) is a
proportional solenoid that is controlled by a pulse width modulated (PWM) signal from pins A10 and A11 of the main controller
(MCZ).

The MCZ activates the arm regenerative solenoid (SC) (Y23) valve when the following conditions have been met:

Either pump 1 or pump 2 delivery pressure low


Arm in pressure sensor sensing high pressure (arm in function fully actuated)
Swing or boom up pressure sensor sensing pressure (swing or boom up function actuated)

When the arm regenerative solenoid (SC) (Y23) valve is activated, pilot oil from the arm regenerative solenoid (SC) (Y23) valve
shifts the arm regenerative valve in the control valve. This blocks the return oil from the arm cylinder rod end from returning to
the hydraulic oil tank and combines it with the oil to the arm cylinder head end. Pilot oil from the arm regenerative solenoid
(SC) (Y23) valve also shifts the arm flow control valve, limiting the oil to the second arm spool to preserve oil flow to other
functions in the control valve. For more information, see Arm Regenerative Valve Circuit Operation . (Group 9025-05.)

Power Dig/Travel Speed Solenoid (SG) (Y24)— The power dig/travel speed solenoid (SG) (Y24) increases digging force by

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

temporarily increasing the main hydraulic system relief pressure. The power dig switch (S7) grounds pin A27 of the main
controller (MCZ). The MCZ then energizes power dig/travel speed solenoid (SG) (Y24) for a maximum of 8 seconds. The power
dig/travel speed solenoid (SG) (Y24) is a proportional solenoid and is controlled by a pulse width modulated (PWM) signal from
pins A12 and A13 of the MCZ.

When the power dig/travel speed solenoid (SG) (Y24) is activated, pilot oil from the power dig/travel speed solenoid (SG) (Y24)
flows to the top of the main relief and power dig valve. The pilot oil pressure pushes the piston in the main relief and power dig
valve down, increasing the pressure setting. The main hydraulic system now operates at the power dig higher operating
pressure. For more information, see Main Relief Valve Circuit Operation . (Group 9025-05.)

Arm 2 Flow Control Solenoid (SD) (Y27)— The arm 2 flow control solenoid (SD) (Y27) maintains boom raise operating
speed when operating digging (boom raise and arm roll in). The arm 2 flow control solenoid (SD) (Y27) is a proportional
solenoid that is controlled by a pulse width modulated (PWM) signal from pins A8 and A9 of the main controller (MCZ).

The MCZ activates the arm 2 flow control solenoid (SD) (Y27) when the following conditions have been met:

Pump 1 and pump 2 delivery pressure high


Arm in pressure sensor sensing pressure
Boom up pressure sensor sensing pressure

When arm 2 flow control solenoid (SD) (Y27) valve is activated, pilot oil is delivered, shifting arm 2 flow control valve. Arm 2
flow control valve reduces pressure oil from pump 1 to arm 2 spool, maintaining boom raise operating speed.

Auxiliary Function Lever (AFL) Theory of Operation

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

Auxiliary Function Lever (AFL) Theory of Operation

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

LEGEND:
A3 Main Controller (MCZ)
B68 Secondary Hydraulic Oil Temperature Sensor
B85 Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1)
F5 Optional and Attachment Connector 5 A Fuse (marked OPT. 1 ALT)
K31 Right Solenoid Relay A (marked RSW1)
S7 Power Dig Switch
S29 Auxiliary Function Lever (AFL) Proportional Control Switch
S31 Right Pilot Control Lever Switch
S45 Auxiliary Function Enable Switch (marked AFL_SW)
V22 Pilot Shutoff Solenoid Diode
W36 Cab Harness Ground 2
W37 Cab Harness Ground 3
X31 Cab Harness-to-Main Controller 31-Pin Connector A
X32 Cab Harness-to-Main Controller 24-Pin Connector B
X33 Cab Harness-to-Main Controller 17-Pin Connector C
X36 Cab Harness-to-Main Controller 26-Pin Connector F
X536 Right Auxiliary Function Lever (AFL) Connector (marked R_GRIP)
X574 Auxiliary Function Lever (AFL) Connector 1
X577 Auxiliary Function Lever (AFL) Harness-to-Auxiliary Function Lever (AFL) Solenoid Harness Connector
Y61 Auxiliary Function Lever (AFL) Solenoid A (marked 1A)
Y62 Auxiliary Function Lever (AFL) Solenoid B (marked 1B)
Y66 Secondary Pilot Shutoff Solenoid Valve (marked PiC)

Auxiliary Function Lever (AFL)— The main controller (MCZ) provides control for AFL control. For more information on MCZ,
see Main Controller (MCZ) Circuit Theory of Operation . (Group 9015-15.)

Auxiliary hydraulic functions are controlled by the MCZ with inputs from the following components:

B68—Secondary Hydraulic Oil Temperature Sensor


B85—Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1)
S29—Auxiliary Function Lever (AFL) Proportional Control Switch
S45—Auxiliary Function Enable Switch (marked AFL_SW)

After the MCZ processes received input signals, output signals are sent to the solenoids to control hydraulic speed and volume
with the following components:

Y61—Auxiliary Function Lever (AFL) Solenoid A (marked 1A)


Y62—Auxiliary Function Lever (AFL) Solenoid B (marked 1B)
Y66—Secondary Pilot Shutoff Solenoid Valve (marked PiC)

→NOTE:

AFL will work only when pilot control shutoff lever is in the (DOWN) unlocked position. If a cycle of the
pilot control shutoff lever is done, AFL will need to be activated again.

By pressing the auxiliary function enable switch (S45), ground is supplied at pin F22. The MCZ provides ground at pin C6,
activating the secondary pilot shutoff solenoid valve (Y66) which is a normally closed solenoid. When the operator actuates AFL
proportional control switch (S29) on the right pilot control lever, a proportional signal is sent to the MCZ. The MCZ converts this
signal and energizes the appropriate AFL solenoid to allow flow to the attachment in the requested speed and volume.

The MCZ monitors secondary hydraulic oil temperature utilizing secondary hydraulic oil temperature sensor (B68) through pin
C7 of the MCZ and grounded through pins F16 and F17 of the MCZ. When hydraulic oil temperature increases or decreases and
remains past a predefined point, the MCZ sends the signal to the monitor controller (DSZ) (A4) via the controller area network
(CAN).

The MCZ monitors hydraulic oil pressure utilizing AFL solenoid pressure sensor through pin B2 of the MCZ and grounded
through pins F25 and F26 of the MCZ. When hydraulic oil pressure increases and remains past a predefined point, the MCZ
sends the signal to the monitor controller (DSZ) (A4) via the controller area network (CAN).

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

Machine Controller (BCZ) Circuit Theory of Operation


The machine controller (BCZ) controls lighting, windshield wiper, and windshield washer circuits.

For more information on windshield wiper and washer circuit theory of operation, see Windshield Wiper and Washer Circuit
Theory of Operation . (Group 9015-15.)

For more information on lighting circuit theory of operation, see Lighting Circuit Theory of Operation . (Group 9015-15.)

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

Windshield Wiper and Washer Circuit Theory of Operation

Windshield Wiper and Washer Circuit Theory of Operation

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

LEGEND:
A4 Monitor Controller (DSZ)
A10 Monitor
A11 Machine Controller (BCZ)
E1 Work Light
E10 Switch Panel Back Light 5
F1 Lights 20 A Fuse
F2 Windshield Wiper and Washer 10 A Fuse (marked WIPER)
F10 Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)
F17 Power On 5 A Fuse (marked POWER ON)
F60 Alternator 65 A Fuse
F61 Battery 45 A Fuse
F62 Wiper Motor Assembly Circuit Breaker
G1 Battery
G2 Battery
K6 Windshield Wiper Relay
K7 Work Light Relay
K9 Windshield Washer Relay
K13 Key Cut Relay
K19 Battery Relay
M5 Windshield Wiper Motor
M6 Windshield Washer Motor
S1 Key Switch
S9 Windshield Wiper and Washer Switch
S28 Window Switch
V3 Load Dump Relay Diode
X3 Cab Harness-to-Machine Harness 100-Pin Connector
X10 Machine Controller 8-Pin Connector A
X11 Machine Controller 20-Pin Connector B
X18 Monitor 12-Pin Connector C
X20 Monitor Controller 28-Pin Connector A
X23 Monitor Controller 12-Pin Connector C
X27 Cab Harness-to-Switch Panel Connector 1
X30 Cab Harness-to-Switch Panel Connector 4
X39 Cab Harness-to-Window Switch

The machine controller (BCZ) (A11) receives unswitched power at pin A4 of machine controller 8-pin connector A (X10) from
information controller and main controller battery power 5 A fuse (F10). Switched battery power is supplied to pin B19 of the
BCZ through key cut relay (K13) with the key switch (S1) in the ON position. Switched power is also supplied to windshield
wiper relay (K6) and windshield washer relay (K9). The BCZ is grounded at pin A8 of machine controller 8-pin connector A.

The windshield wiper and washer circuit has four modes of operation:

Windshield wiper ON (continuous)


Windshield wiper INT (intermittent)
Windshield wiper OFF (park)
Windshield washer

Operation of the windshield wiper and washer circuit is controlled by signals from the BCZ and the state of the windshield wiper
motor (M5) internal position status switch.

Windshield Wiper Continuous Operation— When windshield wiper and washer switch (S9) is placed in the ON position, the
BCZ grounds pin B9 at predetermined intervals. When pin B9 is grounded, the windshield wiper relay (K6) is energized.

→NOTE:

Window switch (S28) must be connected for windshield wiper to operate.

Power to windshield wiper motor (M5) is supplied from windshield wiper and washer 10 amp fuse (F2). When windshield wiper
relay is energized, pin L of the windshield wiper motor is grounded, and the windshield wiper motor operates. The windshield
wiper motor drives a pitman arm assembly which moves the windshield wiper blade back and forth across the windshield.

When the windshield wiper is operating the BCZ and monitor controller (DSZ) (A4) communicate through controller area
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

network (CAN). The DSZ sends a signal to the monitor (A10) which displays the operation of the windshield wiper and washer
switch. For more information on CAN theory of operation, see Controller Area Network (CAN) Theory of Operation . (Group
9015-15.)

Windshield Wiper Intermittent Operation— When windshield wiper and washer switch (S9) is placed in INT position, BCZ
intermittently grounds pin B9. The monitor controller (DSZ) (A4) controls windshield wiper delay time.

→NOTE:

Window switch (S28) must be connected for windshield wiper to operate.

Power to windshield wiper motor (M5) is supplied from windshield wiper and washer 10 amp fuse (F2). When windshield wiper
relay is energized, pin L of the windshield wiper motor is grounded, and the windshield wiper motor operates. The windshield
wiper motor drives a pitman arm assembly which moves the windshield wiper blade back and forth across the windshield.

When the windshield wiper is operating, the BCZ and DSZ communicate through controller area network (CAN). The DSZ sends
a signal to the monitor (A10) which displays the operation of the windshield wiper and washer switch. For more information on
CAN theory of operation, see Controller Area Network (CAN) Theory of Operation . (Group 9015-15.).

Windshield Wiper Park Operation— When windshield wiper and washer switch (S9) is turned to the OFF position, windshield
wiper motor (M5) continues to run until a cam driven switch inside the windshield wiper assembly opens and removes power
from the windshield wiper motor. The cam driven switch applies ground to the windshield wiper motor pin S, causing the motor
to run until a cam in the pitman arm assembly moves the windshield wiper to the left side of the windshield into the park
position. When the windshield wiper motor reaches the park position, ground is removed from motor pin S by the internal
switch, and the windshield wiper motor stops.

Windshield Washer Operation— When windshield wiper and washer switch (S9) is pressed, the BCZ grounds pin A5. When
pin A5 is grounded the windshield washer relay (K9) is energized.

Power is supplied to windshield washer motor (M6) from windshield wiper and washer 10 amp fuse (F2) through pins 3 and 5 of
energized windshield washer relay. The windshield washer motor drives the pump to spray fluid from the windshield washer
fluid reservoir onto the windshield.

When the windshield wiper and washer switch is released, ground is removed from pin A5 of BCZ, and the washer motor stops.

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

Lighting Circuit Theory of Operation

Lighting Circuit Theory of Operation

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

LEGEND:
A4 Monitor Controller (DSZ)
A10 Monitor
A11 Machine Controller (BCZ)
E1 Work Light
E2 Boom Light
E3 Cab Dome Light
E9 Key Switch Light
F1 Work and Boom Lights 20 A Fuse (marked LAMP)
F9 Radio Backup 10 A Fuse (marked BACK UP)
F10 Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)
F12 Radio and Dome 5 A Fuse (marked RADIO)
F17 Power On 5 A Fuse (marked POWER ON)
F60 Alternator 65 A Fuse
F61 Battery 45 A Fuse
G1 Battery
G2 Battery
K7 Work Light Relay
K8 Boom Light Relay
K12 Accessory Cut Relay
K13 Key Cut Relay
K19 Battery Relay
S1 Key Switch
S2 Cab Dome Light Switch
S10 Work Light Switch
S14 Door Switch
V3 Load Dump Relay Diode
V11 Accessory Cut Diode
V12 Starter Cut Diode
V13 Work Light 1 Diode
V14 Work Light 2 Diode
X3 Cab Harness-to-Machine Harness 100-Pin Connector
X10 Machine Controller 8-Pin Connector A
X11 Machine Controller 20-Pin Connector B
X18 Monitor 12-Pin Connector C
X20 Monitor Controller 28-Pin Connector A
X23 Monitor Controller 12-Pin Connector C
X27 Cab Harness-to-Switch Panel Connector 1
X29 Cab Harness-to-Switch Panel Connector 3

The machine controller (BCZ) (A11) receives unswitched power at pin A4 of machine controller 8-pin connector A (X10) from
data converter and main controller battery power 5 A fuse (F10). Switched battery power is supplied to pin B19 of the BCZ
through key cut relay (K13) with the key switch (S1) in the ON position. The BCZ is grounded at pin A8 of machine controller 8-
pin connector A.

Work Light Operation— Turning the work light switch (S10) to position 1 activates the work light (E1).

When key switch (S1) is in the ON position, current from pin M of the key switch is passed to pin 3 of key cut relay (K13).
Utilizing the normally closed contacts of key cut relay, power is passed through power on 5 A fuse (F17) to pin 1 of work light
relay (K7). When work light switch is in position 1, ground is supplied to pin A6 through work light 1 diode (V13) and to pin B7
of machine controller 20-pin connector A (X10). Energizing work light relay, illuminates the work light.

The BCZ communicates the work light switch position to the monitor controller (DSZ) (A4) via the controller area network
(CAN). The DSZ then updates the monitor (A10) with the current work light operation. For more information on CAN theory of
operation, see Controller Area Network (CAN) Theory of Operation . (Group 9015-15.)

Boom Light Operation— Turning the work light switch (S10) to position 2 will activate the work light and boom light (E2).

When key switch (S1) is in the ON position, current from pin M of the key switch is passed to pin 3 of key cut relay (K13).
Utilizing the normally closed contacts of key cut relay, power is passed through power on 5 A fuse (F17) to pin 1 of work light
relay (K7) and boom light relay (K8). When work light switch is in position 2, ground is supplied to pins A2 and A6 of machine
controller 8-pin connector A (X10) through work light 2 diode (V14) and to pin B17 of machine controller 20-pin connector B
(X11). This energizes the work light relay and boom light relay, illuminating the work light and boom light.

The BCZ communicates the work light switch position to the monitor controller (DSZ) (A4) via the controller area network
(CAN). The DSZ then updates the monitor (A10) with the current work light operation. For more information on CAN theory of
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

operation, see Controller Area Network (CAN) Theory of Operation . (Group 9015-15.)

Cab Dome Light (E3) Continuous Operation— The cab dome light (E3) receives unswitched power through radio backup 10
A fuse (F9). While cab dome light switch (S2) is in the ON position, ground from pin B10 of the machine controller (BCZ) is
supplied to the cab dome light, illuminating the cab dome light.

Cab Dome Light (E3) Door Position Operation— The cab dome light (E3) and key switch light (E9) receive unswitched
power through radio backup 10 A fuse (F9). While cab dome light switch (S2) is in the DOWN position, ground from pin A7 of
the machine controller (BCZ) controls cab dome light and key switch light illumination.

Door switch (S14) provides ground to pin B18 of the BCZ while the cab door is closed. While the BCZ detects ground at pin B18,
no ground is provided to pin A7, thus the cab dome light and key switch light remain off.

When the door of the cab is open, the door switch is disconnected from ground. With no ground detected from the door switch
at pin B18, the BCZ provides ground to pin A7, illuminating the cab dome light and key switch light for 30 seconds. After 30
seconds the BCZ removes ground from pin A7 and the cab dome light and key switch light turn off.

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

Travel Alarm Circuit Theory of Operation

Travel Alarm Circuit Schematic (S.N. —040754)

LEGEND:
A3 Main Controller (MCZ)
B34 Travel Pressure Sensor
F5 Travel Alarm 5 A Fuse (marked OPT. 1 ALT)
H4 Travel Alarm
S13 Travel Alarm Cancel Switch
X32 Cab Harness-to-Main Controller 24-Pin Connector B
X35 Cab Harness-to-Main Controller 24-Pin Connector E
X36 Cab Harness-to-Main Controller 26-Pin Connector F

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

Travel Alarm Circuit Schematic (S.N. 040755— )

LEGEND:
A3 Main Controller (MCZ)
B34 Travel Pressure Sensor
F11 Travel Alarm 5 A Fuse (marked TRAVEL ALARM)
H4 Travel Alarm
S13 Travel Alarm Cancel Switch

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

The travel alarm circuit consists of: a travel pressure sensor (B34), main controller (MCZ) (A3), travel alarm (H4), and a travel
alarm cancel switch (S13).

The circuit is designed to warn bystanders of machine movement by signaling with an audible alarm any time the travel levers
are moved.

When the travel levers are moved, travel pressure sensor (B34) senses pilot pressure and sends a signal to the MCZ. When
signal is received from travel pressure sensor, the MCZ provides access to ground to the travel alarm (H4) pin 1, activating the
alarm.

When pressed, the travel alarm cancel switch (S13) applies ground to pin 3 of the travel alarm (H4). The travel alarm cancel
switch (S13) must be pressed and released in order to cancel the alarm. The travel alarm must sound for 13 seconds before the
travel alarm cancel switch will deactivate it. When the control levers are returned to the neutral position, the travel alarm (H4)
is reset.

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

Pilot Shutoff Circuit Theory of Operation

Pilot Shutoff Circuit Theory of Operation Schematic

<- Go to Section TOC Section 9015 page 243 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

LEGEND:
A1 Engine Control Unit (ECU)
A3 Main Controller (MCZ)
A4 Monitor Controller (DSZ)
F4 Solenoid 20 A Fuse (marked SOLENOID)
F18 Idle Stop 5 A Fuse (marked IDLE STOP)
F45 Starter In-Lne 30 A Fuse
F60 Alternator 65 A Fuse
F61 Battery 45 A Fuse
G1 Battery
G2 Battery
G3 Alternator
K2 Pilot Shutoff Solenoid Relay
K4 Starter Cut Relay
K5 Security Relay
K13 Key Cut Relay
K19 Battery Relay
K34 Starter Relay
K35 Starter Protection Relay
M1 Starter Motor
S1 Key Switch
S3 Pilot Shutoff Switch 1
S4 Pilot Shutoff Switch 2
V1 Battery Relay Diode
V3 Load Dump Relay Diode
V4 Security Diode
V5 Starter Cut Relay Diode
V7 Start Relay Diode
V9 Pilot Shutoff Diode
V10 Starter Protection Diode
V44 Starter Relay Diode
V20 Pilot Shutoff Switch Diode
X21 Monitor Controller 36-Pin Connector B
X22 Monitor Controller 16-Pin Connector D
X32 Cab Harness-to-Main Controller 24-Pin Connector B
X33 Cab Harness-to-Main Controller 17-Pin Connector C
X175 Machine Harness-to-Starter Harness Connector
Y10 Pilot Shutoff Solenoid

The pilot shutoff circuit enables or disables (unlocks or locks) the pilot oil thus enabling or disabling the machine hydraulics.
The pilot shutoff circuit consists of the pilot shutoff switches 1 and 2 (S3 and S4), pilot shutoff switch diode (V20), pilot shutoff
solenoid (Y10), pilot shutoff solenoid relay (K2), security relay (K5), monitor controller (DSZ) (A4), security diode (V4), and start
relay diode (V7).

With key switch (S1) in the ON position, current is applied from key switch pin M supplying key cut relay (K13) through idle stop
5 A fuse (F18). Utilizing the normally closed contacts of key cut relay, power is passed through pin 3 of key cut relay, next
through load dump relay diode (V3), and to pin S of battery relay (K19), energizing the battery relay. Ground is provided to pin
E of battery relay. When energized, the battery relay allows current to pass through alternator 65 A fuse (F60) providing power
to pin B of alternator (G3). Power from pin B of alternator passes through solenoid 20 A fuse (F4) to pilot shutoff solenoid relay
(K2), security relay (K5), and pilot shutoff solenoid (Y10).

When the pilot shutoff lever is moved to the unlocked (DOWN) position, pin 10 of monitor controller 36-pin connector B (X21)
detects a ground though pilot shutoff switch diode (V20) indicating that both pilot shutoff switches are in the same position.
This allows the monitor to diagnose if there is a malfunction with one of the switches.

When the pilot shutoff lever is in the unlocked (DOWN) position, ground passes through the pilot shutoff switches, through
starter cut relay diode (V5) to pilot shutoff solenoid relay, energizing the relay. When pilot shutoff solenoid relay is excited, the
ground circuit in pilot shutoff solenoid (Y10) is connected to ground through pilot shutoff solenoid relay and security relay (K5),
thus energizing the solenoid allowing pressure oil from the pilot pump to be supplied to the pilot valve.

When the pilot shutoff lever is in the unlocked (DOWN) position, ground is provided to the starter cut relay (K4) through starter
cut relay diode (V5), energizing starter cut relay. When starter cut relay is energized, starter relay (K34) is de-energized,
removing the start signal from starter motor (M1), preventing the engine from cranking. For more information on the neutral
engine start circuit, see Starting and Charging Circuit Theory of Operation . (Group 9015-15.) With the pilot shutoff lever in the
unlocked (DOWN) position, ground is also provided to pin 13 of cab harness-to-main controller 26-Pin connector F (X36) of the

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

main controller (MCZ) (A3), indicating the pilot shutoff lever is in the unlocked (DOWN) position.

When the pilot shutoff lever is in the locked (UP) position, ground is not detected at pilot shutoff solenoid relay (K2). The relay
remains de-energized thus, the pilot shutoff solenoid (Y10) is de-energized and the pilot hydraulics are disabled (locked).

When the monitor security is active, pin 16 of monitor controller 16-pin connector D (X22) is grounded, energizing the starter
cut relay (K4) and security relay (K5) through security diode (V4). Energized security relay removes ground to pilot shutoff
solenoid relay (K2). When the pilot shutoff lever is in the unlocked (DOWN) position (pilot shutoff solenoid relay energized), the
ground path to the pilot shutoff solenoid is broken, preventing the pilot hydraulics from being enabled (unlocked). This keeps
the machine from being operated when the security system is active.

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

Attachment Control Circuit Theory of Operation

Attachment Control Circuit Schematic (S.N. —040754)

LEGEND:
A3 Main Controller (MCZ)
B60 Attachment Pressure Sensor
B61 Arm Out Pressure Sensor

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

F5 Travel Alarm 5 A Fuse (marked OPT. 1 ALT)


F60 Alternator 65 A Fuse
V40 Selector Valve Solenoid Valve Diode
V41 Secondary Relief Solenoid Valve Diode
V43 2-Speed Activation Solenoid Valve Diode
X31 Cab Harness-to-Main Controller 31-Pin Connector A
X32 Cab Harness-to-Main Controller 24-Pin Connector B
X33 Cab Harness-to-Main Controller 17-Pin Connector C
X35 Cab Harness-to-Main Controller 24-Pin Connector D
X36 Cab Harness-to-Main Controller 26-Pin Connector E
X46 Attachment Connector
Y40 Selector Valve Solenoid Valve
Y41 Secondary Relief Solenoid Valve
Y43 2-Speed Activation Solenoid Valve
Y44 Flow Rate Adjustment Solenoid

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

Attachment Control Circuit Schematic (S.N. 040755— )

LEGEND:
A3 Main Controller (MCZ)
B32 Front Attachment Pressure Sensor (marked FRT)
B60 Attachment Pressure Sensor
B61 Arm Out Pressure Sensor
F5 Optional and Attachment Connector 5 A Fuse (marked OPT. 1 ALT.)

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

F60 Alternator 65 A Fuse


V40 Selector Valve Solenoid Valve Diode
V41 Secondary Relief Solenoid Valve Diode
V42 Accumulator Solenoid Valve Diode
V43 2-Speed Activation Solenoid Valve Diode
X32 Cab Harness-to-Main Controller 24-Pin Connector B
X33 Cab Harness-to-Main Controller 17-Pin Connector C
X34 Cab Harness-to-Main Controller 30-Pin Connector D
X36 Cab Harness-to-Main Controller 26-Pin Connector F
X46 Attachment Connector
X87 Attachment Harness-to-2-Speed Harness Connector
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

The main controller (MCZ) (A3) and monitor allow for the selection of up to eleven attachments plus the standard bucket mode.
Only one attachment mode may be selected at one time. The machine will return-to-bucket mode when the machine is
powered down and restarted; however, this can be changed with MPDr, Service ADVISOR ™ , and the monitor to return the
machine to the attachment that was last selected when the machine was powered down. Each attachment selection (1—11)
can be customized using MPDr, Service ADVISOR™, and the monitor. To customize options in the monitor, see Service Menu .
(Group 9015-16.)

MPDr and Service ADVISOR™ can adjust:

Attachment name
Attachment number
Pump flow
Engine speed
Secondary relief selection
Return oil flow selection
2-speed selection

The monitor can slightly adjust pump 2 flow rate or boom-up, arm-in, swing and travel priority over attachment flow depending
on the options selected. To view the attachment specifications on the monitor, select an attachment from the work mode
menu. The monitor will display:

Attachment name (Breaker, Crusher, Pulverizer, Vibrating Hammer, Other)


Attachment number (1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or 11)
Pump flow
Engine speed
Secondary relief selection (ON or OFF)
Return oil flow selection (O/T or C/V)
2-speed selection (ON or OFF)

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

LEGEND:
1 Bucket Mode
2 ATT 1 (attachment 1)
3 ATT 2 (attachment 2)
4 ATT 3 (attachment 3)
5 ATT 4 (attachment 4)
6 Attachment Name
7 Attachment Number

Work Mode Screen

Attachment Name— The available attachment names are as follows:

Breaker 1—Hydraulic Breaker 1 (BR)


Breaker 2—Hydraulic Breaker 2 (BR)
Crusher 1—Primary Crusher 1 (CR)
Pulverizer 1—Secondary Crusher 1 (PU)
Vibratory Hammer 1—Vibrating Hammer 1 (VI)
Other 1—Other Equipment (UN)
[Removal from monitor screen—(Non)]

Crusher 1—Primary Crusher 1 (CR) is considered a heavier crusher than Pulverizer 1—Secondary Crusher 1 (PU). When Crusher
1—Primary Crusher is selected, more priority is given to boom, arm, swing and travel functions over the attachment function in
a combined arm-out, arm-out boom-up, swing or travel function and attachment function.

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

LEGEND:
8 ATT 1 Type (attachment 1)

Attachment Type

Attachment Number— Each attachment can be assigned a number from 1-5.

Each attachment also has a dynamic number that is user defined to help differentiate attachments with the same name. For
example, ATT 1 (attachment 1) and ATT 2 (attachment 2) could both be set up as breaker 1. The number associated with the
attachment name can be changed to any number from 1 through 5. ATT 2 (attachment 2) breaker 1 could be changed to ATT 2
(attachment 2) breaker 2 (3, 4, or 5) to distinguish between the beakers for ATT 1 (attachment 1) and ATT 2 (attachment 2).

LEGEND:
9 ATT 1 Pump 1 Maximum Flow Rate

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

Attachment Adjustment—Pump Flow Rate

Maximum Pump Flow— The maximum pump flow can be adjusted using MPDr, Service ADVISOR™, and the monitor.
Adjustments made to pump flow are only approximate values. The machine is not designed to measure pump flow and
therefore the values in MPDr, Service ADVISOR™, and the monitor are calculated approximations. Actual flow must be
measured using a flowmeter to accurately adjust pump flow. See Pump Flow Test . (Group 9025-25.)

Pump 1 and pump 2 flow rates can be adjusted individually. If 2-speed is not selected (OFF), only pump 2 is used to run the
attachment. In this mode, only adjustments to pump 2 will affect the flow to the attachment. Pump 2 flow rate adjustments are
controlled by the main controller (MCZ) with the pump 2 flow rate limit solenoid. For more information, see Main Controller
(MCZ) Circuit Theory of Operation . (Group 9015-15.) If 2-speed is selected (ON), both pumps 1 and 2 are used to run the
attachment. With 2-speed ON, flow from pump 1 is combined with flow from pump 2 in the control valve. In this mode, both
pumps may be adjusted to control the flow of the attachment. The monitor will display the combined flow rates of pump 1 and
pump 2. See Service Menu . (Group 9015-16.)

→NOTE:

The 2-speed will not work properly unless appropriate kits are installed on machine.

Pump flow or flow priority may also be finely adjusted in the monitor. If 2-speed is not selected (OFF), small adjustments can be
made to the pump 2 flow rate. Adjustments are only approximate and relative to the overall selected flow. Actual flow must be
measured using a flowmeter to accurately set pump flow. If 2-speed is selected (ON), small adjustments can be made to the
priority of oil flow. The priority can be adjusted to favor the attachment or the boom-up, arm-out, swing and travel functions.
Adjustments are only approximate and relative to the overall selected flow. Actual flow must be measured using a flow meter
to accurately set pump flow. See Pump Flow Test (Group 9025-25.) See Service Menu . (Group 9015-16.)

LEGEND:
10 ATT 1 Engine Speed

ATT 1 Engine Speed

Maximum Engine Speed— The maximum engine speed for an attachment may be adjusted using MPDr, Service ADVISOR™,
and the monitor. The engine will reduce speed when a work mode with reduced engine speed is selected on the monitor. The
engine will run at the preset speed regardless if the attachment is operated or not. The maximum engine speed for an
attachment cannot be set higher than the fast idle speed of the machine.

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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

LEGEND:
12 ATT 1 Selector Valve Setting

ATT 1 Selector Valve

→NOTE:

Selector valve control will not work properly unless appropriate kits are installed on machine.

Valve Selector (Selector Valve)— The selector valve icon on the monitor controls the selector valve solenoid valve (Y40).
The selector valve solenoid valve receives power from the optional and attachment connector 5 A fuse (F5) and is grounded by
the main controller (MCZ) by pin C4. When the monitor displays “0,” the return oil from the attachment flows through the
control valve before it returns to the hydraulic oil tank. When the monitor displays “1,” the return oil from the attachment flows
directly to the hydraulic oil tank, bypassing the control valve. The selector valve solenoid valve can be adjusted for each
attachment using MPDr, Service ADVISOR™, and the monitor. The valve selector will default to “0” or control valve in bucket
mode (no attachment selected).

The selector valve solenoid valve diode (V40) suppresses voltage spikes created when the solenoid valve is activated or
deactivated.

→NOTE:

Accumulator control will not work properly unless appropriate kits are installed on machine.

Accumulator— The accumulator controls the accumulator solenoid valve (Y42). The accumulator solenoid valve is powered by
the optional and attachment connector 5 A fuse (F5) and grounded by the main controller (MCZ) by pin C17. When the
accumulator is ON, the accumulator solenoid valve is activated, pilot oil is sent to the accumulator control valve. The
accumulator shutoff valve shifts, connecting the accumulators to the supply and return lines of the attachment hydraulic
circuit. The accumulators help reduce the shock of oil pressure and buffers vibrations when certain types of attachments are
used, such as breakers. When the accumulator is OFF, the accumulator solenoid valve is deactivated and the accumulators are
isolated from the attachment hydraulic oil circuit. The accumulator status for each attachment can be adjusted using MPDr,
Service ADVISOR™, and the monitor.

The accumulator solenoid valve diode (V42) suppresses voltage spikes created when the solenoid valve is activated or
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics

deactivated.

LEGEND:
13 ATT 1 Auxiliary Flow Combiner Valve Setting

ATT 1 Auxiliary Flow Combiner Valve

→NOTE:

The 2-speed control will not work properly unless appropriate kits are installed on machine.

2-Speed Selector and Auxiliary Flow Combiner Valve— The 2-speed selector icon on the monitor controls the 2-speed
activation solenoid valve (Y43). The 2-speed activation solenoid valve is powered by optional and attachment connector 5 A
fuse (F5) and grounded by the main controller (MCZ) pin C3. The flow rate adjustment solenoid valve (Y44) is powered by MCZ
pin B12 and grounded by pin B11. When activated, the 2-speed activation solenoid valve sends pilot oil to the bypass shutoff
valve blocking hydraulic oil from pump 1 from returning to the hydraulic oil tank. The activated 2-speed activation solenoid
valve also sends pilot oil to the auxiliary flow combiner valve to combine oil flow from pump 1 with that of pump 2. This allows
for combined oil flow from pump 1 and pump 2 to operate the attachment.

When 2-speed is activated, the flow rate adjustment solenoid valve can also be activated. When an arm-out, boom-up, swing or
travel function is actuated in combination with the attachment function, the flow rate adjustment solenoid valve is activated.
When the flow rate adjustment solenoid valve is activated, pilot oil is routed to the auxiliary flow rate control valve. This adjusts
the auxiliary flow rate control valve to provide more or less priority to the arm-out, boom-up, swing and travel functions over
the attachment function. The main controller (MCZ) can vary the signal to the flow rate adjustment solenoid valve to vary the
pilot oil pressure at the auxiliary flow rate control valve. This allows for adjustment of the priority of the attachment function
over arm-out, boom-up, swing and travel. The 2-speed selector status can be adjusted for each attachment using MPDr, Service
ADVISOR™, and the monitor. Adjustments to the priority level can be made in the monitor in the attachment adjustment menu.
See Service Menu . (Group 9015-16.)

The 2-speed activation solenoid valve diode (V43) suppresses voltage spikes created when the solenoid valve is energized and
de-energized.

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Section 9015 - ELECTRICAL SYSTEM Group 16: Monitor Operation

LEGEND:
11 ATT 1 Relief Valve Setting

ATT 1 Relief Valve

Secondary Hydraulic Relief Selector— The secondary hydraulic relief selector icon in the monitor controls the secondary
relief solenoid valve (Y41). The secondary relief solenoid valve receives power from the optional and attachment connector 5 A
fuse (F5) and is grounded by the main controller (MCZ) pin C16. When the secondary relief solenoid valve is activated, pilot oil
shifts the secondary relief shutoff valve, routing hydraulic oil from the high pressure lines of the attachment to the secondary
relief valve. The relief pressure of the circuit will then be equal to the lowest setting of the two relief valves in the circuit. The
secondary hydraulic relief selector status can be adjusted for each attachment using MPDr, Service ADVISOR™, and the
monitor.

The secondary relief solenoid valve diode (V41) suppresses voltage spikes created when the solenoid valve is energized and
de-energized.

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Section 9015 - ELECTRICAL SYSTEM Group 16: Monitor Operation

Group 16 - Monitor Operation


Service Menu
How to Display Service Menu

[1] -
LEGEND:
1 Key Pad
2 Key Switch
3 BACK Button
4 HOME Button
5 Monitor Dial

Right Console Panel

Turn key switch (2) on and wait until the default screen appears on the monitor.

[2] - Hold the number nine key on the key pad (1) and press the monitor dial (5).

[3] - The service menu option will now be displayed at the bottom of the main menu.

[4] - Rotate monitor dial and highlight service menu. Press monitor dial to access to the following systems:

1. Troubleshooting
2. Monitoring
3. Controller Version
4. Issued Warning Record
5. Operation
6. Machine Setting
7. Monitor Setting

[5] - Use the BACK button (3) to return to the service menu.

Troubleshooting
[1] - Access service menu. See Service Menu . (Group 9015-16.)

[2] - Rotate monitor dial to highlight troubleshooting. Press monitor dial to enter the troubleshooting menu.

[3] - Rotate monitor dial to highlight the following systems.

Engine

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Section 9015 - ELECTRICAL SYSTEM Group 16: Monitor Operation

Main
Monitor
Information
Air Conditioner

Press monitor dial to view the trouble codes for systems.

[4] - Use the BACK button to return to the service menu. See Service Menu . (Group 9015-16.)

<- Go to Section TOC Section 9015 page 257 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 16: Monitor Operation

Monitoring

→NOTE:

Items listed in the monitoring section may not be in the same order as the monitor on the machine.

[1] - Access service menu. See Service Menu . (Group 9015-16.)

[2] - Rotate monitor dial to highlight monitoring. Press monitor dial to enter the monitoring menu.

[3] - Rotate monitor dial to highlight a system in the monitoring selections:

Engine
Main
Wiper/Light
Air Conditioner
Start
Clear (Hold)

[4] - Press the monitor dial to select the monitoring item to be viewed in the “Start” monitoring system.

List of Engine Monitoring Items

List of Engine Monitoring Items

Item Unit Data

Engine Torque % Input signal from ECU


-1
Actual Engine Speed min Input signal from crank speed sensor and cam angle sensor

Boost Pressure kPa Input signal from boost pressure signal

Coolant Temperature °C Input signal from coolant temperature sensor

Fuel Temperature °C Input signal from fuel temperature sensor

Engine Oil Pressure kPa Input signal from oil pressure sensor

Boost Temperature °C Input signal from boost temperature sensor

Battery Voltage V Input signal from ECU

Coolant Temp (Meter) °C Input signal from coolant temperature sensor (coolant temperature gauge)

List of Main Controller Monitoring Items

List of Main Controller Monitoring Items

Item Unit Data


-1
Demand Engine Speed min Input signal from engine control dial
-1
Actual Engine Speed min Input signal from ECU
-1
Engine Speed Deviation min Difference between actual engine speed and requested engine speed

EC Dial V Input signal from engine control dial

Hydraulic Oil Temperature °C Input signal from hydraulic oil temperature sensor

Hydraulic Oil Temperature (Pilot) ° C Input signal from hydraulic oil temperature sensor

Tgt Pump 1 Flow Rate L Command signal to maximum pump 1 flow rate limit control solenoid valve

Tgt Pump 2 Flow Rate L Command signal to maximum pump 2 flow rate limit control solenoid valve
3
Tgt Pump 1 Displacement cm Calculation signal from engine speed and input signal from pump 1 delivery pressure sensor
3
Tgt Pump 2 Displacement cm Calculation signal from engine speed and input signal from pump 2 delivery pressure sensor

Pump 1 Load Factor % Calculation signal from engine speed and input signal from pump 1 delivery pressure sensor

Pump 2 Load Factor % Calculation signal from engine speed and input signal from pump 2 delivery pressure sensor

<- Go to Section TOC Section 9015 page 258 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 16: Monitor Operation

List of Main Controller Monitoring Items

Item Unit Data

Pump 1 Delivery Pressure MPa Input signal from pump 1 delivery pressure sensor

Pump 2 Delivery Pressure MPa Input signal from pump 2 delivery pressure sensor

ADD Pump Delivery Press* MPa Input signal from ADD pump delivery pressure sensor

Pump 1 Control Pressure MPa Input signal from pump 1 control pressure

Pump 2 Control Pressure MPa Input signal from pump 2 control pressure

Boom Cyl. Bottom Press* MPa Input signal from pressure sensor (bottom pressure)

Boom Cyl. Rod Pressure* MPa Input signal from pressure signal (rod pressure)

Boom Raise Pilot Pressure MPa Input signal from pressure sensor (boom raise)

Arm Roll-In Pilot Pressure MPa Input signal from pressure sensor (arm roll-in)

Bucket Roll-In Pilot Pressure MPa Input signal from pressure sensor (front)

Travel Pilot Pressure MPa Input signal from pressure sensor (travel)

Front ATT Pilot Pressure MPa Input signal from pressure sensor (front)

Swing Pilot Pressure MPa Input signal from pressure sensor (swing)

ATT 1 Pilot Pressure* MPa Input from pressure sensor (auxiliary 1)

ATT 2 Pilot Pressure* MPa Input from pressure sensor (auxiliary 2)

Arm Roll-Out Pilot Pressure* MPa Input from pressure sensor (arm roll-out)

Pumps 1&2 Torque P/S O/P MPa Control signal to pump 1 and 2 torque control solenoid valve

Pump 2 Flw Limit P/S Output MPa Control signal to maximum pump 2 flow rate limit control solenoid valve

Arm Regen P/S Output MPA Control signal to four spool solenoid valve unit (SC) output

Pressure Boost P/S Output MPa -

Digging Regen P/S O/P MPa Control signal to four spool solenoid valve unit (SF)

Pump 1 Flw Limit P/S Output MPa Control signal to maximum pump 1 flow rate limit control solenoid

Analog Output 14 MPa -

Analog Output 15 MPa -

Analog Output 16 MPa -

Auxil Flw Cont P/S Output MPa Control signal to auxiliary flow rate control solenoid valve

Brk Relief P/S Output* MPa -

Power Digging P/S Output MPa Control signal to four spool solenoid valve unit (SG)

Travel Mode P/S Output MPa Control signal to four spool solenoid valve unit (SI)

Pumps 1&2 Torque P/S O/P FB mA Feedback from pump 1 and 2 torque control solenoid valve output

Pump 2 Flw Limit P/S O/P FB mA Feedback from maximum pump 2 flow rate limit control solenoid valve output

Arm 2 Flw Cont P/S O/P FB mA -

Arm Regen P/S Output FB mA Feedback from four spool solenoid valve unit (SC) output

Pressure Boost P/S Output FB mA -

Digging Regen P/S O/P FB mA Feedback from four spool solenoid valve unit (SF) output

Arm 1 Flw Cont P/S O/P FB mA -

Pump 1 Flw Limit P/S O/P FB mA Feedback from maximum pump 1 flow rate limit control solenoid valve output

Analog Output FB 14 mA -

Analog Output FB 15 mA -

Analog Output FB 16 mA -

Auxil Flw Cont P/S O/P FB mA Feedback from auxiliary flow rate control solenoid valve output

Digital Input 7 OFF/ON -

PCSL Lever Switch OFF/ON Pilot shut-off switch ON/OFF status

Breaker Control Switch OFF/ON -

Power Boost Switch OFF/ON Power digging switch ON/OFF status

Engine Oil Level Switch OFF/ON Engine oil level switch ON/OFF status

Power Mode Button OFF/ON Power mode button operating status

<- Go to Section TOC Section 9015 page 259 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 16: Monitor Operation

List of Main Controller Monitoring Items

Item Unit Data

Travel Mode SW LO/HI Travel mode switch selection status

Auto-Idle Stop Switch OFF/ON Auto-idle switch ON/OFF status

Digital Input 15 OFF/ON -

Digital Input 14 OFF/ON -

Digital Input 13 OFF/ON -

Digital Input 12 OFF/ON -

Digital Input 8 OFF/ON -

Digital Input 23 OFF/ON -

Digital Input 22 OFF/ON -

Digital Input 21 OFF/ON -

Digital Input 20 OFF/ON -

Digital Input 19 OFF/ON -

Digital Input 18 OFF/ON -

Digital Input 17 OFF/ON -

Line Filter Restriction SW* OFF/ON Clogged line filter status

Digital Input 29 OFF/ON -

Digital Input 28 OFF/ON -

Digital Input 27 OFF/ON -

Digital Input 26 OFF/ON -

Digital Input 25 OFF/ON -

Digital Input 24 OFF/ON -

Swing Alarm OFF/ON Swing Alarm ON/OFF status

Travel Alarm OFF/ON Travel alarm ON/OFF status

Auto-Idle Stop Relay OFF/ON Auto-idle stop relay ON/OFF status

3-Port Valve OFF/ON Three Port valve ON/OFF Status

2-speed Combined Flow* OFF/ON Two Speed combined flow control valve ON/OFF status

ON/OFF Valve Output 11 OFF/ON -

ON/OFF Valve Output 10 OFF/ON -

ON/OFF Valve Output 9 OFF/ON -

→NOTE:

*: Optional

List of Wiper/Light Controller Monitoring Items

List of Wiper/Light Controller Monitoring Items

Item Unit Data

Wiper 1 Input V Input signal from wiper switch

Wiper 2 Input V Input signal from wiper switch

Washer 1 Switch OFF/ON Washer 1 switch ON/OFF status

Washer 2 Switch OFF/ON Washer 2 switch ON/OFF status

Work Light 1 Switch OFF/ON Work light switch 1 ON/OFF status

Work Light 2 Switch OFF/ON Work light switch 2 ON/OFF status

Cab Light Switch OFF/ON Cab light switch ON/OFF status

Wiper 1 Output OFF/ON Wiper relay ON/OFF status

Wiper 2 Output OFF/ON Wiper relay ON/OFF status

Washer 1 Output OFF/ON Washer relay ON/OFF status

<- Go to Section TOC Section 9015 page 260 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 16: Monitor Operation

List of Wiper/Light Controller Monitoring Items

Item Unit Data

Washer 2 Output OFF/ON Washer relay ON/OFF status

Work Light 1 Output OFF/ON Work light relay 1 ON/OFF status

Work light 2 Output OFF/ON Work light relay 2 ON/OFF status

Cab Light 1 Output OFF/ON Cab light ON/OFF status

Cab Light 2 Output OFF/ON Cab light ON/OFF status

List of Air Conditioner Unit Monitoring Items

List of Air Conditioner Unit Monitoring Items

Item Unit Data

Compressor Operation OFF/ON Compressor operating status

Outdoor Air Temperature °C Input signal from ambient temperature sensor

Indoor Air Temperature °C Input signal from air conditioner unit


2
Amount of Insolation W/m Input signal from solar radiation sensor

[5] - Rotate monitor dial to highlight Start. Press the monitor dial to view the monitoring items that were selected.

[6] - Rotate monitor dial to highlight Clear (Hold). Press the monitor dial to delete the monitoring items that were selected.

[7] - Use the BACK button to return to the service menu. See Service Menu . (Group 9015-16.)

Controller Version
[1] - Access service menu. See Service Menu . (Group 9015-16.)

[2] - Rotate monitor dial to highlight controller version. Press monitor dial to enter the controller version menu.

[3] - The version of each controller will appear.

[4] - Use the BACK button to return to the service menu. See Service Menu . (Group 9015-16.)

Issued Warning Record


[1] - Access service menu. See Service Menu . (Group 9015-16.)

[2] - Rotate monitor dial to highlight issued warning record. Press monitor dial to enter the issued warning record menu.

[3] - The logo and trouble of 10 alarms that were issued recently will be displayed. See Main Menu—Alarm List . (Operator′s
Manual.)

[4] - Highlight alarm and press monitor dial to view the time of when the alarm occurred and was solved.

[5] - Use the BACK button to return to the service menu. See Service Menu . (Group 9015-16.)

<- Go to Section TOC Section 9015 page 261 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 16: Monitor Operation

Operation
[1] - Access service menu. See Service Menu . (Group 9015-16.)

[2] - Rotate monitor dial to highlight operation. Press monitor dial to enter operation menu.

[3] - The hour meters will be displayed.

Hour Meters

Hour Meters

Hour Meter (Integral Pert) hr.

Hour Meter (Decimal Part) hr.

Brk Hr-Meter (Int Part) hr.

Brk Hr-Meter (Decimal Part) hr.

ATT Hr-Meter (Int Part) hr.

ATT Hr-Meter (Dec Part) hr.

Travel Hr-Meter (Int Part) hr.

Travel Hr-Meter (Dec Part) hr.

Task Hr-Meter (Int Part) hr.

Task Hr-Meter (Dec Part) hr.

[4] - Use the BACK button to return to the service menu. See Service Menu . (Group 9015-16.)

<- Go to Section TOC Section 9015 page 262 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 16: Monitor Operation

Machine Setting
[1] - Access service menu. See Service Menu . (Group 9015-16.)

[2] - Rotate monitor dial to highlight machine setting. Press monitor dial to enter machine setting menu.

[3] - Rotate monitor dial to highlight a setting in the machine setting selections. Press monitor dial to change machine setting.

List of Machine Setting Items (Constant Change)

List of Machine Setting Items (Constant Change)

Item Unit Data


-1
Li Speed min Adjustment of slow idle speed.
-1
Al Speed min Adjustment of auto-idle engine speed.
-1
PWR Mode Speed min Adjustment of PWR mode fast idle engine speed.

Setting of power mode with key switch on.


0: OFF (In case power mode is H/P mode with the key switch OFF, PWR mode is selected when turning the key switch
Power Mode Memory Selection 0, 1 on. In case power mode is ECO or PWR mode with the key switch OFF, ECO or PWR mode is kept when turning the key
switch on.)
1: On (The power mode when turning the key switch OFF is kept.)

ON/OFF of heater control.


Heater Control Selection 0, 1 0: OFF
1: ON

ON/OFF of attachment mode.


Work Mode Memory Selection 0, 1 0: OFF
1: ON

Setting of power mode selection.


0: ECO, PWR mode: Selected
1: ECO mode: Fixed
Power Mode Selection 0—4
2: PWR mode: Fixed
3: ECO, PWR, H/P mode: Selected
4: H/P mode: Fixed

Setting of auto shut-down control with the key switch ON.


0: OFF when starting
Auto Shut-Down Control 0—2
1: ON when starting
2: Previous setting is held

The time until starting shut down control is held.


Auto Shut-Down Set Time Holding 0, 1 0: Settable
1: Unsettable

Selection of air conditioner specification.


0: Unused (without an air conditioner)
1: STD Cab (middle) (with an air conditioner)
2: STD Cab (middle) (without an air conditioner)
3: STD Cab (large) (with an air conditioner)
4: STD Cab (large) (without an air conditioner)
Air Conditioner Control Mode 0—10
5: US Cab (7 t class) (with an air conditioner)
6: US Cab (7 t class) (without an air conditioner)
7: US Cab (10 t class) (with an air conditioner)
8: US Cab (10 t class) (without an air conditioner)
9: US Cab (20 t class) (with an air conditioner)
10: US Cab (20 t class) (without an air conditioner)

ATT Speed Deceleration Waiting Time ms The time when the increased engine speed is held at attachment operation speed increased control.

List of Setting Item (Attachment Constant Change)

List of Setting Item (Attachment Constant Change)

Item Unit Data

Kinds of attachments:
0: Unset
1: Breaker
2: Pulverizer
ATT 1 Type 0—7 3: Crusher
4: Vibrating Hammer
5: Others
6: Grapple
7: Clamshell

<- Go to Section TOC Section 9015 page 263 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 16: Monitor Operation

List of Setting Item (Attachment Constant Change)

Item Unit Data

Selection of attachments setting No.


1: 1
2: 2
ATT1 No. 1—5
3: 3
4: 4
5: 5

ATT1 Pump 1 Maximum Flow Rate L/min Adjustment of maximum pump 1 flow rate when using attachment.

ATT1 Pump 2 Maximum Flow Rate L/min Adjustment of maximum pump 2 flow rate when using attachment.

ATT1 Pump 3 Maximum Flow Rate L/min Adjustment of maximum pump 3 flow rate when using attachment.
-1
ATT1 Engine Speed min Adjustment of engine speed when using attachment.

Selection of breaker relief solenoid valve, auxiliary overload relief solenoid valve.
0: Both are disabled
ATT1 Relief Valve (OPT) 0—2
1: ATT relief is enabled
2: Breaker relief is enabled

Selection of return circuit connection of selector valve.


ATT1 Selector Valve (OPT) 0, 1 0: C/V
1: O/T

Setting of auxilliary flow combiner valve selection.


ATT1 Auxiliary Flow Combiner Valve 0, 1 0: OFF
1: ON

List of Adjustment (Attachment Constant Change)

List of Adjustment (Attachment Constant Change)


ATT1

Item Unit Minimum Adjustment Adjustable Range Initial Value

ATT1 Type 0—7 - 0—7 1

ATT1 No. 1—5 - 1—5 1

ATT1 Pump 1 Maximum Flow Rate L/min 0.5 112—224 224

ATT1 Pump 2 Maximum Flow Rate L/min 0.5 112—224 224


-1
ATT1 Engine Speed min 10 -500—100 0

ATT1 Relief Valve (OPT) 0—2 - 0—2 0

ATT1 Selector Valve (OPT) 0, 1 - 0, 1 1

ATT1 Auxiliary Flow Combiner Valve (OPT) 0, 1 - 0, 1 0

List of Adjustment (Attachment Constant Change)

List of Adjustment (Attachment Constant Change)


ATT2

Item Unit Minimum Adjustment Adjustable Range Initial Value

ATT2 Type 0—7 - 0—7 1

ATT2 No. 1—5 - 1—5 2

ATT2 Pump 1 Maximum Flow Rate L/min 0.5 112—224 224

ATT2 Pump 2 Maximum Flow Rate L/min 0.5 112—224 224


-1
ATT2 Engine Speed min 10 -500—100 0

ATT2 Relief Valve (OPT) 0—2 - 0—2 0

ATT2 Selector Valve (OPT) 0, 1 - 0, 1 1

ATT2 Auxiliary Flow Combiner Valve (OPT) 0, 1 - 0, 1 0

List of Adjustment (Attachment Constant Change)

List of Adjustment (Attachment Constant Change)


ATT3

Item Unit Minimum Adjustment Adjustable Range Initial Value

ATT3 Type 0—7 - 0—7 2

ATT3 No. 1—5 - 1—5 1

ATT3 Pump 1 Maximum Flow Rate L/min 0.5 112—224 224

<- Go to Section TOC Section 9015 page 264 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 16: Monitor Operation

List of Adjustment (Attachment Constant Change)


ATT3

Item Unit Minimum Adjustment Adjustable Range Initial Value

ATT3 Pump 2 Maximum Flow Rate L/min 0.5 112—224 224


-1
ATT3 Engine Speed min 10 -500—100 0

ATT3 Relief Valve (OPT) 0—2 - 0—2 1

ATT3 Selector Valve (OPT) 0, 1 - 0, 1 0

ATT3 Auxiliary Flow Combiner Valve (OPT) 0, 1 - 0, 1 1

List of Adjustment (Attachment Constant Change)

List of Adjustment (Attachment Constant Change)


ATT4

Item Unit Minimum Adjustment Adjustable Range Initial Value

ATT4 Type 0—7 - 0—7 3

ATT4 No. 1—5 - 1—5 1

ATT4 Pump 1 Maximum Flow Rate L/min 0.5 112—224 224

ATT4 Pump 2 Maximum Flow Rate L/min 0.5 112—224 224


-1
ATT4 Engine Speed min 10 -500—100 0

ATT4 Relief Valve (OPT) 0—2 - 0—2 1

ATT4 Selector Valve (OPT) 0, 1 - 0, 1 0

ATT4 Auxiliary Flow Combiner Valve (OPT) 0, 1 - 0, 1 1

List of Adjustment (Attachment Constant Change)

List of Adjustment (Attachment Constant Change)


ATT5

Item Unit Minimum Adjustment Adjustable Range Initial Value

ATT5 Type 0—7 - 0—7 6

ATT5 No. 1—5 - 1—5 1

ATT5 Pump 1 Maximum Flow Rate L/min 0.5 112—224 224

ATT5 Pump 2 Maximum Flow Rate L/min 0.5 112—224 224


-1
ATT5 Engine Speed min 10 -500—100 0

ATT5 Relief Valve (OPT) 0—2 - 0—2 1

ATT5 Selector Valve (OPT) 0, 1 - 0, 1 0

ATT5 Auxiliary Flow Combiner Valve (OPT) 0, 1 - 0, 1 0

List of Adjustment (Attachment Constant Change)

List of Adjustment (Attachment Constant Change)


ATT6—11

Item Unit Minimum Adjustment Adjustable Range Initial Value

ATT6—11 Type 0—7 - 0—7 0

ATT6—11 No. 1—5 - 1—5 0

ATT6—11 Pump 1 Maximum Flow Rate L/min 0.5 112—224 224

ATT6—11 Pump 2 Maximum Flow Rate L/min 0.5 112—224 224


-1
ATT6—11 Engine Speed min 10 -500—100 0

ATT6—11 Relief Valve (OPT) 0—2 - 0—2 1

ATT6—11 Selector Valve (OPT) 0, 1 - 0, 1 0

ATT6—11 Auxiliary Flow Combiner Valve (OPT) 0, 1 - 0, 1 0

<- Go to Section TOC Section 9015 page 265 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 16: Monitor Operation

Monitor Setting
[1] - Access service menu. See Service Menu . (Group 9015-16.)

[2] - Rotate monitor dial to highlight monitor setting. Press monitor dial to enter monitor setting menu.

[3] - Rotate monitor dial to highlight a setting in the monitor setting selections. Press monitor dial to change monitor setting.

List of Monitor Setting Items

List of Monitor Setting Items

Item Unit Details Initial Value

0: System Starting
1: HITACHI
Start Up Screen Image 2: John Deere - 1
3: System Starting (Fixed)
4: REC

0: Auto-control: OFF
Startup Screen Control - 1
1: Auto-control: ON

0: Void
Work Mode With or without function 1
1: Exist

0: Void
Setting Menu With or without function 1
1: Exist

0: Void
Date and Time With or without function 1
1: Exist

0: Void
Attachment Adjust With or without function 1
1: Exist

0: Void
Attachment Name Input With or without function 1
1: Exist

0: Void
Breaker Alarm With or without function 1
1: Exist

0: Void
Auto Shut-down With or without function 1
1: Exist

0: Void
Sub Meter Selection With or without function 1
1: Exist

0: Void
Rear View Camera Monitor With or without function 0
1: Exist

0: Void
Display Item Selection With or without function 1
1: Exist

0: Void
Brightness Adjustment With or without function 1
1: Exist

0: Void
Language With or without function 1
1: Exist

0: Void
Unit Selection With or without function 1
1: Exist

0: Void
Main Menu Sequence Change With or without function 1
1: Exist

0: Void
Information Menu With or without function 1
1: Exist

0: Void
Operation With or without function 1
1: Exist

0: Void
Maintenance With or without function 1
1: Exist

0: Inhibited
Operation Permission - 1
1: Permission

0: Un-displayed
Engine Oil Display 1
1:0 Permission

0: Un-displayed
Engine Oil Filter Display 1
1:0 Permission

0: Un-displayed
Hydraulic Oil Display 1
1:0 Permission

<- Go to Section TOC Section 9015 page 266 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

List of Monitor Setting Items

Item Unit Details Initial Value

0: Un-displayed
Pilot Hydraulic Oil Filter Display 1
1:0 Permission

0: Un-displayed
Hydraulic Oil Full-Flow Filter Display 1
1:0 Permission

0: Un-displayed
Pump Transmission Oil Display 1
1:0 Permission

0: Un-displayed
Travel Reduction Gear Oil Display 1
1:0 Permission

0: Un-displayed
Swing Reduction Gear Oil Display 1
1:0 Permission

0: Un-displayed
Swing Motor Drain Filter Display 1
1:0 Permission

0: Un-displayed
Swing Bearing Grease Display 1
1:0 Permission

0: Un-displayed
Air Cleaner Element Display 1
1:0 Permission

0: Un-displayed
Fuel Filter Display 1
1:0 Permission

0: Un-displayed
Air Conditioner Filter Display 1
1:0 Permission

0: Un-displayed
Line Filter Display 1
1:0 Permission

0: Un-displayed
User Setting 1 Display 1
1:0 Permission

0: Un-displayed
User setting 2 Display 1
1:0 Permission

0: Void
Troubleshooting With or without function 1
1: Exist

0: Void
Monitoring With or without function 1
1: Exist

[4] - Use the BACK button to return to the service menu. See Service Menu . (Group 9015-16.)

<- Go to Section TOC Section 9015 page 267 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Group 20 - References
Reading Diagnostic Trouble Codes with Monitor Display
[1] - Access service menu. See Service Menu . (Group 9015-16.)

[2] - Rotate monitor dial to highlight troubleshooting. Press monitor dial to enter the troubleshooting menu.

[3] -

→NOTE:

The monitor can display up to 20 diagnostic trouble codes for each controller.

The amount of currently generated diagnostic trouble codes (DTC) are displayed at the right side of each item in parenthesis.
Rotate monitor dial to highlight the following systems:

Engine (00)
Main (00)
Monitor (00)
Information (00)
Air Conditioner (00)

[4] - Press monitor dial to view the trouble codes present for the highlighted system. For more information on the displayed
DTCs see:

See Main Controller (MCZ) Diagnostic Trouble Codes . (Group 9001-10.)


See Engine Control Unit (ECU) Diagnostic Trouble Codes . (Group 9001-20.)
See Monitor Controller (DSZ) Diagnostic Trouble Codes . (Group 9001-30.)
See Air Conditioner Controller (ACF) Diagnostic Trouble Codes . (Group 9001-40.)

[5] - Use the BACK button to return to the troubleshooting screen and select another system.

Service ADVISOR™ Diagnostic Application


The Service ADVISOR ™ application is what technicians use to diagnose and troubleshoot equipment. The application allows
technicians to quickly and easily find information and solve equipment problems.

The Service ADVISOR™ application provides access to manuals, the Dealer Technical Assistance Center (DTAC), real-time
diagnostics, and system readings. The application also allows technicians to perform calibrations, run tests, and program
controllers, when possible.

The Connection-Readings shortcut bar within Service ADVISOR™ is used to connect to a machine. A connection allows a
technician to take live system readings, create recordings, diagnose problems, calibrate, interactively test, and program
controllers. With a connection established, the Readings menu allows a technician to add or remove a reading, set a readings
baseline, and create and check recording triggers.

With Service ADVISOR™ connected to a machine, the Diagnostics shortcut bar can be used to read machine diagnostic trouble
codes. The diagnostic codes can then be reviewed by code number for specific details. When a diagnostic trouble code is
opened, code information displays in a window similar to the way a manual would. The details of a diagnostic trouble code
often are in a procedural format with links so the technician can work to correct the problem with the equipment while
following the step-by-step process in the diagnostic trouble code details.

See Service ADVISOR™ Connection Procedure . (Group 9015-20.)

See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.)

<- Go to Section TOC Section 9015 page 268 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Service ADVISOR™ Connection Procedure


(S.N. —040754)

[1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9000-01.)

[2] - Locate service laptop close to machine, or in the cab if diagnostics are to be performed while machine is being operated.

[3] -
LEGEND:
1 Diagnostic Connector
2 Service Laptop
3 PDM-to-Service Laptop Cable
4 PDM
5 PDM-to-Machine Cable

Service ADVISOR™ Machine Connection

Open left-side compartment behind cab and remove cap from diagnostic connector (1).

[4] - Connect service laptop to machine using appropriate cables (3 and 5). Methods for connection include:

Electronic Data Link (EDL) Stand-Alone USB Device


EDL Using Bluetooth ™
Parallel Data Module (PDM)
PDM with USB Adaptor

[5] - Make sure power indicator light displays on EDL or PDM, depending on connection method. If power indicator light does
not display, check fuse to diagnostic connector.

[6] - Turn machine key switch to ON position.

[7] - Refer to Service ADVISOR ™ system instructions to log into service laptop and connect to machine.

See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.)

(S.N. 040755— )

[1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9000-01.)

[2] - Locate service laptop close to machine, or in the cab if diagnostics are to be performed while machine is being operated.

[3] -

<- Go to Section TOC Section 9015 page 269 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

LEGEND:
1 Diagnostic Connector
2 Service Laptop
3 PDM-to-Service Laptop Cable
4 PDM
5 PDM-to-Machine Cable

Service ADVISOR™ Machine Connection

Remove fuse box cover.

[4] - Remove cap from diagnostic connector (1).

[5] - Connect service laptop to machine using appropriate cables (3 and 5). Methods for connection include:

Electronic Data Link (EDL) Stand-Alone USB Device


EDL Using Bluetooth ™
Parallel Data Module (PDM)
PDM with USB Adaptor

[6] - Make sure power indicator light displays on EDL or PDM, depending on connection method. If power indicator light does
not display, check fuse to diagnostic connector.

[7] - Turn machine key switch to ON position.

[8] - Refer to Service ADVISOR ™ system instructions to log into service laptop and connect to machine.

See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.)

<- Go to Section TOC Section 9015 page 270 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic


Application

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] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9001-01.)

[2] - Connect service laptop to machine. See Service ADVISOR™ Connection Procedure . (Group 9015-20.)

[3] - Open Service ADVISOR ™ and display appropriate model information.

[4] - From the Shortcut bar, click Diagnostics to open the Diagnostics shortcut bar (1).

[5] - Click the Connected Diagnostic Trouble Codes folder (2).

[6] -

<- Go to Section TOC Section 9015 page 271 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Connection Options Dialog Box

Select the Connect to Model(s) radio button on the Connection Options dialog box, and click OK.

[7] -

Select Readings Adapter Dialog Box

LEGEND:
5 Available Adaptors Drop-Down List
6 Selected Models List
7 Change Selected Models Button
On the Select Readings Adapter dialog box, make sure the appropriate adapter is displayed. If not, select correct adapter from
drop-down list (5). Options include:

Electronic Data Link (EDL) Stand-alone USB Device


Electronic Data Link (EDL) Using Bluetooth ™
Parallel Data Module (PDM)
Parallel Data Module (PDM) With USB Adapter

[8] - Make sure to select the correct machine to connect to, shown in the Selected Models list (6) display list. If not, click the
Change Selected Models button (7).

[9] - Click OK to connect to machine.

[10] - After Service ADVISOR™ connects to machine, both the Readings tab (3) and Connected Diagnostic Trouble Codes tab
(4) display.

<- Go to Section TOC Section 9015 page 272 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

[11] - Double-click an underlined code on the Connected Diagnostic Trouble Codes tab to display a detailed description for
servicing that diagnostic trouble code.

[12] -

→NOTE:

Use the lock topic feature within Service ADVISOR to open multiple windows if machine is transmitting
more than one diagnostic trouble code. Refer to Service ADVISOR system instructions for using this
feature.

Click the Connected Diagnostic Trouble Codes tab (4) to select and view details for additional diagnostic trouble codes.

MPDr Application
MPDr is an application that helps technicians diagnose and troubleshoot machines. MPDr provides access to machine
diagnostic trouble codes, their descriptions and limited troubleshooting procedures. MPDr can also display and record live
readings for the different controllers on the machine. Special functions in certain controllers may also be manipulated with
MPDr. The special functions available to manipulate vary by controller and by machine model. MPDr is also used to set up some
controllers after a controller has been replaced or after other work has been performed on the machine regarding a controller.

For more information, see MPDr Operation Manual.

<- Go to Section TOC Section 9015 page 273 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

MPDr Connection Procedure


[1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9001-01.)

[2] - Locate service laptop close to machine, or in the cab if diagnostics are to be performed while machine is being operated.

[3] -
LEGEND:
1 Cover

Fuse Box Cover

Remove fuse box cover (1).

[4] -

→NOTE:

If the service laptop is not equipped with a serial COM port, a USB-to-serial adapter cable will be required
to simulate a COM port for use with MPDr.

LEGEND:
2 MPDr Connector
3 Service Laptop
4 TH3100010 MPDr Cable
5 4668565 RS232C Cable
6 USB-to-Serial Adapter Cable

MPDr Connection Procedure (USB-to-serial adapter


cable shown)

Connect service laptop (3) to MPDr connector (2) using TH3100010 MPDr Cable (4), 4668565 RS232C Cable (5), and USB-to-
serial adapter cable (6) if needed.

MPDr Cable

<- Go to Section TOC Section 9015 page 274 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

TH3100010

Provide connection from machine to RS232C cable for use with MPDr

RS232C Cable

4668565

Provide connection from MPDr cable to computer for use with MPDr

[5] - Turn machine key switch to the ON position.

[6] - Refer to the MPDr Operation Manual to complete connection procedure.

<- Go to Section TOC Section 9015 page 275 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Fuse Test
Fuse Test (S.N. —040754)

Fuse Block 1

LEGEND:
F1 Work and Boom Lights 20 A Fuse (marked LAMP)
F2 Windshield Wiper and Washer 10 A Fuse (marked WIPER)
F3 Air Conditioner and Heater 20 A Fuse (marked HEATER)
F4 Solenoid 20 A Fuse (marked SOLENOID)
F5 Travel Alarm 5 A Fuse (marked OPT. 1 ALT)
F6 12-Volt Power Outlet 20 A Fuse (marked OPT. 2 ALT)
F7 Start Position Signal 5 A Fuse (marked START)
F8 Engine Control Unit (ECU) 30 A Fuse (marked ECU)
F9 Radio Backup 10 A Fuse (marked BACK UP)
F10 Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)
F11 Not Used
F12 Radio and Dome 5 A Fuse (marked RADIO)
F13 Lighter 10 A Fuse (marked LIGHTER)
F14 Monitor 5 A Fuse (marked MONITOR)
F15 Cab Auxiliary Power Connector One 10 A Fuse (marked AUX)
F16 Start Aid 20 A Fuse (marked START AID)
F17 Power On 5 A Fuse (marked POWER ON)
F18 Idle Stop 5 A Fuse (marked IDLE STOP)
F19 Horn 10 A Fuse (marked HORN)
F20 Optional Equipment 5 A Fuse (marked OPT. 3 BATT)

Some symptoms may indicate an expensive component malfunction, when in fact a fuse has malfunctioned. Machine functions
can be performed without test equipment to determine if fuses have malfunctioned. If certain circuits or components operate,
fuses are considered to be OK.

<- Go to Section TOC Section 9015 page 276 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Fuse Test

Fuse Test

Fuse Test Results of Fuse Malfunction

Turn key switch ON.


F1—Work and Boom Lights 20 A Fuse (marked LAMP) Turn light switch to first or second position. If work Work and boom lights will not operate.
or boom lights operate, fuse is OK.

Turn key switch ON.


F2—Windshield Wiper and Washer 10 A Fuse (marked WIPER) Turn windshield wiper ON. If wiper operates, fuse is Windshield wiper will not operate.
OK.

Turn key switch ON.


Heater or air conditioner blower will not
F3—Air Conditioner and Heater 20 A Fuse (marked HEATER) Press blower speed switch. If blower operates in any
operate.
speed, fuse is OK.

F4—Solenoid 20 A Fuse (marked SOLENOID) If hydraulic system functions normally, fuse is OK. Travel and stick functions will not operate.

Turn key switch to START.


Place pilot shutoff lever to unlocked (DOWN)
F5—Travel Alarm 5 A Fuse (marked OPT. 1 ALT) position. Travel alarm will not operate.
Push travel pedals or levers forward. If travel alarm
sounds, fuse is OK.

F6—12-Volt Power Outlet 20 A Fuse (marked OPT. 2 ALT) Check with multimeter. 12 volt power outlet will not operate.

Engine starts hard when cold.


F7—Start Position Signal 5 A Fuse (marked START) If start aid works, fuse is OK.
Start aid will not operate.

Turn key switch to START.


F8—Engine Control Unit (ECU) 30 A Fuse (marked ECU) Display will not light and engine will not start.
If engine starts and display lights, fuse is OK.

Turn key switch to ON.


F9—Radio Backup 10 A Fuse (marked BACK UP) Radio will not retain presets.
If radio presets are retained, fuse is OK.

Turn engine ON.


F10—Data Converter and Main Controller Battery Power 5 A
If monitor alarm does not sound continuously, fuse Monitor alarm will sound continuously.
Fuse (marked CONTROLLER)
is OK.

Turn key switch ON.


F12—Radio and Dome 5 A Fuse (marked RADIO) Radio and dome light will not operate.
If radio operates, fuse is OK.

Turn key switch ON.


F13—Lighter 10 A Fuse (marked LIGHTER) Lighter will not operate.
Push lighter. If lighter gets hot, fuse is OK.

Turn key switch ON.


F14—Monitor 5 A Fuse (marked MONITOR) Monitor will not operate.
If monitor operates, fuse is OK.

F15—Cab Auxiliary Power Connector One 10 A Fuse (marked Cab auxiliary power connector will not
Check with multimeter.
AUX) operate.

F16—Start Aid (marked SA) If start aid works, fuse is OK. Start aid will not operate.

Turn key switch to START.


F17—Power On 5 A Fuse (marked POWER ON) Engine will not start.
If engine starts, fuse is OK.

Controller feedback protection will not


F18—Idle Stop 5 A Fuse (marked IDLE STOP) Check with multimeter.
operate.

Turn key switch ON.


F19—Horn 10 A Fuse (marked HORN) Horn will not operate.
Press horn switch. If horn operates, fuse is OK.

F20—Optional Equipment 5 A Fuse (marked OPT. 3 BATT) Check with multimeter. Optional equipment will not operate.

<- Go to Section TOC Section 9015 page 277 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Fuse Block 2

LEGEND:
F21 Heated Air Seat 10 A Fuse (marked SEAT HEATER)
F22 Front Cab Light One 10 A Fuse (marked CAB LAMP FRONT)
F23 Rear Cab Light 10 A Fuse (marked CAB LAMP REAR)
F24 12-Volt Power Unit 10 A Fuse (marked 12V UNIT)
F25 IMOBI 5 A Fuse (marked IMOBI)
F26 Quick Hitch 5 A Fuse (marked QUICK HITCH)
F27 Cab Auxiliary Power Connector Three 5 A Fuse (marked AUX. 3)
F28 Not Used
F29 Not Used
F30 Not Used
F31 Seat Compressor 10 A Fuse (marked SEAT COMPR)
F32 Front Cab Light Two 10 A Fuse (marked CAB LAMP FRONT +2)
F33 Warning Lamp 10 A Fuse (marked WARNING LAMP)
F34 Cab Auxiliary Power Connector Two 10 A Fuse (marked AUX. 2)
F35 Not Used
F36 Not Used
F37 Not Used
F38 Not Used
F39 Not Used
F40 Not Used

Fuse Test

Fuse Test

Fuse Test Results of Fuse Malfunction

F21—Heated Air Seat 10 A Fuse (marked SEAT HEATER) Check with multimeter. Optional equipment will not operate.

F22—Front Cab Light One 10 A Fuse (marked CAB LAMP FRONT) Check with multimeter. Optional equipment will not operate.

F23—Rear Cab Light 10 A Fuse (marked CAB LAMP REAR) Check with multimeter. Optional equipment will not operate.

F24—12-Volt Power Unit 10 A Fuse (marked 12V UNIT) Check with multimeter. Optional equipment will not operate.

F25—IMOBI 5 A Fuse (marked IMOBI) Check with multimeter. Optional equipment will not operate.

F26—Quick Hitch 5 A Fuse (marked QUICK HITCH) Check with multimeter. Optional equipment will not operate.

<- Go to Section TOC Section 9015 page 278 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

F27—Cab Auxiliary Power Connector Three 5 A Fuse (marked AUX. 3) Check with multimeter. Optional equipment will not operate.

F31—Seat Compressor 10 A Fuse (marked SEAT COMPR) Check with multimeter. Optional equipment will not operate.

F32—Front Cab Light Two 10 A Fuse (marked CAB LAMP FRONT +2) Check with multimeter. Optional equipment will not operate.

F33—Warning Lamp 10 A Fuse (marked WARNING LAMP) Check with multimeter. Optional equipment will not operate.

F34—Cab Auxiliary Power Connector Two 10 A Fuse (marked AUX. 2) Check with multimeter. Optional equipment will not operate.

Fuse Test

Fuse Test

Fuse Test Results of Fuse Malfunction

F60—Alternator 65 A Fuse Check with multimeter. Alternator will not charge electrical system.

Turn key switch to START.


F61—Battery 45 A Fuse Engine will not crank.
If engine cranks, fuse is OK.

F5002—Fuel Transfer Pump 15 A Fuse Check with multimeter. Engine will run out of fuel.

F6000— JDLink ™ Unswitched Power 7.5 A Fuse Check with multimeter. JDLink will not operate.

F6001—JDLink™ Ground 7.5 A Fuse Check with multimeter. JDLink will not operate.

F6002—JDLink™ Switched Power 7.5 A Fuse Check with multimeter. JDLink will not operate.

(S.N. 040755— )

Fuse Block 1

LEGEND:
F1 Work and Boom Lights 20 A Fuse (marked LAMP)
F2 Windshield Wiper and Washer 10 A Fuse (marked WIPER)
F3 Air Conditioner and Heater 20 A Fuse (marked HEATER)
F4 Solenoid 20 A Fuse (marked SOLENOID)
F5 Optional and Attachment Connector 5 A Fuse (marked OPT. 1 ALT)
F6 Optional Connector and Reversing Fan 20 A Fuse (marked OPT. 2 ALT)
F7 Start Position Signal 5 A Fuse (marked START)
F8 Engine Control Unit (ECU) 20 A Fuse (marked ECU P1)
F9 Radio Backup 10 A Fuse (marked BACK UP)
F10 Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)
<- Go to Section TOC Section 9015 page 279 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

F11 Travel Alarm 5 A Fuse (marked TRAVEL ALARM)


F12 Radio and Dome 5 A Fuse (marked RADIO)
F13 Lighter 10 A Fuse (marked LIGHTER)
F14 Monitor 5 A Fuse (marked MONITOR)
F15 Cab Auxiliary Power Connector 1 10 A Fuse (marked AUX)
F16 12-Volt Power Unit 10 A Fuse (marked 12V UNIT)
F17 Power On 5 A Fuse (marked POWER ON)
F18 Idle Stop 5 A Fuse (marked IDLE STOP)
F19 Horn 10 A Fuse (marked HORN)
F20 Optional Equipment 5 A Fuse (marked OPT. 3 BATT)

Some symptoms may indicate an expensive component malfunction, when in fact a fuse has malfunctioned. Machine functions
can be performed without test equipment to determine if fuses have malfunctioned. If certain circuits or components operate,
fuses are considered to be OK.

Fuse Test

Fuse Test

Fuse Test Results of Fuse Malfunction

Turn key switch ON.


F1—Work and Boom Lights 20 A Fuse (marked LAMP) Turn light switch to first or second position. If work Work and boom lights will not operate.
or boom lights operate, fuse is OK.

Turn key switch ON.


F2—Windshield Wiper and Washer 10 A Fuse (marked WIPER) Turn windshield wiper ON. If wiper operates, fuse Windshield wiper will not operate.
is OK.

Turn key switch ON.


Heater or air conditioner blower will not
F3—Air Conditioner and Heater 20 A Fuse (marked HEATER) Press blower speed switch. If blower operates in
operate.
any speed, fuse is OK.

F4—Solenoid 20 A Fuse (marked SOLENOID) If hydraulic system functions normally, fuse is OK. Travel and stick functions will not operate.

F5—Optional and Attachment Connector 5 A Fuse (marked OPT.


Check with multimeter. Optional equipment will not operate.
1 ALT)

F6—Optional Connector and Reversing Fan 20 A Fuse (marked


Check with multimeter. Optional equipment will not operate.
OPT. 2 ALT)

Engine starts hard when cold.


F7—Start Position Signal 5 A Fuse (marked START) If start aid works, fuse is OK.
Start aid will not operate.

Turn key switch to START.


F8—Engine Control Unit (ECU) 20 A Fuse (marked ECU P1) Display will not light and engine will not start.
If engine starts and display lights, fuse is OK.

Turn key switch to ON.


F9—Radio Backup 10 A Fuse (marked BACK UP) Radio will not retain presets.
If radio presets are retained, fuse is OK.

Turn engine ON.


F10—Data Converter and Main Controller Battery Power 5 A
If monitor alarm does not sound continuously, fuse Monitor alarm will sound continuously.
Fuse (marked CONTROLLER)
is OK.

Turn key switch to START.


Place pilot shutoff lever to unlocked (DOWN)
F11—Travel Alarm 5 A Fuse (marked TRAVEL ALARM) position. Travel alarm will not operate.
Push travel pedals or levers forward. If travel
alarm sounds, fuse is OK.

Turn key switch ON.


F12—Radio and Dome 5 A Fuse (marked RADIO) Radio and dome light will not operate.
If radio operates, fuse is OK.

Turn key switch ON.


F13—Lighter 10 A Fuse (marked LIGHTER) Lighter will not operate.
Push lighter. If lighter gets hot, fuse is OK.

Turn key switch ON.


F14—Monitor 5 A Fuse (marked MONITOR) Monitor will not operate.
If monitor operates, fuse is OK.

Cab auxiliary power connector will not


F15—Cab Auxiliary Power Connector 1 10 A Fuse (marked AUX) Check with multimeter.
operate.

F16—12-Volt Power Unit 10 A Fuse (marked 12V UNIT) Check with multimeter. 12-Volt Power Outlet will not operate.

Turn key switch to START.


F17—Power On 5 A Fuse (marked POWER ON) Engine will not start.
If engine starts, fuse is OK.

Controller feedback protection will not


F18—Idle Stop 5 A Fuse (marked IDLE STOP) Check with multimeter.
operate.

Turn key switch ON.


F19—Horn 10 A Fuse (marked HORN) Horn will not operate.
Press horn switch. If horn operates, fuse is OK.

F20—Optional Equipment 5 A Fuse (marked OPT. 3 BATT) Check with multimeter. Optional equipment will not operate.

<- Go to Section TOC Section 9015 page 280 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Fuse Block 2

LEGEND:
F21 Heated Air Seat 10 A Fuse (marked SEAT HEATER)
F22 Front Cab Light 1 10 A Fuse (marked CAB LAMP FRONT)
F23 Rear Cab Light 10 A Fuse (marked CAB LAMP REAR)
F24 IMOBI 5 A Fuse (marked IMOBI)
F25 Quick Hitch 5 A Fuse (marked QUICK HITCH)
F26 Cab Auxiliary Power Connector 3 5 A Fuse (marked AUX. 3)
F27 Not Used
F28 Not Used
F29 Not Used
F30 Not Used
F31 Seat Compressor 10 A Fuse (marked SEAT COMPR)
F32 Front Cab Light 2 10 A Fuse (marked CAB LAMP FRONT +2)
F33 Warning Lamp 10 A Fuse (marked WARNING LAMP)
F34 Cab Auxiliary Power Connector 2 10 A Fuse (marked AUX. 2)
F35 Service Advisor Diagnostic Connector 5 A Fuse (marked DIAG)
F36 Engine Control Unit (ECU) 20 A Fuse (marked ECU P2, not used)
F37 Engine Control Unit (ECU) 20 A Fuse (marked ECU P3, not used)
F38 Fuel Transfer Pump/Controllers 20 A Fuse (marked ECU P4, not used)
F39 Not Used
F40 Not Used

Fuse Test

Fuse Test

Fuse Test Results of Fuse Malfunction

F21—Heated Air Seat 10 A Fuse (marked SEAT HEATER) Check with multimeter. Optional equipment will not operate.

F22—Front Cab Light One 10 A Fuse (marked CAB LAMP FRONT) Check with multimeter. Optional equipment will not operate.

F23—Rear Cab Light 10 A Fuse (marked CAB LAMP REAR) Check with multimeter. Optional equipment will not operate.

F24—IMOBI 5 A Fuse (marked IMOBI) Check with multimeter. Optional equipment will not operate.

F25—Quick Hitch 5 A Fuse (marked QUICK HITCH) Check with multimeter. Optional equipment will not operate.

F26—Cab Auxiliary Power Connector Three 5 A Fuse (marked AUX. 3) Check with multimeter. Optional equipment will not operate.

<- Go to Section TOC Section 9015 page 281 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

F31—Seat Compressor 10 A Fuse (marked SEAT COMPR) Check with multimeter. Optional equipment will not operate.

F32—Front Cab Light Two 10 A Fuse (marked CAB LAMP FRONT +2) Check with multimeter. Optional equipment will not operate.

F33—Warning Lamp 10 A Fuse (marked WARNING LAMP) Check with multimeter. Optional equipment will not operate.

F34—Cab Auxiliary Power Connector Two 10 A Fuse (marked AUX. 2) Check with multimeter. Optional equipment will not operate.

F35—Service Advisor Diagnostic Connector 5 A Fuse (marked DIAG) Check with multimeter. Service ADVISOR ™ will not connect to machine.

Fuse Test

Fuse Test

Fuse Test Results of Fuse Malfunction

F60—Alternator 65 A Fuse Check with multimeter. Alternator will not charge electrical system.

Turn key switch to START.


F61—Battery 45 A Fuse Engine will not crank.
If engine cranks, fuse is OK.

Engine starts hard when cold.


F63—Glow Plug 50 A Fuse Check with multimeter.
Start aid will not operate.

F5002—Fuel Transfer Pump 15 A Fuse Check with multimeter. Engine will run out of fuel.

F6000— JDLink ™ Unswitched Power 7.5 A Fuse Check with multimeter. JDLink will not operate.

F6001—JDLink™ Ground 7.5 A Fuse Check with multimeter. JDLink will not operate.

F6002—JDLink™ Switched Power 7.5 A Fuse Check with multimeter. JDLink will not operate.

<- Go to Section TOC Section 9015 page 282 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Relay Test

Relay Test

For location of relays:

See Cab Harness (W1) Component Location . (Group 9015-10.)


See Machine Harness (W2) Component Location . (Group 9015-10.)
See Heated Air Seat Harness (W14) Component Location . (Group 9015-10.)
See Multi-Function Pilot Control Lever Harness (W15) Component Location . (Group 9015-10.)
See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)

[1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9001-01.)

[2] - Connect a multimeter to terminals 1 and 2. About 420—460 ohms must be measured. If not, relay has malfunctioned.

[3] - Connect multimeter to terminals 3 and 4. Less than 0.4 ohms must be measured. If not, relay has malfunctioned.

[4] - Connect multimeter to terminals 3 and 5, then 4 and 5. Multimeter must read open in both connections. If not, relay has
malfunctioned.

[5] -

IMPORTANT:

To prevent possible relay damage, do not connect relay directly to battery. Use a fused power source
such as auxiliary power connector (X25) in cab or external power supply.

Connect 24 volts (+) to terminal 1, ground (-) terminal 2.

[6] - Connect multimeter to terminals 3 and 5. Multimeter must read less than 0.4 ohms. If not, relay has malfunctioned.

<- Go to Section TOC Section 9015 page 283 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Pressure Sensor Test


Pressure Sensor Resistance Test

[1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9001-01.)

[2] - A suspect pressure sensor can be checked by switching positions with a known good sensor. If the problem follows the
suspect pressure sensor, it has malfunctioned.

If the problem remains, the harness has malfunctioned.

[3] - To check a pressure sensor using a multimeter, remove it from the machine.

Multimeter

Measure resistance on electrical component

[4] -

→NOTE:

Resistance values for pump 1 delivery pressure sensor (B35) and pump 2 delivery pressure sensor (B37)
may vary widely.

To verify the sensor′s functionality, use the on-board monitor or in Service ADVISOR ™ , check for diagnostic trouble codes to
monitor the sensor′s output. See Monitoring . (Group 9015-16.) See SERVICE ADVISOR™ Diagnostic Application . (Group
9015-20.)

[5] - Measure resistance as indicated. Resistance may vary from one sensor to another.

Item Measurement Specification

Pressure Sensor Resistance Ranges


Pump 1 Control Pressure Sensor (B36) Resistance 5—15 kilo-ohms (Pins 1—2)

30—50 kilo-ohms (Pins 2—3)

Pump 2 Control Pressure Sensor (B38) Resistance 5—15 kilo-ohms (Pins 1—2)

30—50 kilo-ohms (Pins 2—3)

Boom Up Pressure Sensor (B30) Resistance 5—15 kilo-ohms (Pins 1—2)

30—50 kilo-ohms (Pins 2—3)

Front Attachment Pressure Sensor (B32) Resistance 5—15 kilo-ohms (Pins 1—2)

30—50 kilo-ohms (Pins 2—3)

Travel Pressure Sensor (B34) Resistance 5—15 kilo-ohms (Pins 1—2)

30—50 kilo-ohms (Pins 2—3)

Swing Pressure Sensor (B33) Resistance 5—15 kilo-ohms (Pins 1—2)

30—50 kilo-ohms (Pins 2—3)

Arm In Pressure Sensor (B31) Resistance 5—15 kilo-ohms (Pins 1—2)

30—50 kilo-ohms (Pins 2—3)

For location of pressure sensors, see Machine Harness (W2) Component Location and see Pump Harness (W8) Component
Location . (Group 9015-10.)

Pressure Sensor Voltage Test

[1] - No voltage at pressure sensors will generate diagnostic trouble codes. Disconnect harness connector from a pressure

<- Go to Section TOC Section 9015 page 284 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

sensor.

[2] - With key switch ON, measure voltage between terminals 1 and 3 of pressure sensor harness connector.

Item Measurement Specification

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

Multimeter

To measure voltage

[3] - If voltage is lower or no voltage is present, check wiring.

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb.-in.

See Cab Harness (W1) Wiring Diagram . (Group 9015-10.)


See Machine Harness (W2) Wiring Diagram . (Group 9015-10.)
See Pump Harness (W8) Wiring Diagram . (Group 9015-10.)

Solenoid Test
[1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9001-01.)

[2] - A suspect solenoid can be checked by switching positions with a known good solenoid. If the problem follows the suspect
solenoid, it has malfunctioned.

If the problem remains, the harness has malfunctioned.

[3] - To check a solenoid using an ohmmeter, remove it from the machine.

[4] - Measure resistance as indicated. Resistance may vary from one solenoid to another.

Item Measurement Specification

Excavator Solenoids
Pilot Shut-Off Solenoid (Y10) Resistance 42—58 ohms

<- Go to Section TOC Section 9015 page 285 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Proportional Solenoid Test


[1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9001-01.)

[2] - A solenoid with a potential problem may be tested by switching connections with a known, proper functioning solenoid. If
the problem follows the solenoid, replace solenoid.

If the problem remains, inspect connections and test appropriate harness.

See Machine Harness (W2) Component Location . (Group 9015-10.)


See Engine Interface Harness (W5) Component Location . (Group 9015-10.)
See Pump Harness (W8) Component Location . (Group 9015-10.)
See Attachment Harness (W17) Component Location . (Group 9015-10.)

[3] - Remove solenoid from machine prior to testing with an ohmmeter.

[4] - Measure resistance between pins on the solenoid and record results. Compare recorded resistance value to specification
below. If solenoid is not within specification, replace solenoid.

Item Measurement Specification

Main Controller Solenoids


Reversing Fan Solenoid (Y9) Resistance 37—46 ohms

Pump 2 Flow Rate Limit Solenoid (marked SB) (Y20) Resistance 20—24 ohms

Torque Control Solenoid (marked ST) (Y21) Resistance 20—24 ohms

Dig Regenerative Solenoid (marked SF) (Y22) Resistance 20—24 ohms

Arm Regenerative Solenoid (marked SC) (Y23) Resistance 20—24 ohms

Power Dig Solenoid (marked SG) (Y24) (S.N. —XXXXXX) Resistance 20—24 ohms

Power Dig/Travel Speed Solenoid (marked SI) (Y24) (S.N. XXXXXX— ) Resistance 20—24 ohms

Arm 2 Flow Control Solenoid (marked SD) (Y27) Resistance 20—24 ohms

Selector Valve Solenoid Valve (Y40) Resistance 44—54 ohms

Secondary Relief Solenoid Valve (Y41) Resistance 17.5—21.5 ohms

Accumulator Solenoid Valve (Y42) Resistance 17.5—21.5 ohms

2-Speed Activation Solenoid Valve (Y43) Resistance 17.5—21.5 ohms

Variable Speed Fan Solenoid (Y5005) Resistance 37—46 ohms

<- Go to Section TOC Section 9015 page 286 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Temperature Sensor Test


Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JDG1478 Digital Multimeter

[1] - To check a temperature sensor using a JDG1478 Digital Multimeter, remove sensor from machine.

Digital Multimeter

JDG1478

Measure resistance on electrical component

[2] - Measure resistance as indicated. Resistance may vary from one sensor to another.

Ambient Air Temperature Sensor Ranges

Ambient Air Temperature Sensor (B22) Ranges

Resistance Temperature

0°C
9900 ohms
32°F

40°C
1600 ohms
104°F

Hydraulic Oil Temperature Sensor Ranges

Hydraulic Oil Temperature Sensor (B40) Ranges

Resistance Temperature

-20°C
13 840—16 330 ohms
-4°F

0°C
5740 ohms
32°F

20°C
2320—2590 ohms
68°F

40°C
1150 ohms
104°F

60°C
584 ohms
140°F

80°C
310—326 ohms
176°F

Air Recirculation Sensor Ranges

Air Recirculation Sensor (B55) Ranges

Resistance Temperature

0°C
9900 ohms
32°F

40°C
1600 ohms
104°F

See Machine Harness (W2) Component Location for ambient air temperature sensor (B22) location, see Pump Harness (W8)
Component Location for hydraulic oil temperature sensor (B40) location, and see Heater and Air Conditioner Harness (W41)
Component Location for air recirculation sensor (B55) location. (Group 9015-10.)

<- Go to Section TOC Section 9015 page 287 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Alternator Test

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)

Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9000-01.)

[1] - 12 V System — With engine running at slow idle, check DC voltage between terminal D+ and ground. Voltage should be
13.5 VDC or greater

[ Note: For 12 V systems with maintenance free batteries, D+ and B+ voltage should be 14.1 VDC or greater. ]
.

[2] - With engine running at fast idle, check DC voltage between terminal B+ and ground. Voltage should be 13.5 VDC or
greater

[ Note: For 12 V systems with maintenance free batteries, D+ and B+ voltage should be 14.1 VDC or greater. ]
.

[3] - If voltage from previous steps is below 13.5 VDC

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Section 9015 - ELECTRICAL SYSTEM Group 20: References
[ Note: For 12 V systems with maintenance free batteries, D+ and B+ voltage should be 14.1 VDC or greater. ]
, check excitation by placing a jumper wire between terminals D+ and B+ with the engine running. If output at terminals B+
and D+ rise to 13.5 VDC or greater, check for an open diode, wiring problem or blown fuse in the alternator excitation circuit
(wire to D+ terminal).

[4] - With engine running, check AC voltage between terminal W (if equipped) and ground. Voltage should be 6—7 VAC .

[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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Section 9015 - ELECTRICAL SYSTEM Group 20: References

Electrical Component Checks


The following checks can be used to test electrical components in all machine circuits.

Component Checks
( 1 ) Key Switch Check

Action:
LEGEND:
1 B Terminal
2 G1 Terminal
3 G2 Terminal
4 ACC Terminal
5 M Terminal
6 ST Terminal

Key Switch Check

Remove starter switch harness (W29) from key switch (S1). See Starter Switch Harness (W29) Component Location . (Group
9015-10.)

Turn key switch to the ACC position.

Measure continuity between key switch terminals 1 to 4.

Turn key switch to the ON position.

Measure continuity between key switch terminals 1 to 5 and 1 to 4.

Turn key switch to the START position.

Measure continuity between key switch terminals 1 to 6, 1 to 5, and 1 to 3.

Multimeter

To read continuity.

sss:

Is continuity measured between terminals?

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb.-in.

Result:

YES:Key switch is OK. Check the wiring harness. See Cab Harness (W1) Wiring Diagram and see Starter Switch Harness (W29)
Wiring Diagram . (Group 9015-10.)

NO:Key switch has malfunctioned. Replace the key switch. See Key Switch Remove and Install . (Group 9015-20.)

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Section 9015 - ELECTRICAL SYSTEM Group 20: References

( 2 ) Battery Relay Check

Action:

Battery Relay Check

Disconnect machine harness (W2) from battery relay (K19). See Machine Harness (W2) Component Location . (Group 9015-10.)

Connect 24 volts to small terminal S and ground small terminal E.

sss:

Does the relay click?

Connect the multimeter to large terminals A and B.

Multimeter

To read continuity.

sss:

Is continuity measured?

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb.-in.

Result:

YES:Battery relay is OK. Check the wiring harness. See Machine Harness (W2) Wiring Diagram . (Group 9015-10.)

NO:Battery relay malfunctioned. Replace the relay.

( 3 ) Battery Voltage Check

Action:

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Section 9015 - ELECTRICAL SYSTEM Group 20: References

Voltage Check

Measure battery voltage by connecting a multimeter to (-) negative battery terminal grounded to frame and (+) positive
battery terminal connected to machine harness.

Multimeter

To read voltage.

sss:

Are 24 to 28 volts measured?

Result:

YES:Batteries are OK.

NO:Batteries are undercharged. Charge batteries. See Using Battery Charger . (Operator′s Manual.)

( 4 ) Alternator and Battery Fuse Check

Action:
LEGEND:
1 Locking Tab
2 Lift Direction

Alternator and Battery Fuse Check

Press locking tab on side of fuse and lift from holder.

Connect a multimeter to female terminals inside fuse.

Multimeter

To read continuity.

sss:

Does the multimeter read continuity?

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Section 9015 - ELECTRICAL SYSTEM Group 20: References

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb.-in.

Result:

YES:Fuse is OK. Check the wiring harness. See Machine Harness (W2) Wiring Diagram . (Group 9015-10.)

NO:Fuse malfunctioned. Replace the fuse. See Fuse and Relay Specifications . (Group 9015-10.)

( 5 ) Diode Check

Action:

Diode Check

Remove diode from connector.

Test diode using diode test function of multimeter.

Multimeter

To test diode.

sss:

Does the multimeter beep?

Reverse multimeter probes.

sss:

Does the multimeter beep?

Result:

YES:If multimeter beeps in both checks, diode malfunctioned. Replace the diode.

NO:If multimeter does not beep in either check, diode malfunctioned. Replace the diode.

NO:If multimeter beeps in one check and not the other, diode is OK.

( 6 ) Travel Alarm Check

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Section 9015 - ELECTRICAL SYSTEM Group 20: References

Action:

Travel Alarm Harness Check

Multimeter

To read voltage and continuity.

Disconnect travel alarm harness (W26) from travel alarm (H4). See Travel Alarm Harness (W26) Component Location . (Group
9015-10.)

Connect multimeter to travel alarm connector pin B and frame ground.

Turn key switch to ON position.

sss:

Is battery voltage measured?

Connect multimeter to travel alarm connector pin D and frame ground.

sss:

Is continuity measured?

Connect multimeter to travel alarm connector pin A and frame ground.

sss:

Is continuity measured when the travel alarm cancel switch is pressed?

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb.-in.

Result:

YES:Travel alarm has malfunctioned. Replace the travel alarm. See Travel Alarm Remove and Install . (Group 9015-20.)

NO:If battery voltage is not measured, check travel alarm 5 A fuse. See Fuse and Relay Specifications . (Group 9015-10.)

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Section 9015 - ELECTRICAL SYSTEM Group 20: References

NO:Check travel alarm cancel switch. See Travel Alarm Cancel Switch Harness (W16) Wiring Diagram . (Group 9015-10.)

NO:Check the travel alarm cancel switch harness and machine harness. See Travel Alarm Cancel Switch Harness (W16) Wiring
Diagram , see Travel Alarm Harness (W26) Wiring Diagram , and see Machine Harness (W2) Wiring Diagram . (Group 9015-10.)

( 7 ) Monitor Warning Alarm Check

Action:

Disconnect monitor harness (W3) from monitor warning alarm (H3). See Monitor Harness (W3) Component Location . (Group
9015-10.)

Connect 24 volts to terminal 1 and ground terminal 2.

sss:

Does monitor warning alarm sound?

Result:

YES:Alarm is OK. Check power on 5 A fuse. See Fuse and Relay Specifications . (Group 9015-10.)

YES:Check wiring harness. See Monitor Harness (W3) Wiring Diagram . (Group 9015-10.)

NO:Alarm malfunction. Replace monitor warning alarm. See Monitor Harness (W3) Component Location . (Group 9015-10.)

( 8 ) CAN Bus Terminator Check

Action:

Turn key switch OFF.

Disconnect harness from CAN bus terminator.

CAN Bus Terminator

Measure resistance across terminator pins.

Multimeter

To read continuity.

sss:

Does the multimeter read 105—135 ohms?

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Section 9015 - ELECTRICAL SYSTEM Group 20: References

Result:

YES:CAN bus terminator is OK.

NO:CAN bus terminator malfunctioned. Replace the CAN bus terminator.

( 9 ) Alternator Resistor Check

Action:

Turn key switch OFF.

Disconnect harness from alternator resistor (R13).

LEGEND:
1 Terminal 1
2 Terminal 2

Alternator Resistor

Measure resistance across resistor terminals 1 and 2.

Multimeter

To read continuity.

sss:

Does the multimeter read 1350—1650 ohms?

Result:

YES:Alternator resistor is OK.

NO:Alternator resistor malfunctioned. Replace the alternator resistor.

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Section 9015 - ELECTRICAL SYSTEM Group 20: References

Battery Remove and Install


[1] -

CAUTION:

Prevent personal injury from exploding battery. Keep sparks and flames away from batteries.

Always remove grounded (-) battery clamp first and replace it last.

Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9000-01.)

Battery Connections

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Section 9015 - ELECTRICAL SYSTEM Group 20: References

LEGEND:
1 Battery (2 used)
2 Wing Nut (4 used)
3 Washer (8 used)
4 Cover (2 used)
5 Spacer (4 used)
6 Nut (4 used)
7 Clamp
8 Bracket (2 used)
9 Bolt (4 used)
10 Positive Cable
11 Jumper Cable
12 Negative Cable
13 Cap Screw

[2] - Remove wing nuts (2) and washers (3).

[3] - Remove covers (4) and brackets (8).

[4] - Disconnect cables (10—12).

[5] - Remove batteries (1).

[6] - Check cables and clamps for wear or corrosion. Verify batteries are fully charged.

[7] -

IMPORTANT:

Prevent electrical system damage. If one battery in a 24-volt system has malfunctioned, replace both
batteries.

Install batteries.

[8] - Connect cables.

[9] - Install brackets and covers.

[10] - Install washers and wing nuts.

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Section 9015 - ELECTRICAL SYSTEM Group 20: References

Rear Cover Remove and Install


[1] -

Rear Cover Assembly

LEGEND:
1 Plug (2 used)
2 Cap Screw (3 used)
3 Right Cover
4 Cap Screw
5 Cap Screw
6 Left Cover
7 Plug (2 used)
8 Cap Screw (2 used)
9 Upper Rear Cover
10 Cap Screw (2 used)
11 Washer (2 used)

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Section 9015 - ELECTRICAL SYSTEM Group 20: References

12 Plug (3 used)
13 Cap Screw (3 used)
14 Lower Rear Cover
G5 12 Volt Power Outlet
R9 Lighter
Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 0001.)

[2] - Remove plugs (1) and cap screws (2).

[3] - Remove right cover (3).

[4] - Remove cap screws (4 and 5).

[5] - Tag and disconnect lighter (R9) and 12 volt power outlet (G5) from cab harness and remove left cover (6).

[6] - Remove plugs (7) and cap screws (8).

[7] - Remove upper rear cover (9).

[8] - Remove plugs (12) and cap screws and washers (10, 11 and 13).

[9] - Remove lower rear cover (14).

[10] - Repair or replace as necessary.

[11] - Install lower rear cover (14).

[12] - Install cap screws and washers (10, 11 and 13) and plugs (12).

[13] - Install upper rear cover (9).

[14] - Install cap screws (8) and plugs (7).

[15] - Connect lighter (R9) and 12 volt power outlet (G5) to cab harness and install left cover (6).

[16] - Install cap screws (4 and 5).

[17] - Install right cover (3).

[18] - Install cap screws (2) and plugs (1).

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Section 9015 - ELECTRICAL SYSTEM Group 20: References

Main Controller (MCZ) Remove and Install


(S.N. —040754)

[1] -
LEGEND:
1 Cap Screw (4 used)
2 Screw (4 used)
3 Cap Screw (2 used)
4 MCZ Bracket
5 Relay Bracket
A3 Main Controller (MCZ)
X31 Cab Harness-to-Main Controller 31-Pin Connector A
X32 Cab Harness-to-Main Controller 24-Pin Connector B
X33 Cab Harness-to-Main Controller 17-Pin Connector C
X35 Cab Harness-to-Main Controller 24-Pin Connector D
X36 Cab Harness-to-Main Controller 26-Pin Connector E

Main Controller (MCZ)

Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9001-01.)

[2] - Disconnect battery negative (-) cable.

[3] - Remove rear cover. See Rear Cover Remove and Install . (Group 9015-20.)

[4] - Remove cap screws (3) and set aside relay bracket (5).

[5] - Tag and disconnect electrical connectors (X31— X33, X35, and X36). See Cab Harness (W1) Component Location . (Group
9015-10.)

[6] - Remove cap screws (1) and remove MCZ bracket (4).

[7] - Remove screws (2) and main controller (MCZ) (A3) from bracket.

[8] - Repair or replace as necessary.

[9] - Install MCZ on to bracket and screws.

[10] - Install MCZ bracket and cap screws.

[11] - Connect electrical connectors. See Cab Harness (W1) Component Location . (Group 9015-10.)

[12] - Install relay bracket and cap screws.

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Section 9015 - ELECTRICAL SYSTEM Group 20: References

[13] - Install rear cover. See Rear Cover Remove and Install . (Group 9015-20.)

[14] - Connect battery negative (-) cable.

(S.N. 040755— )

[1] -
LEGEND:
1 Cap Screw (4 used)
2 Screw (4 used)
3 Cap Screw (2 used)
4 MCZ Bracket
5 Relay Bracket
A3 Main Controller (MCZ)
X31 Cab Harness-to-Main Controller 31-Pin Connector A
X32 Cab Harness-to-Main Controller 24-Pin Connector B
X33 Cab Harness-to-Main Controller 17-Pin Connector C
X34 Cab Harness-to-Main Controller 30-Pin Connector D
X35 Cab Harness-to-Main Controller 24-Pin Connector E
X36 Cab Harness-to-Main Controller 26-Pin Connector F

Main Controller (MCZ)

Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9001-01.)

[2] - Disconnect battery negative (-) cable.

[3] - Remove rear cover. See Rear Cover Remove and Install . (Group 9015-20.)

[4] - Remove cap screws (3) and set aside relay bracket (5).

[5] - Tag and disconnect electrical connectors (X31—X36). See Cab Harness (W1) Component Location . (Group 9015-10.)

[6] - Remove cap screws (1) and remove MCZ bracket (4).

[7] - Remove screws (2). Remove main controller (MCZ) (A3) from relay bracket.

[8] - Repair or replace as necessary.

[9] - Install main controller in bracket. Install screws.

[10] - Install MCZ bracket and cap screws.

[11] - Connect electrical connectors. See Cab Harness (W1) Component Location . (Group 9015-10.)

[12] - Install relay bracket and cap screws.

[13] - Install rear cover. See Rear Cover Remove and Install . (Group 9015-20.)
<- Go to Section TOC Section 9015 page 302 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

[14] - Connect battery negative (-) cable.

<- Go to Section TOC Section 9015 page 303 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Machine Controller (BCZ) Remove and Install


[1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9001-01.)

[2] - Disconnect battery negative (-) cable.

[3] - Remove rear cover. See Rear Cover Remove and Install . (Group 9015-20.)

[4] -
LEGEND:
1 Screw (4 used)
2 Screw (4 used)
3 Bracket
A7 Air Conditioner Controller (ACF)

Air Conditioner Controller

Disconnect air conditioner controller (ACF) connector (A7). See Heater and Air Conditioner Harness (W41) Component Location
. (Group 9015-10.)

[5] - Remove screws (1) and ACF.

[6] - Remove screws (2) and bracket (3).

[7] -
LEGEND:
4 Screw (2 used)
A11 Machine Controller (BCZ)

<- Go to Section TOC Section 9015 page 304 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Machine Controller (BCZ)

Remove screws (4) and lift up machine controller (BCZ) (A11).

[8] -
LEGEND:
A11 Machine Controller (BCZ)
X10 Machine Controller 8-Pin Connector A
X11 Machine Controller 20-Pin Connector B

Machine Controller (BCZ)

Disconnect electrical connectors; machine controller 8-pin connector A (X10) and machine controller 20-pin connector B (X11).

[9] - Remove machine controller.

[10] - Repair or replace as necessary.

[11] - Connect electrical connectors and install machine controller and screws.

[12] - Install bracket and screws.

[13] - Install air conditioner controller (ACF) (A7) and screws.

[14] - Connect air conditioner controller connector (A7).

[15] - Install rear cover. See Rear Cover Remove and Install . (Group 9015-20.)

[16] - Connect battery negative (-) cable.

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Section 9015 - ELECTRICAL SYSTEM Group 20: References

Engine Control Unit (ECU) Remove and Install


[1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9000-01.)

[2] - Disconnect battery negative (-) cable.

[3] -
LEGEND:
1 Cap Screw (2 used)
A1 Engine Control Unit (ECU)
R12 CAN 0 Termination Resistor
Engine Control Unit (ECU)-to-Engine Harness
X14
Connector 1
Engine Control Unit (ECU)-to-Engine Harness
X15
Connector 2

Engine Control Unit (ECU)

Tag and disconnect engine control unit (ECU) electrical connectors (X14 and X15) from ECU (A1). See Engine Harness (W4)
Component Location . (Group 9015-10.)

[4] - Remove cap screws (1) and remove ECU.

[5] - Repair or replace as necessary.

[6] - Install ECU (A1) and cap screws.

[7] - Connect ECU electrical connectors. See Engine Harness (W4) Component Location . (Group 9015-10.)

[8] - Connect battery negative (-) cable.

Data Converter Remove and Install


[1] -

<- Go to Section TOC Section 9015 page 306 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

LEGEND:
1 Screw (3 used)
A5 Data Converter

Data Converter

Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9000-01.)

[2] - Disconnect battery negative (-) cable.

[3] - Remove rear cover. See Rear Cover Remove and Install . (Group 9015-20.)

[4] - Disconnect data converter (A5). See Cab Harness (W1) Component Location . (Group 9015-10

[5] - Remove screws (1) and data converter.

[6] - Repair or replace as necessary.

[7] - Install data converter and screws.

[8] - Install rear cover. See Rear Cover Remove and Install . (Group 9015-20.)

[9] - Connect battery negative (-) cable.

<- Go to Section TOC Section 9015 page 307 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Monitor Controller (DSZ) Remove and Install

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

100-Pin Connector (X3) Torque 10 N·m

89 lb.-in.

[1] -
LEGEND:
1 Cap Screw (4 used)
A4 Monitor Controller (DSZ)
X20 Monitor Controller 28-Pin Connector A
X21 Monitor Controller 36-Pin Connector B
X22 Monitor Controller 16-Pin Connector D
X23 Monitor Controller 12-Pin Connector C
X24 Monitor Controller 2-Pin Connector G

Monitor Controller (DSZ)

Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9000-01.)

[2] - Remove battery negative (-) cable.

[3] - Remove rear cover. See Rear Cover Remove and Install . (Group 9015-20.)

[4] - Disconnect electrical connectors (X20—X24) from monitor controller (DSZ) (A4).

[5] - Remove cap screws (1) and monitor controller (DSZ).

[6] - Repair or replace as necessary.

[7] - Install monitor controller (DSZ) and cap screws.

[8] - Connect electrical connectors to monitor controller (DSZ). See Cab Harness (W1) Component Location and see Monitor
Harness (W3) Component Location . (Group 9015-10.)

[9] - Install rear cover. See Rear Cover Remove and Install . (Group 9015-20.)

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Section 9015 - ELECTRICAL SYSTEM Group 20: References

[10] - Connect battery negative (-) cable.

<- Go to Section TOC Section 9015 page 309 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Air Conditioner Controller (ACF) Remove and Install


[1] -
LEGEND:
1 Cap Screw (4 used)
A7 Air Conditioner Controller (ACF)

Air Conditioner Controller (ACF)

Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9001-01.)

[2] - Remove battery negative (-) cable.

[3] - Remove rear cover. See Rear Cover Remove and Install . (Group 9015-20.)

[4] - Disconnect air conditioner controller (ACF) (A7). See Heater and Air Conditioner Harness (W41) Component Location .
(Group 9015-10.)

[5] - Remove cap screws (1) and remove ACF.

[6] - Repair or replace as necessary.

[7] - Install ACF and caps screws.

[8] - Install rear cover. See Rear Cover Remove and Install . (Group 9015-20.)

[9] - Connect battery negative (-) cable.

Key Switch Remove and Install


LEGEND:
1 Cap Screw (3 used)
S1 Key Switch

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Section 9015 - ELECTRICAL SYSTEM Group 20: References

Key Switch

[1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9000-01.)

[2] - Remove right switch console. See Right Switch Console Remove and Install . (Group 9015-20.)

[3] - Disconnect key switch (S1). See Cab Harness (W1) Component Location . (Group 9015-10.)

[4] - Remove cap screws (1) and remove key switch.

[5] - Repair or replace as necessary.

[6] - Install key switch and cap screws.

[7] - Connect key switch. See Cab Harness (W1) Component Location . (Group 9015-10.)

[8] - Install right switch console. See Right Switch Console Remove and Install . (Group 9015-20.)

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Section 9015 - ELECTRICAL SYSTEM Group 20: References

Right Switch Console Remove and Install

Right Switch Console (pilot control lever not shown)

LEGEND:
1 Cap Screw (2 used)
2 Armrest
3 Storage Compartment
4 Cap Screw (3 used)
5 Rear Switch Console
6 Cap Screw (2 used)
7 Pilot Control Lever Bezel
8 Cap Screw (2 used)
9 Right Switch Console
10 Right Switch Console Bezel

[1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9000-01.)

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Section 9015 - ELECTRICAL SYSTEM Group 20: References

[2] - Remove cap screws (1) and armrest (2).

[3] - Remove storage compartment (3).

[4] - Remove cap screws (4).

[5] - Disconnect cab harness (W1) electrical connectors from rear switch console (5). See Cab Harness (W1) Component
Location . (Group 9015-10.)

[6] - Remove rear switch console.

[7] - Pull pilot control lever boot up and remove cap screws (6).

[8] - Remove pilot control lever bezel (7).

[9] - Remove cap screws (8).

[10] - Disconnect cab harness (W1) electrical connectors from right switch console (9). See Cab Harness (W1) Component
Location . (Group 9015-10.)

[11] - Remove right switch console.

[12] - Repair or replace as necessary.

[13] - Connect cab harness electrical connectors to right switch console and install right switch console and cap screws. See
Cab Harness (W1) Component Location . (Group 9015-10.)

[14] - Install pilot control lever bezel and pilot control lever boot.

[15] - Connect cab harness electrical connectors to rear switch console and install rear switch console and cap screws. See
Cab Harness (W1) Component Location . (Group 9015-10.)

[16] - Install storage compartment.

[17] - Install armrest and cap screws.

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Section 9015 - ELECTRICAL SYSTEM Group 20: References

Left Switch Console Remove and Install

Left Switch Console (pilot control lever not shown)

LEGEND:
1 Cap Screw (2 used)
2 Washer (2 used)
3 Armrest
4 Cap Screw (3 used)
5 Left Switch Console

[1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9000-01.)

[2] - Remove cap screws (1) and washers (2).

[3] - Remove armrest (3).

[4] - Pull pilot control lever boot up and remove cap screws (4).

[5] - Lift to remove left switch console (5).

[6] - Tag and disconnect cab harness (W1) electrical connectors. See Cab Harness (W1) Component Location . (Group
9015-10.)

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Section 9015 - ELECTRICAL SYSTEM Group 20: References

[7] - Repair or replace as necessary.

[8] - Connect cab harness electrical connectors. See Cab Harness (W1) Component Location . (Group 9015-10.)

[9] - Install left switch console.

[10] - Install cap screws and pilot control lever boot.

[11] - Install armrest.

[12] - Install cap screws and washers.

Travel Alarm Remove and Install


LEGEND:
1 Cap Screw (2 used)
H4 Travel Alarm
W26 Travel Alarm Harness

Travel Alarm

[1] -

→NOTE:

Travel alarm (H4) is located in the hydraulic pump compartment below the main hydraulic pump.

Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9000-01.)

[2] - Disconnect travel alarm (H4). See Travel Alarm Harness (W26) Component Location . (Group 9015-10.)

[3] - Remove cap screws (1) and remove travel alarm.

[4] - Repair or replace as necessary.

[5] - Install travel alarm and cap screws.

[6] - Connect electrical connector to (H4).

Disconnect Tab Retainer Connectors

<- Go to Section TOC Section 9015 page 315 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

IMPORTANT:

Do not disconnect electrical connectors while the engine is running. Damage to controllers or other
components may result. Disconnect connectors only when instructed during a test or check.

DO NOT pull on wires to disconnect connector or damage to wires or connector may result. Grasp both
halves of the connector to pull connector apart.

[1] -
LEGEND:
A Retainer Tab

Retainer Tab

Push retainer tab (A).

[2] - While holding tab in, grasp other half of connector and pull connector halves apart.

[3] - To connect, push connector halves together until retainer “clicks”.

Disconnecting Spring Wire Clip Connectors

Spring Wire Clip Connectors

[1] - Remove wire clip from connector.

<- Go to Section TOC Section 9015 page 316 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Grasp connector; move connector halves from side-to-side as they′re being pulled apart. Do not pull on wiring leads.

[2] - To reconnect, install wire clip on connector half, push connector halves together until wire retainer “clicks” over tabs.

<- Go to Section TOC Section 9015 page 317 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Replace DEUTSCH™ Connectors

Deutsch ™ Connector Extractor Tool

Slide Extractor Tool

[1] - Select correct size extractor tool for size of wire to be removed:

JDG361 Extractor Tool for 12 to 14 gauge wire.


JDG362 Extractor Tool for 16 to 18 gauge wire.
JDG363 Extractor Tool for 20 gauge wire.

[2] - Start correct size extractor tool over wire at handle (A).

[3] - Slide extractor tool rearward along wire until tool tip snaps onto wire.

[4] -

IMPORTANT:

Do NOT twist tool when inserting in connector.

Slide extractor tool along wire into connector body until it is positioned over terminal contact.

[5] - Pull wire out of connector body, using extractor tool.

[6] -

IMPORTANT:

Install contact in proper location using correct size grommet.

<- Go to Section TOC Section 9015 page 318 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Push Contact

Push contact straight into connector body until positive stop is felt.

[7] - Pull on wire slightly to be certain contact is locked in place.

[8] - Transfer remaining wires to correct terminal in new connector.

<- Go to Section TOC Section 9015 page 319 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Replace DEUTSCH™ Rectangular or Triangular Connectors


[1] -

→NOTE:

Connector shown is the female half or a 4-pin square connector. Other similar styles of Deutsch™
connectors can be serviced using the same procedure.

LEGEND:
1 Connector
2 Locking Wedge

Removing 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.

DEUTSCH ™ Connector Service Tool

JDG1383

Remove secondary contact lock.

[3] -
LEGEND:
3 Primary Locking Latches

Releasing Primary Latch

<- Go to Section TOC Section 9015 page 320 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Removing Wire

Release primary locking latch (3) next to the pin to be removed using screwdriver on JDG1383 service tool.

[4] - Gently pull wire out from back of connector.

[5] - Replace connector contact as necessary. See Install DEUTSCH™ Contact . (Group 9015-20.)

[6] - Install wire terminal back into connector until it clicks into place.

[7] -

→NOTE:

Locking wedge in 2-pin connector is not symmetrical. Position latch shoulder next to terminals.

Install locking wedge until it snaps into place.

<- Go to Section TOC Section 9015 page 321 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Install DEUTSCH™ Contact

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.

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.

<- Go to Section TOC Section 9015 page 322 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Crimp

Insert wire in contact and crimp until handle touches stop.

[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.

Inspect Deutsch ™ Contact

Inspect contact to be certain all wires are in crimped barrel.

<- Go to Section TOC Section 9015 page 323 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Replace WEATHER PACK™ Connector

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:

Weather Pack ™ 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.

<- Go to Section TOC Section 9015 page 324 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

[6] - Transfer remaining wires to correct terminal in new connector.

[7] - Close connector body.

<- Go to Section TOC Section 9015 page 325 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Install WEATHER PACK™ Contact

Correct Size Cable

Strip Insulation

→NOTE:

Cable seals are color coded for three sizes of wire:

Green - 18 to 20 gauge wire


Gray - 14 to 16 gauge wire
Blue - 10 to 12 gauge wire

[1] - Slip correct size cable seal on wire.

[2] - Strip insulation from wire to expose 6 mm (1/4 in.) and align cable seal with edge of insulation.

[3] -

→NOTE:

Contacts have numbered identification for two sizes of wire: a) #15 for 14 to 16 gauge wire b) #19 for 18
to 20 gauge wire

Put proper size contact on wire and crimp in place with a "W" type crimp, using JDG783 Terminal Applicator.

[4] -

<- Go to Section TOC Section 9015 page 326 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

IMPORTANT:

Weather Pack ™ Contact Installation

Proper contact installation for "sleeve" (A) and "pin” (B) is shown.

Secure cable seal to contact as shown, using JDG783 Terminal Applicator.

<- Go to Section TOC Section 9015 page 327 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Replace (Pull Type) Metri-Pack™ Connectors


LEGEND:
A Connector
B “T” Pin
C Body Socket
D Locking Tab
E Push Terminal

Connector

Socket

Terminals

Disconnect the Metri-Pack ™ connector (A). Remove tie bands and tape.

Insert a “T” pin (B) 6.4 mm (1/4 in.) into connector body socket (C).

→NOTE:

Use JDG777

[ Included in JT07195A Electrical Repair Kit ]


Terminal Extraction Tool or “T” pin to remove terminals.

Angle “T” pin so pin tip slides close to the plastic socket edge pushing terminal locking tab (D) inward.

Remove “T” pin and push terminal (E) out of socket.

Remove terminal, cut strip and crimp wire through connector.

Check to make sure locking tab on new terminal is in outward position, then pull on wire until terminal locks in connector body
socket.

<- Go to Section TOC Section 9015 page 328 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

→NOTE:

Terminal will seat only one way. If terminal does not pull into the connector body socket, check to make
sure terminal is aligned correctly.

Replace (Push Type) Metri-Pack™ Connectors


LEGEND:
A Connector Lock
B Extraction Tool JDG777
C Connector Body Socket
D Terminal
E Locking Tab

Push Type Connector

Disconnect the Metri-Pack ™ connector. Remove the tie bands and tape.

Remove the connector lock (A), and mark wire colors for identification.

Identify wire color locations with connector terminal letters.

Insert JDG776 or JDG777

[ Included in JT07195A Electrical Repair Kit ]


Terminal Extraction Tool (B) into connector body socket (C) pushing the terminal locking tab inward.

→NOTE:

Use JDG776 Extraction Tool with 56, 280 and 630 series METRI-PACK® terminals. Use JDG777 Extraction
Tool with 150 series METRI-PACK® terminals.

Remove extraction tool and pull terminal (D) out of the socket.

Replace terminal. Make sure locking tab (E) on the new terminal is in the outward position.

terminal into connector body socket until terminal locks.

<- Go to Section TOC Section 9015 page 329 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Replace CINCH™ Connectors


[1] -
LEGEND:
1 Extraction Tool
2 Secondary Lock Locking Tabs
3 Secondary Lock

Unlock Secondary Lock of Cinch ™ Connector

Remove extraction tool (1) from the loading side of connector.

[2] - Insert blade of extraction tool into locking tabs (2) of secondary lock (3). Rotate tool away from the connector to pry one
side of the secondary lock out of the locked position. Repeat this step for the other locking tab.

→NOTE:

After unlocking one side of the secondary lock, a screw driver or similar device may need to be used to
hold it in the unlocked position while unlocking the second locking tab.

[3] -
LEGEND:
3 Secondary Lock

Remove Secondary Lock

Remove secondary lock (3).

[4] -

<- Go to Section TOC Section 9015 page 330 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Removing Terminals

Insert pointed side of extraction tool into the contact cavity so that the flat side of tool faces secondary lock cavity (4). This will
release the primary contact locking tab.

[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.

<- Go to Section TOC Section 9015 page 331 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Install CINCH™ Contact


[1] -

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.

Crimper

JDG708

Install Cinch ™ contacts

[2] -

IMPORTANT:

Make sure that both sides of the insulation barrel are started evenly into the crimping section. Do NOT
attempt to crimp an improperly positioned contact.

Position the contact so that the mating end of the contact (G) is on the locator side of the tool (C). Wire and insulation tabs (I
and J) should point to top of tool (A). Butt wire tab (I) against the movable locator (C).
<- Go to Section TOC Section 9015 page 332 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

[3] - Hold the contact in position and squeeze the tool handles together until ratchet engages sufficiently to hold the contact in
position. Do NOT deform wire and insulation tabs (I and J).

[4] - Insert stripped wire into contact insulation and wire tabs until it is butted against locator (C).

[5] - Hold the wire in place. Squeeze tool handles together until ratchet releases. Allow tool handles to open and remove
crimped contact.

[6] - Install contact into connector. (Go to procedure in this group.)

<- Go to Section TOC Section 9015 page 333 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

Repair 32 and 48 Way CINCH™ Connectors


[1] -
LEGEND:
A Tab
B Locking Cam
C Cover Locks
D Cover

Cinch ™ Connector

CINCH™ Cover Lock Tabs

CINCH™ Cover

Press tab (A) and rotate locking cam (B) 90° to disconnect connector from flexbox.

[2] - Move cover locks (C) slightly outward with a small screwdriver.

[3] - Remove cover (D) away from wires.

[4] -

<- Go to Section TOC Section 9015 page 334 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

LEGEND:
A Terminal Lock

Terminal Lock

Pull terminal lock (A) out as far as it will go, but do not force its removal.

[5] -

→NOTE:

JDG1725 Terminal Extractor Tool has two different sizes of pins, 0.6 for smaller 20 gauge holes (A), and
1.5 for larger 16 and 18 gauge holes (B).

LEGEND:
A 20 Gauge Holes
B 16 & 18 Gauge Holes
C Holes
D Terminal Hole
E Terminal

Connector Holes

CINCH™ Connector Terminal Holes

<- Go to Section TOC Section 9015 page 335 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

CINCH™ Terminal Extraction Tool

Insert JDG1725 Terminal Extractor Tool

Flexbox Terminal Repair Kit

JDG1744

JDG1744

[ Includes JDG1725 Terminal Removal Tool and JDG1727 Crimping Tool ]

Repair CINCH™ wire connectors

into holes (C) next to terminal opening (D) to unlock terminal.

[6] - Pull wire and terminal (E) from connector body.

[7] -
LEGEND:
A CINCH™ Terminal Crimping Tool
B Terminal Receptacle
C Terminal
D Wire

Crimp terminal

<- Go to Section TOC Section 9015 page 336 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References

CINCH™ Terminal Crimping Tool

Terminal Crimping Tool

Remove old terminal and strip 4.85 mm (0.191 in.) of insulation from wire.

[8] - Grip JDG1727 Terminal Crimping Tool (A) securely, and squeeze ratcheting mechanism until it bottoms out. Then allow it
to open completely

[9] - With tool in ready position (open handle), open terminal receptacle (B).

[10] - Insert terminal (C) into proper wire gauge window, crimp wings facing up.

[11] - Close terminal receptacle (B).

[12] - Squeeze handle until two clicks are heard.

[13] - Insert stripped wire (D) into terminal.

[14] - Hold wire stationary and squeeze tool together until ratchet releases.

[15] - Remove terminated wire from tool.

[16] - Terminal into connector body until fully seated. Pull on wire slightly to ensure terminal is locked in position.

[17] - Push terminal lock closed.

[18] - Install cover.

<- Go to Section TOC Section 9015 page 337 130G Excavator Diagnostic
POWER TRAIN (g) by Belgreen v2.0

[19] - Install connector to controller and close connector body locking cam.

Remove Connector Body from Blade Terminals

Blade Terminals

[1] - Depress locking tang (A) on terminal, using a small screw driver. Slide connector body off.

[2] - Be sure to bend locking tang back to its original position (B) before installing connector body.

<- Go to Section TOC Section 9020 page 338 130G Excavator Diagnostic
130G Excavator Diagnostic (g) by Belgreen v2.1

Section 9020 - POWER TRAIN


Table of contents
Group 05 - Theory of Operation ............................................................................................................. 1
Track Adjuster and Recoil Spring Operation ......................................................................................... 1
Travel Gear Case Operation ................................................................................................................. 3
Group 15 - Diagnostic Information ........................................................................................................ 4
Noisy or Loose Track Chain Diagnostic Procedure ................................................................................ 4
Tight Track Chain Diagnostic Procedure ............................................................................................... 4
Frequent Track Chain Sag Adjustment Required Diagnostic Procedure ............................................... 5
Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers Diagnostic Procedure .......... 5
Bent Track Shoes Diagnostic Procedure ............................................................................................... 6
‘Popping” of Track Diagnostic Procedure ............................................................................................. 7
Cracked Track Link Diagnostic Procedure ............................................................................................ 8
Chipped Link Rails Diagnostic Procedure .............................................................................................. 9
Individual Undercarriage Component Wear Diagnostic Procedure ....................................................... 9
Measure Swing Bearing Wear ............................................................................................................. 11

<- Go to Global Table of contents 130G Excavator Diagnostic


Section 9020 - POWER TRAIN Group 05: Theory of Operation

Group 05 - Theory of Operation


Track Adjuster and Recoil Spring Operation

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

The track adjuster and recoil spring is supported by the track frame. Shock loads on the track and front idler (6) are absorbed
by the recoil spring (8).

To decrease track sag, grease (9) is pumped into the cylinder (4) through the grease fitting (1). The grease pushes the piston
(7) against the yoke moving the front idler (6) out, reducing track sag. The grease fitting (1) is protected from excess pressure
by a check ball.

CAUTION:

Prevent possible injury from high pressure grease. DO NOT remove grease fitting (1) from valve (2).

<- Go to Section TOC Section 9020 page 1 130G Excavator Diagnostic


Section 9020 - POWER TRAIN Group 05: Theory of Operation

Increasing track sag is accomplished by loosening the valve (2) to release grease from the cylinder through the grease relief
passage (3). When releasing grease from the cylinder, only loosen the valve (2).

<- Go to Section TOC Section 9020 page 2 130G Excavator Diagnostic


Section 9020 - POWER TRAIN Group 15: Diagnostic Information

Travel Gear Case Operation

Travel Gear Case Operation

LEGEND:
1 Ring Gear
2 Second Stage Carrier
3 Second Stage Sun Gear
4 First Stage Carrier
5 First Stage Sun Gear (input shaft)
6 First Stage Planetary Gear
7 Second Stage Planetary Gear
8 Bearing Nut
9 Sprocket
10 Drum
11 Travel Motor Housing
12 Bearing Cone and Cup (2 used)
13 Travel Motor Valve Housing
14 Thrust Pad

The travel gear case is a two-stage planetary reduction gear system. It converts high speed, low torque from travel motor into
low speed, high torque rotation. The gear case is interchangeable from right side to left side of machine. The travel gear case
housing is fastened to the track frame.

The travel motor drive shaft is connected to first stage sun gear (input shaft) (5) by a spline coupler. Travel motion is
transferred from first stage sun gear to sprocket (9) by two planetary gear sets that mesh with the ring gear (1). As the first
stage sun gear is rotated, it rotates the first stage planetary gear (6), causing the first stage carrier (4) to rotate.

The first stage carrier is connected to second stage sun gear (3). The second stage sun gear meshes with second stage
planetary gear (7). Second stage planetary gears are connected to second stage carrier (2). The second stage carrier is
fastened to the gear case housing and does not rotate. The rotation is transferred to the ring gear. The ring gear, drum (10),
and sprocket are fastened together and turn as one unit which rotates the track to move the machine. A replaceable thrust pad
(14) is used in the gear case cover to keep the first stage sun gear in position.

<- Go to Section TOC Section 9020 page 3 130G Excavator Diagnostic


Section 9020 - POWER TRAIN Group 15: Diagnostic Information

Group 15 - Diagnostic Information


Noisy or Loose Track Chain
81

Noisy or Loose Track Chain Diagnostic Procedure


( 1 ) Incorrect Track Sag Adjustment

Action:

Check track sag. See Check and Adjust Track Sag . (Operator′s Manual.)

Is track sag within specification?

Result:

YES:Go to Loose Track Shoes.

NO:Adjust track sag.

( 2 ) Loose Track Shoes

Action:

Remove loose track shoes to clean material from between track shoes and links. Install track shoes and tighten cap screws in
proper sequence. See Track Shoe Remove and Install . (Group 0130.)

Are track shoes properly installed and clean of debris?

Result:

YES:Go to Grease Leaking from Track Adjuster Seals, Grease Fittings, or Relief Valve.

NO:Clean and install track shoes properly.

( 3 ) Grease Leaking from Track Adjuster Seals, Grease Fittings, or Relief Valve

Action:

Check that grease fittings and valves are tight. Replace grease fittings or relief valves. See Track Adjuster and Recoil Spring
Disassemble and Assemble for seal replacement. (Group 0130.)

Are grease fittings, relief valves, or seals leaking?

Result:

YES:Replace grease fitting, relief valve or seals as necessary.

NO:Diagnostic checkout complete.

Tight Track Chain


81

Tight Track Chain Diagnostic Procedure


( 1 ) Material Packing in Sprocket

Action:

Clean material from sprockets.

Is sprocket free of material?

<- Go to Section TOC Section 9020 page 4 130G Excavator Diagnostic


Section 9020 - POWER TRAIN Group 15: Diagnostic Information

Result:

YES:Go to Track Sag Less Than Specification.

NO:Clean material from sprockets.

( 2 ) Track Sag Less Than Specification

Action:

Check track sag. See Check and Adjust Track Sag . (Operator′s Manual.)

Is track sag within specification?

Result:

YES:Diagnostic checkout complete.

NO:Adjust track sag.

Frequent Track Chain Sag Adjustment Required


81

Frequent Track Chain Sag Adjustment Required Diagnostic Procedure


( 1 ) Grease Leaking from Track Adjuster Seals, Grease Fittings, or Relief Valve

Action:

Check that grease fittings and valve are tight. Replace grease fittings or relief valve. See Track Adjuster and Recoil Spring
Disassemble and Assemble for seal replacement. (Group 0130.)

Are grease fittings, relief valves, or seals leaking?

Result:

YES:Replace grease fitting, relief valve or seals as necessary.

NO:Diagnostic checkout complete.

Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers
81

Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers
Diagnostic Procedure
( 1 ) Loose Plugs, Worn or Damaged O-rings, or Metal Faced Seals

Action:

Check for loose, worn or damaged plugs, O-rings, or metal faced seals.

Are plugs, O-rings or metal faced seals leaking?

Result:

YES:Repair plugs, O-rings, or metal faced seals. See Front Idler Remove and Install , see Track Roller Remove and Install , or
see Track Carrier Roller Remove and Install . (Group 0130.)

NO:Diagnostic checkout complete.

<- Go to Section TOC Section 9020 page 5 130G Excavator Diagnostic


Section 9020 - POWER TRAIN Group 15: Diagnostic Information

Bent Track Shoes


81

Bent Track Shoes Diagnostic Procedure


( 1 ) Excessive Grouser Wear

Action:

Measure grouser height specification for rebuilding or replacing track shoes. See 130G Three Bar Grouser Height . (SP326VOL1
Undercarriage Appraisal Manual.)

Is grouser height to specification?

Result:

YES:Go to Loose Track Shoes.

NO:Repair or replace track shoes. See Track Shoe Remove and Install . (Group 0130.)

( 2 ) Loose Track Shoes

Action:

Remove loose track shoes to clean material from between track shoes and links. Install track shoes and tighten cap screws in
proper sequence. See Track Shoe Remove and Install . (Group 0130.)

Are track shoes properly installed?

Result:

YES:Go to Excessive High Speed Operation On Rough and Rocky Terrain.

NO:Install track shoes properly.

( 3 ) Excessive High Speed Operation On Rough and Rocky Terrain

Action:

Reduce speed on rough and rocky terrain. Place travel speed switch in slow speed (turtle) mode. See Switch Panel . (Operator′s
Manual.)

Is travel speed switch in slow seed (turtle) mode?

Result:

YES:Diagnostic checkout complete

NO:Place travel speed switch in slow speed (turtle) mode.

<- Go to Section TOC Section 9020 page 6 130G Excavator Diagnostic


Section 9020 - POWER TRAIN Group 15: Diagnostic Information

“Popping” of Track
81

“Popping” of Track Diagnostic Procedure


( 1 ) High Travel Loads in Reverse

Action:

High travel speeds in reverse can cause the recoil spring to retract allowing sprocket to slip in chain. Minimize travel loads in
reverse.

Are travel loads in reverse minimized?

Result:

YES:Go to Material Packing in Sprocket.

NO:Minimize travel loads in reverse.

( 2 ) Material Packing in Sprocket

Action:

Clean material from sprockets.

Is sprocket free of material?

Result:

YES:Go to Track Sag Less Than Specification.

NO:Clean material from sprockets.

( 3 ) Track Sag Less Than Specification

Action:

Check track sag. See Check and Adjust Track Sag . (Operator′s Manual.)

Is track sag within specification?

Result:

YES:Diagnostic checkout complete.

NO:Adjust track sag.

<- Go to Section TOC Section 9020 page 7 130G Excavator Diagnostic


Section 9020 - POWER TRAIN Group 15: Diagnostic Information

Cracked Track Link


81

Cracked Track Link Diagnostic Procedure


( 1 ) Material Packing in Sprocket

Action:

Clean material from sprockets.

Is sprocket free of material?

Result:

YES:Go to Track Sag Less Than Specification.

NO:Clean material from sprockets.

( 2 ) Track Sag Less Than Specification

Action:

Check track sag. See Check and Adjust Track Sag . (Operator′s Manual.)

Is track sag within specification?

Result:

YES:Go to Excessive High Speed Operation On Rough and Rocky Terrain.

NO:Adjust track sag.

( 3 ) Excessive High Speed Operation On Rough and Rocky Terrain

Action:

Reduce speed on rough and rocky terrain. Place travel speed switch in slow speed (turtle) mode. See Switch Panel . (Operator′s
Manual.)

Is travel speed switch in slow seed (turtle) mode?

Result:

YES:Go to Track Shoes too Wide for Ground Conditions.

NO:Place travel speed switch in slow speed (turtle) mode.

( 4 ) Track Shoes too Wide for Ground Conditions

Action:

Use the narrowest possible shoes for required flotation.

Are the narrowest possible shoes for required flotation being used?

Result:

YES:Diagnostic checkout complete.

NO:Select the narrowest shoes possible for required flotation.

<- Go to Section TOC Section 9020 page 8 130G Excavator Diagnostic


Section 9020 - POWER TRAIN Group 15: Diagnostic Information

Chipped Link Rails


81

Chipped Link Rails Diagnostic Procedure


( 1 ) Repeated High Impacts With Roller Tread On Flanges Caused by a Loose or Snaky Track

Action:

Check track sag. See Check and Adjust Track Sag . (Operator′s Manual.)

Is track sag within specification?

Result:

YES:Go to Track Shoes too Wide for Ground Conditions.

NO:Adjust track sag.

( 2 ) Track Shoes too Wide for Ground Conditions

Action:

Use the narrowest possible shoes for required flotation.

Are the narrowest possible shoes for required flotation being used?

Result:

YES:Go to Correct Track Chain Pitch.

NO:Select the narrowest shoes possible for required flotation.

( 3 ) Correct Track Chain Pitch

Action:

Check track chain pitch specifications. See 130G Track Chain Pitch . (SP326VOL1 Undercarriage Appraisal Manual.)

Is track chain pitch within specification?

Result:

YES:Diagnostic checkout complete.

NO:Repair or replace track chain as necessary. See Track Chain Remove and Install . (Group 0130.)

Individual Undercarriage Component Wear


81

Individual Undercarriage Component Wear Diagnostic Procedure


( 1 ) Some Wear is Normal

Action:

Measure components to determine if they can be rebuilt using weld. See Component Rebuild . (SP326VOL1 Undercarriage
Appraisal Manual.)

Is component wear within specification?

Result:

YES:Diagnostic checkout complete.

<- Go to Section TOC Section 9020 page 9 130G Excavator Diagnostic


Section 9020 - POWER TRAIN Group 15: Diagnostic Information

NO:Repair or replace components as necessary.

<- Go to Section TOC Section 9020 page 10 130G Excavator Diagnostic


Section 9020 - POWER TRAIN Group 15: Diagnostic Information

Measure Swing Bearing Wear


Specifications

SPECIFICATIONS

Swing Bearing

0.2—1.00 mm normal
Swing Bearing Play
0.008—0.039 in. normal

2.80 mm maximum allowable


Swing Bearing Play
0.110 in. maximum allowable

Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Dial Indicator

[1] -

CAUTION:

Avoid personal injury or death. Stay clear of moving parts. Position dial indicator so it can be seen while
the operator can see you.

→NOTE:

Two people are needed to take the measurement. One to operate the machine and one to take the
readings.

<- Go to Section TOC Section 9020 page 11 130G Excavator Diagnostic


Section 9020 - POWER TRAIN Group 15: Diagnostic Information

Dial Indicator Location

<- Go to Section TOC Section 9020 page 12 130G Excavator Diagnostic


Section 9020 - POWER TRAIN Group 15: Diagnostic Information

Machine Positions for Check

Check that swing bearing-to-main frame cap screws are tightened to specification.

[2] - Check that swing bearing is lubricated with the specified grease. See Track Adjuster, Working Tool Pivot, Swing Bearing,
and Swing Bearing Gear Grease . (Operator′s Manual.)

[3] - Check that bearing rotation is smooth and without noise.

[4] -

→NOTE:

Readings vary depending on the location of dial indicator base with respect to the swing bearing support
tower. To obtain an accurate reading, the base for dial indicator must be attached to the support tower
or as close to it as possible.

Install dial indicator with needle point contacting bottom face of bearing outer race and base attached to the swing bearing
support tower or as close to it as possible.

Dial Indicator

To measure swing bearing play.

[5] - Move boom and arm to the position shown with bucket off the ground. Bucket must be empty.

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HYDRAULIC SYSTEM (g) by Belgreen v2.0

[6] - Turn dial indicator to zero.

[7] - Lower the boom to raise front idlers off the ground approximately 500 mm (20 in.).

[8] - Record dial indicator reading.

Item Measurement Specification

Swing Bearing
Swing Bearing Play 0.2—1.00 mm normal

0.008—0.039 in. normal

Play 2.80 mm maximum allowable

0.110 in. maximum allowable

If play is more than specified, check for wear to balls, spacers, and bearing race. See Swing Bearing Remove and Install .
(Group 4350.)

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130G Excavator Diagnostic (g) by Belgreen v2.1

Section 9025 - HYDRAULIC SYSTEM


Table of contents
Group 05 - Theory of Operation ............................................................................................................. 1
Hydraulic System Operation ................................................................................................................. 1
Fan Drive Hydraulic System Operation ................................................................................................. 2
Pilot System Operation ......................................................................................................................... 4
Pilot Pump, Pressure Regulating Valve, and Filter Operation ............................................................... 6
Pilot Shutoff Solenoid Valve Operation ................................................................................................. 7
Pilot Control Valve Operation ............................................................................................................. 12
Travel Pilot Control Valve Operation ................................................................................................... 14
Pilot Operation of Control Valve Operation ......................................................................................... 17
Pilot Signal Manifold Operation ........................................................................................................... 18
Pump 1, Pump 2, and Drive Gear Case Operation .............................................................................. 28
Pump 1 and Pump 2 Regulator Operation .......................................................................................... 32
Engine Speed Sensing Control Circuit Operation ................................................................................ 39
Control Valve Operation ..................................................................................................................... 41
Control Valve Check Valves Identification and Operation ................................................................... 53
Main Relief Valve Circuit Operation .................................................................................................... 56
Circuit Relief and Anticavitation Valve Operation ............................................................................... 60
Travel Flow Combiner Valve Operation .............................................................................................. 62
Auxiliary Flow Combiner Valve and Bypass Shutoff Valve Operation ................................................. 67
Boom Lower Meter-In Cut Valve Operation ......................................................................................... 72
Boom Regenerative Valve Circuit Operation ...................................................................................... 76
Dig Regenerative Valve Circuit Operation .......................................................................................... 78
Arm Regenerative Valve Circuit Operation ......................................................................................... 85
Bucket Regenerative Valve Circuit Operation ..................................................................................... 92
Boom and Arm Reduced Leakage Valves Operation ........................................................................... 94
Arm 1 Flow Rate Control Valve Circuit Operation ............................................................................... 97
Arm 2 Flow Rate Control Valve Circuit Operation ............................................................................. 103
Bucket Flow Rate Control Valve Circuit Operation ............................................................................ 109
Boom Flow Rate Control Valve Circuit Operation .............................................................................. 115
Auxiliary Flow Rate Control Valve Circuit Operation ......................................................................... 121
Blade Circuit Operation—If Equipped ............................................................................................... 127
Swing Reduction Gear Case Operation ............................................................................................. 130
Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation .................................... 131
Swing Motor Park Brake Release Circuit Operation .......................................................................... 134
Center Joint Operation ...................................................................................................................... 136
Travel Motor and Park Brake Valve Operation .................................................................................. 138
Travel Motor Speed Circuit Operation ............................................................................................... 145
Cylinder Operation ........................................................................................................................... 149
Return Filter Operation ..................................................................................................................... 151
Auxiliary System Operation .............................................................................................................. 151
Auxiliary Pilot Control Valve Operation ............................................................................................. 153
Flow Rate Select Solenoid Valve Operation ...................................................................................... 161
Flow Rate Pressure Reducing Valve Operation ................................................................................. 162
Selector Valve Solenoid Valve Operation .......................................................................................... 163
Selector Valve Operation .................................................................................................................. 163
Auxiliary Shuttle Valve Operation ..................................................................................................... 164
Auxiliary High Flow Line Kit Operation .............................................................................................. 167
Two Way Solenoid Kit Operation ...................................................................................................... 172
Two Pump Combined Flow Kit Operation .......................................................................................... 177
Group 15 - Diagnostic Information .................................................................................................... 185

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130G Excavator Diagnostic (g) by Belgreen v2.1

All Hydraulic Functions Slow Diagnostic Procedure .......................................................................... 185


Hydraulic Oil Overheats Diagnostic Procedure ................................................................................. 189
No Hydraulic Functions Diagnostic Procedure .................................................................................. 192
Poor Combined Operation Diagnostic Procedure .............................................................................. 194
All Functions Cannot Be Operated Diagnostic Procedure ................................................................. 195
Function Does Not Stop When Control Lever Released Diagnostic Procedure .................................. 196
Some Functions Cannot Be Operated, All Others Are Normal Diagnostic Procedure ........................ 197
All Functions Slow Diagnostic Procedure .......................................................................................... 199
Functions Move in Opposite Direction Diagnostic Procedure ............................................................ 200
All Dig Functions Slow or No Power Diagnostic Procedure ................................................................ 201
Some Dig Functions Slow (Not All) Diagnostic Procedure ................................................................. 202
Load Drifts Down When Control Lever is in Neutral Position Diagnostic Procedure .......................... 204
Load Falls When Control Valve is Actuated To Raise Load With Engine Running at Slow Idle Diagnostic
Procedure .................................................................................................................................. 205
H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal Diagnostic Procedure
................................................................................................................................................... 206
Swing Speed Slow in Both Directions Diagnostic Procedure ............................................................. 208
Swing Speed Slow or Does Not Operate in One Direction Diagnostic Procedure .............................. 210
Upperstructure Drift with Swing Valve in Neutral Diagnostic Procedure .......................................... 212
Swing Function Does Not Operate Diagnostic Procedure ................................................................. 214
Travel Park Brakes Do Not Apply Diagnostic Procedure ................................................................... 215
Track Will Not Move in One Direction Diagnostic Procedure ............................................................. 216
Track Will Not Move in Either Direction Diagnostic Procedure .......................................................... 218
Machine Mistracks at All Speeds in Both Directions Diagnostic Procedure ....................................... 220
Slow Travel Speed or Low Power Diagnostic Procedure ................................................................... 222
Combined Travel and Dig Functions Slow or No Power Diagnostic Procedure .................................. 224
Travel is ‘Jerky” Diagnostic Procedure .............................................................................................. 225
Machine Will Not Hold Back and Park Brakes Engage and Disengage When Traveling Down an Incline
Diagnostic Procedure ................................................................................................................. 226
Machine Will Not Turn Smoothly in One Direction or Park Brake Grabs Diagnostic Procedure ......... 226
Pump 1, Pump 2, and Pilot Pump Line Identification ........................................................................ 227
Control Valve Line Identification ....................................................................................................... 229
Swing Motor Line Identification ........................................................................................................ 232
Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern ...................... 233
Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern ........................ 235
Pilot Signal Manifold-to-Control Valve Line Connection .................................................................... 237
Travel System Component Location ................................................................................................. 240
Travel Hydraulic System Line Connection ........................................................................................ 242
Blade Hydraulic System Component Location .................................................................................. 244
Auxiliary Attachment Schematic ...................................................................................................... 246
Auxiliary System Line Connections ................................................................................................... 255
Hydraulic System Schematic ............................................................................................................ 260
Hydraulic System Component Location ............................................................................................ 276
Hydraulic System Line Connections ................................................................................................. 278
Fan Drive System Component Location ............................................................................................ 280
Fan Drive Hydraulic System Schematic ............................................................................................ 282
Group 25 - Tests ................................................................................................................................... 284
JT05800 Digital Thermometer Installation ........................................................................................ 284
JT02156A Digital Pressure and Temperature Analyzer Kit Installation .............................................. 285
Hydraulic Oil Cleanup Procedure ...................................................................................................... 287
Hydraulic Oil Tank Pressure Release Procedure ............................................................................... 289
Hydraulic Oil Warm-Up Procedure .................................................................................................... 291
Pilot Pressure Regulating Valve Test and Adjustment ...................................................................... 293

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130G Excavator Diagnostic (g) by Belgreen v2.1

Control Valve Spool Actuating Pilot Pressure Test ............................................................................ 297


Dig Regenerative Solenoid Valve Test and Adjustment .................................................................... 300
Arm Regenerative Solenoid Valve Test and Adjustment .................................................................. 305
Power Dig Solenoid Valve Test and Adjustment ............................................................................... 310
Arm 2 Flow Control Solenoid Valve Test and Adjustment ................................................................. 315
Torque Control Solenoid Valve Test and Adjustment ........................................................................ 320
Pump Control Pilot Pressure Signal Test ........................................................................................... 324
Main Relief and Power Dig Valve Test and Adjustment .................................................................... 326
Circuit Relief Valve Test and Adjustment ......................................................................................... 332
Blade Main Relief Valve Test and Adjustment .................................................................................. 338
Swing Motor Crossover Relief Valve Test and Adjustment ............................................................... 343
Travel Motor Crossover Relief Valve Test and Adjustment ............................................................... 348
Pump Regulator Test and Adjustment—Minimum Flow .................................................................... 354
Pump Regulator Test and Adjustment—Maximum Flow ................................................................... 357
Pump Flow Test ................................................................................................................................ 360
Swing Motor Leakage Test ................................................................................................................ 368
Travel Motor Leakage Test ............................................................................................................... 371
Cylinder Drift Test—Boom, Arm, and Bucket .................................................................................... 375
Fan Drive Pump Flow Test ................................................................................................................ 378
Fan Speed Test ................................................................................................................................. 381

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Group 05 - Theory of Operation


Hydraulic System Operation
Main hydraulic system is an open-center hydraulic system.

The main hydraulic pump housing contains two pumps in an in-line configuration; pump 1 and pump 2. The pump 1 end of
housing is fastened to the engine flywheel housing. Engine output is transmitted to the pump 1 drive shaft through a flex
coupling. Engine output is transmitted from the pump 1 drive shaft to the pump 2 drive shaft and then to the pilot pump drive
shaft. The pilot pump is mounted on the pump 2 end of housing. The pumps are driven at engine speed.

For additional information, see Pump 1, Pump 2, and Drive Gear Case Operation . (Group 9025-05.) Also, see Pilot Pump,
Pressure Regulating Valve, and Filter Operation . (Group 9025-05.)

Hydraulic oil flow is through suction screen, out of the hydraulic oil tank, and through the suction line to the pumps. Pump 1
delivers high pressure oil to the front control valve (4-spool). Pump 2 delivers high pressure oil to the rear control valve (5-
spool). High pressure oil is routed to the motors and cylinders by valve spools for their respective function. Hydraulic oil tank is
pressurized to ensure that oil flows from the tank, through the suction line, and into the pumps.

For additional information, see Control Valve Operation . (Group 9025-05.) Also, see Control Valve Check Valves Identification
and Operation . (Group 9025-05.)

Return oil from the motors and cylinders is routed into return passages in control valve by the valve spools. From the return
passages, return oil flows out of control valve, through hydraulic oil cooler, through the restriction valve, and then through the
return filter in the hydraulic oil tank. The restriction valve is used in the return line after the hydraulic oil cooler to create some
back pressure in the return passage of control valve. The back pressure ensures a flow of makeup oil to keep the swing motor
case full of oil and a flow of oil through the anticavitation valves to prevent cylinder cavitation.

For additional information, see Circuit Relief and Anticavitation Valve Operation . (Group 9025-05.)

The hydraulic oil cooler bypass valve opens to route return oil around hydraulic oil cooler and directly to hydraulic oil tank when
resistance to flow through oil cooler becomes high because the oil is cold (high viscosity), there is a surge of return oil, or oil
cooler becomes plugged. The pressure setting for the bypass valve is higher than the restriction valve.

If equipped, blade pump is mounted in line with fan drive pump. Engine output is transmitted from fan drive pump drive shaft
to blade pump drive shaft. Blade pump delivers high pressure oil through blade control valve to blade cylinders. Return oil from
blade cylinders is routed through blade control valve directly to return filter in hydraulic oil tank.

For additional information, see Blade Circuit Operation—If Equipped . (Group 9025-05.) Also, see Hydraulic System Schematic .
(Group 9025-15.)

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Fan Drive Hydraulic System Operation

Fan Drive Hydraulic System Schematic

LEGEND:
31 Hydraulic Oil Tank
32 Return Filter
34 Filter Bypass
35 Suction Screen
132 Fan Drive Pump
133 Fan Drive Motor
134 Fan Speed Control Valve
600 High Pressure Oil
604 Return Oil
Y5005 Variable Speed Fan Solenoid

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Fan Drive Hydraulic System Schematic—Reversing (if equipped)

LEGEND:
31 Hydraulic Oil Tank
32 Return Filter
34 Filter Bypass
35 Suction Screen
132 Fan Drive Pump
133 Fan Drive Motor
135 Fan Speed and Reversing Control Valve (if equipped)
600 High Pressure Oil
604 Return Oil
Y9 Reversing Fan Solenoid
Y5005 Variable Speed Fan Solenoid

Standard Hydraulic Fan Function

See Fan Drive Hydraulic System Schematic . (Group 9025-15.)


<- Go to Section TOC Section 9025 page 3 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

See Fan Drive System Component Location . (Group 9025-15.)

A hydraulic-powered cooling fan is used to provide air flow for the machine′s cooling package. The fan drive system consists of:

Gear type fan drive pump (132)


Fan speed control valve (134) or fan speed and reversing control valve (if equipped) (135)
Gear type fan drive motor (133)

The fan drive pump is directly driven off the front gear train of the engine. Oil flow to the pump comes from the hydraulic oil
tank (31). Return oil (604) from the fan drive motor is routed to the return filter (32) in the hydraulic oil tank.

The variable speed fan solenoid (Y5005) regulates oil flow and pressure buildup in the fan drive system. The more oil flow to
the fan drive motor, the greater the fan speed. How much oil flow is routed to the fan drive motor, depends on the current
applied to the fan speed solenoid valve from the engine control unit (ECU).

The ECU uses five parameters to control the current sent to the integrated variable speed fan solenoid. The engine coolant
temperature sensor (B4), hydraulic oil temperature sensor (B40), charge air cooler outlet temperature sensor (B5205), fuel
temperature sensor (B5), and ambient air temperature sensor (B22) send system temperatures to the ECU. Each temperature
input calculates a desired fan speed, the maximum of the fan speeds is used as output to the fan speed control valve.

When machine systems are cold, the ECU sends maximum current to the variable speed fan solenoid. This shifts the solenoid
valve, to allow most oil flow to be returned to the hydraulic oil tank and bypass the fan drive motor. The fan drive motor and
cooling fan operate at a low speed.

As the machine warms up during operation, the ECU decreases the current to the fan speed solenoid valve. The decrease in
current applied, causes the solenoid valve to shift and restrict oil flow through the fan speed solenoid valve, increasing oil flow
to the fan drive motor. As oil flow to the fan drive motor increases, cooling fan speed increases.

When maximum cooling is required, the ECU supplies low current to the variable speed fan solenoid with the solenoid valve at
a set minimum current, LOW VOLTAGE fan speed current, the fan drive motor and cooling fan operate at the set maximum
speed of LOW VOLTAGE maximum speed. This controlled fan speed is more economical and fuel efficient. During a fan system
malfunction or unplugged fan speed solenoid, the ECU supplies no current to the variable speed fan solenoid. With the solenoid
valve de-energized, the variable speed fan solenoid is fully shifted to allow maximum oil flow to the fan drive motor. The fan
drive motor and cooling fan operate at maximum speed.

Reverse Fan Function—If Equipped

The optional reversing function, reverses the cooling fan to help clean the machine cooling package of dirt and debris. The
reversing function can be initiated manually by the operator, or automatically by the ECU. If set to reverse automatically, the
ECU will reverse the fan at a preset interval.

For additional information, see Reversing Fan Switch—If Equipped . (Operator′s Manual.)

The integrated fan speed and reversing control valve is used with the optional reverse fan function. The control valve controls
both fan speed and reversing fan direction.

To start a reversing cycle, the ECU first increases current to the variable speed fan solenoid in the fan speed and reversing
control valve. The engine control unit briefly applies maximum current to stop the fan, while the reversing fan solenoid valve
(Y9) shifts to reverse oil flow. The ECU then removes current to the variable speed fan solenoid, to operate the fan at maximum
speed in reverse for a short period of time. The ECU continues to calculate the desired speed for the fan forward inputs. After
the reverse cycle completes, the ECU will return to the maximum desired speed. Returning to normal operation, the ECU briefly
applies maximum current to the variable speed fan solenoid, while the reversing fan solenoid resets to normal operation.

Pilot System Operation


For additional hydraulic system information, see Hydraulic System Schematic . (Group 9025-15.)

The pilot system is used to operate control circuits for pump 1 and pump 2 regulators, to shift the control valve spools, to
release the swing park brake, and as a supply source for the functions of solenoid valve manifold.

The pilot pump supplies oil to the pilot system. From the pilot pump, oil flows to the pilot filter housing. The pilot filter housing
houses pilot filter and bypass valve, and pilot pressure regulating valve.

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

From the pilot filter housing, oil is supplied to solenoid valve manifold where it is used as supply oil for the arm regenerative
and travel speed solenoids.

From the solenoid valve manifold, oil flows to pilot shutoff solenoid valve and blade signal selector combiner valve (if
equipped). When pilot shutoff solenoid valve is activated, oil flows to the left and right pilot control valves, travel pilot control
valve, auxiliary pilot control valve (if equipped), blade pilot control valve (if equipped), and pilot signal manifold. When a pilot
control valve is activated, oil flows through the pilot control valve, through the pilot signal manifold, to the front or rear control
valve and actuates the desired spool, allowing high pressure oil to flow to the desired motor and or cylinders.

When a blade function (if equipped) is activated, blade signal selector valve pilot oil flows through the spool, through travel
flow combiner shuttle valve, to flow combiner valve in the control valve.

When no functions are activated, the oil returns to hydraulic oil tank through the pilot pressure regulating valve.

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Pilot Pump, Pressure Regulating Valve, and Filter Operation

Pilot Pump, Pressure Regulating Valve, and Filter

LEGEND:
2 Driven Gear
3 From Hydraulic Pump Suction Line
4 Drive Gear
5 Port PE-to-Pump 1 and 2 Servo Pistons and Regulators
6 Port TA-to-Hydraulic Return Manifold
7 Plug (port PC)
8 Plug (port PG)
10 Regulated Pilot Oil (marked PD)-to-Solenoid Valve Manifold
11 Test Port (marked PF)
12 From Pilot Pump Outlet (marked PA)
13 Pilot Filter Element
14 Pilot Pressure Regulating Valve Spool
15 Spring
16 Shim (as required)
28 Pilot Pump
30 Pilot Pressure Regulating Valve

Pilot filter element (13), bypass valve, and pilot pressure regulating valve (30) are incorporated into one assembly.

Pilot filter bypass valve senses differential pressure between inlet side and outlet side of filter element. During normal
operation, bypass valve is held closed by a spring and pilot oil flows through filter element to pilot pressure regulating valve
and out to pilot circuit. When the filter element becomes plugged, pressure on inlet side increases forcing bypass valve open.
Pilot oil now bypasses the filter element and unfiltered oil flows to pilot pressure regulating valve spool (14) and out to the pilot
circuit.

The pilot pressure regulating valve is a relief valve that is used to regulate pilot oil pressure to a constant pressure in pilot oil
circuit. When pressure in pilot circuit increases to pressure setting of spring (15), spool is pushed against spring. Regulated
pilot oil flows from port PD to solenoid valve manifold (10) and from port PE to pump 1 and 2 servo pistons and regulators (5).
Oil not needed to maintain pressure in pilot circuit flows out port TA to hydraulic return manifold (6).

For additional hydraulic system information, see Hydraulic System Schematic . (Group 9025-15.)

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Pilot Shutoff Solenoid Valve Operation

Pilot Shutoff Solenoid Valve Port Locations

LEGEND:
A1 To Right Pilot Control Valve
A2 To Travel Pilot Control Valve
A3 To Left Pilot Control Valve and To Blade Pilot Control Valve (if equipped)
A4 To Pilot Signal Manifold Port PI
HT Port HT (plugged)
P Pilot Oil From Pilot Pump
T1 From Travel Pilot Control Valve
T2 From Left Pilot Control Valve and From Blade Pilot Control Valve (if equipped)
T3 From Right Pilot Control Valve
T4 Return to Hydraulic Oil Tank
The pilot shutoff solenoid valve is a solenoid actuated spool type valve. The solenoid is electrically operated by the pilot control
shutoff lever.

For additional information, see Pilot Shutoff Circuit Theory of Operation . (Group 9015-15.)

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

De-Energized Pilot Shutoff Solenoid Valve Schematic

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

De-Energized Pilot Shutoff Solenoid Valve Section

LEGEND:
604 Pilot Oil
609 Return Oil
A1 To Right Pilot Control Valve
A2 To Travel Pilot Control Valve
A3 To Left Pilot Control Valve and To Blade Pilot Control Valve (if equipped)
A4 To Pilot Signal Manifold Port PI
HT Port HT (plugged)
P Pilot Oil From Pilot Pump
T1 From Travel Pilot Control Valve
T2 From Left Pilot Control Valve and From Blade Pilot Control Valve (if equipped)
T3 From Right Pilot Control Valve
T4 To Hydraulic Oil Tank
Y10 Pilot Shutoff Solenoid
With the pilot control shutoff lever in the locked position, the lever is up. The solenoid for the pilot shutoff solenoid valve is de-
energized. Pilot oil from pilot pump (P) is blocked by the spool. Ports to the pilot control valves (A1—A3) and pilot signal
manifold port PI (A4) are open to the hydraulic oil tank (T4) through the spool. Therefore, no hydraulic function is actuated
when a control lever for a pilot control valve is operated.

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Energized Pilot Shutoff Solenoid Valve Schematic

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Energized Pilot Shutoff Solenoid Valve Section

LEGEND:
604 Return Oil
609 Pilot Oil
A1 To Right Pilot Control Valve
A2 To Travel Pilot Control Valve
A3 To Left Pilot Control Valve and To Blade Pilot Control Valve (if equipped)
A4 To Pilot Signal Manifold Port PI
HT Port HT (plugged)
P Pilot Oil From Pilot Pump
T1 From Travel Pilot Control Valve
T2 From Left Pilot Control Valve and From Blade Pilot Control Valve (if equipped)
T3 From Right Pilot Control Valve
T4 To Hydraulic Oil Tank
Y10 Pilot Shutoff Solenoid
With the pilot control shutoff lever in the unlocked position, the lever is down. The solenoid for the pilot shutoff solenoid is
energized. Ports to the pilot control valves (A1—A3) and pilot signal manifold port PI (A4) are now open to pilot oil from pilot
pump (P). Now operating a control lever actuates a function.

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Pilot Control Valve Operation

Pilot Control Valve Metering and Full Stroke

LEGEND:
1 Control Lever
2 Plunger
3 Spring Guide
4 Balance Spring
5 Return Spring
6 Orifice
7 Spool
8 Hole (4 used)
9 Housing
10 Work Port 1, 2, 3, or 4-to-Control Valve Pilot Caps
11 Port P From Pilot Shutoff Solenoid Valve
12 Port T-to-Pilot Shutoff Solenoid Valve
13 Deadband Area
14 Initial Movement
604 Return Oil
609 Pilot Oil
The left and right pilot control valves regulate the pilot oil (609) pressure to actuate the pilot valves in the pilot signal manifold
and to shift the control valve spools to actuate each function.

For additional information, see Pilot Signal Manifold Operation . (Group 9025-05.) Also, see Pilot Operation of Control Valve
Operation . (Group 9025-05.)

Each pilot control valve contains four valves, one for each function. The ports (10, 11, and 12) in housing (9) are identified by
numbers and letters next to each port. The valves are pressure-reducing valves controlled by movement of the control lever (1)
and plunger (2).

Moving the control lever to actuate a function pushes the plunger and spring guide (3) against the balance spring (4) pushing
the spool (7) down. The return spring (5) is also compressed by the plunger and spring guide.

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

During the initial movement (14), the spool goes through a deadband area (13) where the flow of return oil (604) through the
holes (8) to port T is blocked before pilot oil flows from port P through the holes down through the spool to the work port and
out to the control valve pilot caps (10). Pilot oil also flows through the orifice (6) to the top of spool to dampen the upward
movement of spool. Pilot oil pressure out the work port increases until the pressure is equal to the force of balance spring
pushing the spool up until the oil flow through the holes is blocked in the deadband area. With the oil flow blocked, the control
valve spool is held stationary until the control lever is again actuated.

When the control lever is actuated to full stroke, the plunger contacts the spool, pushing it down until the plunger contacts a
shoulder in the housing. Oil pressure to the control valve pilot caps is now approximately equal to pilot system pressure.

When the control lever is returned to neutral, the spool is pushed up by the return spring, pushing the plunger up. The return
springs hold the control lever in the neutral position. When the spool is up, the passage to the control valve pilot cap is open to
port T and pilot oil from port P is blocked.

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Travel Pilot Control Valve Operation

Travel Pilot Control Valve Operation

LEGEND:
1 Spool
2 Washer
3 Spring Guide

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

4 Plunger
5 Adjustment Screw
6 Cam and Pedal
7 Sleeve
8 Balance Spring
9 Return Spring
10 Port T to Hydraulic Oil Tank
11 Port P From Pilot Shutoff Solenoid Valve
12 Port 1, 2, 3, or 4-to-Control Valve Pilot Cap
13 Travel Pilot Control Valve—Full Stroke
604 Return Oil
609 Pilot Oil

The travel pilot control valve regulates the pilot oil (609) pressure to actuate the pilot valves in the pilot signal manifold and to
shift the control valve spools to actuate the travel functions.

For additional information, see Pilot Signal Manifold Operation . (Group 9025-05.) Also, see Pilot Operation of Control Valve
Operation . (Group 9025-05.)

One pilot control valve is used to control the travel functions. The pilot control valve contains four valve assemblies, one for
each direction of travel for each track. The valves are pressure-reducing valves controlled by movement of the cams and
pedals (6), and push against plunger (4). The ports (10, 11, and 12) in housing are identified by numbers and letters next to
each port.

In neutral, the spool is pushed up by the return spring (9) pushing the plunger up. The return springs hold the pedal in the
neutral position. With the spool up, ports 1, 2, 3, and 4 to control valve pilot cap (12) are open to port T to the hydraulic oil tank
(10) through the passage and holes in spool. Port P for pilot oil from the pilot shutoff solenoid valve (11) is blocked by the
spool.

When the pedal is pushed to move the machine, the cam pushes the plunger and spring guide down against the return spring
and balance spring. The balance spring pushes the spool down. As the spool is pushed down and the holes move through the
deadband area, the passage from control valve pilot cap to the hydraulic oil tank is closed and then opened to the pilot oil from
pilot shutoff solenoid valve. Pilot oil pressure increases until it is equal to the force applied by the balance spring pushing the
spool up until the oil flow through the holes is blocked in the deadband area. With the oil flow blocked, the control valve spool
is held stationary until the pedal is again actuated.

When the pedal and cam is pushed to full stroke, the plunger is pushed down farther by the balance spring, opening the
passage through the spool to pilot oil pressure. When pressure to the control valve pilot cap is equal to the force applied by the
balance spring, the spool moves up until it contacts the plunger. The plunger holds the spool down so the passage through the
spool remains open to pilot oil pressure. Oil pressure to the control valve pilot cap now approximately equals pilot oil pressure.

LEGEND:
14 Travel Pedal
15 Spring Pin
16 Damper
17 Support
18 Bracket
19 Gear 2
20 Gear 1

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Travel Pilot Pedal (shockless function)

The travel pedal is equipped with a shockless function. The shockless function consists of a bracket (18) connected to the
travel pedal (14) and a support (17) connected to the bracket with a spring pin (15). Gear 1 (20) is connected to the support.
When the travel pedal is released while traveling, the spring forces the travel pedal to the neutral position. At this time, gear 1
and gear 2 (19) inside the damper (16) receive resistance due to friction. The travel pedal gradually returns to neutral,
preventing a sudden stop due to sudden release of the travel pedal.

<- Go to Section TOC Section 9025 page 16 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Pilot Operation of Control Valve Operation


For additional information and reference, see Pilot Signal Manifold Operation . (Group 9025-05.)

The left pilot control valve (39), right pilot control valve (40), and travel pilot control valve (38) are connected to the left control
valve (5-spool) (74) and right control valve (4-spool) (73) by pilot lines through the pilot signal manifold (41). Actuating a pilot
control valve routes pilot oil (609) through the pilot signal manifold to the control valve pilot cap to shift a spool. Boom up
function (1), arm in function (4), left travel forward function (9), and right travel forward function (11) are shown energized.
Pilot oil also flows through the shuttle valves in the pilot signal manifold and shifts the pilot valves (42—48).

For additional information and reference, see Control Valve Operation . (Group 9025-05.)

The following valves in the control valve are controlled by pilot oil from the pilot control valves and pilot valves:

Auxiliary Flow Combiner Valve (118)


Left and Right Travel Valve Spools (110 and 75)
Bucket Flow Rate Control Valve (valve and poppet) (77)
Bucket Regenerative Spool (78)
Boom 1 and Boom 2 Valve Spools (81 and 104)
Boom Up Pressure Sensor (B30)
Boom Reduced Leakage Valve (valve and check valve) (85)
Arm 2 and Arm 1 Spools (97 and 90)
Arm In Pressure Sensor (B31)
Bypass Shutoff Valve (93)
Swing Spool (95)
Arm Reduced Leakage Valve (valve and poppet) (101)
Auxiliary Spool (107)
Auxiliary Flow Rate Control Valve (valve and poppet) (108)
Travel Flow Combiner Valve (120)

For additional information and reference, see Control Valve Operation and see Travel Motor Speed Circuit Operation . (Group
9025-05.)

The following valves in the control valve and left and right travel motors are controlled by the solenoid valves (Y23 and Y24) in
the solenoid valve manifold:

Arm Regenerative Valve (94)


Travel Speed Change Valve (66)

→NOTE:

Blade is optional.

For additional information and reference, see Blade Circuit Operation—If Equipped . (Group 9025-05.)

The blade pilot control valve (150) is connected to the left control valve (74), right control valve (73), and pilot signal manifold
(41), blade control valve (144) by pilot lines through blade signal shuttle valve (148).

Actuating the blade pilot control valve routes pilot oil through the blade signal shuttle valve to the travel flow combiner valve,
to blade control valve, to shift blade spool (140). Pilot oil is also routed to the left control valve to shift bypass shutoff valve
(93) and to front attachment pressure sensor (B32) inside swing parking brake shuttle valve (146).

<- Go to Section TOC Section 9025 page 17 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Pilot Signal Manifold Operation

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)
41A Control Valve Side of Pilot Signal Manifold
41B Pilot Control Valve Side of Pilot Signal Manifold
42 Boom Down Shockless Valve
43 Arm 1 (swing priority) Flow Rate Pilot Valve (port SE)
44 Travel Flow Combiner Pilot Valve (port SL)
45 Swing Park Brake Release Pilot Valve (port SH)
46 Bucket Flow Rate Pilot Valve (port SK)
47 Pump 2 Flow Rate Pilot Valve (port SB)
48 Pump 1 Flow Rate Pilot Valve (port SA)
70 Orifice

<- Go to Section TOC Section 9025 page 18 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

B33 Swing Pressure Sensor


B34 Travel Pressure Sensor
DF To Hydraulic Oil Tank
PH Plug
PI From Pilot Shutoff Solenoid Valve
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)

→NOTE:

The numbers 1—14 and letters A—N, DF, TR, S3, SA, SB, SE, SH, SK, SL, SM, SN, SP, PH, and PI are next to
the respective ports on the pilot signal manifold.

The pilot signal manifold is in the pilot system between the pilot control valves and the control valve and regulators. The
manifold receives a pilot signal from the pilot control valves and sends the signal on multiple paths. One path is used to shift
the spools in the control valve and the other sends a signal to the regulators through pump 2 flow rate pilot valve (47) and
pump 1 flow rate pilot valve (48). This is done simultaneously, so there is little lag between operation of the pilot control
valves, pump stroke, and function movement. The manifold also houses additional pilot valves that provide pilot oil for various
other functions.

For additional Information, see Hydraulic System Schematic . (Group 9025-15.)

<- Go to Section TOC Section 9025 page 19 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Boom Down Shockless Valve

LEGEND:
1 To Bottom Pilot Cap
41A Control Valve Side of Pilot Signal Manifold
41B Pilot Control Valve Side of Pilot Signal Manifold
42 Boom Down Shockless Valve
50 Shuttle Valve
<- Go to Section TOC Section 9025 page 20 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

138 Spring A
139 Passage 1
140 Tapered Land
141 Orifice
142 Spring B
143 Passage 3
144 Oil Chamber
145 Passage 2
A From Pilot Control Valve—Boom Up

Boom Down Shockless Valve

The boom down shockless valve (42) regulates the return oil flow from the pilot cap during boom down operation. Regulating
the return oil flow controls the movement of boom 1 and boom 2 spools, to provide precise control of boom down function.

Actuating boom up sends pilot oil to pilot signal manifold port A. Pilot oil flows past the tapered land (140) on the boom down
shockless valve spool and into the oil chamber (144). The tapered land acts as a variable orifice between the spool and
manifold as the spool is shifted back and forth. Pilot oil flows from the oil chamber, through the orifice (141), into passage 2
(145), and out port 1 to the control valve pilot cap. Pilot oil also flows through passage 3 (143) into spring B (142) cavity and
passage 1 (139) into spring A (138) cavity. Spring B is the larger spring. The increasing pilot oil pressure shifts the valve spool
to the left, opening the passage from port A to port 1 and allowing pilot oil to flow unrestricted to the pilot cap shifting the
boom 1 and boom 2 valve spools.

Actuating boom down sends return oil from the pilot cap to port 1. From port 1 pilot oil flows through passage 1 to spring A
cavity and through passage 2, through the orifice, and into the oil chamber. From the oil chamber, return oil flows through
passage 3 to spring B cavity and past the tapered land to port A. Because of the pressure drop across the orifice, the return oil
pressure in the oil chamber and spring B cavity is less than the return oil pressure in spring A cavity. The increasing return oil
pressure shifts the valve spool to the right, causing the tapped land to restrict and then block the flow of return oil from port 1
to port A. When the tapered land blocks the return oil flow, the pressure increases in the oil chamber and spring B cavity. The
valve spool now shifts to the left allowing return oil to flow past the tapered land to port A. The opening and closing continues
until the return oil is gradually returned through port A, controlling the movement of the boom 1 and boom 2 spools.

Pump 1 or Pump 2 Flow Rate Pilot Valve

<- Go to Section TOC Section 9025 page 21 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

LEGEND:
41A Control Valve Side of Pilot Signal Manifold
41B Pilot Control Valve Side of Pilot Signal Manifold
47 Pump 2 Flow Rate Pilot Valve Spool (port SB)
48 Pump 1 Flow Rate Pilot Valve Spool (port SA)
50 Shuttle Valve
146 To Hydraulic Oil Tank by Port DF
147 Pilot Oil From Actuated Pilot Control Valves
148 Pilot Oil From Actuated Pilot Control Valves
149 Pilot Oil From Port PI
150 Spring Chamber
151 Passage A
SA Port SA to Pump 1 Regulator
SB Port SB to Pump 2 Regulator

Pump 1 Flow Rate Pilot Valve (SA) and Pump 2 Flow Rate Pilot Valve (SB)

The function of pump 1 and pump 2 flow rate pilot valves is to deliver a regulated amount of pilot oil to the pump 1 and pump 2
regulators in proportion to the pilot oil pressure applied to the flow rate pilot valve spools (47 or 48) by the actuated pilot
control valves (147). The pilot oil delivered by the flow rate pilot valves is from the pilot control shutoff valve port A4 to the
pilot signal manifold through port PI (149). Pump 1 flow rate pilot valve delivers regulated pilot oil to pump 1 through port SA.
Pump 2 flow rate pilot valve delivers regulated pilot oil to pump 2 through port SB. The pilot oil from the actuated pilot control
valve is routed to the flow rate pilot valves by the shuttle valves.

Actuating a function sends pilot oil from the pilot control valve to the pilot signal manifold. The pilot oil flows through the
manifold to the control valve pilot cap and within the manifold to the spring chamber (150). The pilot oil pressure in the spring
chamber increases, shifting the flow rate pilot valve spool to the right and allowing a regulated amount of pilot oil to flow past
the spool to the right end of spool and out the port (SA or SB) to pump regulator through passage A (151). The spool is shifted
back to the left until the regulated pilot oil pressure equals the oil pressure in the spring chamber and spring force stopping the
oil pressure increase to the pump regulator.

For additional information, see Pump 1 and Pump 2 Regulator Operation . (Group 9025-05.)

→NOTE:

Ports SA and SB are located on the control valve side of pilot signal manifold (41A) but, for simplification
of the schematic, are shown on the pilot control valve side of pilot signal manifold (41B).

When the function is returned to neutral, oil pressure in the spring chamber is released to the hydraulic oil tank through the
pilot control valve. The regulated pilot pressure on the right end of spool shifts the spool to the left against the spring, releasing
the regulated pilot oil pressure to the hydraulic oil tank by port DF (146). As the regulated pilot oil pressure decreases, the
spool is shifted back to the right by the spring until the spring force and oil pressure are equal.

Bucket Flow Rate Pilot Valve

LEGEND:
152 Pilot Oil Pressure
153 To Hydraulic Oil Tank
154 To Bucket Flow Rate Valve

<- Go to Section TOC Section 9025 page 22 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

155 Pilot Oil Pressure From Boom Up


156 Spring
Bucket Flow Rate Pilot Valve (Port SK)

Bucket flow rate pilot valve is shifted by the pilot oil pressure (152) from arm in to port D and through the shuttle valves. The
pilot valve routes pilot oil pressure from boom up (Port A) (155) to the bucket flow rate valve in the control valve. The bucket
flow rate valve restricts the flow of high pressure oil to the bucket spool during arm in and boom up operation to ensure a flow
of high pressure oil to the boom 1 spool.

Travel Flow Combiner Pilot Valve

LEGEND:
152 Pilot Oil Pressure
153 To Hydraulic Oil Tank
156 Spring
157 To Travel Flow Combiner Valve
158 Control Pressure Pilot Oil
Travel Flow Combiner Pilot Valve (Port SL)

Travel flow combiner pilot valve is shifted by pilot oil pressure (152) from right travel to port L (right reverse) or port K (right
forward) and through the shuttle valves. The pilot valve then routes control pressure pilot oil (158) from the swing park brake
release pilot valve to the travel flow combiner valve in the control valve. The control pressure pilot oil is from the pilot shutoff
solenoid valve port A4 to the pilot signal manifold through port PI.

For additional information, see Travel Flow Combiner Valve Operation . (Group 9025-05.)

Swing Park Brake Release Pilot Valve

LEGEND:
152 Pilot Oil Pressure
153 To Hydraulic Oil Tank
156 Spring
158 Control Pressure Pilot Oil
159 To Swing Park Brake
Swing Park Brake Release Pilot Valve (Port SH)

Swing park brake release pilot valve is shifted by pilot oil pressure (152) from boom up to port A, boom down to port B, arm out
to port C, arm in to port D, bucket curl to port G, bucket dump to port H, or auxiliary to port M or N and through the shuttle

<- Go to Section TOC Section 9025 page 23 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

valves. The pilot valve routes control pressure pilot oil (158) out port SH to the swing motor park brake piston through port SH.
The control pressure pilot oil is from the pilot shutoff solenoid valve port A4 to the pilot signal manifold through port PI.

For additional information, see Swing Motor Park Brake Release Circuit Operation . (Group 9025-05.)

Arm 1 Flow Rate Control Pilot Valve

LEGEND:
153 To Hydraulic Oil Tank
156 Spring
160 Arm In Pilot Oil Pressure
161 To Arm 1 Flow Rate Control Valve
162 Swing Pressure Pilot Oil
Arm 1 Swing Priority Flow Rate Control Pilot Valve (Port SE)

Arm 1 flow rate control pilot valve is shifted by arm in pilot oil pressure (160). The pilot valve then routes swing pressure pilot
oil (162) to arm 1 flow rate control valve (161) in the control valve.

<- Go to Section TOC Section 9025 page 24 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Pilot Signal Manifold Shuttle Valve

<- Go to Section TOC Section 9025 page 25 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

LEGEND:
20 Check Valve (4 used)
21 Auxiliary Valve (if equipped)
22 Swing and Auxiliary Valve (if equipped)
23 Swing Valve
24 Bucket Valve
25 Arm, Boom Up, Auxiliary Valve (if equipped)
26 Boom, Arm, Bucket, Swing, Auxiliary Valve (if equipped)
27 Boom, Arm, Bucket Valve
28 Boom Up, Arm, Bucket, Left Travel, Swing, Auxiliary Valve (if equipped)
29 Arm, Boom, Bucket, Right Travel Valve
30 Boom Valve
31 Boom, Arm, Bucket, Right Travel Valve
32 Boom, Arm Valve
33 Arm Valve
34 Boom, Arm, Right Travel Valve
35 Right Travel Valve
36 Left Travel, Right Travel Valve
37 Left Travel Valve
38 Travel Pilot Control Valve
39 Left Pilot Control Valve
40 Right Pilot Control Valve
41 Pilot Signal Manifold
42 Boom Down Shockless Valve
43 Swing Priority Flow Rate Pilot Valve (port SE)
44 Travel Flow Combiner Pilot Valve (port SL)
45 Swing Park Brake Release Pilot Valve (port SH)
46 Bucket Flow Rate Pilot Valve (port SK)
47 Pump 2 Flow Rate Pilot Valve (port SB)
48 Pump 1 Flow Rate Pilot Valve (port SA)
134 Pilot Shutoff Valve
B33 Swing Pressure Sensor
B34 Travel Pressure Sensor
Y10 Pilot Shutoff Solenoid
Shuttle Valves (21—37)

Control pilot oil pressure from the actuated left, right, travel, and auxiliary (if equipped) pilot control valves to the pilot signal
manifold is routed by the shuttle valves (21—37) to shift the respective pilot valves (44, 45, 47, and 48) and actuate the swing
pressure sensor (B33) and travel pressure sensor (B34). The bucket flow rate pilot valve (46) and swing priority flow rate pilot
valve (43) are shifted directly by control pilot oil from port D (arm in function).

Actuated Function To Shift Pilot Valve

Actuated Function to Shift Pilot Valve

Travel Flow Arm 1 (Swing


Pump 1 Flow Pump 2 Flow Bucket Flow Swing Park Brake
Function and Pilot Signal Manifold Ports Combiner Valve Pilot Priority) Flow Rate
Rate Pilot Valve Rate Pilot Valve Rate Pilot Valve Release Pilot Valve
Valve Pilot Valve

Boom Up, A X X X

Boom Down, B X X

Arm In, D X X X X X

Arm Out, C X X X

Bucket Curl, G X X

Bucket Dump, H X X

Right Swing, F X X

Left Swing, E X X

Right Travel, L, K X X

Left Travel, I, J X

Auxiliary, N, M X X

There are six outputs of the pilot signal manifold other than providing passages for pilot oil to shift control valve spools.

<- Go to Section TOC Section 9025 page 26 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
Six Additional Outputs of Pilot Signal Manifold

Six Outputs of Pilot Signal Manifold

Output Input Number 1 Input Number 2

Travel Flow Combiner Any Dig or Swing Function Right Travel

Bucket Flow Rate Control Arm In Boom Up

Arm 1 (Swing Priority) Flow Rate Control Arm In Swing

Release Swing Brake Any Dig or Swing Function

P1 Flow Rate Control Right Travel, Boom, Arm or Bucket

P2 Flow Rate Control Left Travel, Boom, Arm or Swing

<- Go to Section TOC Section 9025 page 27 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Pump 1, Pump 2, and Drive Gear Case Operation

Pump 1, Pump 2, and Pilot Pump

LEGEND:
7 Pilot Pressure Regulating Valve Port PC-to-Maximum Displacement Servo Pistons
11 Damper Drive (flex coupling)
15 Pump 1 (4-spool)

<- Go to Section TOC Section 9025 page 28 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

16 Pump 2 (5-spool)
17 Pump 1 Regulator
18 Pump 2 Regulator
28 Pilot Pump
B35 Pump 1 Delivery Pressure Sensor
B36 Pump 1 Control Pressure Sensor
B37 Pump 2 Delivery Pressure Sensor
B38 Pump 2 Control Pressure Sensor
Y20 Pump 2 Flow Rate Limit Solenoid (marked SB)
Y21 Torque Control Solenoid (marked ST)

<- Go to Section TOC Section 9025 page 29 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Pump 1 and Pump 2 Cross Section

LEGEND:
7 Pilot Pressure Regulating Valve Port PC-to-Maximum Displacement Servo Pistons
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
17 Pump 1 Regulator
18 Pump 2 Regulator
<- Go to Section TOC Section 9025 page 30 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

25 Feedback Lever
26 Feedback Link
27 Swash Plate
28 Pilot Pump
29 Minimum Displacement Servo Piston (2 used)
30 Maximum Displacement Servo Piston (2 used)
Y20 Pump 2 Flow Rate Limit Solenoid (marked SB)
Y21 Torque Control Solenoid (marked ST)

Pump 1 (15) and pump 2 (16) are swash plate type, variable-displacement, axial piston pumps. Pump 1 and pump 2 are
identical pumps in an in-line configuration in one housing. The pump 1 drive shaft is connected to the engine flywheel through
a damper drive (flex coupling) (11). Pilot pump (28) is a gear pump connected to the output shaft of pump 2. Pump 1, pump 2,
and the pilot pump are driven at engine speed. Pressure sensors (B35—B38) and solenoids (Y20 and Y21) are used to control
the pump operation.

The pumps vary from minimum to maximum displacement, generating the supply oil flow in the hydraulic system depending
on the hydraulic demand of the system. Pump 1 regulator (17) and pump 2 regulator (18) control the movement of the
minimum displacement servo piston (29) by sending or releasing oil from the piston bores. A constant pilot oil pressure from
the pilot pressure regulating valve port (7) is supplied to the maximum displacement servo pistons (30). The servo pistons
move the swash plate (27), changing the pump displacement. The pump displacement, or flow rate, is varied by changing the
angle of the swash plate with respect to the drive shaft. Increasing the angle increases the distance that each piston travels
into and out of the bore, which increases displacement. Decreasing the angle reduces the distance that each piston travels into
and out of the bore, which decreases displacement.

The movement of the swash plate is transmitted mechanically by the feedback lever (25) and feedback link (26), providing a
feedback to the remote control sleeve and load sleeve in the regulators. The sleeves block the flow of pilot oil and traps the oil
to the servo piston, stopping swash plate movement at the flow rate in proportion to the control lever actuation.

For additional information, see Pump 1 and Pump 2 Regulator Operation . (Group 9025-05.) Also, see Hydraulic System
Schematic . (Group 9025-15.)

<- Go to Section TOC Section 9025 page 31 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Pump 1 and Pump 2 Regulator Operation

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 Screw (inner spring)
9 Load Adjusting Cartridge (outer spring)
10 Inner Spring
11 Outer Spring
12 Load Sleeve
13 Load Spool
14 Load Piston 2
15 Load Piston 1
16 Feedback Link

Pump Regulator Component Identification— Function of pump 1 and pump 2 regulators is to control pump 1 and pump 2
flow rates (displacement) in response to various oil pressure signals so pump drive torque does not exceed engine torque.

Piston (6) controls the remote control spool (5) movement against spring in response to flow rate valve pilot oil pressure from
pump 1 and pump 2 flow rate pilot valves. Actuating control levers or pedals shifts flow rate pilot valves.

For additional information, see Pilot Signal Manifold Operation . (Group 9025-05.)

Load piston 1 (15) and load piston 2 (14) control the load spool (13) movement against inner and outer springs (8 and 9) in
response to pilot oil pressure from torque control solenoid valve and high pressure oil pressure from pump 1 and pump 2. High

<- Go to Section TOC Section 9025 page 32 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

pressure oil pressure from pump 1 is sensed on one shoulder of load piston and from pump 2 on other shoulder. Pilot oil
pressure increases or decreases in response to actual engine speed to target engine speed difference or when a travel function
is actuated at slow engine speed.

For additional information, see Engine Speed Sensing Control Circuit Operation . (Group 9025-05.)

Remote control sleeve (4) and load sleeve (12) are moved by feedback link (16) blocking flow of oil to or from large end of
servo piston.

Pump 1 and pump 2 regulators are mounted on top of pump housing. Torque control solenoid valve and pump 2 flow rate limit
solenoid valve are located in housing on top of pump 2 regulator.

Pump 1 and pump 2 regulators are mounted on the top of pump housing. Torque control solenoid, pump 2 flow rate solenoid,
and pump 1 flow rate limit solenoid are located in housing on top of pump 2 regulator.

For minimum flow adjusting screw (7) tests and adjustments, see Pump Regulator Test and Adjustment—Minimum Flow .
(Group 9025-25.)

For flow adjusting cartridge (track cycle time) (1) and maximum flow adjusting screw (2) tests and adjustments, see Pump
Regulator Test and Adjustment—Maximum Flow . (Group 9025-25.)

Pump Regulator Control by Flow Rate Pilot Valve—Increasing

LEGEND:
1 Flow Adjusting Cartridge (track cycle time)
2 Maximum Flow Adjusting Screw
3 Spring
4 Remote Control Sleeve
<- Go to Section TOC Section 9025 page 33 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

5 Remote Control Spool


6 Piston
8 Load Adjusting Cartridge (outer spring)
9 Load Adjusting Screw (inner spring)
10 Inner Spring
11 Outer Spring
12 Load Sleeve
13 Load Spool
14 Load Piston 2
15 Load Piston 1
16 Feedback Link
17 Servo Piston
18 To Large End of Servo Piston
19 Return to Pump Housing
20 Pump 1 Pressure Inlet
21 Pump 2 Pressure Inlet
22 Torque Control Port
23 From Pump 1 or 2 Flow Rate Pilot Valve (port SA or SB)
24 Pilot Oil Inlet
600 High Pressure Oil
604 Return Oil
609 Pilot Oil
611 Charge Oil
613 Reduced Pilot Oil

Pump Regulator Control by Flow Rate Pilot Valve

Pilot oil (609) from pilot pump is constantly supplied through drilled passages in pump housing to small end of servo pistons, to
pilot oil inlet (24) at the pump 1 and pump 2 regulators, and to torque control solenoid valve located on top of pump 2
regulator.

Pump flow rate (displacement) is changed by sending pilot oil to or releasing it from the large end of servo piston (17) through
the passages to large end of servo piston (18).

Pilot oil (609) from pump 1 or 2 flow rate pilot valves (23) in pilot signal manifold is sensed by the piston (6) in its respective
regulator.

High pressure oil (600) from pump 1 and pump 2 is sensed through drilled passages in pump housing to pump 1 pressure inlet
(20) and pump 2 pressure inlet (21) in each pump regulator.

Charge oil (611) from torque control solenoid valve is routed through steel lines to torque control port (22) in each pump
regulator.

Increasing Flow Rate (Displacement)

Actuating a control lever or pedal increases the pump control lever or pedal increases the reduced charge or pilot oil (613)
pressure from pump 1 and/or flow rate pilot valve to the piston (6). Pilot oil pressure pushes the piston and remote control
spool (5) to left against the spring (3).

Movement of spool opens the passage from large end of servo piston (18) to return to pump housing (19). Primary pilot oil on
small end of servo piston pushes piston down, increasing pump angle which increases flow rate (displacement). Movement of
the cylinder block, valve plate, and servo piston is transmitted to remote control sleeve (4) and load sleeve (12) by the
feedback link (16). Sleeves move left until passages return is closed. Oil at large end of servo piston is now trapped, holding
the pump at flow rate (displacement) that is proportional to pressure of pump control pilot oil from pump 1 and/or 2 flow rate
pilot valve to the piston.

Maximum Flow Rate (Displacement)

When control lever or pedal is actuated to full stroke, pilot oil (609) from pump 1 or 2 flow rate pilot valve (port SA or SB) (23)
to piston (6) increases to its maximum pressure. Oil pressure pushes the piston to remote control spool to left until spool
contacts maximum flow adjusting screw (2). Movement of spool opens the passage from large end of servo piston (18) to
return in pump housing (19). Pilot oil on small end of servo piston pushes piston down, increasing pump flow rate
(displacement). As flow rate (displacement) increases, servo piston movement is transmitted to remote control sleeve (4) and
load sleeve (12) by feedback link (16). Sleeves move left until passage to return is closed. Oil at large end of servo piston is
now trapped, holding pump at maximum flow rate (displacement).
<- Go to Section TOC Section 9025 page 34 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Decreasing Flow Rate (Displacement)

As control lever or pedal is returned to neutral, reduced pilot oil (613) pressure sensed at piston (6) also decreases. Spring (3)
pushes remote control spool and piston to the right. Movement of spool opens a passage for pilot oil (609) from pilot oil inlet
(24) to flow to large end of servo piston (18). Pilot oil pressure applied to large end of servo piston (17) pushed it up against
pilot oil pressure applied to small end decreasing pump flow. Remote control spool continues to move to right in response to
decreasing pump pilot oil pressure until it contacts piston cylinder. As pump flow rate (displacement) decreases, movement of
cylinder block, valve plate, and servo piston is transmitted to remote control sleeve (4) and load sleeve (12) by the feedback
link (16). Sleeves move right until passage for pilot oil is closed. Oil at large end of servo piston is now trapped, holding pump
at flow rate (displacement) that is proportional to pressure of pump pilot oil.

Pump Regulator Control by High Pressure Oil Pressure—Decreasing

LEGEND:
1 Flow Adjusting Cartridge (track cycle time)
2 Maximum Flow Adjusting Screw
3 Spring
4 Remote Control Sleeve
5 Remote Control Spool
6 Piston
8 Load Adjusting Cartridge (outer spring)
9 Load Adjusting Screw (inner spring)
10 Inner Spring
11 Outer Spring
12 Load Sleeve
13 Load Spool
14 Load Piston 2
15 Load Piston 1

<- Go to Section TOC Section 9025 page 35 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

16 Feedback Link
17 Servo Piston
18 To Large End of Servo Piston
19 Return to Pump Housing
20 Pump 1 Pressure Inlet
21 Pump 2 Pressure Inlet
22 Torque Control Port
23 From Pump 1 or 2 Flow Rate Pilot Valve (port SA or SB)
24 Pilot Oil Inlet
600 High Pressure Oil
604 Return Oil
609 Pilot Oil
611 Charge Oil
613 Reduced Pilot Oil

Pump Regulator Control by High Pressure Oil Pressure

High pressure oil (600) pressure (load) for each pump is sensed on shoulders of load piston 2 (14) through pump 1 and pump 2
pressure inlets (20 and 21) in each pump regulator. The area of each shoulder is equal. Therefore, force applied through load
piston 2 (14) to inner and outer springs (10 and 11) is an average of high pressure oil pressures. Springs are adjusted against
the average pressure so flow rate of each pump is approximately equal and uses approximately one-half engine torque.

Increasing high pressure oil pressure (load) pushes the load piston 2 and load spool against inner and outer springs, opening
passage for pilot oil (609) to flow from pilot oil inlet (24), through load sleeve (12) to large end of servo pistons (18). Flow rate
decreases until feedback link (16) moves load sleeve and remote control sleeve (4) blocking flow of oil. Flow rate of both
pumps decreases so load on pumps does not exceed engine torque.

When high pressure oil pressure (load) decreases, the inner and outer springs push the load spool and pistons to the right
against the high pressure oil pressure. The movement opens the passage for oil to flow from large end of servo piston (18)
through load sleeve and remote control sleeve to return to pump housing (19). Flow rate increases until feedback link moves
load sleeve and remote control sleeve blocking the flow of oil.

Engine torque is not exceeded, even if one pump is loaded relatively high while other pump stays relatively low.

As long as a control lever or pedal is held constant, the pump pilot oil (609) pressure from pump 1 or 2 flow rate pilot valve (23)
to the piston (6) does not change as high pressure oil pressure changes.

<- Go to Section TOC Section 9025 page 36 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Pump Regulator Control by High Pressure Oil Pressure (torque control solenoid valve)—Decreasing

LEGEND:
1 Flow Adjusting Cartridge (track cycle time)
2 Maximum Flow Adjusting Screw
3 Spring
4 Remote Control Sleeve
5 Remote Control Spool
6 Piston
8 Load Adjusting Cartridge (outer spring)
9 Load Adjusting Screw (inner spring)
10 Inner Spring
11 Outer Spring
12 Load Sleeve
13 Load Spool
14 Load Piston 2
15 Load Piston 1
16 Feedback Link
17 Servo Piston
18 To Large End of Servo Piston
19 Return to Pump Housing
20 Pump 1 Pressure Inlet
21 Pump 2 Pressure Inlet
22 Torque Control Port
23 From Pump 1 or 2 Flow Rate Pilot Valve (port SA or SB)
24 Pilot Oil Inlet
600 High Pressure Oil
604 Return Oil
609 Pilot Oil
<- Go to Section TOC Section 9025 page 37 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

611 Charge Oil


613 Reduced Pilot Oil

Pump Regulator Control by Engine Speed Sensing (Torque Control Solenoid Valve)

As engine speed changes, the main controller calculates speed difference between target and actual engine speed. Main
controller then actuates torque control solenoid valve to increase or decrease torque charge oil (611) pressure to torque
control port (22) and load piston 1 (15).

As the load on engine increases, speed difference between target and actual engine speed increases. Main controller decreases
electrical signal to torque control solenoid valve, which increases torque charge oil (611) pressure to load piston 1. Torque pilot
oil along with high pressure oil pressure on load piston 2 (14) shifts load spool (13) so pilot oil (609) flows to large end of servo
piston (18), decreasing flow rate (displacement). As flow rate of both pumps decreases, load on engine also decreases allowing
actual engine speed to increase.

As the load on engine decreases, speed difference between target and actual engine speed decreases. Main controller
increases electrical signal to torque control solenoid valve, which decreases torque pilot oil pressure to load piston 1. Inner and
outer springs (10 and 11) shifts load spool in response to decreasing torque control pilot oil pressure, releasing oil from large
end of servo piston to return to pump housing (19) allowing pump flow (displacement) to increase. As pump flow rate
increases, engine output is used more efficiently.

Pump Regulator Control by Travel Torque-Up Control (Slow Speed Sensing)

The function of travel to torque-up control is to increase the pump flow rate when the travel function is actuated at slow engine
speed.

Actuating travel function with the engine at slow idle causes the pump to go to maximum displacement. Therefore, pump 1 and
2 flow rates are increased to prevent mistracking, which can occur at the lower flow rate if there are differences between
pumps 1 and 2.

When the engine speed requested by the engine speed dial is slow, the main controller processes electrical signals from the
travel pressure sensor and pump 1 and 2 delivery pressure sensors. Main controller then increases the electrical signal to
torque control solenoid valve, which decreases torque charge oil (611) pressure to load piston 1. Inner and outer springs shift
the load spool in response to decreasing torque pilot oil pressure, releasing oil from large end of servo piston allowing pump
displacement to go to maximum. The pump flow rate increases and the machine does not mistrack at slow engine speed. The
increased flow rate continues even if a dig function is actuated while traveling at slow engine speed.

For additional information, see Engine Speed Sensing Control Circuit Operation . (Group 9025-05.)

<- Go to Section TOC Section 9025 page 38 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Engine Speed Sensing Control Circuit Operation

Engine Speed Sensing Control Circuit

Torque Control Solenoid

LEGEND:
1 Spring
2 Spool Return Spring
3 Inlet Port
4 Sleeve
5 Outlet Port to Load Piston
6 Spool
7 Return Port to Pump Case
17 Pump 1 Regulator
18 Pump 2 Regulator
600 High Pressure Oil
604 Return Oil
609 Pilot Oil

<- Go to Section TOC Section 9025 page 39 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

650 Electrical Voltage


A3 Main Controller (MCZ)
B1 Crankshaft Position Sensor
B34 Travel Pressure Sensor
B35 Pump 1 Delivery Pressure Sensor
B37 Pump 2 Delivery Pressure Sensor
R15 Engine Speed Dial
Y21 Torque Control Solenoid (marked ST)

Engine Speed Sensing Control (Torque Control Solenoid)

The function of the engine speed sensing control is to control pump flow rate in response to engine speed changes caused by
load variations so the engine output is used efficiently.

The main controller (MCZ) (A3) calculates the speed difference between target and actual engine speed. The MCZ then
actuates the torque control solenoid (Y21) to change the pump displacement to increase or decrease pump flow rate. Target
engine speed is a value set by the position of engine speed dial (R15). Actual engine speed is sensed by the crankshaft position
sensor (B1).

As a load on the engine increases, the actual engine speed becomes less than the target engine speed. The MCZ decreases the
electrical voltage to the torque control solenoid valve, which increases the pilot oil (609) pressure to the load piston 1 in the
pump 1 and pump 2 regulators (17 and 18). Pilot oil pressure on load piston 1 and high pressure oil (600) pressure on load
piston 2 shifts the load spool (6) so pilot oil flows to the large end of servo piston, decreasing the pump displacement. As the
flow rate is reduced, the load on the engine is reduced.

As the load on the engine decreases, the actual engine speed becomes greater than the target engine speed. The MCZ
increases the electrical voltage to the torque control solenoid valve, which decreases the pilot oil pressure to the load piston in
the regulators. The spring (1) shifts the load spool in response to the decreasing pilot oil pressure, releasing oil from the large
end of servo piston allowing the pump displacement to increase. As the pump flow rate increases, the engine output is used
more efficiently.

For additional information, see Pump 1 and Pump 2 Regulator Operation . (Group 9025-05.)

Travel Torque-Up Control (Slow Speed Sensing)

The function of travel torque-up control is to increase the pump flow rate when the travel function is actuated at slow engine
speed.

Actuating travel function with the engine at slow idle causes the pump to go to maximum displacement. Therefore, pump 1 and
2 flow rates are increased to prevent mistracking, which can occur at the lower flow rate if there are differences between
pumps 1 and 2.

When the engine speed requested by the engine speed dial (R15) is slow, the main controller processes the electrical signals
from the travel pressure sensor (B34), pump 1 delivery pressure sensor (B35), and pump 2 delivery pressure sensor (B37). The
main controller sends an increasing electrical voltage to the torque control solenoid which decreases the pilot oil pressure to
load piston 1 in the regulators. The springs shift the load spool in response to the decreasing pilot oil pressure, releasing oil
from the large end of servo piston allowing pump displacement to increase. At the increased flow rate the machine does not
mistrack at slow engine speed.

For additional information, see Pump 1 and Pump 2 Regulator Operation . (Group 9025-05.)

The increased flow rate continues even if a dig function is actuated while traveling at slow engine speed.

<- Go to Section TOC Section 9025 page 40 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Control Valve Operation

Control Valve—Left 5-Spool Side

LEGEND:
73 4-Spool Control Valve
74 5-Spool Control Valve
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
87 Boom Lower Meter-In Cut Valve
89 Boom Down Circuit Relief and Anticavitation Valve
90 Arm 2 Spool
95 Swing Spool
97 Arm 1 Spool
98 Arm 1 Flow Rate Control Valve (valve and poppet)
102 Arm In Circuit Relief and Anticavitation Valve
103 Arm Out Circuit Relief and Anticavitation Valve

<- Go to Section TOC Section 9025 page 41 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

104 Boom 2 Spool


107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
110 Left Travel Spool
117 Main Relief and Power Dig Valve (P1, P2)
118 Auxiliary Function Flow Combiner Valve
119 Check Valve—Flow Combiner Valve Circuit
149 Arm Regenerative Cut Valve
166 Bucket Regenerative Cut Valve

Control Valve—Right 4-Spool Side

LEGEND:
73 4-Spool Control Valve
74 5-Spool Control Valve
75 Right Travel Spool
76 Bucket Spool
77 Bucket Flow Rate Control Valve (valve and poppet)
79 Bucket Dump Circuit Relief and Anticavitation Valve
<- Go to Section TOC Section 9025 page 42 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

80 Bucket Curl Circuit Relief and Anticavitation Valve


81 Boom 1 Spool
83 Boom Flow Rate Control Valve (valve and poppet)
84 Dig Regenerative Valve
85 Boom Reduced Leakage Valve (valve and check valve)
88 Boom Up Circuit Relief and Anticavitation Valve
90 Arm 2 Spool
91 Arm 2 Flow Rate Control Valve (valve and poppet)
93 Bypass Shutoff Valve
94 Arm Regenerative Cut Valve
95 Swing Spool
97 Arm 1 Spool
100 Check Valve (lift check)—Dig Regenerative Circuit
104 Boom 2 Spool
107 Auxiliary Spool
110 Left Travel Spool
118 Auxiliary Function Flow Combiner Valve
120 Travel Flow Combiner Valve
121 Check Valve—Travel Flow Combiner Valve Circuit
122 Check Valve (lift check)—Bucket

The control valve consists of two monoblock valves referred to as the 5-spool control valve (74) and 4-spool control valve (73).
The 5-spool control valve and 4-spool control valve are mounted back-to-back so the oil passages in the valves are connected.
The spools are selectively fitted. There is a spool in each valve to control the boom (81 and 104), arm (90 and 97), and travel
(75 and 110) functions. The spools in 4-spool control valve consist of right travel spool (75), bucket spool (76), boom 1 spool
(81), and arm 2 spool (90). The spools in 5-spool control valve consist of left travel spool (110), auxiliary spool (107), boom 2
spool (104), arm 1 spool (97), and swing spool (95). All other functions are supplied by a single spool in one or the other of the
valves. All spools are operated by pilot oil pressure. Check valves are used as lift checks and to route high pressure oil between
the 4-spool and 5-spool valves for combined operation. The control valve is an open-center type valve. Each valve section
controls the flow rate and direction for its hydraulic circuit.

For more information, See Hydraulic System Schematic (Group 9025-15.)

All valves are accessible from the outside of control valve by removing a plug, cover, or the pilot caps. See Control Valve Line
Identification . (Group 9025-15.)

For additional information, See Control Valve Check Valves Identification and Operation (Group 9025-05.)

For check valve (lift check) and orifice—travel and bucket combiner circuit (122) and check valve—travel flow combiner valve
circuit (121) information. See Travel Flow Combiner Valve Operation (Group 9025-05.)

<- Go to Section TOC Section 9025 page 43 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Neutral and Power Passages Operation

LEGEND:
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
52 Swing Motor
61 Right Travel Motor
63 Left Travel Motor
<- Go to Section TOC Section 9025 page 44 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

73 4-Spool Control Valve


74 5-Spool Control Valve
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
90 Arm 2 Spool
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 Cylinder (2 used)
126 Bucket Cylinder
127 Arm Cylinder
600 High Pressure Oil
604 Return Oil
612 Combiner Oil

High Pressure oil (600) from pump 1 (15) flows to the right control valve (73). High pressure oil from pump 2 (16) flows to the
left control valve (74). When all functions are in neutral, high pressure oil flows through the neutral and power passages for
each valve spool section and then into return oil (604) the return passage. Neutral and power passages in the left and right
control valves are used to route high pressure oil for the combined operation of functions. Combiner oil (612) is connected in
combiner passages between arm 1 and 2 spools (97 and 90), and boom 1 and 2 spools (81 and 104), so high pressure oil from
both pump 1 and pump 2 flows to the cylinders during a single operation. High pressure oil from pump 2 can be combined with
high pressure oil from pump 1 by the auxiliary combiner power passage to supply the auxiliary spool (107).

Left and Right Travel Cross Section (from rear)

<- Go to Section TOC Section 9025 page 45 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

LEGEND:
73 4-Spool Control Valve
74 5-Spool Control Valve
75 Right Travel Spool
110 Left Travel Spool
111 Check Valve (lift check)—Left Travel Neutral Passage
112 Check Valve (lift check)—Left Travel Power Passage

The left and right travel spools (110 and 75) are pilot actuated, three-position, four-way, spool type valves.

In neutral, the forward and reverse work ports are connected together and open to the return passages so oil is not trapped
between the travel valve spools and the counterbalance valves in the travel motors. The circuit is open to return passage so
the counterbalance valve is not shifted and travel park brake is not released by thermal expansion of the oil.

For additional information, See Travel Motor and Park Brake Valve Operation for more information. (Group 9025-05.)

Actuating the travel pilot controller sends pilot oil through the pilot signal manifold to the pilot cap shifting the valve spools.
See Pilot Signal Manifold Operation for pilot oil functions in pilot signal manifold. (Group 9025-05.)

The travel alarm will sound when traveling in forward or reverse. See Travel Alarm Circuit Theory of Operation . (Group
9015-15.

Pump 2 high pressure oil flows through the 5-spool control valve neutral passage, through the left travel neutral passage lift
check valve (112), past the valve spool, and out the work port to the travel motor. When left travel is actuated in combined
operation with a dig or swing function, pump high pressure oil flows through the power passage, through the travel power
passage lift check (115) and orifice, past the valve spool, and out the work port to the travel motor.

For additional information, See Control Valve Check Valves Identification and Operation (Group 9025-05.)

Pump 1 high pressure oil flows from the right control valve neutral passage, past the right travel valve spool, and out the work
port to the motor. In combined operation with a dig or swing function, high pressure oil from pump 1 also flows to the left travel
valve and bucket valve through the flow combiner valve . High pressure oil from pump 2 flows to the boom and arm valves.
Return oil from the motors flows past the spools and into the return passage.

For additional information, See Travel Flow Combiner Valve Operation . (Group 9025-05.)

<- Go to Section TOC Section 9025 page 46 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Auxiliary and Bucket Cross Section (from rear)

LEGEND:
73 4-Spool Control Valve
74 5-Spool Control Valve
76 Bucket Spool
77 Bucket Flow Rate Control Valve (valve and poppet)
78 Bucket Regenerative Valve
79 Bucket Dump Circuit Relief and Anticavitation Valve
80 Bucket Curl Circuit Relief and Anticavitation Valve
107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
109 Plug (2 used)

The bucket spool (76) and auxiliary spool (107) are pilot actuated, three-position, four-way, spool type valves. In neutral, oil is
trapped between the work ports and cylinder by the valve spool.

Actuating the pilot controller sends pilot oil through the pilot signal manifold to the pilot cap shifting the valve spool. See Pilot
Signal Manifold Operation for pilot oil functions in pilot signal manifold. (Group 9025-05.)

For bucket dump and curl, pump 1 high pressure oil is routed from the right control valve neutral passage, through the bucket
flow rate control valve—poppet (76) and bucket flow rate control valve—switch valve (77), past the valve spool, and out to the
cylinder. Return oil from the cylinder flows past the spool and into the return passage.

In combined operation with right propel valve, pump 1 high pressure oil also flows from the right control valve neutral passage,
through the power passage, flow combiner circuit check valve, flow combiner valve and check valve, travel and bucket
combined function check valve and orifice, and past the valve spool out to the cylinder. Pump 2 high pressure oil flows to the
swing, arm, and boom functions. See the following for more information:
<- Go to Section TOC Section 9025 page 47 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Check valves— See Control Valve Check Valves Identification and Operation (Group 9025-05.)
Travel flow combiner valve— See Travel Flow Combiner Valve Operation (Group 9025-05.)

→NOTE:

The auxiliary valve is not connected for operation as received from the factory. Plugs are installed in the
pilot caps and covers are installed on the work ports. Field kits are available for connecting the valve for
auxiliary functions.

The flow of high pressure oil for the auxiliary valve is from pump 2, through the right control valve neutral passage, through the
power passage, through the auxiliary flow rate control valve (108) poppet and switch valve, past the valve spool, and out to the
auxiliary function. Return oil from the auxiliary function flows past the valve spool and into the return passage. High pressure
oil from pump 1 can be combined with high pressure oil from pump 2 by using the bypass shutoff valve and auxiliary flow
combiner valve to operate an auxiliary functions. The pilot lines to the auxiliary flow combiner valve and bypass shutoff valve
are connected to the hydraulic oil tank.

For additional information, See Auxiliary Flow Rate Control Valve Circuit Operation . (Group 9025-05.)

Front Cross Section (from rear)

LEGEND:
73 4-Spool Control Valve
74 5-Spool Control Valve
115 Main Relief Valve Isolation Check Valve (P1)
116 Main Relief Valve Isolation Check Valve (P2)

<- Go to Section TOC Section 9025 page 48 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

118 Auxiliary Function Flow Combiner Valve


119 Check Valve—Flow Combiner Valve Circuit
120 Travel Flow Combiner Valve
121 Check Valve—Travel Flow Combiner Valve Circuit

The front section of 4-spool control valve (15) serves as the inlet for supply oil from pump 1.

See the following for more information on the components in front section:

See Control Valve Check Valves Identification and Operation (Group 9025-05.)
See Main Relief Valve Circuit Operation (Group 9025-05.)
See Travel Flow Combiner Valve Operation (Group 9025-05.)
See Auxiliary Flow Combiner Valve and Bypass Shut-Off Valve Operation (Group 9025-05.)

Boom 1 and Boom 2 Valve Cross Section (from rear)

LEGEND:
73 4-Spool Control Valve
74 5-Spool Control Valve
81 Boom 1 Spool
82 Boom Regenerative Valve
83 Boom Flow Rate Control Valve (valve and poppet)
85 Boom Reduced Leakage Valve (valve and check valve)
89 Boom Down Circuit Relief and Anticavitation Valve
103 Arm Out Circuit Relief and Anticavitation Valve
104 Boom 2 Spool
105 Check Valve (lift check)—Boom 2 Power Circuit
156 Manual Boom Lower Screw
B30 Boom Up Pressure Sensor
<- Go to Section TOC Section 9025 page 49 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

See Boom Regenerative Valve Circuit Operation for boom regenerative valve (82). (Group 9025-05.)

See Boom Flow Rate Control Valve Circuit Operation for boom flow rate control valve (83). (Group 9025-05.)

See Boom and Arm Reduced Leakage Valves Operation for boom reduced leakage valve (valve and check valve) (85). (Group
9025-05.)

See Circuit Relief and Anticavitation Valve Operation for boom down and arm out circuit relief and anticavitation valve (89 and
103). (Group 9025-05.)

See Control Valve Check Valves Identification and Operation for boom down and arm out circuit relief and anticavitation valve
(89 and 103). (Group 9025-05.)

See Lower Boom With Engine Stopped for use of manual boom lower screw (156). (Operator′s Manual.)

See System Functional Schematic, Component Location, and Wiring Diagram Master Legend for boom up pressure sensor
(B30). (Group 9015-10.)

Arm 1 and Arm 2 Valve Cross Section (from rear)

LEGEND:
73 4-Spool Control Valve
74 5-Spool Control Valve
88 Boom Up Circuit Relief and Anticavitation Valve
90 Arm 2 Spool
91 Arm 2 Flow Rate Control Valve (valve and poppet)
94 Arm Regenerative Valve
97 Arm 1 Spool

<- Go to Section TOC Section 9025 page 50 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

98 Arm 1 Flow Rate Control Valve (valve and poppet)


101 Arm Reduced Leakage Valve (valve and poppet)
102 Arm In Circuit Relief and Anticavitation Valve
B31 Arm In Pressure Sensor

See Circuit Relief and Anticavitation Valve Operation for boom up and arm in circuit relief and anticavitation valves (88 and
102.) (Group 9025-05.)

See Arm 2 Flow Rate Control Valve Circuit Operation for arm 2 flow rate control valve (valve and poppet) (91). (Group
9025-05.)

See Arm 1 Flow Rate Control Valve Circuit Operation for arm 1 flow rate control valve (valve and poppet) (98). (Group
9025-05.)

See Boom and Arm Reduced Leakage Valves Operation for arm reduced leakage valve (valve and poppet) (101). (Group
9025-05.)

See System Functional Schematic, Component Location, and Wiring Diagram Master Legend for arm in pressure sensor (B31).
(Group 9015-10.)

Swing, Arm Regenerative Cut, and Bypass Shutoff Valve Cross Section (from rear)

LEGEND:
73 4-Spool Control Valve
74 5-Spool Control Valve
93 Bypass Shutoff Valve
95 Swing Spool
96 Check Valve (lift check)—Swing Neutral Passage

<- Go to Section TOC Section 9025 page 51 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

149 Arm Regenerative Cut Valve

See Arm Regenerative Valve Circuit Operation for arm regenerative cut valve (149). (Group 9025-05.)

See Control Valve Check Valves Identification and Operation for check valve (lift check)—swing neutral passage (96). (Group
9025-05.)

Bypass shutoff valve (93) is used when optional attachments are installed on the machine. See Auxiliary Flow Combiner Valve
and Bypass Shut-Off Valve Operation . (Group 9025-05.)

<- Go to Section TOC Section 9025 page 52 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Control Valve Check Valves Identification and Operation

Control Valve Check Valves Schematic

<- Go to Section TOC Section 9025 page 53 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

LEGEND:
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
36 Hydraulic Oil Cooler
73 4-Spool Control Valve
74 5-Spool Control Valve
75 Right Travel Spool
76 Bucket Spool
77 Bucket Flow Rate Control Valve (valve and poppet)
78 Bucket Regenerative Valve
79 Bucket Dump Circuit Relief and Anticavitation Valve
80 Bucket Curl Circuit Relief and Anticavitation Valve
81 Boom 1 Spool
82 Boom Regenerative Valve
83 Boom Flow Rate Control Valve (valve and poppet)
84 Dig Regenerative Valve
85 Boom Reduced Leakage Valve (valve and check valve)
87 Boom Lower Meter-In Cut Valve
88 Boom Up Circuit Relief and Anticavitation Valve
89 Boom Down Circuit Relief and Anticavitation Valve
90 Arm 2 Spool
91 Arm 2 Flow Rate Control Valve (valve and poppet)
92 Check Valve (lift check)—Arm 2 Neutral Passage
93 Bypass Shutoff Valve
94 Arm Regenerative Valve
95 Swing Spool
96 Check Valve (lift check)—Swing Neutral Passage
97 Arm 1 Spool
98 Arm 1 Flow Rate Control Valve (valve and poppet)
100 Check Valve (lift check)—Dig Regenerative Circuit
101 Arm Reduced Leakage Valve (valve and poppet)
102 Arm In Circuit Relief and Anticavitation Valve
103 Arm Out Circuit Relief and Anticavitation Valve
104 Boom 2 Spool
105 Check Valve (lift check)—Boom 2 Power Circuit
107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
110 Left Travel Spool
111 Check Valve (lift check)—Left Travel Neutral Passage
112 Check Valve (lift check)—Left Travel Power Passage
113 Orifice—Left Travel Power Passage
115 Main Relief Valve Isolation Check Valve—5-Spool
116 Main Relief Valve Isolation Check Valve—4-Spool
117 Main Relief and Power Dig Valve
118 Auxiliary Function Flow Combiner Valve
119 Check Valve—Auxiliary Function Flow Combiner Valve Circuit
120 Travel Flow Combiner Valve
121 Check Valve—Travel Flow Combiner Valve Circuit
122 Check Valve (lift check)—Bucket
123 Orifice—Bucket Power Circuit
124 Hydraulic Oil Cooler Bypass Valve
128 Check Valve
149 Arm 1 Regenerative Cut Valve
166 Bucket Regenerative Cut Valve

For location of check valves and orifices in the 4-spool and 5-spool control valves (73 and 74), see Control Valve Operation .
(Group 9025-05.)

Check Valves (92, 96, and 111): Check valves function as lift checks in the neutral passages.

Check Valves (105 and 112): Check valves function as lift checks in the power passages.

Check Valve (lift check)—Dig Regenerative Circuit (100): Functions as a lift check for arm in function when dig
regenerative solenoid valve is actuated. See Dig Regenerative Valve Circuit Operation for solenoid valve operation. (Group
9025-05.)

See Control Valve Operation for location and operation of dig regenerative valve. (Group 9025-05.)
<- Go to Section TOC Section 9025 page 54 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Orifice—Left Travel Power Passage (113): Restricts the flow of high pressure oil from pump 2 (16) through the power
passage to the left travel spool (110).

Arm 1 Spool (97) and Arm Regenerative Valve (94): During arm in operation the arm regenerative valve opens when
return oil pressure becomes greater than supply oil pressure to provide make-up oil to prevent cavitation in the arm cylinder.
See Arm Regenerative Valve Circuit Operation for more information. (Group 9025-05.)

Bucket Spool (76) and Bucket Regenerative Valve (78): During bucket curl operation from the full dumped position to
the vertical position, the bucket regenerative valve opens when return oil pressure becomes greater than supply oil pressure to
provide make-up oil to prevent cavitation in the head end of bucket cylinder.

Operational Check: Bucket curl is slow or does not move smoothly in single operation. Check bucket flow rate control valve
(valve and poppet) (77). See Bucket Regenerative Valve Circuit Operation and See Bucket Flow Rate Control Valve Circuit
Operation for more information. (Group 9025-05.)

Boom 1 Spool (81) and Boom Regenerative Valve (82): During boom down operation, the regenerative valve opens when
return oil pressure becomes greater than supply oil pressure to provide make-up oil to prevent cavitation in the rod end of
boom cylinder. See Boom Regenerative Valve Circuit Operation for more information. (Group 9025-05.)

Main Relief Valve Isolation Check Valve—5-Spool (115): One main relief and power dig valve (117) is used to limit the
high pressure oil pressure. The higher pressure closes the check valve against the lower pressure so it cannot flow to the lower
pressure side of control valve. The higher pressure is sensed by the main relief and power dig valve.

Operational Check: Pump 2 (16) high pressure oil pressure becomes hard to increase. To check, operate bucket dump function
over relief and check pressure at pump 1. If pressure is less than main relief and power dig valve pressure setting, inspect
isolation check valve (115). Also, power and neutral passage oil flow pressure for the 5-spool side is high because oil is flowing
past the isolation check valve (115).

Main Relief Valve Isolation Check Valve—4-Spool (116): Operational Check: Pump 1 (15) high pressure oil pressure
becomes hard to increase. Operate swing function at stall and check pressure at pump 2. If pressure is less than swing
crossover relief valve pressure setting, inspect the isolation check valve (116). Also, neutral passage oil flow pressure for the 4-
spool side is high because oil is flowing past the isolation check valve (116).

Check Valve—Auxiliary Function Flow Combiner Valve Circuit (119): For pump 1 (15) and pump 2 (16) combined flow to
the auxiliary spool (107), a pilot line from the auxiliary spool pilot cap must be connected to shift the auxiliary function flow
combiner valve (118) and bypass shutoff valve (93). Check valve closes if high pressure oil in the left control valve (74) power
passage becomes higher than high pressure oil pressure in the right control valve (73) neutral passage.

Check Valve—Travel Flow Combiner Valve Circuit (121): Blocks a higher high pressure oil pressure in the left control
valve (5-spool) (74) from flowing to the right control valve (4-spool) (73) in travel flow combiner circuit.

Operational Check: Machine mistracks to the left, forward or reverse, when traveling and operating a dig function. To check,
operate a dig function over relief while traveling. If mistracking stops, inspect check valve (121).

Circuit Relief and Anticavitation Valves (79, 80, 88, 89, 102, and 103): The anticavitation valves open when return oil
pressure becomes greater than high pressure oil pressure to provide makeup oil to prevent cavitation in the cylinder.

Check Valve (lift check) (122) and Orifice (123): The check valve functions as a lift check for the bucket spool (76).

High pressure oil flow from pump 1 to the bucket spool is blocked by the right travel spool (75) when actuated. High pressure
oil flow from pump 1 to the bucket spool is now through the travel flow combiner valve (120), check valve (121), check valve
(122), and orifice (123). The orifice restricts the flow of pump 1 high pressure oil to the bucket spool.

Operational Check: Actuate left and right travel and bucket functions. If bucket does not move, inspect check valve and orifice.

Hydraulic Oil Cooler Bypass Valve (124): Opens to route return oil around hydraulic oil cooler and directly to hydraulic oil
tank when resistance to flow through oil cooler becomes high because the oil is cold (high viscosity), there is a surge of return
oil, or oil cooler becomes plugged. The pressure setting for the bypass valve is higher than the restriction valve.

Operational Check: Hydraulic oil continues to run hot. Check for an open bypass valve.

<- Go to Section TOC Section 9025 page 55 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Main Relief Valve Circuit Operation

Main Relief Valve Operation

LEGEND:
1 Main Poppet
2 Orifice A
3 Orifice B
4 Seat
5 Passage A
6 Spring B
7 Piston
8 Pilot Poppet
9 Spring Chamber
10 Spring A
11 Sleeve
12 Normal Operation
13 Relief Operation
<- Go to Section TOC Section 9025 page 56 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

117 Main Relief and Power Dig Valve


200 From Main Circuit
201 To Return
600 High Pressure Oil
604 Return Oil
SG To Solenoid Valve Manifold (port SG)

The function of main relief and power dig valve (117) is to limit the main hydraulic system operating pressure. The relief valve
senses high pressure oil (600) pressure from main circuit (200). For location of main relief and power dig valve location, see
Control Valve Operation . (Group 9025-05.) For main relief and power dig valve test and adjustment procedures, see Main
Relief and Power Dig Valve Test and Adjustment . (Group 9025-25.)

Pressure from main circuit is routed to pilot poppet (8) through orifice A (2) in main poppet (1) and orifice B (3) in seat (4).
When pressure reaches set pressure of spring B (6), pilot poppet is opened and high pressure oil from passage A (5) flows
along sleeve (11) to return (201). A pressure difference is caused between main circuit and spring chamber (9) due to orifice A.
When pressure difference reaches set pressure of spring A (10), main poppet is opened, allowing main circuit oil flow to return
and causing main circuit to reduce pressure. Main poppet is then closed by spring A once below set pressure.

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

<- Go to Section TOC Section 9025 page 58 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Main Relief Valve Power Dig Operation

LEGEND:
1 Main Poppet
2 Orifice A
3 Orifice B
4 Seat
5 Passage A
6 Spring B
7 Piston
8 Pilot Poppet
9 Spring Chamber
10 Spring A
11 Sleeve
117 Main Relief and Power Dig Valve
200 From Main Circuit
201 To Return
600 High Pressure Oil
604 Return Oil
609 Pilot Oil
SG From Solenoid Valve Manifold (port SG)

When power dig solenoid (Y24) is active, pilot oil is routed from solenoid valve manifold (port SG) (SG) to main relief and power
dig valve (117). Pilot oil presses on piston (7) compressing spring B (6), increasing spring set pressure and relief set pressure.
For more information on power dig solenoid, see Main Controller (MCZ) Circuit Theory of Operation . (Group 9015-15.)

<- Go to Section TOC Section 9025 page 59 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Circuit Relief and Anticavitation Valve Operation

Circuit Relief and Anticavitation Valve

LEGEND:
1 Adjusting Screw
2 Pilot Poppet Spring
3 Pilot Poppet

<- Go to Section TOC Section 9025 page 60 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

4 Main Poppet
5 Main Poppet Spring
6 Orifice
7 Anticavitation Valve Poppet
8 Anticavitation Valve Spring
9 Conical Face
10 From Work Circuit
11 Return Passage
12 Drain Passage
13 Closed Relief Valve
14 Relief Operation
15 Anticavitation Operation
600 High Pressure Oil
601 Low Pressure Oil
604 Return Oil

The main function of a circuit relief and anticavitation valve is to protect the components of a work circuit from a pressure
spike. When the control valve spool is in neutral, it provides a path for return oil (604) to flow to a cylinder to prevent
cavitation. The circuit relief valve is a pilot-operated, poppet-type relief valve. The anticavitation valve poppet (7) also
functions as the valve seat for the main poppet (4). Circuit relief and anticavitation valves are used in the bucket, boom, and
arm work circuits. The circuit relief valves can be adjusted using the adjusting screw (1). For adjustment procedures, see Circuit
Relief Valve Test and Adjustment . (Group 9025-25.)

At pressures below the circuit relief valve setting, the relief valve remains closed (13). The main poppet (4) is seated against
the anticavitation valve poppet (7). The anticavitation valve poppet is held against the main poppet by the anticavitation valve
spring (8) and high pressure oil (600) from the work circuit (10). Oil pressure is sensed on the end of pilot poppet (3) through
the orifice (6) in the main poppet.

In relief operation, oil pressure in the work circuit exceeds the pressure setting of the pilot poppet spring (2) pushing the pilot
poppet off its seat. The oil behind main poppet, flows past the pilot poppet and through the drain passage (12) to the return
passage (11). The oil pressure behind the main poppet is reduced, creating pressure differences across main poppet as oil
flows out faster than oil can flow through orifice in the main poppet. The main poppet is pushed open to relieve pressure oil to
the return passage. The anticavitation valve poppet bottoms against a shoulder and does not follow the main poppet.

When the oil pressure in the work circuit decreases below the pressure setting, the pilot poppet is pushed closed by the spring,
stopping the flow of oil past the pilot poppet to return. The oil pressure behind the main poppet increases, pushing the main
poppet closed against the anticavitation valve poppet.

During anticavitation operation, the pressure of oil in the work circuit becomes less than the pressure in the return passage.
The higher pressure of return oil acts on the conical face (9) of anticavitation valve poppet, pushing it away from the main
poppet. Return oil flows from the return passage into the work circuit preventing cavitation. The main poppet bottoms against
a shoulder and does not follow the anticavitation valve poppet.

<- Go to Section TOC Section 9025 page 61 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Travel Flow Combiner Valve Operation

<- Go to Section TOC Section 9025 page 62 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Travel Flow Combiner Valve Schematic

<- Go to Section TOC Section 9025 page 63 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

LEGEND:
4 Arm In (pilot)
9 Left Travel Forward (pilot)
11 Right Travel Forward (pilot)
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
36 Hydraulic Oil Cooler
61 Right Travel Motor
63 Left Travel Motor
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
90 Arm 2 Spool
91 Arm 2 Flow Rate Control Valve (valve and poppet)
92 Check Valve (lift check)—Arm 2 Neutral Passage
93 Bypass Shutoff Valve
95 Swing Spool
97 Arm 1 Spool
102 Arm In Circuit Relief and Anticavitation Valve
103 Arm Out Circuit Relief and Anticavitation Valve
104 Boom 2 Spool
107 Auxiliary Spool
110 Left Travel Spool
117 Main Relief and Power Dig Valve
120 Travel Flow Combiner Valve
121 Check Valve—Travel Flow Combiner Circuit
124 Oil Cooler Bypass Valve
127 Arm Cylinder
144 To Blade Control Valve
145 From Travel Flow Combiner Shuttle Valve
600 High Pressure Oil
604 Return Oil
606 Trapped Oil
609 Pilot Oil
B31 Arm In Pressure Sensor

<- Go to Section TOC Section 9025 page 64 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

<- Go to Section TOC Section 9025 page 65 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Travel Flow Combiner Valve

LEGEND:
15 From Pump 1
110 To Left Travel Spool
120 Travel Flow Combiner Valve
145 From Travel Flow Combiner Shuttle Valve
600 High Pressure Oil
604 Return Oil
609 Pilot Oil

When only travel functions are actuated, high pressure oil (600) from pump 2 (16) flows through the neutral passage of swing
(95), arm 1 (97), boom 2 (104), and auxiliary (107) spools, then through the left travel spool (110) and out to the left travel
motor (63). High pressure oil from pump 1 (15) flows through the right travel spool (75) and out to the right travel motor (61).
Right travel spool blocks the flow of high pressure oil through the neutral passages of bucket (76), boom 1 (81), and arm 2 (90)
spools. The travel flow combiner valve (120) ensures machine does not mistrack during combined travel and front attachment
operation by routing high pressure oil from pump 1 to both the left and right travel motors and bucket spool. High pressure oil
from pump 2 is dedicated to the boom 2, arm 1, auxiliary, and swing spools.

The travel flow combiner valve may also be shifted to combine pump flow for blade operation. See Blade Circuit Operation—If
Equipped . (Group 9025-05.)

For location of travel flow combiner valve, see Control Valve Operation . (Group 9025-05.)

When right travel is in neutral, travel flow combiner valve is held closed by spring pressure, blocking flow of high pressure oil
from pump 1 to left travel spool.

Actuating a right travel function shifts travel flow combiner valve pilot valve. When a dig function is activated in conjunction
with a right travel function, pilot oil (609) from the swing park brake release pilot valve is routed to the travel flow combiner
valve, causing the valve to shift. See Pilot Signal Manifold Operation . (Group 9025-05.)

With travel flow combiner valve shifted, high pressure oil from the pump 1 now flows through the valve to the left travel spool
and travel motor and to bucket spool. Flow combiner valve circuit check valve (119) prevents back flow through the travel flow
combiner valve.

<- Go to Section TOC Section 9025 page 66 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Auxiliary Flow Combiner Valve and Bypass Shutoff Valve Operation

<- Go to Section TOC Section 9025 page 67 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Auxiliary Flow Combiner Valve and Bypass Shutoff Valve Schematic

<- Go to Section TOC Section 9025 page 68 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

LEGEND:
13 Auxiliary (pilot)
14 Auxiliary (pilot)
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
73 4-Spool Control Valve
74 5-Spool Left Control Valve
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
90 Arm 2 Spool
93 Bypass Shutoff Valve
95 Swing Spool
97 Arm 1 Spool
104 Boom 2 Spool
107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
110 Left Travel Spool
117 Main Relief and Power Dig Valve
118 Auxiliary Flow Combiner Valve
119 Check Valve—Flow Combiner Valve Circuit
120 Travel Flow Combiner Valve
155 From Shuttle Valve
170 Auxiliary Shuttle Valve
174 Auxiliary Attachment
177 From Flow Rate Select Solenoid Valve
178 To Flow Rate Select Reducing Valve
600 High-Pressure Oil
604 Return Oil
609 Pilot Oil

→NOTE:

Auxiliary flow combiner valve and bypass shutoff valve will not wok properly unless appropriate kits are
installed on machine.

The combined functions of auxiliary flow combiner valve (118) and bypass shutoff valve (93) combine high-pressure oil (600)
flow from pump 1 (15) with pump 2 (16) at the auxiliary spool (107) to increase hydraulic oil flow to auxiliary attachment (174).

Auxiliary Flow Combiner Valve Operation

<- Go to Section TOC Section 9025 page 69 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Auxiliary Flow Combiner Valve

LEGEND:
15 From Pump 1
107 To Auxiliary Spool
118 Auxiliary Flow Combiner Valve
119 Check Valve—Flow Combiner Valve Circuit
177 From Flow Rate Select Solenoid Valve
178 To Flow Rate Select Reducing Valve
600 High-Pressure Oil
604 Return Oil
609 Pilot Oil

Actuating an auxiliary function with 2-speed activation solenoid valve (Y43) energized routes pilot oil (609) from flow rate
select solenoid valve (177) to the auxiliary flow combiner valve, shifting the spool. The auxiliary flow combiner valve works in
conjunction with the bypass shutoff valve. When the bypass shutoff valve is shifted, pump 1 high-pressure oil in neutral
passage flow to return passage is blocked. High-pressure oil now flows through the auxiliary flow combiner valve and combines
with pump 2 oil at the auxiliary spool (107). Check valve—flow combiner valve circuit (119) prevents backflow of oil through
the auxiliary flow combiner valve.

In combined operation with travel and dig functions, pilot oil from flow rate select reducing valve (178) flows to the auxiliary
flow combiner valve. This pilot oil pressure, in addition to spring pressure, causes the auxiliary flow combiner valve to return to
<- Go to Section TOC Section 9025 page 70 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

neutral position and block flow of pump 1 oil to the auxiliary spool.

Bypass Shutoff Valve Operation

Bypass Shutoff Valve

LEGEND:
15 From Pump 1
31 To Hydraulic Oil Tank
93 Bypass Shutoff Valve
170 From Auxiliary Shuttle Valve
600 High-Pressure Oil
604 Return Oil
609 Pilot Oil

When an auxiliary or blade function is actuated, pilot pressure is applied to bypass shutoff valve, causing the valve to shift.
When the bypass shutoff valve is shifted, pump 1 high-pressure oil in neutral passage flow to return passage is blocked.

High-pressure oil from pump 1 can then be routed through the auxiliary flow combiner valve if equipped with two pump
combined flow kit or through the travel flow combiner valve (120) if equipped with blade option.

<- Go to Section TOC Section 9025 page 71 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Boom Lower Meter-In Cut Valve Operation

<- Go to Section TOC Section 9025 page 72 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Boom Lower Meter-In Cut Valve Circuit Operation Schematic

<- Go to Section TOC Section 9025 page 73 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

LEGEND:
2 Boom Down (pilot)
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
36 Hydraulic Oil Cooler
81 Boom 1 Spool
82 Boom Regenerative Valve
83 Boom Flow Rate Control Valve (valve and poppet)
84 Dig Regenerative Valve
85 Boom Reduced Leakage Valve (valve and check valve)
86 Orifice
87 Boom Lower Meter-In Cut Valve
88 Boom Up Circuit Relief and Anticavitation Valve
89 Boom Down Circuit Relief and Anticavitation Valve
104 Boom 2 Spool
117 Main Relief and Power Dig Valve
124 Oil Cooler Bypass Valve
125 Boom Cylinder (2 used)
128 Check Valve
154 To Shuttle Valve
600 High Pressure Oil
602 Low Pressure Oil
604 Return Oil
606 Trapped Oil
609 Pilot Oil
610 Regeneration Oil

Boom Lower Meter-In Cut Valve

LEGEND:
2 Boom Down (pilot)

<- Go to Section TOC Section 9025 page 74 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

3 From Boom Cylinders


4 Spring
31 To Hydraulic Oil Tank
83 To Boom Flow Rate Control Valve (valve)
86 Orifice
87 Boom Lower Meter-In Cut Valve
104 To Boom 2 Spool
604 Return Oil
609 Pilot Oil
610 Regeneration Oil
The boom lower meter-in cut valve (87), located in the boom lower circuit, controls the boom flow rate control valve (83) and
pilot oil (609) to the boom 2 spool (104).

During initial boom down (2) operation, pilot oil flows to the boom 2 spool through boom lower meter-in cut valve.

During boom down operation the boom lower meter-in cut valve is shifted by high pressure return oil from the boom cylinders
(3) when return pressure overcomes spring (4) pressure. With boom meter-in cut valve shifted, boom down pilot oil is blocked
to boom 2 spool, causing the spool to return to neutral, and pilot oil is routed to the switch valve in the boom flow rate control
valve (83) causing the valve to shift. The poppet of boom flow rate control valve now restricts high pressure oil (600) flow from
pump 1 to the boom 1 spool (81). See Boom Flow Rate Control Valve Circuit Operation and see Boom Regenerative Valve
Circuit Operation . (Group 9025-05.)

<- Go to Section TOC Section 9025 page 75 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Boom Regenerative Valve Circuit Operation

Boom Regenerative Valve Operation

LEGEND:
1 Boom Up (pilot)
2 Boom Down (pilot)
3 Hole A
15 From Pump 1
81 Boom 1 Spool
82 Boom Regenerative Valve
83 Boom Flow Rate Control Valve (valve and poppet)
85 Boom Reduced Leakage Valve (valve and check valve)
87 Boom Meter-In Cut Valve
87A From Boom Meter-In Cut Valve
104 From Boom 2 Spool
125 Boom Cylinder (2 used)
125A From Boom Cylinders (head end)
125B To Boom Cylinders (rod end)
600 High Pressure Oil
604 Return Oil
609 Pilot Oil
610 Regeneration Oil
DD To Solenoid Valve Manifold Port DD

The function of the boom regenerative valve (82) is to combine return oil from the boom cylinders (head end) (125A) with
supply oil from pump 1 (15) to the boom cylinder rod end to prevent cavitation and improve function controllability.

Return oil from boom cylinders (125A) flows back to the control valve top work port and is restricted as it flows past the spool
<- Go to Section TOC Section 9025 page 76 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

to the return passage. The return oil also flows through hole A (3) in the valve spool and down the center of spool to the boom
regenerative valve. If return oil pressure is higher than supply oil pressure the return oil pressure pushes the boom
regenerative valve open allowing oil to combine with the supply oil and flow out the bottom work port to the cylinder.

When supply oil pressure becomes higher than return oil pressure, the boom regenerative valve is pushed closed.

<- Go to Section TOC Section 9025 page 77 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Dig Regenerative Valve Circuit Operation

<- Go to Section TOC Section 9025 page 78 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Dig Regenerative Valve Schematic

<- Go to Section TOC Section 9025 page 79 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

LEGEND:
1 Boom Up (pilot)
4 Arm In (pilot)
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
36 Hydraulic Oil Cooler
73 4-Spool Control Valve
74 5-Spool Rear Control Valve
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
83 Boom Flow Rate Control Valve (valve and poppet)
84 Dig Regenerative Valve
90 Arm 2 Spool
91 Arm 2 Flow Rate Control Valve (valve and poppet)
93 Bypass Shutoff Valve
95 Swing Spool
97 Arm 1 Spool
98 Arm 1 Flow Rate Control Valve (valve and poppet)
100 Check Valve (lift check)—Dig Regenerative Circuit
104 Boom 2 Spool
107 Auxiliary Spool
110 Left Travel Spool
124 Oil Cooler Bypass Valve
125 Boom Cylinder (2 used)
127 Arm Cylinder
128 Check Valve
149 Arm 1 Regenerative Cut Valve
600 High Pressure Oil
602 Low Pressure Oil
604 Return Oil
606 Trapped Oil
609 Pilot Oil
610 Regenerative Oil
650 Voltage Signal
A3 Main Controller (MCZ)
B30 Boom Up Pressure Sensor
B31 Arm In Pressure Sensor
B35 Pump 1 Delivery Pressure Sensor
B37 Pump 2 Delivery Pressure Sensor
DZ To Solenoid Valve Manifold Port DZ
Y22 Dig Regenerative Solenoid (marked SF)

<- Go to Section TOC Section 9025 page 80 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Dig Regenerative Valve Section

LEGEND:
81 From Boom 1 Spool
84 Dig Regenerative Valve
90 To Arm 2 Spool
100 Check Valve (lift check)—Dig Regenerative Circuit
104 To Boom 2 Spool
604 Return Oil
609 Pilot Oil
610 Regenerative Oil
DZ To Solenoid Valve Manifold Port DZ
Y22 From Dig Regenerative Solenoid (marked SF)
The dig regenerative valve (84) improves arm control and prevents arm cylinder (127) cavitation during the combined
operations of boom up and arm in by combining the return oil from boom cylinder (125) rod ends with the pump high pressure
oil to the arm cylinder (127).

The main controller (MCZ) (A3) sends a voltage signal (650) to the dig regenerative solenoid (Y22) to energize the coil under
the following conditions:

High pressure at pump 1 delivery pressure sensor (B35) or pump 2 delivery pressure sensor (B37)
Pressure at arm in pressure sensor (B31)

<- Go to Section TOC Section 9025 page 81 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Pressure at boom up pressure sensor (B30)

See Main Controller (MCZ) Circuit Theory of Operation . (Group 9015-15.)

The solenoid valve then sends pilot oil (609) pressure to shift the dig regenerative valve (84). With the dig regenerative valve
shifted, return oil from the boom cylinder rod ends flows through boom 1 spool (81), dig regenerative valve, and check valve
(lift check)—dig regenerative circuit and is combined with high pressure oil from hydraulic pump 2 and routed through the arm
1 spool (97) to the arm cylinder head end increasing cylinder speed and preventing cavitation.

<- Go to Section TOC Section 9025 page 82 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Dig Regenerative Solenoid Operation

LEGEND:
1 Solenoid Coil
2 Spool
3 To Valve Function
4 De-Energized
5 Energized
<- Go to Section TOC Section 9025 page 83 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

6 Pressure Equals Magnetic Force


29 From Pilot Filter and Bypass Valve
31 To Hydraulic Oil Tank
37 Solenoid Valve Manifold
604 Return Oil
609 Pilot Oil
613 Reduced Pilot Oil
Y22 Dig Regenerative Solenoid (marked SF)
Y23 Arm Regenerative Solenoid (marked SC)
Y24 Power Dig/Travel Speed Solenoid (marked SG)
Y27 Arm 2 Flow Control Solenoid (marked SD)
The dig regenerative solenoid (marked SF) (Y22) is a proportional-type solenoid valve. The solenoid valve is actuated by a
voltage signal from the main controller (MCZ). The voltage signal is a DC voltage that is turned on and off to form a pulse width
modulated signal. The solenoid coil (1) reacts to the “average” voltage to create a magnetic force to shift the spool (2) left
against a spring. The reduced pilot oil (613) pressure sent to the valve function (3) depends on how long the voltage signal is
on verses on how long it is off. The reduced pilot oil pressure is in proportion to the voltage signal.

When de-energized (4), the spool is pushed to the right by a spring. The valve function port is connected to the hydraulic oil
tank (31) port.

When energized (5), the magnetic force shifts the spool left against the spring. Pilot oil (609) from the pilot filter and bypass
valve (29) flows past the spool flange and out the valve function port as reduced pilot oil. Because the flange on the right is
larger than the flange on the left, the spool is pushed to the right against the magnetic force as the oil pressure to the valve
function increases. When the oil pressure becomes equal to or greater than the magnetic force, the spool is pushed to the right
closing the passage stopping the pressure increase. The oil pressure to the valve function is trapped. The spool is moving
constantly to maintain the oil pressure in response to the voltage signal to the solenoid coil. See Control Valve Operation .
(Group 9025-05.) and see Main Controller (MCZ) Circuit Theory of Operation . (Group 9015-15.)

<- Go to Section TOC Section 9025 page 84 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Arm Regenerative Valve Circuit Operation

<- Go to Section TOC Section 9025 page 85 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Arm Regenerative Valve Circuit Schematic (arm in and swing left actuated)

<- Go to Section TOC Section 9025 page 86 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

LEGEND:
1 Boom Up (pilot)
3 Arm Out (pilot)
4 Arm In (pilot)
5 Swing Left (pilot)
6 Swing Right (pilot)
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
36 Hydraulic Oil Cooler
43 From Arm 1 Flow Rate Pilot Valve (port SK)
52 Swing Motor
73 4-Spool Control Valve
74 5-Spool Control Valve
90 Arm 2 Spool
91 Arm 2 Flow Rate Control Valve (valve and poppet)
92 Check Valve (lift check)—Arm 2 Neutral Passage
93 Bypass Shutoff Valve
94 Arm Regenerative Valve
95 Swing Spool
96 Check Valve (lift check)—Swing Neutral Passage
97 Arm 1 Spool
98 Arm 1 Flow Rate Control Valve (valve and poppet)
101 Arm Reduced Leakage Valve (valve and poppet)
102 Arm In Circuit Relief and Anticavitation Valve
103 Arm Out Circuit Relief and Anticavitation Valve
124 Oil Cooler Bypass Valve
127 Arm Cylinder
149 Arm 1 Regenerative Cut Valve
600 High-Pressure Oil
602 Low-Pressure Oil
604 Return Oil
606 Trapped Oil
609 Pilot Oil
610 Regenerative Oil
650 Voltage Signal
A3 Main Controller (MCZ)
B30 Boom Up Pressure Sensor
B31 Arm In Pressure Sensor
B33 Swing Pressure Sensor
B35 Pump 1 Delivery Pressure Sensor
B37 Pump 2 Delivery Pressure Sensor
DE To Solenoid Valve Manifold Port DE
Y23 Arm Regenerative Solenoid (SC)

<- Go to Section TOC Section 9025 page 87 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Arm Regenerative Valve Section

LEGEND:
3 Arm Out (pilot)
4 Arm In (pilot)
94 Arm Regenerative Valve
97 Arm 1 Spool
98 Arm 1 Flow Rate Control Valve (valve and poppet)

<- Go to Section TOC Section 9025 page 88 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

101 Arm Reduced Leakage Valve (valve and poppet)


127A To Arm Cylinder (head end)
127B From Arm Cylinder (rod end)
149 Arm Regenerative Cut Valve
600 High-Pressure Oil
602 Low-Pressure Oil
604 Return Oil
609 Pilot Oil
610 Regenerative Oil
SC From Solenoid Valve Manifold Port SC
The arm regenerative valve (94) accelerates arm in speed in order to prevent arm hesitation and cavitation during arm in
operation by combining return oil (604) from arm cylinder (rod end) (127B) with supply oil to arm cylinder (head end) (127A).

The main controller (MCZ) (A3) sends a voltage signal (650) to arm regenerative solenoid (SC) (Y23) to energize the coil under
the following conditions:

Low pressure at pump 1 delivery pressure sensor (B35) or pump 2 delivery pressure sensor (B37)
High pressure (arm in fully actuated) at arm in pressure sensor (B31)
Pressure at swing pressure sensor (B33) or boom up pressure sensor (B30)

See Main Controller (MCZ) Circuit Theory of Operation . (Group 9015-15.)

During arm in operation, return oil from arm cylinder (rod end) is routed to arm reduced leakage valve (valve and poppet)
(101). Return oil pressure unseats the reduced leakage valve poppet, routing return oil through arm 1 spool. See Boom and
Arm Reduced Leakage Valve Operation . (Group 9025-05.)

With arm regenerative solenoid active, pilot oil (609) shifts the arm regenerative cut valve (149), shifting the valve and
blocking the primary flow of cylinder return oil to tank. With arm regenerative cut valve shifted, return oil pressure rises. When
return pressure is greater than supply oil pressure, return oil shifts arm regenerative valve (94) and combines with supply oil to
arm cylinder (head end).

<- Go to Section TOC Section 9025 page 89 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Arm Regenerative Solenoid Operation

LEGEND:
1 Solenoid Coil
2 Spool
3 To Valve Function
4 De-Energized
5 Energized
<- Go to Section TOC Section 9025 page 90 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

6 Pressure Equals Magnetic Force


29 From Pilot Filter and Bypass Valve
31 To Hydraulic Oil Tank
37 Solenoid Valve Manifold
604 Return Oil
609 Pilot Oil
613 Reduced Pilot Oil
Y22 Dig Regenerative Solenoid (marked SF)
Y23 Arm Regenerative Solenoid (marked SC)
Y24 Power Dig/Travel Speed Solenoid (marked SG)
Y27 Arm 2 Flow Control Solenoid (marked SD)
The arm regenerative solenoid (marked SC) (Y23) is a proportional-type solenoid valve. The solenoid valve is actuated by a
voltage signal from the main controller (MCZ) (A3). The voltage signal is a DC voltage that is turned on and off to form a pulse-
width modulated signal. The solenoid coil (1) reacts to the “average” voltage to create a magnetic force to shift the spool (2)
left against a spring. The reduced pilot oil (613) pressure sent to the valve function (3) depends on how long the voltage signal
is on versus on how long it is off. The reduced pilot oil pressure is in proportion to the voltage signal.

When de-energized (4), the spool is pushed to the right by a spring. The valve function port is connected to the hydraulic oil
tank (31) port.

When energized (5), the magnetic force shifts the spool left against the spring. Pilot oil (609) from the pilot filter and bypass
valve (29) flows past the spool flange and out the valve function port as reduced pilot oil. Because the flange on the right is
larger than the flange on the left, the spool is pushed to the right against the magnetic force as the oil pressure to the valve
function increases. When the oil pressure becomes equal to or greater than the magnetic force, the spool is pushed to the
right, closing the passage stopping the pressure increase. The oil pressure to the valve function is trapped. The spool is moving
constantly to maintain the oil pressure in response to the voltage signal to the solenoid coil. See Control Valve Operation .
(Group 9025-05.) Also see Main Controller (MCZ) Circuit Theory of Operation . (Group 9015-15.)

<- Go to Section TOC Section 9025 page 91 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Bucket Regenerative Valve Circuit Operation

Bucket Regenerative Valve Operation

LEGEND:
1 Hole A
7 Bucket Curl (pilot)
8 Bucket Dump (pilot)
15 From Pump 1
76 Bucket Spool
77 Bucket Flow Rate Control Valve (valve and poppet)
78 Bucket Regenerative Valve
126 Bucket Cylinder
126A To Bucket Cylinder Head End
126B From Bucket Cylinder Rod End
166 Bucket Regeneration Cut Valve
166A To Bucket Regeneration Cut Valve
600 High Pressure Oil
604 Return Oil
609 Pilot Oil
610 Regeneration Oil

The function of the bucket regenerative valve (78) is to combine return oil from the bucket cylinder rod end (126B) with supply
oil from pump 1 (15) to the bucket cylinder head end (126A) to prevent cavitation and improve function controllability.

Return oil from the cylinder rod end flows to the control valve top work port and is restricted as it flows past the spool to the
return passage. The return oil also flows through hole A (1) in the valve spool and down the center of spool to the bucket
regenerative valve. If return oil pressure is higher than supply oil pressure the return oil pressure pushes the bucket

<- Go to Section TOC Section 9025 page 92 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

regenerative valve open allowing return oil to combine with the supply oil and flow out the bottom work port to bucket cylinder
head end.

Supply oil flow to the bucket spool is restricted by the bucket flow rate control valve (valve and poppet) (77) during combined
operation. See Bucket Flow Rate Control Valve Circuit Operation for more information. (Group 9025-05.)

When supply oil pressure becomes higher than return oil pressure, the bucket regenerative valve is pushed closed.

<- Go to Section TOC Section 9025 page 93 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Boom and Arm Reduced Leakage Valves Operation

→NOTE:

The operation of boom reduced leakage valve and arm reduced leakage valve is similar. Boom reduced
leakage valve operation is depicted.

Boom Reduced Leakage Valve—Neutral

LEGEND:
1 Boom Up (pilot)
2 Boom Down (pilot)
3 Spring A
4 Spring B
5 Orifice
15 From Pump 1
81 Boom 1 Spool
81A To Boom 1 Spool
85 Boom Reduced Leakage Valve (valve and check valve)
125 Boom Cylinder (2 used)
125A From Boom Cylinder Head Ends
200 Valve
201 Check Valve
600 High Pressure Oil
604 Return Oil
606 Trapped Oil

<- Go to Section TOC Section 9025 page 94 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

The function of the boom and arm reduced leakage valves is to reduce cylinder drift by stopping leakage from the cylinder
back through the control valve. A reduced leakage valve is used in the boom head end circuit and arm rod end circuit.

In neutral, the oil pressure generated in the boom cylinder head end or arm cylinder rod end circuit by the load on the cylinders
is routed through the valve (200) and applies pressure to the poppet along with spring A (3) pressure. The check valve (201) is
held closed against the seat in the control valve housing trapping the oil in the cylinders. See Control Valve Operation for
location in the control valve. (Group 9025-05.)

Boom Reduced Leakage Valve—Boom Down

LEGEND:
1 Boom Up (pilot)
2 Boom Down (pilot)
3 Spring A
4 Spring B
5 Orifice
15 From Pump 1
81 Boom 1 Spool
81A To Boom 1 Spool
85 Boom Reduced Leakage Valve (valve and check valve)
125 Boom Cylinder (2 used)
125A From Boom Cylinder Head Ends
200 Valve
201 Check Valve
600 High Pressure Oil
604 Return Oil
606 Trapped Oil
609 Pilot Oil

<- Go to Section TOC Section 9025 page 95 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Actuating the boom down (2) function routes pilot oil (609) pressure from pilot controller to shift the boom 1 spool (81) and
valve (200). The trapped oil pressure in spring A (3) cavity is released past the valve to the hydraulic oil tank. The return oil
(604) pressure from the boom cylinder head ends (125A) pushes the check valve (201) off its seat, opening the passage for oil
to flow to return. The check valve is pushed off its seat because the outside diameter of the upper land at the head end of
check valve is slightly larger than the lower land. With the check valve open, return oil from the boom cylinders is routed to
return through the boom 1 spool. Orifice (5) decreases pressure in the spring B (4) chamber, preventing the check valve from
moving quickly, thus reducing shock during boom down operation.

<- Go to Section TOC Section 9025 page 96 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Arm 1 Flow Rate Control Valve Circuit Operation

<- Go to Section TOC Section 9025 page 97 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Arm 1 Flow Rate Control Valve Circuit Schematic

<- Go to Section TOC Section 9025 page 98 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

LEGEND:
4 Arm In (pilot)
5 Swing Left (pilot)
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
36 Hydraulic Oil Cooler
43 From Arm 1 Flow Rate Pilot Valve (port SE)
52 Swing Motor
90 Arm 2 Spool
91 Arm 2 Flow Rate Control Valve (valve and poppet)
92 Check Valve (lift check)—Arm 2 Neutral Passage
93 Bypass Shutoff Valve
95 Swing Spool
96 Check Valve (lift check)—Swing Neutral Passage
97 Arm 1 Spool
98 Arm 2 Flow Rate Control Valve (valve and poppet)
102 Arm In Circuit Relief and Anticavitation Valve
103 Arm Out Circuit Relief and Anticavitation Valve
117 Main Relief and Power Dig Valve
124 Oil Cooler Bypass Valve
127 Arm Cylinder
149 Arm 1 Regenerative Cut Valve
600 High Pressure Oil
602 Low Pressure Oil
604 Return Oil
606 Trapped Oil
609 Pilot Oil
B31 Arm In Pressure Sensor
DE To Solenoid Valve Manifold (port DE)

The function of arm 1 flow rate control valve (valve and poppet) (98) is to restrict the flow of high pressure oil (600) from pump
2 (16) to the arm 1 spool (97) to ensure a priority flow of high pressure oil to the swing spool (95) during combined operation.

<- Go to Section TOC Section 9025 page 99 130G Excavator Diagnostic


Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Arm 1 Flow Rate Control Valve Normal Operation (low load)

<- Go to Section TOC Section 9025 page 100 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Arm 1 Flow Rate Control Valve Normal Operation (high load)

LEGEND:
16 From Pump 2
43 From Arm 1 Flow Rate Pilot Valve (port SE)
97 To Arm 1 Spool
98 Arm 1 Flow Rate Control Valve
200 Check Valve
201 Poppet
202 Switch Valve
600 High Pressure Oil
604 Return Oil
DE To Solenoid Valve Manifold (port DE)

Normal Operation— High pressure oil (600) from pump 2 (16) opens check valve (200) in poppet (201) of arm 1 flow rate
control valve (98) because switch valve (202) is open. High pressure oil flows through the check valve and switch valve to the
arm 1 spool (97). As load increases, pressure increases pushing the poppet open and high pressure oil flows through the
poppet to arm 1 spool.

<- Go to Section TOC Section 9025 page 101 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Arm 1 Flow Rate Control Valve Combined Operation

LEGEND:
16 From Pump 2
43 From Arm 1 Flow Rate Pilot Valve (port SE)
97 To Arm 1 Spool
98 Arm 1 Flow Rate Control Valve
200 Check Valve
201 Poppet
202 Switch Valve
600 High Pressure Oil
602 Low Pressure Oil
604 Return Oil
606 Trapped Oil
609 Pilot Oil
DE From Solenoid Valve Manifold (port DE)

Combined Operation— During swing and arm in combined operation, the arm 1 flow rate pilot valve (port SE), in the pilot
signal manifold, is shifted by arm in pilot oil (609). The pilot valve then routes a portion of pilot oil from swing function to switch
valve (202) of arm 1 flow rate control valve (98). For operation of pilot valves, see Pilot Signal Manifold Operation . (Group
9025-05.)

Pilot oil shifts the switch valve, creating trapped oil (606) on backside of poppet (201) which forces the poppet towards the
closed position. The poppet now restricts the flow of high pressure oil (600) to arm 1 spool. High pressure oil now flows through
the swing spool to the swing motor against the higher load pressure.

<- Go to Section TOC Section 9025 page 102 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Arm 2 Flow Rate Control Valve Circuit Operation

<- Go to Section TOC Section 9025 page 103 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Arm 2 Flow Rate Control Valve Circuit Schematic

<- Go to Section TOC Section 9025 page 104 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

LEGEND:
1 Boom Up (pilot)
4 Arm In (pilot)
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
36 Hydraulic Oil Cooler
81 Boom 1 Spool
83 Boom Flow Rate Control Valve (valve and poppet)
84 Dig Regenerative Valve
85 Boom Reduced Leakage Valve
88 Boom Up Circuit Relief and Anticavitation Valve
89 Boom Down Circuit Relief and Anticavitation Valve
90 Arm 2 Spool
91 Arm 2 Flow Rate Control Valve (valve and poppet)
92 Check Valve (lift check)—Arm 2 Neutral Passage
94 Arm Regenerative Valve
97 Arm 1 Spool
98 Arm 1 Flow Rate Control Valve (valve and poppet)
100 Check Valve (lift check)—Dig Regenerative Circuit
101 Arm Reduced Leakage Valve (valve and poppet)
102 Arm In Circuit Relief and Anticavitation Valve
103 Arm Out Circuit Relief and Anticavitation Valve
117 Main Relief and Power Dig Valve
124 Oil Coolet Bypass Valve
125 Boom Cylinder (2 used)
127 Arm Cylinder
149 Arm 1 Regenerative Cut Valve
600 High Pressure Oil
602 Low Pressure Oil
604 Return Oil
606 Trapped Oil
609 Pilot Oil
B30 Boom Up Pressure Sensor
B31 Arm In Pressure Sensor
DD To Solenoid Valve Manifold Port DD
SI To Solenoid Valve Manifold Port SI

The function of arm 2 flow rate control valve (valve and poppet) (91) is to restrict the flow of high pressure oil (600) from pump
1 (15) to the arm 2 spool (90) to ensure a priority flow of high pressure oil to the boom 1 spool (81) during arm in and boom up
combined operation. For location of arm 2 flow rate control valve, see Control Valve Operation . (Group 9025-05.)

<- Go to Section TOC Section 9025 page 105 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Arm 2 Flow Rate Control Valve Normal Operation (low load)

<- Go to Section TOC Section 9025 page 106 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Arm 2 Flow Rate Control Valve Normal Operation (high load)

LEGEND:
15 From Pump 1
90 To Arm 2 Spool
91 Arm 2 Flow Rate Control Valve (valve and poppet)
200 Check Valve
201 Poppet
202 Switch Valve
600 High Pressure Oil
604 Return Oil
DD To Solenoid Valve Manifold Port DD
SI To Solenoid Valve Manifold Port SI
Normal Operation— High pressure oil (600) from pump 1 (15) opens the check valve (200) in the poppet (201) of arm 2 flow
rate control valve (91) because the switch valve (202) is open. High pressure oil flows through the check valve and switch valve
to arm 2 spool (90). As the load increases, the pressure increases pushing the poppet open and high pressure oil flows through
the poppet to arm 2 spool.

<- Go to Section TOC Section 9025 page 107 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Arm 2 Flow Rate Control Valve (combined operation)

LEGEND:
15 From Pump 1
90 To Arm 2 Spool
91 Arm 2 Flow Rate Control Valve (valve and poppet)
200 Check Valve
201 Poppet
202 Switch Valve
600 High Pressure Oil
602 Low Pressure Oil
604 Return Oil
606 Trapped Oil
609 Pilot Oil
DD To Solenoid Valve Manifold Port DD
SI From Solenoid Valve Manifold Port SI
Combined Operation— During combined operation of boom up and arm in the arm 2 flow control solenoid (Y27) is activated.
When solenoid is activated pilot oil from solenoid valve manifold port SI (SI) shifts the switch valve (202). See Main Controller
(MCZ) Circuit Theory of Operation . (Group 9015-15.)

With the switch valve shifted, high pressure oil (600) is trapped on the backside of poppet (201) which forces the poppet
towards the closed position. The poppet now restricts the flow of high pressure oil to arm 2 spool. Consequently, more pump 1
high pressure oil is available to the boom 1 spool, maintaining the boom up speed.

During combined operation the arm in function is maintained by the arm or dig regenerative circuit. See Arm Regenerative
Valve Circuit Operation or see Dig Regenerative Valve Circuit Operation . (Group 9025-05.)

<- Go to Section TOC Section 9025 page 108 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Bucket Flow Rate Control Valve Circuit Operation

<- Go to Section TOC Section 9025 page 109 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Bucket Flow Rate Control Valve Circuit Operation

<- Go to Section TOC Section 9025 page 110 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

LEGEND:
1 Boom Up (pilot)
4 Arm In (pilot)
7 Bucket Curl (pilot)
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
36 Hydraulic Oil Cooler
46 From Bucket Flow Rate Pilot Valve (port SK)
76 Bucket Spool
77 Bucket Flow Rate Control Valve (valve and poppet)
78 Bucket Regenerative Valve
79 Bucket Dump Circuit Relief and Anticavitation Valve
80 Bucket Curl Circuit Relief and Anticavitation Valve
81 Boom 1 Spool
83 Boom Flow Rate Control Valve (valve and poppet)
84 Dig Regenerative Valve
85 Boom Reduced Leakage Valve
88 Boom Up Circuit Relief and Anticavitation Valve
89 Boom Down Circuit Relief and Anticavitation Valve
90 Arm 2 Spool
91 Arm 2 Flow Rate Control Valve (valve and poppet)
92 Check Valve (lift check)—Arm 2 Neutral Passage
94 Arm Regenerative Valve
97 Arm 1 Spool
98 Arm 1 Flow Rate Control Valve (valve and poppet)
100 Check Valve (lift check)—Dig Regenerative Circuit
101 Arm Reduced Leakage Valve (valve and poppet)
102 Arm In Circuit Relief and Anticavitation Valve
103 Arm Out Circuit Relief and Anticavitation Valve
117 Main Relief and Power Dig Valve
124 Oil Coolet Bypass Valve
125 Boom Cylinder (2 used)
126 Bucket Cylinder
127 Arm Cylinder
149 Arm 1 Regenerative Cut Valve
166 Bucket Regenerative Cut Valve
600 High Pressure Oil
602 Low Pressure Oil
604 Return Oil
606 Trapped Oil
609 Pilot Oil
B30 Boom Up Pressure Sensor
B31 Arm In Pressure Sensor
DD To Solenoid Valve Manifold Port DD
DK To Solenoid Valve Manifold Port DK
SI To Solenoid Valve Manifold Port SI

The function of the bucket flow rate control valve (valve and poppet) (77) is to restrict the flow of high pressure oil from pump
1 (15) to the bucket spool (76) during bucket, arm in, and boom up combined operation. Restricting oil flow to the bucket spool
ensures a priority flow of high pressure oil to the boom 1 spool (81) during combined operation.

<- Go to Section TOC Section 9025 page 111 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Bucket Flow Rate Control Valve Normal Operation (low load)

<- Go to Section TOC Section 9025 page 112 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Bucket Flow Rate Control Valve Normal Operation (high load)

LEGEND:
15 From Pump 1
46 To Bucket Flow Rate Pilot Valve (port SK)
76 To Bucket Spool
77 Bucket Flow Rate Control Valve (valve and poppet)
200 Check Valve
201 Poppet
202 Switch Valve
600 High Pressure Oil
604 Return Oil
DK To Solenoid Valve Manifold Port DK
Normal Operation— High pressure oil (600) from pump 1 (15) opens the check valve (200) in the poppet (201) of bucket flow
rate control valve (77) because the switch valve (202) is open. The high pressure oil flows through the check valve and switch
valve to bucket spool (76). As the load increases, the pressure increases pushing the poppet open and high pressure oil flows
through the poppet to bucket spool. See Control Valve Operation for bucket flow rate control valve circuit location information.
(Group 9025-05.)

<- Go to Section TOC Section 9025 page 113 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Bucket Flow Rate Control Valve Combined Operation

LEGEND:
15 From Pump 1
46 From Bucket Flow Rate Pilot Valve (port SK)
76 To Bucket Spool
77 Bucket Flow Rate Control Valve (valve and poppet)
200 Check Valve
201 Poppet
202 Switch Valve
600 High Pressure Oil
602 Low Pressure Oil
604 Return Oil
606 Trapped Oil
609 Pilot Oil
DK To Solenoid Valve Manifold Port DK
Combined Operation— During combined operation of boom up and arm in, arm in pilot pressure shifts the bucket flow rate
pilot valve allowing boom up pilot pressure to flow out port SK of the pilot signal manifold to the bucket flow rate control valve
(77). See Pilot Signal Manifold Operation . (Group 9025-05.)

Boom up pilot pressure from bucket flow rate pilot valve (port SK) (46) shifts the switch valve (202) trapping oil (606) on the
backside of the poppet (201). The poppet now restricts the flow of high pressure oil to the bucket spool (76). High pressure oil
(600) now flows to the arm 2 and boom 1 spools to ensure priority flow of high pressure oil to the arm in and boom up
functions.

During combined operation of arm in and boom up, the arm 2 flow rate control valve circuit is active. Priority is given to the
boom up function. See Arm 2 Flow Rate Control Valve Circuit Operation . (Group 9025-05.)

<- Go to Section TOC Section 9025 page 114 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Boom Flow Rate Control Valve Circuit Operation

<- Go to Section TOC Section 9025 page 115 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Boom Flow Rate Control Valve Circuit Schematic

<- Go to Section TOC Section 9025 page 116 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

LEGEND:
2 Boom Down (pilot)
3 Arm Out (pilot)
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
36 Hydraulic Oil Cooler
81 Boom 1 Spool
82 Boom Regenerative Valve
83 Boom Flow Rate Control Valve (valve and poppet)
85 Boom Reduced Leakage Valve (valve and check valve)
87 Boom Lower Meter-In Cut Valve
88 Boom Up Circuit Relief and Anticavitation Valve
89 Boom Down Circuit Relief and Anticavitation Valve
90 Arm 2 Spool
91 Arm 2 Flow Rate Control Valve (valve and poppet)
92 Check Valve (lift check)—Arm 2 Neutral Passage
97 Arm 1 Spool
98 Arm 1Flow Rate Control Valve (valve and poppet)
101 Arm Reduced Leakage Valve (valve and poppet)
102 Arm In Circuit Relief and Anticavitation Valve
103 Arm Out Circuit Relief and Anticavitation Valve
104 Boom 2 Spool
117 Main Relief and Power Dig Valve
124 Oil Cooler Bypass Valve
125 Boom Cylinder (2 used)
127 Arm Cylinder
128 Check Valve
149 Arm 1 Regenerative Cut Valve
154 To Shuttle Valve
600 High Pressure Oil
602 Low Pressure Oil
604 Return Oil
606 Trapped Oil
609 Pilot Oil
610 Regeneration Oil
DD To Solenoid Valve Manifold Port DD

The purpose of the boom flow rate control valve (valve and poppet) (83) is to restrict high pressure oil (600) in the circuit to
ensure that there will be sufficient high pressure oil for other functions during boom down and to restrict high pressure oil
through boom 1 spool (81) during boom down so that boom regenerative valve (82) in boom 1 spool works properly.

During boom down, the boom flow rate control valve restricts high pressure oil flow to the boom 1 spool from pump 1 (15).

During boom down and other functions, the boom lowers due to its own weight by the boom regenerative circuit and uses high
pressure oil from the pump for other functions. This ensures other functions will maintain normal operation. See Boom
Regenerative Valve Circuit Operation . (Group 9025-05.)

<- Go to Section TOC Section 9025 page 117 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Boom Flow Rate Control Valve Normal Operation (low load)

<- Go to Section TOC Section 9025 page 118 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Boom Flow Rate Control Valve Normal Operation (high load)

LEGEND:
15 From Pump 1
81 To Boom 1 Spool
83 Boom Flow Rate Control Valve (valve and poppet)
87 To Boom Lower Meter-In Cut Valve
200 Check Valve
201 Poppet
202 Switch Valve
600 High Pressure Oil
604 Return Oil
DD To Solenoid Valve Manifold Port DD
Normal Operation— When boom down is actuated, high pressure oil (600) flows to the 4-spool side of the control valve from
pump 1 (15). High pressure oil opens the check valve (200) in the poppet (201) of the boom flow rate control valve (83)
because the switch valve (202) is open due to no control pilot oil. High pressure oil flows through boom flow rate control valve
without restriction to boom 1 spool (81).

<- Go to Section TOC Section 9025 page 119 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Boom Flow Rate Control Valve Combined Operation

LEGEND:
15 From Pump 1
81 To Boom 1 Spool
83 Boom Flow Rate Control Valve (valve and poppet)
87 From Boom Lower Meter-In Cut Valve
200 Check Valve
201 Poppet
202 Switch Valve
600 High Pressure Oil
602 Low Pressure Oil
604 Return Oil
606 Trapped Oil
609 Pilot Oil
DD To Solenoid Valve Manifold Port DD
Combined Operation— When boom down is actuated, return oil from the boom cylinders is under pressure from the weight of
the boom. Return oil pressure causes boom lower meter-in cut valve to shift, routing boom down pilot oil to the boom flow rate
control valve (83). See Boom Lower Meter-In Cut Valve Operation (Group 9025-05.)

Boom down pilot oil (609) from boom lower meter-in cut valve (87) shifts the switch valve (202) in the boom flow rate control
valve.

With the switch valve shifted, high pressure oil is trapped on the backside of poppet (201) which forces the poppet towards the
closed position. The poppet now restricts the flow of high pressure oil to boom 1 spool. Consequently more pump 1 high
pressure oil is available to other functions.

When supply oil pressure to boom 1 spool is less than return oil pressure during boom down operation, the return oil will shift
the boom regeneration valve (82) and combine with supply oil. See Boom Regenerative Valve Circuit Operation . (Group
9025-05.)

<- Go to Section TOC Section 9025 page 120 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Auxiliary Flow Rate Control Valve Circuit Operation

<- Go to Section TOC Section 9025 page 121 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Auxiliary Flow Rate Control Valve Circuit Operation

<- Go to Section TOC Section 9025 page 122 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

LEGEND:
5 Swing Left (pilot)
6 Swing Right (pilot)
13 Auxiliary (pilot)
14 Auxiliary (pilot)
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
52 Swing Motor
73 4-Spool Control Valve
74 5-Spool Control Valve
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
90 Arm 2 Spool
93 Bypass Shutoff Valve
95 Swing Spool
97 Arm 1 Spool
104 Boom 2 Spool
107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
110 Left Travel Spool
117 Main Relief and Power Dig Valve
118 Auxiliary Flow Combiner Valve
119 Check Valve—Flow Combiner Valve Circuit
120 Travel Flow Combiner Valve
155 From Shuttle Valve
170 Auxiliary Shuttle Valve
174 Auxiliary Attachment
177 From Flow Rate Select Solenoid Valve (2 used)
178 To Flow Rate Select Reducing Valve
600 High-Pressure Oil
602 Low-Pressure Oil
604 Return Oil
606 Trapped Oil
609 Pilot Oil
DY To Solenoid Valve Manifold Port DY

→NOTE:

The auxiliary flow rate control valve will not work properly unless two pump combined flow kit is installed
on machine.

The function of the auxiliary flow rate control valve (valve and poppet) (108) is to restrict high-pressure oil (600) flow from
pump 2 (16) through the auxiliary spool (107) when used under the following conditions:

Two speed on (combined flow on)


Pressure on attachment pressure sensor (B60)

Combined with any of these inputs:

Pressure on arm out pressure sensor (B61)


Pressure on arm out pressure sensor (B61) and boom up pressure sensor (B30)
Pressure on swing pressure sensor (B33)
Pressure on travel pressure sensor (B34)

For more information on sensors, see System Functional Schematic . (Group 9015-10.)

<- Go to Section TOC Section 9025 page 123 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Auxiliary Flow Rate Control Valve Normal Operation (low load)

<- Go to Section TOC Section 9025 page 124 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Auxiliary Flow Rate Control Valve Normal Operation (high load)

LEGEND:
16 From Pump 2
107 To Auxiliary Spool
108 Auxiliary Flow Rate Control Valve
177 To Flow Rate Select Solenoid Valve
200 Check Valve
201 Poppet
202 Switch Valve
600 High-Pressure Oil
604 Return Oil
DY To Solenoid Valve Manifold Port DY
Normal Operation— High-pressure oil (600) from pump 2 (16) opens the check valve (200) in the poppet (201) of auxiliary
flow rate control valve (108) because the switch valve (202) is open. The high-pressure oil flows through the check valve and
switch valve to auxiliary spool (107). As the load increases, the pressure increases, pushing the poppet open, and high-
pressure oil flows through the poppet to auxiliary spool. For auxiliary flow rate control valve circuit location information, see
Control Valve Operation . (Group 9025-05.)

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Auxiliary Flow Rate Control Valve Combined Operation

LEGEND:
16 From Pump 2
107 To Auxiliary Spool
108 Auxiliary Flow Rate Control Valve
177 From Flow Rate Select Solenoid Valve
200 Check Valve
201 Poppet
202 Switch Valve
600 High-Pressure Oil
602 Low-Pressure Oil
604 Return Oil
606 Trapped Oil
609 Pilot Oil
DY To Solenoid Valve Manifold Port DY
Combined Operation— Switch valve (202) is shifted by pilot oil (609) from flow rate select solenoid valve (177) when an
auxiliary function is combined with one of the following operations:

Arm out
Arm out and boom up
Swing
Travel

See Flow Rate Select Solenoid Valve Operation and see Two Pump Combined Flow Kit Operation . (Group 9025-05.)

Pilot pressure from flow rate select solenoid valve shifts the switch valve creating trapped oil (606) on the backside of the
poppet (201). The poppet now restricts the flow of high-pressure oil (600) from pump 2 (16) to the auxiliary spool (107). High
pressure-oil from pump 2 flows to arm, boom, swing, or travel spools to ensure priority of oil flow to these functions.

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Blade Circuit Operation—If Equipped

Blade Circuit Operation (blade down shown)

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

LEGEND:
15 Pump 1
16 Pump 2
37A From Solenoid Valve Manifold
37B From Solenoid Valve Manifold
73 Right Control Valve
74 Left Control Valve
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
90 Arm 2 Spool
93 Bypass Shutoff Valve
95 Swing Spool
97 Arm 1 Spool
104 Boom 2 Spool
107 Auxiliary Spool
110 Left Travel Spool
111 Check Valve (lift check)—Left Travel Neutral Passage
112 Check Valve (lift check)—Left Travel Power Passage
113 Orifice—Left Travel Power Passage
115 Main Relief Valve Isolation Check Valve—5-Spool
116 Main Relief Valve Isolation Check Valve—4-Spool
117 Main Relief and Power Dig Valve
120 Travel Flow Combiner Valve
121 Check Valve—Travel Flow Combiner Valve Circuit
140 Blade Spool
141 Blade Up Circuit Relief and Anticavitation Valve
142 Blade Down Circuit Relief and Anticavitation Valve
143 Blade Cylinder (2 used)
144 Blade Control Valve
145 Travel Flow Combiner Shuttle Valve
146 Swing Parking Brake Shuttle Valve
147 Blade Signal Selector Valve
148 Blade Signal Shuttle Valve
150 Blade Pilot Control Valve
151 Blade Main Relief Valve
152 Blade Pump
153 Pilot Shutoff Valve
155 Shuttle Valve
600 High Pressure Oil
604 Return Oil
609 Pilot Oil
B32 Front Attachment Pressure Sensor
Y10 Pilot Shutoff Solenoid

Blade pump (152) delivers pressure oil to blade main relief valve (151) and blade control valve (144). Return oil (604) from
blade cylinders (143) is routed through blade control valve directly to return filter in hydraulic oil tank.

Blade circuit is controlled by the blade pilot control valve (150). Pilot oil (609) is supplied to blade pilot control valve through
pilot shutoff valve (153). Pilot oil is also supplied to blade signal selector valve (147) from solenoid valve manifold (37B).

When blade function is activated, pilot oil from blade pilot control valve is routed to blade signal shuttle valve (148). From
blade signal shuttle valve, pilot oil flows in four directions:

To blade spool (140) inside blade control valve.


To front attachment pressure sensor (B32) via swing parking brake shuttle valve (146).
To blade signal selector valve.
To bypass shuttle valve (93) from shuttle valve (155).

Pilot oil to bypass shutoff valve causes the valve to shift and blocks pump 1 (15) flow to return.

With blade signal selector valve shifted, pilot oil is routed through the travel flow combiner shuttle valve (145) to travel flow
combiner valve (120) causing the valve to shift and allowing pump 1 pressure oil to combine with pump 2 (16) pressure oil.

With blade spool shifted, combined oil flow from pump 1, pump 2, and blade pump travels to the blade cylinders.

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

When control lever is in neutral, high pressure oil from blade pump returns to the hydraulic oil tank through blade control
valve.

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Swing Reduction Gear Case Operation

Swing Gear Case Cross Section

LEGEND:
1 Swing Motor Shaft
2 First Stage Planetary Gear
3 Ring Gear
4 Second Stage Planetary Gear
5 Swing Bearing Internal Gear
6 Shaft
7 Second Stage Carrier
8 Second Stage Sun Gear
9 First Stage Carrier
10 First Stage Sun Gear
52 Swing Motor

Swing gear case is a two-stage, planetary-type gear case. The ring gear (3) is attached to gear case housing. The swing motor
shaft (1) rotates first stage sun gear (10). Power is transferred from the first stage sun gear to second stage sun gear (8)
through first stage planetary gear (2) and first stage carrier (9). The second stage sun gear rotates shaft (6) through second
stage planetary gear (4) and second stage carrier (7).

The swing bearing internal gear (5) is mounted to the undercarriage. The shaft (6) is engaged in the internal gear and rotates
the upperstructure.

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Swing Motor, Crossover Relief Valve, and Make-Up Check Valve


Operation

Swing Motor

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

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Swing Crossover Relief Valve and Make-Up Check Valve

LEGEND:
11 Poppet (2 used)
53 Swing Motor Make-Up Check Valve (2 used)
54 Swing Crossover Relief Valve (2 used)

Swing Crossover Relief Valve—Neutral Position

LEGEND:
12 Low Pressure Port (return circuit)
13 High Pressure Port (swing circuit)
14 Poppet
15 Spring (2 used)
54 Swing Crossover Relief Valve
600 High Pressure Oil
604 Return Oil

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Swing Crossover Relief Valve—Relief Operation

LEGEND:
12 Low Pressure Port (return circuit)
13 High Pressure Port (swing circuit)
14 Poppet
15 Spring (2 used)
54 Swing Crossover Relief Valve
601 Medium Pressure Oil
604 Return Oil
Swing Motor Crossover Relief Valve— The swing crossover relief valve (54) prevents the occurrence of surge pressures
and protects the circuit from being overloaded.

Pressure in high pressure port (13) is applied to the poppet (14) until it reaches the spring set pressure. The poppet opens and
allows pressure oil to flow into low pressure port (12). The pressure in the swing circuit decreases and the spring set force
closes the poppet.

Swing Motor Make-Up Check Valve— When the swing control lever is returned to the neutral position while the
upperstructure is in motion, the weight of the upperstructure will continue to turn the swing motor which causes it to act like a
pump. The flow caused by the pumping action of the swing motor cannot flow through the control valve, because the work
ports are blocked by the valve spool. The high pressure oil is forced through the crossover relief valve. The swing motor make-
up check valve (53) provides oil to the low pressure side of the swing motor to prevent cavitation.

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Swing Motor Park Brake Release Circuit Operation

Swing Park Brake Release Circuit Operation (brake released)

LEGEND:
1 Spring
2 Brake Piston
3 Brake Piston Chamber
4 Friction Plate (4 used)
5 Plate (4 used)
6 Rotor
51 Swing Device
57 Orifice
58 Check Valve
59 Flow Control Valve
604 Return Oil
609 Pilot Oil
SH From Swing Park Brake Release Pilot Valve (port SH)
Releasing Park Brake— When any dig or swing function is operated, the swing park brake release pilot valve is shifted,
allowing pilot oil (609) through check valve (58) to move brake piston (2). As brake piston moves, plates (5) and friction plates
(4) disengage, which releases the swing park brake.

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Swing Park Brake Release Circuit Operation (brake applied)

LEGEND:
1 Spring
2 Brake Piston
3 Brake Piston Chamber
4 Friction Plate (4 used)
5 Plate (4 used)
6 Rotor
51 Swing Device
57 Orifice
58 Check Valve
59 Flow Control Valve
604 Return Oil
SH To Swing Park Brake Release Pilot Valve (port SH)
Applying Park Brake— When the dig or swing pilot control lever is returned to neutral, the swing park brake release pilot
valve stops the flow of pilot oil to the swing motor.

The spring (1) pushes the brake piston down, forcing oil through orifice (57) into the swing motor case. The orifice prevents the
brake piston from moving quickly and delays the application of the swing park brake until the upperstructure is stopped or
nearly stopped. The spring force on the brake piston, which acts on the cylinder block, engages the friction plates (4) and
plates (5), which acts on the inside of the swing motor housing, securing the upperstructure.

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Center Joint Operation

Center Joint (forward travel; fast travel selected)

LEGEND:
31A To Hydraulic Oil Tank
37B From Solenoid Valve Manifold
61 Right Travel Motor
61A To Right Travel Motor
61B From Right Travel Motor
63 Left Travel Motor
63A To Left Travel Motor
63B From Left Travel Motor
72 Center Joint
75A To Right Travel Spool
75B From Right Travel Spool
110A To Left Travel Spool
110B From Left Travel Spool
143 Blade Cylinder (2 used)
143A To Blade Cylinder (piston side)
143B To Blade Cylinder (rod side)
144A From Blade Control Valve (blade down)
144B From Blade Control Valve (blade up)
600 High Pressure Oil
604 Return Oil
606 Trapped Oil
609 Pilot Oil

The center joint (72) is a 360° rotary manifold. The center joint allows oil to flow to and from the travel motors (61 and 63) and
the blade cylinders (143) without twisting hoses when the upperstructure is rotated.

The inner spindle is connected to the upperstructure and the housing is connected to the undercarriage. The housing rotates
about the spindle during swing operation.

Oil flows into and through the spindle to passages in the housing, and then out of the housing to the travel motors and the
blade cylinders. Sealing rings stop oil from leaking between the spindle and housing into adjacent passages.

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

See Travel Hydraulic System Line Connection for line identification and connections. (Group 9025-15.)

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Travel Motor and Park Brake Valve Operation

Travel Motor and Brake Valve Schematic

LEGEND:
60 Right Travel Device
61 Right Travel Motor
62 Left Travel Device

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

63 Left Travel Motor


64 Travel Park Brake (2 used)
65 Travel Speed Servo Piston (2 used)
66 Travel Speed Change Valve (2 used)
66A Travel Speed Solenoid (SI)
67 Shuttle Valve (2 used)
68 Travel Motor Crossover Relief Valve (4 used)
69 Check Valve (4 used)
70 Orifice (4 used)
71 Counterbalance Valve (2 used)
72 Center Joint
75A Right Travel Spool Top Port—Forward
75B Right Travel Spool Top Port—Reverse
110A Left Spool Top Port—Forward
110B Left Spool Top Port—Reverse
143A Blade Cylinder (piston side)
143B To Blade Cylinder (rod side)
144A From Blade Control Valve (blade dn)
144B Blade Cylinder (blade up)
604 Return Oil
606 Trapped Oil

Travel Motor and Brake Valve Components

LEGEND:
1 Drum
2 Piston
3 Housing
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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

4 Drive Shaft
5 Valve Plate
6 Brake Valve Housing
7 Park Brake Piston
8 Swash Plate
64 Travel Park Brake
65 Travel Speed Servo Piston
66 Travel Speed Change Valve
67 Shuttle Valve

Travel Motor and Brake Valve— The travel motor is a variable-displacement, swash plate, axial-piston type motor that
includes the brake valve housing (6) and travel park brake (64). Brake valve housing consists of the following components:

Travel Speed Change Valve (66)


Shuttle Valve (67)
Orifice (70)
Counterbalance Valve (71)
Travel Motor Crossover Relief Valve (68) (2 used)
Check Valve (69) (2 used)

Travel Park Brake— The travel park brake is a wet-type, multiple-disk brake. The brake is spring-applied and hydraulically
released (negative type). The brake is released when travel function is actuated and high pressure oil is routed to the park
brake piston by the counterbalance valve. The brake is applied when no functions or only the dig and swing functions are
actuated.

When travel function is released, the counterbalance valve returns to center position blocking the high pressure oil acting on
park brake piston (7). The disk spring pushing against the park brake piston forces the oil to flow through the orifice (70) in the
piston and into travel motor housing. The delay caused by oil flowing through the orifice is enough to slow engagement, to
ensure park brake is only fully applied after the machine has stopped.

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Travel Motor Slow Speed Operation

LEGEND:
2 Piston
8 Swash Plate
10 Spring
37 From Solenoid Valve Manifold—Power Dig Solenoid (marked SG)
65 Travel Speed Servo Piston
66 Travel Speed Change Valve
67 Shuttle Valve
70 Orifice
604 Return Oil

Travel Motor Slow Speed— At slow speed (turtle), the oil acting on the travel speed change valve (66) is open to return
through the solenoid valve manifold (37). Travel speed change valve is held up by the spring (10). For more information, see
Travel Motor Speed Circuit Operation . (Group 9025-05.)

The oil acting on the travel speed servo piston (65) is routed to return through the center of travel speed change valve. The
travel speed change valve blocks the flow of high pressure oil to the servo piston. High pressure oil from the pressurized motor
work port is routed to the valve by the shuttle valve (67).

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

The swash plate (8) is held at maximum displacement. At maximum displacement the motor turns at slow speed with high
torque.

Travel Motor Fast Speed Operation

LEGEND:
2 Piston
8 Swash Plate
10 Spring
37 From Solenoid Valve Manifold—Power Dig Solenoid (marked SG)
65 Travel Speed Servo Piston
66 Travel Speed Change Valve
67 Shuttle Valve
70 Orifice
600 High Pressure Oil
602 Pilot Oil
604 Return Oil

Travel Motor Fast Speed— At fast speed (rabbit), pilot oil (602) from the solenoid valve manifold (37) pushes the travel
speed change valve (66) down. For more information, see Travel Motor Speed Circuit Operation . (Group 9025-05.)

<- Go to Section TOC Section 9025 page 142 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

High pressure oil (600) flows from the motor work port, through the shuttle valve (67), travel speed change valve, orifice (70),
and to the travel speed servo piston (65). The piston then moves the swash plate (8) to its minimum angle. At minimum angle,
the travel motors turn at fast speed with reduced torque. Orifice controls the flow of high pressure oil to the piston to modulate
the change in speed.

Brake Valve Housing—Braking Operation

LEGEND:
7 To Park Brake Piston
11 To Travel Motor
12 Poppet
13 Orifice
14 Piston
15 Spring (4 used)
16 Spring (4 used)
17 Restriction
67 Shuttle Valve
68 Travel Motor Crossover Relief Valve (2 used)
<- Go to Section TOC Section 9025 page 143 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

69 Check Valve (2 used)


70 Orifice
71 Counterbalance Valve
75 Right Travel Spool
600 High Pressure Oil
601 Medium Pressure Oil
602 Low Pressure Oil
604 Return Oil

Counterbalance Valve (71)— When the travel spools in the main control valve are in neutral, counterbalance spool is held in
the center position by springs (16). Right travel spool (75) are open to return through the control valve return passage. The
check valves (69) and counterbalance valve traps the oil in each motor holding them stationary.

When travel function is first actuated, high pressure oil pressure builds on one side of motor due to the motor′s resistance to
turning and because the check valve and counterbalance valve blocks the flow of return oil from the motor. The increased
pressure is sensed at the end of counterbalance valve through orifice (70) and begins to shift the counterbalance valve (71). As
the valve shifts, a path is opened for return oil to flow to the control valve. High pressure oil (600) flows to the park brake
piston (7) to release the travel park brake. High pressure oil flows around counterbalance valve and opens the check valve to
supply the motor.

When a machine is traveling down a hill, the weight can cause it to overrun the travel motors. Overrunning would cause faster
travel than desired and cavitation in the motors. As pressure decreases in the work port of the motor, the spring begins to shift
the valve toward the center position. A restriction (17) is created by restricting the flow of return oil (604) from the motor and
keeps the motor from turning faster than desired.

Travel Motor Crossover Relief Valves (68)— The crossover relief valves are direct acting relief valves with a shock
reducing function. As oil flows through the orifice (13) and moves the piston (14), a pressure difference is created from one
side of the poppet (12) to the other. The pressure difference allows the poppet to open below the set pressure to reduce
pressure spikes. Once the piston reaches full stroke, the pressure difference is eliminated and the pressure in the travel circuit
increases to the set pressure.

Check Valves (69)— When travel control lever is returned to the neutral position while the machine is in motion, the inertia of
machine continues to turn the travel motor, which causes it to act like a pump. High pressure is then created in the return side
of motor and low pressure on the other. When pressure in the return side becomes higher than the low pressure side of motor,
the check valve (69) is pushed open. Return oil from the return side flows to low pressure side preventing cavitation.

<- Go to Section TOC Section 9025 page 144 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Travel Motor Speed Circuit Operation

Travel Motor Speed Circuit Fast Speed Operation

LEGEND:
1 Fast (rabbit) Speed
2 Slow (turtle) Speed
47 Pump 2 Flow Rate Pilot Valve (port SB)
48 Pump 1 Flow Rate Pilot Valve (port SA)
61 Right Travel Motor
63 Left Travel Motor
66 Travel Speed Change Valve (2 used)
609 Pilot Oil
650 Electrical Voltage
A3 Main Controller (MCZ)
B32 Front Attachment Pressure Sensor
B34 Travel Pressure Sensor
B35 Pump 1 Delivery Pressure Sensor
B36 Pump 1 Control Pressure Sensor
B37 Pump 2 Delivery Pressure Sensor
B38 Pump 2 Control Pressure Sensor
S11 Travel Speed Switch
Y24 Power Dig/Travel Speed Solenoid (marked SG)

Travel Motor Slow (Turtle) Speed— When the travel speed switch (S11) is in the slow (turtle) speed (2) position, the power
dig/travel speed solenoid (Y24) is de-energized. Pilot oil (609) is open to return through the power dig/travel speed solenoid
(Y24) and the travel motors are at slow speed. See Travel Motor and Park Brake Valve Operation . (Group 9025-05.)

Travel Motor Fast (Rabbit) Speed— When travel speed switch is in the fast (rabbit) speed (1) position, the power dig/travel
<- Go to Section TOC Section 9025 page 145 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

speed solenoid is energized. Pilot oil is routed to the travel speed change valves (66), and the travel motors are shifted to fast
speed. See Travel Motor and Park Brake Valve Operation . (Group 9025-05.) The power dig/travel speed solenoid is energized
only when all of the following conditions are met:

Travel speed switch is at fast (rabbit) speed position


Pressure at travel pressure sensor (B34)
No pressure at front attachment pressure sensor (B32)
Both pump 1 delivery pressure sensor (B35) and pump 2 delivery pressure sensor (B37) must indicate low pressure
Both pump 1 control pressure sensor (B36) and pump 2 control pressure sensor (B38) must indicate high pressure.

For electrical circuit information, see System Functional Schematic, Component Location, and Wiring Diagram Master Legend .
(Group 9015-10.)

Once the machine is operating in fast (rabbit) speed, a dig or swing function will not cause the travel speed to change to slow
(turtle) speed, even though pressure is sensed at the front attachment pressure sensor (B32).

<- Go to Section TOC Section 9025 page 146 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Power Dig/Travel Speed Solenoid Operation

LEGEND:
1 Solenoid Coil
2 Spool
3 To Valve Function
4 De-Energized
5 Energized
<- Go to Section TOC Section 9025 page 147 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

6 Pressure Equals Magnetic Force


29 From Pilot Filter and Bypass Valve
31 To Hydraulic Oil Tank
37 Solenoid Valve Manifold
604 Return Oil
609 Pilot Oil
613 Reduced Pilot Oil
Y22 Dig Regenerative Solenoid (marked SF)
Y23 Arm Regenerative Solenoid (marked SC)
Y24 Power Dig/Travel Speed Solenoid (marked SG)
Y27 Arm 2 Flow Control Solenoid (marked SD)
The power dig/travel speed solenoid (marked SG) (Y24) is a proportional-type solenoid valve. The solenoid valve is actuated by
a voltage signal from the main controller (MCZ). The voltage signal is a DC voltage that is turned on and off to form a pulse
width modulated signal. The solenoid coil (1) reacts to the “average” voltage to create a magnetic force to shift the spool (2)
left against a spring. The reduced pilot oil (613) pressure sent to the valve function (3) depends on how long the voltage signal
is on verses on how long it is off. The reduced pilot oil pressure is in proportion to the voltage signal.

When de-energized (4), the spool is pushed to the right by a spring. The valve function port is connected to the hydraulic oil
tank (31) port.

When energized (5), the magnetic force shifts the spool left against the spring. Pilot oil (609) from the pilot filter and bypass
valve (29) flows past the spool flange and out the valve function port as reduced pilot oil. Because the flange on the right is
larger than the flange on the left, the spool is pushed to the right against the magnetic force as the oil pressure to the valve
function increases. When the oil pressure becomes equal to or greater than the magnetic force, the spool is pushed to the right
closing the passage stopping the pressure increase. The oil pressure to the valve function is trapped. The spool is moving
constantly to maintain the oil pressure in response to the voltage signal to the solenoid coil. See Control Valve Operation .
(Group 9025-05.) and see Main Controller (MCZ) Circuit Theory of Operation . (Group 9015-15.)

<- Go to Section TOC Section 9025 page 148 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Cylinder Operation

Cylinder Operation

LEGEND:
1 Snap Ring
2 Wiper Seal
3 Backup Ring
4 U-Cup Seal
5 Buffer Ring
6 Wear Ring
7 Snap Ring
8 Piston
9 Buffer Ring (2 used)
10 Wear Ring (2 used)
11 Cap Seal
12 Set Screw
13 Nut
14 Cushion
15 Barrel
16 Cylinder Rod
17 Rod Guide
18 Bucket Cylinder

Boom, Arm, and Bucket Cylinders

The boom, arm, and bucket cylinders are similar in design. The bucket cylinder (18) is illustrated. The rod guide (17) is
fastened to the cylinder barrel with cap screws and is fitted with a wear ring (6) held in place by a snap ring (7). A buffer ring
(5), U-cup seal (4), backup ring (3), and wiper seal (2) are used in the rod guide. A snap ring (1) is used to help hold wiper seal
in place. The U-cup seal (4) is protected against high pressure by the buffer ring (5) and stops the small amount of oil that may
pass by the buffer ring.

The piston (8) is a slip-fit on the cylinder rod (16) and is retained with a nut (13). A set screw (12) prevents loosening of the
nut. The piston is fitted with a cap seal (11), wear rings (10), and buffer rings (9).

Boom, bucket, and arm cylinders have a cushion (14) in front of the piston to provide cushioning action in cylinder extension.
As the cylinder nears the end of its stroke, the cushion enters a bore in the rod guide. The remaining return oil ahead of the
piston must flow through a small clearance between the cushion and rod guide. Only the arm cylinder is cushioned in

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

retraction. The end of the rod enters a bore in the head end of cylinder. The remaining return oil ahead of the piston and nut
must flow through this small clearance as the cylinder bottoms out in this direction.

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Return Filter Operation

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.

Auxiliary System Operation

→NOTE:

For auxiliary attachments to work properly multiple kits may be required.

The auxiliary system consist of a pilot control system to shift the auxiliary control valve spool. The shifted auxiliary control
valve spool allows high pressure oil flow to work port of the auxiliary attachment depending on attachment and kits installed.
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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

The following kits are available for auxiliary attachments:

Auxiliary High Flow Line Kit, for more information, see Auxiliary High Flow Line Kit Operation . (Group 9025-05.)
Two Pump Combined Flow Kit, for more information, see Two Pump Combined Flow Kit Operation . (Group 9025-05.)
Two Way Solenoid Kit Operation, for more information, see Two Way Solenoid Kit Operation . (Group 9025-05.)
Two Way Foot Pedal Kit.
One Way Foot Switch.

For more information on attachment and required kits to operate go to info to go at www.dealernet.deere.com.

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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Auxiliary Pilot Control Valve Operation


The auxiliary pilot control valve regulates the pilot oil pressure to actuate the pilot valve in the pilot signal manifold and to shift
the auxiliary control valve spool to actuate the auxiliary functions.

For pilot valve operation see Pilot Signal Manifold Operation . (Group 9025-05.)

For control valve operation See Pilot Operation of Control Valve Operation . (Group 9025-05.)

<- Go to Section TOC Section 9025 page 153 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Auxiliary Pilot Control Valve Schematic (auxiliary spool shown shifted)

<- Go to Section TOC Section 9025 page 154 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

LEGEND:
28 Pilot Pump
41 Pilot Signal Manifold
45 Swing Park Brake Release Pilot Valve (port SH)
47 Pump 2 Flow Rate Pilot Valve (port SB)
56 To Swing Park Brake
73 4-Spool Control Valve
74 5-Spool Control Valve
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
90 Arm 2 Spool
93 Bypass Shutoff Valve
95 Swing Spool
97 Arm 1 Spool
104 Boom 2 Spool
107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
110 Left Travel Spool
117 Main Relief and Power Dig Valve
118 Auxiliary Flow Combiner Valve
153 Pilot Shutoff Valve
179 To Pump 2 Flow Rate Solenoid Valve
604 Return Oil
609 Pilot Oil
B60 Attachment Pressure Sensor

<- Go to Section TOC Section 9025 page 155 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Auxiliary Pilot Control Valve

LEGEND:
1 Spool
2 Washer
3 Spring Guide
4 Plunger
5 Adjustment Screw
<- Go to Section TOC Section 9025 page 156 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

6 Pedal
7 Sleeve
8 Balance Spring
9 Return Spring
10 To Pilot Shutoff Solenoid Valve Port T2
11 From Pilot Shutoff Solenoid Valve Port A3
12 Port 13 or 14 To Control Valve Pilot Cap
15 Auxiliary Pilot Control Valve—Full Stroke
604 Pilot Oil
609 Return Oil

One pilot control valve is used to control the auxiliary functions. The pilot control valve contains two valve assemblies. The
valves are controlled by movement of the pedals against the plunger (4). The ports (10, 11, and 12) in housing are identified by
numbers and letters next to each port.

In neutral, the spool is pushed up by the return spring (8) pushing the plunger up. The return springs hold the pedal in the
neutral position. With the spool up, ports 13 and 14 to the control valve pilot cap (12) are open to pilot shutoff solenoid valve
port T2 (10) through the passage and holes in spool. Pilot oil from the pilot shutoff solenoid valve port A3 (11) is blocked by the
spool.

When the pedal is pushed to actuate an auxiliary function, the pedal pushes the plunger and spring guide down against the
return spring and balance spring. The balance spring pushes the spool down. As the spool is pushed down and the holes move
through the deadband area, the passage from control valve pilot cap to the hydraulic oil tank is closed and then opened to the
pilot oil from pilot shutoff solenoid valve. Pilot oil pressure increases until it is equal to the force applied by the balance spring,
the spool moves up until the oil flowing through the holes is blocked in the deadband area. With the oil flow blocked, the
control valve spool is held stationary until the pedal is again actuated.

When the pedal is pushed to full stroke, the plunger is pushed down farther by the balance spring opening the passage through
the spool to pilot oil pressure. When pressure to the control valve pilot cap is equal to the force applied by the balance spring,
the spool moves up until it contacts the plunger. The plunger holds the spool down so the passage through the spool remains
open to pilot oil pressure. Oil pressure to the control valve pilot cap now approximately equals pilot oil pressure.

<- Go to Section TOC Section 9025 page 157 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Auxiliary Solenoid Valve Operation of Control Valve (auxiliary spool shown shifted)

<- Go to Section TOC Section 9025 page 158 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

LEGEND:
28 Pilot Pump
41 Pilot Signal Manifold
45 Swing Park Brake Release Pilot Valve (port SH)
47 Pump 2 Flow Rate Pilot Valve (port SB)
56 To Swing Park Brake
73 4-Spool Control Valve
74 5-Spool Control Valve
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
90 Arm 2 Spool
93 Bypass Shutoff Valve
95 Swing Spool
97 Arm 1 Spool
104 Boom 2 Spool
107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
110 Left Travel Spool
117 Main Relief and Power Dig Valve
118 Auxiliary Flow Combiner Valve
153 Pilot Shutoff Valve
172 Auxiliary Soleniod Valve
173 Auxiliary Pressure Reducing Valve
179 To Pump 2 Flow Rate Solenoid Valve
604 Return Oil
609 Pilot Oil
B60 Attachment Pressure Sensor

Auxiliary Solenoid Valve Operation

LEGEND:
153 From Pilot Shutoff Valve
172 Auxiliary Soleniod Valve
173 Auxiliary Pressure Reducing Valve
220 To Pilot Signal Manifold Port N
221 To Pilot Signal Manifold Port M
604 Return Oil
609 Pilot Oil

Auxiliary Solenoid Valve Operation— When auxiliary solenoid valve (172) is shifted, pilot oil (609) is sent to pilot signal
manifold port M (221). Pilot signal manifold port 13 outputs pilot oil to the control valve auxiliary valve spool. Shifting control
valve auxiliary spool and high-pressure oil is output to the auxiliary attachment.

<- Go to Section TOC Section 9025 page 159 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Auxiliary Solenoid Valve Operation

LEGEND:
153 From Pilot Shutoff Valve
172 Auxiliary Soleniod Valve
173 Auxiliary Pressure Reducing Valve
220 To Pilot Signal Manifold Port N
221 To Pilot Signal Manifold Port M
604 Return Oil
609 Pilot Oil

When auxiliary solenoid valve (172) is shifted, pilot oil (609) is sent to pilot signal manifold port N (220). Pilot signal manifold
port 14 outputs pilot oil to the control valve auxiliary valve spool. Shifting control valve auxiliary spool and high-pressure oil is
output to the auxiliary attachment.

<- Go to Section TOC Section 9025 page 160 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Flow Rate Select Solenoid Valve Operation

Flow Rate Select Solenoid Valve Schematic (2-speed solenoid energized)

LEGEND:
29 From Pilot Filter and Bypass Valve
93 To Bypass Shutoff Valve
108 To Auxiliary Flow Rate Control Valve
118 To Auxiliary Flow Combiner Valve
177 Flow Rate Select Solenoid Valve
SM From Pilot Signal Manifold Port SM
SP To Pilot Signal Manifold Port SP
Y43 2-Speed Activation Solenoid Valve
Y44 Flow Rate Adjustment Solenoid Valve

The function of the flow rate select solenoid valve (177) is to allow for combined oil flow from pump 1 and pump 2, and to
provide more or less priority to the functions under the following conditions:

Two speed on (combined flow on)


Pressure on attachment pressure sensor (B60)

Combined with any of these inputs:

Pressure on arm out pressure sensor (B61)


Pressure on arm out pressure sensor (B61) and boom up pressure sensor (B30)
Pressure on swing pressure sensor (B33)
Pressure on travel pressure sensor (B34)

For more information on sensors, see System Functional Schematic . (Group 9015-10.)

<- Go to Section TOC Section 9025 page 161 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

→NOTE:

Two-Speed control will not work properly unless appropriate kits are installed on machine.

When energized, the 2-speed activation solenoid valve (Y43) sends pilot oil from pilot signal manifold port SM (SM), to pilot
signal manifold port SP (SP), to bypass shutoff valve (93), and to auxiliary flow combiner valve (118). Pilot oil sent to auxiliary
flow combiner valve allows for combined oil flow from pump 1 and pump 2 to operate the attachment. Pilot oil to pilot signal
manifold port SP shifts the pump 1 flow rate pilot valve to send full control pressure to pump 1 and bypass shutoff valve
allowing pump 1 pressure to increase. When de-energized, 2-speed activation solenoid valve spring tension shifts the valve
allowing the circuit to drain to hydraulic oil tank.

When energized, the flow rate adjustment solenoid valve (Y44) routes pilot oil from pilot filter and bypass valve (29) to auxiliary
flow rate control valve (108). This adjusts the auxiliary flow rate control valve to provide more or less priority to the dig, swing,
and travel functions over the attachment function. See Auxiliary Flow Rate Control Valve Circuit Operation . (Group 9025-05.)

The main controller varies the signal to the flow rate adjustment solenoid valve to vary the pilot oil pressure at the auxiliary
flow rate control valve. This allows for adjustment of the priority of the attachment function over arm out, arm out and boom
up, swing, and travel using the monitor. For information on adjusting flow rate and priority level, see Attachment Control Circuit
Theory of Operation (Group 9015-16.) and see Machine Setting . (Group 9015-16.) When de-energized, the flow rate
adjustment solenoid valve spring tension shifts the valve allowing the circuit to drain to hydraulic oil tank.

Flow Rate Pressure Reducing Valve Operation

Flow Rate Pressure Reducing Valve Schematic

LEGEND:
118 To Auxiliary Flow Combiner Valve
178 Flow Rate Pressure Reducing Valve
DP To Solenoid Valve Manifold Port DP
SN From Pilot Signal Manifold Port SN

The function of the flow rate pressure reducing valve (178) is to control the amount of pump 1 flow that is directed to the
auxiliary spool when combining auxiliary with a pump 1 function.

Pilot pressure is sent from pilot signal manifold port SN (SN) when a pump 1 function is activated. The pilot oil is then routed
through the flow rate pressure reducing valve to auxiliary flow combiner valve (118). This shifts the auxiliary flow combiner
valve to stop the flow of pump 1 high-pressure oil to the auxiliary spool, “de-combining” the flow. Flow rate reducing valve is
adjustable, turn counterclockwise to give auxiliary priority flow over pump 1 functions or clockwise to give pump 1 functions
priority over auxiliary.

When pilot oil pressure to auxiliary flow combiner valve exceeds set pressure of flow rate reducing valve, the valve shifts

<- Go to Section TOC Section 9025 page 162 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

allowing pilot oil to flow to solenoid valve manifold port DP (DP) allowing the auxiliary flow combiner valve to shift combining
pump 1 and pump 2 high-pressure oil flow.

For more information, see Two Pump Combined Flow Kit Operation . (Group 9025-05.)

Selector Valve Solenoid Valve Operation

Selector Valve Solenoid Valve Schematic

LEGEND:
29 From Pilot Filter and Bypass Valve
175 Selector Valve Solenoid Valve
176 To Selector Valve
Y40 Selector Valve Solenoid Valve

The function of the selector valve solenoid valve (175) is to shift the selector valve for attachment flow to return to the control
valve or directly to hydraulic oil tank.

→NOTE:

Selector valve control will not work properly unless appropriate kits are installed on machine.

The selector valve solenoid valve is controlled by MPDr or Service ADVISOR ™ . See Attachment Control Circuit Theory of
Operation . (Group 9015-15.)

When the selector valve solenoid valve (Y40) is energized, pilot oil from pilot filter and bypass valve (29) is directed to selector
valve (176). When the selector valve solenoid valve (Y40) is de-energized, spring tension shifts the spool and pilot oil to the
selector will flow to hydraulic oil tank.

For more information, see Auxiliary High Flow Line Kit Operation . (Group 9025-05.)

Selector Valve Operation

<- Go to Section TOC Section 9025 page 163 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Selector Valve Operation

LEGEND:
107 To or From Auxiliary Spool
174 From Auxiliary Attachment
175 From Selector Valve Solenoid Valve
176 Selector Valve
DM To Solenoid Valve Manifold Port DM

The function of the selector valve (176) is to allow the attachment to operate in one-way flow or two-way flow.

→NOTE:

Selector valve control will not work properly unless appropriate kits are installed on machine.

One-Way Flow Operation

Pilot oil from selector valve solenoid valve (175) shifts selector valve allowing high-pressure oil from auxiliary attachment (174)
to flow directly to hydraulic oil tank.

Two-Way Flow Operation

Without pilot oil from selector valve solenoid valve, spring tension shifts selector valve allowing high-pressure oil to or from
auxiliary spool (107). High-pressure oil is directed to front attachment to operate two modes of use. For example, up-down, in-
out, left-right. Return oil then passes through the auxiliary spool to control valve return passage.

For more information, see Auxiliary High Flow Line Kit Operation . (Group 9025-05.)

Auxiliary Shuttle Valve Operation

<- Go to Section TOC Section 9025 page 164 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Auxiliary Shuttle Valve Schematic

Auxiliary Shuttle Valve

LEGEND:
93 To Bypass Shutoff Valve
118 To Auxiliary Flow Combiner Valve
155 From Shuttle Valve
170 Auxiliary Shuttle Valve
177 From Flow Rate Select Solenoid Valve
SP To Pilot Signal Manifold Port SP

The auxiliary shuttle valve (170) allows pilot oil from flow rate select solenoid valve (177) or from shuttle valve (155) to shift
bypass shutoff valve (93). Pilot oil from flow rate select solenoid valve port or from shuttle valve is sent to auxiliary shuttle

<- Go to Section TOC Section 9025 page 165 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

valve to prevent backfeeding between the circuits.

For more information, see Control Valve Operation and see Two Pump Combined Flow Kit Operation . (Group 9025-05.)

<- Go to Section TOC Section 9025 page 166 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Auxiliary High Flow Line Kit Operation

<- Go to Section TOC Section 9025 page 167 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Auxiliary High Flow Line Kit Schematic (auxiliary spool shifted)

<- Go to Section TOC Section 9025 page 168 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

LEGEND:
13 Auxiliary (pilot)
14 Auxiliary (pilot)
15 Pump 1
16 Pump 2
28 Pilot Pump
37 Solenoid Valve Manifold
73 4-Spool Control Valve
74 5-Spool Control Valve
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
90 Arm 2 Spool
93 Bypass Shutoff Valve
95 Swing Spool
97 Arm 1 Spool
104 Boom 2 Spool
107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
110 Left Travel Spool
117 Main Relief and Power Dig Valve
118 Auxiliary Flow Combiner Valve
120 Travel Flow Combiner Valve
174 Auxiliary Attachment
175 Selector Valve Solenoid Valve
176 Selector Valve
600 High-Pressure Oil
604 Return Oil
609 Pilot Oil
Y40 Selector Valve Solenoid Valve

The function of the auxiliary high flow line kit is to operate auxiliary function in one-way flow operation or two-way flow
operation.

→NOTE:

Auxiliary attachments will not work properly unless appropriate kits are installed on machine.

The selector valve solenoid valve (Y40) is controlled by settings in the monitor. For more information, see Attachment Control
Circuit Theory of Operation . (Group 9015-15.)

Selector Valve Solenoid Valve De-Energized

<- Go to Section TOC Section 9025 page 169 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

LEGEND:
29 From Pilot Filter and Bypass Valve
175 Selector Valve Solenoid Valve
176 From Selector Valve
604 Return Oil
609 Pilot Oil
Y40 Selector Valve Solenoid Valve

Selector Valve Solenoid Valve De-Energized— For operation of selector valve solenoid valve (Y40), see Selector Valve
Solenoid Valve Operation . (Group 9025-05.)

Selector Valve Solenoid Valve Energized

LEGEND:
29 From Pilot Filter and Bypass Valve
175 Selector Valve Solenoid Valve
176 To Selector Valve
604 Return Oil
609 Pilot Oil
Y40 Selector Valve Solenoid Valve

Selector Valve Solenoid Valve Energized— For operation of selector valve solenoid valve (Y40), see Selector Valve
Solenoid Valve Operation . (Group 9025-05.)

<- Go to Section TOC Section 9025 page 170 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Selector Valve One-Way Operation

LEGEND:
107 To Auxiliary Spool
174 From Auxiliary Attachment
175 From Selector Valve Solenoid Valve
176 Selector Valve
604 Return Oil
609 Pilot Oil
DM To Solenoid Valve Manifold Port DM

Selector Valve One-Way Operation— For operation of the selector valve (176), see Selector Valve Operation . (Group
9025-05.)

Selector Valve Two-Way Operation

LEGEND:
107 To Auxiliary Spool
174 From Auxiliary Attachment
175 To Selector Valve Solenoid Valve
176 Selector Valve
604 Return Oil
DM To Solenoid Valve Manifold Port DM

Selector Valve Two-Way Operation— For operation of the selector valve (176), see Selector Valve Operation . (Group
9025-05.)

<- Go to Section TOC Section 9025 page 171 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Two Way Solenoid Kit Operation

<- Go to Section TOC Section 9025 page 172 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Auxiliary Solenoid Valve Operation of Control Valve (auxiliary spool shown shifted)

<- Go to Section TOC Section 9025 page 173 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

LEGEND:
28 Pilot Pump
41 Pilot Signal Manifold
45 Swing Park Brake Release Pilot Valve (port SH)
47 Pump 2 Flow Rate Pilot Valve (port SB)
56 To Swing Park Brake
73 4-Spool Control Valve
74 5-Spool Control Valve
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
90 Arm 2 Spool
93 Bypass Shutoff Valve
95 Swing Spool
97 Arm 1 Spool
104 Boom 2 Spool
107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
110 Left Travel Spool
117 Main Relief and Power Dig Valve
118 Auxiliary Flow Combiner Valve
153 Pilot Shutoff Valve
172 Auxiliary Soleniod Valve
173 Auxiliary Pressure Reducing Valve
179 To Pump 2 Flow Rate Solenoid Valve
604 Return Oil
609 Pilot Oil
B60 Attachment Pressure Sensor

→NOTE:

Two way solenoid kit can be used on auxiliary high flow and auxiliary low flow.

The function of two way solenoid kit is to operate the auxiliary function from the left or right pilot control lever momentary and
proportional switches.

→NOTE:

The right pilot control lever switches are standard from the factory, left pilot control lever switches are a
field kit installation.

Pressure Reducing Valve— The auxiliary pressure reducing valve (173) reduces the pressure to the auxiliary solenoid valve
(172) to limit the control valve auxiliary spool movement. The pressure reducing valve is adjustable, turn the adjustment screw
clockwise to increase pressure and counterclockwise to decrease pressure.

<- Go to Section TOC Section 9025 page 174 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Auxiliary Solenoid Valve Schematic

LEGEND:
153 From Pilot Shutoff Valve
172 Auxiliary Solenoid Valve
173 Auxiliary Pressure Reducing Valve
220 To Pilot Signal Manifold Port N
221 To Pilot Signal Manifold Port M
604 Return Oil
609 Pilot Oil

Auxiliary Solenoid Valve— When the auxiliary solenoid valve (172) is shifted, pilot oil (609) is sent to pilot signal manifold
port M (221), pilot signal manifold port 13 outputs pilot oil to the control valve auxiliary valve spool. This shifts the control valve
auxiliary valve spool and high-pressure oil is output to the auxiliary attachment.

Auxiliary Solenoid Valve Schematic

LEGEND:
153 From Pilot Shutoff Valve
172 Auxiliary Solenoid Valve
173 Auxiliary Pressure Reducing Valve
220 To Pilot Signal Manifold Port N

<- Go to Section TOC Section 9025 page 175 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

221 To Pilot Signal Manifold Port M


604 Return Oil
609 Pilot Oil

When the auxiliary solenoid valve (172) is shifted, pilot oil (609) is sent to pilot signal manifold port N (220), pilot signal
manifold port 14 outputs pilot oil to the control valve auxiliary valve spool. This shifts the control valve auxiliary valve spool
and high-pressure oil is output to the auxiliary attachment.

<- Go to Section TOC Section 9025 page 176 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Two Pump Combined Flow Kit Operation

<- Go to Section TOC Section 9025 page 177 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Two Pump Combined Flow Kit Schematic (auxiliary function active, 2-speed activation solenoid valve [Y43] energized)

<- Go to Section TOC Section 9025 page 178 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

LEGEND:
15 Pump 1
16 Pump 2
28 Pilot Pump
41 Pilot Signal Manifold
45 Swing Park Brake Release Pilot Valve (port SH)
47 Pump 2 Flow Rate Pilot Valve (port SB)
48 Pump 1 Flow Rate Pilot Valve (port SA)
56 To Swing Park Brake
73 4-Spool Control Valve
74 5-Spool Control Valve
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
90 Arm 2 Spool
93 Bypass Shutoff Valve
95 Swing Spool
97 Arm 1 Spool
104 Boom 2 Spool
107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
110 Left Travel Spool
117 Main Relief and Power Dig Valve
118 Auxiliary Flow Combiner Valve
119 Check Valve—Flow Combiner Valve Circuit
120 Travel Flow Combiner Valve
155 From Shuttle Valve
170 Auxiliary Shuttle Valve
177 Flow Rate Select Solenoid Valve
178 Flow Rate Select Reducing Valve
179 To Pump 2 Flow Rate Solenoid Valve
180 To Torque Control Solenoid Valve
600 High-Pressure Oil
604 Return Oil
609 Pilot Oil
B60 Attachment Pressure Sensor
B61 Arm Out Pressure Sensor
DP To Solenoid Valve Manifold Port DP
DY To Solenoid Valve Manifold Port DY
Y43 2-Speed Activation Solenoid Valve
Y44 Flow Rate Adjustment Solenoid Valve

→NOTE:

Two pump combined flow kit will not work properly unless appropriate kits are installed on machine.

The function of the two pump combined flow kit is to control auxiliary flow combiner valve (118) and auxiliary flow rate control
valve (valve and poppet) (108) when multiple function are used with auxiliary attachments.

<- Go to Section TOC Section 9025 page 179 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Auxiliary Shuttle Valve Schematic

LEGEND:
93 To Bypass Shutoff Valve
118 To Auxiliary Flow Combiner Valve
155 From Shuttle Valve
170 Auxiliary Shuttle Valve
177 From Flow Rate Select Solenoid Valve
SP To Pilot Signal Manifold Port SP

Auxiliary Shuttle Valve— For more information, see Auxiliary Shuttle Valve Operation . (Group 9025-05.)

<- Go to Section TOC Section 9025 page 180 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Flow Rate Pressure Reducing Valve Operating Below Set Pressure

LEGEND:
28 Pilot Pump
108 To Auxiliary Flow Rate Control Valve
118 To Auxiliary Flow Combiner (2 used)
170 To Auxiliary Shuttle Valve
177 Flow Rate Select Solenoid Valve
178 Flow Rate Select Reducing Valve
604 Return Oil
609 Pilot Oil
B60 Attachment Pressure Sensor
DP To Solenoid Valve Manifold Port DP
SM From Pilot Signal Manifold Port SM
SN From Pilot Signal Manifold Port SN
SP To Pilot Signal Manifold Port SP
Y43 2-Speed Activation Solenoid Valve
Y44 Flow Rate Adjustment Solenoid Valve

Flow Rate Pressure Reducing Valve Operating Below Set Pressure— For more information, see Flow Rate Pressure
Reducing Valve Operation . (Group 9025-05.)

<- Go to Section TOC Section 9025 page 181 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Flow Rate Pressure Reducing Valve Operating Above Set Pressure

LEGEND:
28 Pilot Pump
108 To Auxiliary Flow Rate Control Valve
118 From Auxiliary Flow Combiner (2 used)
170 To Auxiliary Shuttle Valve
177 Flow Rate Select Solenoid Valve
178 Flow Rate Select Reducing Valve
604 Return Oil
609 Pilot Oil
B60 Attachment Pressure Sensor
DP To Solenoid Valve Manifold Port DP
SM From Pilot Signal Manifold Port SM
SN From Pilot Signal Manifold Port SN
SP To Pilot Signal Manifold Port SP
Y43 2-Speed Activation Solenoid Valve
Y44 Flow Rate Adjustment Solenoid Valve

Flow Rate Pressure Reducing Valve Above Set Pressure— For more information, see Flow Rate Pressure Reducing Valve
Operation . (Group 9025-05.)

<- Go to Section TOC Section 9025 page 182 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Flow Rate Select Solenoid Valve Energized

LEGEND:
28 Pilot Pump
108 To Auxiliary Flow Rate Control Valve
118 To Auxiliary Flow Combiner (2 used)
170 To Auxiliary Shuttle Valve
177 Flow Rate Select Solenoid Valve
178 Flow Rate Select Reducing Valve
604 Return Oil
609 Pilot Oil
B60 Attachment Pressure Sensor
DP To Solenoid Valve Manifold Port DP
SM From Pilot Signal Manifold Port SM
SN From Pilot Signal Manifold Port SN
SP To Pilot Signal Manifold Port SP
Y43 2-Speed Activation Solenoid Valve
Y44 Flow Rate Adjustment Solenoid Valve

Flow Rate Select Solenoid Valve Energized— For more information, see Flow Rate Select Solenoid Valve Operation .
(Group 9025-05.)

<- Go to Section TOC Section 9025 page 183 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Flow Rate Solenoid Valve De-Energized

LEGEND:
28 Pilot Pump
108 To Auxiliary Flow Rate Control Valve
118 To Auxiliary Flow Combiner (2 used)
170 To Auxiliary Shuttle Valve
177 Flow Rate Select Solenoid Valve
178 Flow Rate Select Reducing Valve
604 Return Oil
609 Pilot Oil
B60 Attachment Pressure Sensor
DP To Solenoid Valve Manifold Port DP
SM From Pilot Signal Manifold Port SM
SN From Pilot Signal Manifold Port SN
SP To Pilot Signal Manifold Port SP
Y43 2-Speed Activation Solenoid Valve
Y44 Flow Rate Adjustment Solenoid Valve

Flow Rate Solenoid Valve De-Energized— For more information, see Flow Rate Select Solenoid Valve Operation . (Group
9025-05.)

<- Go to Section TOC Section 9025 page 184 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Group 15 - Diagnostic Information


All Hydraulic Functions Slow
73

All Hydraulic Functions Slow Diagnostic Procedure


( 1 ) Low Hydraulic Oil Level

Action:

Check hydraulic oil level. See Check Hydraulic Tank Oil Level . (Operator’s Manual.)

Is hydraulic oil at proper level?

Result:

YES:Go to Cold Hydraulic Oil.

NO:Fill hydraulic tank to proper level.

( 2 ) Cold Hydraulic Oil

Action:

Check hydraulic oil temperature. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)

Does hydraulic oil temperature meet specification?

Result:

YES:Go to Oil Viscosity Too Heavy.

NO:Perform hydraulic oil warm-up procedure.

( 3 ) Oil Viscosity Too Heavy

Action:

Check hydraulic oil for proper viscosity. See Hydraulic Oil . (Operator’s Manual.)

Is specified hydraulic oil used?

Result:

YES:Go to Slow Engine Speed.

NO:Use correct viscosity hydraulic oil for operating conditions.

( 4 ) Slow Engine Speed

Action:

Check engine speed. See Engine Speed Control System Operation . (Group 9010-05.) Also see Main Controller (MCZ) Circuit
Theory of Operation . (Group 9015-15.)

Does engine speed meet specification?

Result:

YES:Go to Air Leak in Pump Suction Line.

NO:Select correct engine speed.

<- Go to Section TOC Section 9025 page 185 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

( 5 ) Air Leak in Pump Suction Line

Action:

Inspect pump suction line for leaks. See Hydraulic System Component Location . (Group 9025-15.)

Is pump suction line free of leaks?

Result:

YES:Go to Pump Control Pilot Pressure Signal Low.

NO:Repair or replace pump suction line.

( 6 ) Pump Control Pilot Pressure Signal Low

Action:

Perform Pump Control Pilot Pressure Signal Test . (Group 9025-25.)

Does pump control pilot pressure meet specification?

Result:

YES:Go to Pilot Circuit Malfunction.

NO:Check pump 1 or pump 2 flow rate pilot valve. See Pilot Signal Manifold Disassemble and Assemble . (Group 3360.)

( 7 ) Pilot Circuit Malfunction

Action:

Check pilot circuit for malfunction.

Is pilot circuit OK?

Result:

YES:Go to Restricted Hydraulic Oil Tank Suction Screen.

NO:Repair or replace pilot circuit.

( 8 ) Restricted Hydraulic Oil Tank Suction Screen

Action:

Inspect hydraulic oil tank suction screen. See Replace Hydraulic Tank Oil Filter . (Operator’s Manual.)

Is hydraulic oil tank suction screen free of restriction?

Result:

YES:Go to Pump 1 or Pump 2 Regulator Malfunction.

NO:Clean or replace hydraulic oil tank suction screen.

( 9 ) Pump 1 or Pump 2 Regulator Malfunction

Action:

Check pump 1 or pump 2 regulator. See Pump Regulator Test and Adjustment—Maximum Flow . (Group 9025-25.)

<- Go to Section TOC Section 9025 page 186 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Does pump 1 or pump 2 regulator meet specification?

Result:

YES:Go to Worn Pump.

NO:Repair or replace pump 1 or pump 2 regulator. See Pump 1 and 2 Regulator Disassemble and Assemble . (Group 3360.)

( 10 ) Worn Pump

Action:

Slow travel cycle times may indicate a worn pump. Check travel cycle times. See Operational Checkout . (Group 9005-10.)

If travel cycle times do not meet specification, check pump flow. See Pump Flow Test . (Group 9025-25.)

Do travel cycle times and pump flow meet specification?

Result:

YES:Go to Main Relief Valve Setting Too Low or Malfunctioning.

NO:Repair or replace pump. See Pump 1 and 2 Remove and Install . (Group 3360.)

( 11 ) Main Relief Valve Setting Too Low or Malfunctioning

Action:

Perform main relief valve test and adjustment. See Main Relief and Power Dig Valve Test and Adjustment . (Group 9025-25.)

Does main relief valve settings meet specification?

Result:

YES:Go to Power Dig Solenoid Valve Setting Too Low or Malfunctioning.

NO:Adjust or replace main relief valve. See Control Valve (5-Spool) Disassemble and Assemble . (Group 3360.)

( 12 ) Power Dig Solenoid Valve Setting Too Low or Malfunctioning

Action:

See Power Dig Solenoid Valve Test and Adjustment . (Group 9025-25.)

Does power dig solenoid valve setting meet specification?

Result:

YES:Go to Low Pilot Oil Pressure.

NO:Adjust or replace power dig solenoid valve. See Control Valve (5-Spool) Disassemble and Assemble . (Group 3360.)

( 13 ) Low Pilot Oil Pressure

Action:

Check pilot oil pressure. See Pilot Pressure Regulating Valve Test and Adjustment . (Group 9025-25.)

Does pilot oil pressure meet specification?

<- Go to Section TOC Section 9025 page 187 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Result:

YES:Diagnostic checkout complete.

NO:Adjust, repair, or replace pilot pressure regulating valve. See Pilot Pressure Regulating Valve and Filter Remove and Install .
(Group 3360.)

<- Go to Section TOC Section 9025 page 188 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Hydraulic Oil Overheats


73

Hydraulic Oil Overheats Diagnostic Procedure


( 1 ) Low Hydraulic Oil Level

Action:

Check hydraulic oil level. See Check Hydraulic Tank Oil Level . (Operator’s Manual.)

Is hydraulic oil at proper level?

Result:

YES:Go to Restricted Hydraulic Oil Cooler.

NO:Fill hydraulic tank to proper level.

( 2 ) Restricted Hydraulic Oil Cooler

Action:

Inspect hydraulic oil cooler.

Is hydraulic oil cooler free of restriction?

Result:

YES:Go to Oil Viscosity Too Light.

NO:Clean, repair, or replace hydraulic oil cooler.

( 3 ) Oil Viscosity Too Light

Action:

Check hydraulic oil for correct viscosity. See Hydraulic Oil . (Operator’s Manual.)

Is specified hydraulic oil used?

Result:

YES:Go to Fan Drive Malfunction.

NO:Use correct viscosity hydraulic oil for operating conditions.

( 4 ) Fan Drive Malfunction

Action:

Inspect fan drive. See Fan Speed Test and see Fan Drive Pump Flow Test . (Group 9025-25.)

Does fan drive operate properly?

Result:

YES:Go to Machine Lift Capacity Exceeded.

NO:Repair or replace fan drive. See Fan Drive Motor Remove and Install . (Group 0510.)

( 5 ) Machine Lift Capacity Exceeded

<- Go to Section TOC Section 9025 page 189 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Action:

Check machine lift capacity. See Miscellaneous—Specifications . (Operator’s Manual.)

Is amount of weight being lifted within machine lifting capacity?

Result:

YES:Go to Restricted Hydraulic Oil Return Filter.

NO:Reduce amount of weight being lifted.

( 6 ) Restricted Hydraulic Oil Return Filter

Action:

Check hydraulic oil return filter for restriction. See Hydraulic System Component Location . (Group 9025-15.)

Is hydraulic oil tank return filter restricted?

Result:

YES:Replace hydraulic oil tank return filter. See Replace Hydraulic Tank Oil Filter . (Operator’s Manual.)

NO:Go to Main Relief Valve Setting Too Low or Malfunctioning.

( 7 ) Main Relief Valve Setting Too Low or Malfunctioning

Action:

Perform main relief valve test and adjustment. See Main Relief and Power Dig Valve Test and Adjustment . (Group 9025-25.)

Does main relief valve operate correctly?

Result:

YES:Go to Power Dig Valve Setting Too Low or Malfunctioning.

NO:Replace main relief valve. See Control Valve (5-Spool) Disassemble and Assemble . (Group 3360.)

( 8 ) Power Dig Valve Setting Too Low or Malfunctioning

Action:

Perform main relief and power dig valve test. See Main Relief and Power Dig Valve Test and Adjustment . (Group 9025-25.)

Is power dig valve operating correctly?

Result:

YES:Go to Oil Cooler Bypass Valve Stuck Open.

NO:Replace power dig valve. See Control Valve (5-Spool) Disassemble and Assemble . (Group 3360.)

( 9 ) Oil Cooler Bypass Valve Stuck Open

Action:

Inspect oil cooler bypass valve. See Hydraulic Oil Cooler Bypass Valve Remove and Install . (Group 3360.)

Does oil cooler bypass valve operate correctly?

<- Go to Section TOC Section 9025 page 190 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Result:

YES:Go to Pump Stuck at Maximum Displacement.

NO:Replace oil cooler bypass valve.

( 10 ) Pump Stuck at Maximum Displacement

Action:

See Pump Regulator Test and Adjustment—Minimum Flow . (Group 9025-25.)

Does pump control pilot pressure meet specification?

Result:

YES:Diagnostic checkout complete.

NO:Repair or replace pump 1 or pump 2 regulator. See Pump 1 and 2 Regulator Remove and Install . (Group 3360.)

NO:Check pump 1 or pump 2 flow rate pilot valve. See Pilot Signal Manifold Disassemble and Assemble . (Group 3360.)

<- Go to Section TOC Section 9025 page 191 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

No Hydraulic Functions
73

No Hydraulic Functions Diagnostic Procedure


( 1 ) Pilot Shutoff Lever in Locked (UP) Position

Action:

Check position of pilot shutoff lever.

Is pilot shutoff lever in unlocked (DOWN) position?

Result:

YES:Go to Pilot Shutoff Solenoid Malfunction.

NO:Place pilot shutoff lever in unlocked (DOWN) position.

( 2 ) Pilot Shutoff Solenoid Malfunction

Action:

Check pilot shutoff solenoid. See Solenoid Test . (Group 9015-20.)

Does pilot shutoff solenoid operate correctly?

Result:

YES:Go to Low Hydraulic Oil Level.

NO: See Pilot Shutoff Circuit Theory of Operation . (Group 9015-15.)

( 3 ) Low Hydraulic Oil Level

Action:

Check hydraulic oil level. See Check Hydraulic Tank Oil Level . (Operator’s Manual.)

Is hydraulic oil at proper level?

Result:

YES:Go to Pump Drive Failure.

NO:Add proper hydraulic oil. See Hydraulic Oil . (Operator’s Manual.)

( 4 ) Pump Drive Failure

Action:

Check damper drive (flex coupling). See Damper Drive (Flex Coupling) Remove and Install . (Group 0752.)

Does damper drive (flex coupling) operate correctly?

Result:

YES:Go to Restricted Hydraulic Oil Tank Suction Screen.

NO:Repair or replace damper drive (flex coupling).

( 5 ) Restricted Hydraulic Oil Tank Suction Screen

<- Go to Section TOC Section 9025 page 192 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Action:

Inspect hydraulic oil tank suction screen. See Replace Hydraulic Tank Oil Filter . (Operator’s Manual.)

Is hydraulic oil tank suction screen free of restriction?

Result:

YES:Diagnostic checkout complete.

NO:Clean or replace hydraulic oil tank suction screen.

<- Go to Section TOC Section 9025 page 193 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Poor Combined Operation


73

Poor Combined Operation Diagnostic Procedure


( 1 ) Front Attachment Pressure Sensor (B32) or Travel Pressure Sensor (B34) Malfunction

Action:

Check front attachment pressure sensor (B32) or travel pressure sensor (B34). See Pressure Sensor Test . (Group 9015-20.)

Do front attachment pressure sensor (B32) or travel pressure sensor (B34) operate correctly?

Result:

YES:Go to Pilot Control Valve Malfunction.

NO:Replace front attachment pressure sensor (B32) or travel pressure sensor (B34).

( 2 ) Pilot Control Valve Malfunction

Action:

Check control valve spool actuating pressure. See Control Valve Spool Actuating Pilot Pressure Test . (Group 9025-25.)

Does control valve spool actuating pressure meet specification?

Result:

YES:Go to Check Valves or Pump 1 or Pump 2 Flow Rate Pilot Valve Stuck.

NO:Inspect and repair or replace pilot control valve. See Pilot Shutoff Solenoid Valve Disassemble and Assemble . (Group
3360.)

( 3 ) Check Valves or Pump 1 or Pump 2 Flow Rate Pilot Valve Stuck

Action:

Inspect check valves. See Control Valve Check Valves Identification and Operation . (Group 9025-05.)

Inspect pump 1 or pump 2 flow rate pilot valves. See Pilot Signal Manifold Operation . (Group 9025-05.)

Do check valves or flow rate pilot valves operate correctly?

Result:

YES:Diagnostic checkout complete.

NO:Repair or replace check valve. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve (4-Spool)
Disassemble and Assemble . (Group 3360.)

NO:Repair or replace flow rate pilot valve. See Pilot Signal Manifold Disassemble and Assemble . (Group 3360.)

<- Go to Section TOC Section 9025 page 194 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

All Functions Cannot Be Operated


73

All Functions Cannot Be Operated Diagnostic Procedure


( 1 ) Pilot Shutoff Lever in Unlocked (DOWN) Position

Action:

Check position of pilot shutoff lever.

Is pilot shutoff lever in the unlocked (DOWN) position?

Result:

YES:Go to Pilot Shutoff Solenoid Malfunction.

NO:Place pilot shutoff lever in unlocked (DOWN) position.

( 2 ) Pilot Shutoff Solenoid Malfunction

Action:

Check pilot shutoff solenoid. See Solenoid Test . (Group 9015-20.)

Does pilot shutoff solenoid operate correctly?

Result:

YES:Go to Low Pilot Oil Pressure.

NO: See Pilot Shutoff Circuit Theory of Operation . (Group 9015-15.)

( 3 ) Low Pilot Oil Pressure

Action:

Check pilot oil pressure. See Pilot Pressure Regulating Valve and Filter Remove and Install . (Group 9025-25.)

Does pilot pressure meet specification?

Result:

YES:Diagnostic checkout complete.

NO:Adjust, repair, or replace pilot pressure valve. See Pilot Pressure Regulating Valve and Filter Remove and Install . (Group
3360.)

NO:Pilot pump worn. Inspect and repair or replace pilot pump. See Pilot Pump Remove and Install . (Group 3360.)

<- Go to Section TOC Section 9025 page 195 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Function Does Not Stop When Control Lever Released


73

Function Does Not Stop When Control Lever Released Diagnostic


Procedure
( 1 ) Control Valve Spool Stuck

Action:

Inspect control valve spool. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve (4-Spool)
Disassemble and Assemble . (Group 3360.)

Do control valve spools move freely?

Result:

YES:Go to Pilot Signal Manifold Malfunction.

NO:Repair or replace control valve components.

( 2 ) Pilot Signal Manifold Malfunction

Action:

Inspect pilot signal manifold for sticking spools. See Pilot Signal Manifold Disassemble and Assemble . (Group 3360.)

Do pilot signal manifold spools move freely?

Result:

YES:Go to Left and Right Pilot Valve Malfunction.

NO:Repair or replace pilot signal manifold.

( 3 ) Left and Right Pilot Valve Malfunction

Action:

Inspect left and right pilot valve spools. See Pilot Valve (Left and Right) Disassemble and Assemble . (Group 3360.)

Do left and right pilot valve spools move freely?

Result:

YES:Diagnostic checkout complete.

NO:Repair or replace left and right pilot valves.

<- Go to Section TOC Section 9025 page 196 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Some Functions Cannot Be Operated, All Others Are Normal


73

Some Functions Cannot Be Operated, All Others Are Normal Diagnostic


Procedure
( 1 ) Pilot Cap Loose

Action:

Inspect pilot cap for leakage or damage. Check pilot cap screws for proper torque specification. See Control Valve (5-Spool)
Disassemble and Assemble and see Control Valve (4-Spool) Disassemble and Assemble . (Group 3360.)

Do control valve components meet specification?

Result:

YES:Go to Pilot Control Valve or Hydraulic Line Malfunction.

NO:Repair or replace control valve components.

( 2 ) Pilot Control Valve or Hydraulic Line Malfunction

Action:

Inspect pilot control valve or hydraulic lines for function that can not be operated. Check for leaks or damage. See Pilot Control
Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern or see Pilot Control Valve-to-Pilot Signal Manifold
Component Location—Backhoe Pattern and see Pilot Signal Manifold-to-Control Valve Line Connection . (Group 9025-15.)

Are components free of leaks or damage?

Result:

YES:Go to Pump 1 or Pump 2 Flow Rate Pilot Valve Spool Stuck.

NO:Inspect and repair or replace leaking or damaged components.

( 3 ) Pump 1 or Pump 2 Flow Rate Pilot Valve Spool Stuck

Action:

Inspect pump 1 or pump 2 flow rate pilot valves. See Pilot Signal Manifold Operation . (Group 9025-05.)

Do flow rate pilot spools move freely?

Result:

YES:Go to Control Valve Spool Stuck.

NO:Repair or replace pilot signal flow rate pilot spool. See Pilot Signal Manifold Disassemble and Assemble . (Group 3360.)

( 4 ) Control Valve Spool Stuck

Action:

Inspect control valve spools. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve (4-Spool)
Disassemble and Assemble . (Group 3360.)

Do control valve spools move freely?

<- Go to Section TOC Section 9025 page 197 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Result:

YES:Diagnostic checkout complete.

NO:Repair or replace control valve components.

<- Go to Section TOC Section 9025 page 198 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

All Functions Slow


73

All Functions Slow Diagnostic Procedure


( 1 ) Restricted Pilot Filter

Action:

Inspect pilot filter for restriction. See Hydraulic System Component Location . (Group 9025-15.)

Is pilot filter free of restriction?

Result:

YES:Go to Torque Control Solenoid Malfunction.

NO:Replace pilot filter. See Replace Pilot Oil Filter . (Operator’s Manual.)

( 2 ) Torque Control Solenoid Malfunction

Action:

Check torque control solenoid connection. Check torque control solenoid. See Proportional Solenoid Test . (Group 9015-20.)

Check torque control solenoid valve. See Torque Control Solenoid Valve Test and Adjustment . (Group 9025-25.)

Is torque control solenoid and solenoid valve operate correctly?

Result:

YES:Go to Low Pilot Oil Pressure.

NO:Repair or replace torque control solenoid and solenoid valve.

( 3 ) Low Pilot Oil Pressure

Action:

Check pilot oil pressure. See Pilot Pressure Regulating Valve Test and Adjustment . (Group 9025-25.)

Does pilot pressure meet specification?

Result:

YES:Go to Restricted Pilot Shutoff Solenoid Valve.

NO:Adjust or replace pilot pressure regulating valve. See Pilot Pressure Regulating Valve and Filter Remove and Install . (Group
3360.)

NO:Pilot pump worn. See Pilot Pump Remove and Install . (Group 3360.)

( 4 ) Restricted Pilot Shutoff Solenoid Valve

Action:

Inspect pilot shutoff solenoid valve for restriction. See Hydraulic System Component Location . (Group 9025-15.)

Is pilot shutoff solenoid valve free of restriction?

Result:

YES:Diagnostic checkout complete.

<- Go to Section TOC Section 9025 page 199 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

NO:Repair or replace pilot shutoff solenoid valve. See Pilot Shutoff Solenoid Valve Remove and Install . (Group 3360.)

Functions Move in Opposite Direction


73

Functions Move in Opposite Direction Diagnostic Procedure


( 1 ) Pilot Control Hoses Connected Incorrectly

Action:

Check pilot control hose connections. See Control Lever Pattern Operation . (Operator′s Manual.)

See Pilot Signal Manifold-to-Control Valve Line Connection . (Group 9025-15.) Also see Pilot Control Valve-to-Pilot Signal
Manifold Component Location—Excavator Pattern or see Pilot Control Valve-to-Pilot Signal Manifold Component
Location—Backhoe Pattern . (Group 9025-15.)

Are pilot control hoses connected correctly?

Result:

YES:Diagnostic checkout complete.

NO:Correct pilot control hose connections.

<- Go to Section TOC Section 9025 page 200 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

All Dig Functions Slow or No Power


73

All Dig Functions Slow or No Power Diagnostic Procedure


( 1 ) Hydraulic System Malfunction

Action:

Inspect hydraulic system for malfunctions. See All Hydraulic Functions Slow . (Group 9025-15.)

Is hydraulic system operating correctly?

Result:

YES:Go to Pilot Circuit Malfunction.

NO:Repair or replace hydraulic system component causing malfunction.

( 2 ) Pilot Circuit Malfunction

Action:

Inspect pilot circuit for malfunction. See All Functions Cannot Be Operated . (Group 9025-15.)

Is pilot circuit operating correctly?

Result:

YES:Go to Pump 1 or Pump 2 Regulator Malfunction.

NO:Repair or replace pilot circuit component causing malfunction.

( 3 ) Pump 1 or Pump 2 Regulator Malfunction

Action:

Check pump 1 or pump 2 regulator. See Pump Regulator Test and Adjustment—Minimum Flow and see Pump Regulator Test
and Adjustment—Maximum Flow . (Group 9025-25.)

Does pump 1 or pump 2 regulator meet specification?

Result:

YES:Diagnostic checkout complete.

NO:Repair or replace pump 1 or pump 2 regulator. See Pump 1 and 2 Regulator Remove and Install . (Group 3360.)

<- Go to Section TOC Section 9025 page 201 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Some Dig Functions Slow (Not All)


73

Some Dig Functions Slow (Not All) Diagnostic Procedure


( 1 ) Pilot Circuit Malfunction

Action:

Inspect pilot circuit for malfunction. See All Functions Cannot Be Operated . (Group 9025-15.)

Is pilot circuit operating correctly?

Result:

YES:Go to Control Valve Leakage.

NO:Repair or replace pilot circuit component causing malfunction.

( 2 ) Control Valve Leakage

Action:

Inspect control valve for leakage. See Travel System Component Location . (Group 9025-15.)

Is control valve free of leaks?

Result:

YES:Go to Cylinder Leakage.

NO:Repair or replace control valve components. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve
(4-Spool) Disassemble and Assemble . (Group 3360.)

( 3 ) Cylinder Leakage

Action:

Inspect cylinders for leaks. See Cylinder Drift Test—Boom, Arm, and Bucket . (Group 9025-25.)

Are cylinders free of leaks?

Result:

YES:Go to Circuit Relief Valve Setting Too Low or Malfunctioning.

NO:Repair or replace cylinder. See Boom Cylinder Remove and Install , see Arm Cylinder Remove and Install or see Bucket
Cylinder Remove and Install . (Group 3360.)

( 4 ) Circuit Relief Valve Setting Too Low or Malfunctioning

Action:

Check circuit relief valve setting of slow function. See Circuit Relief Valve Test and Adjustment . (Group 9025-25.)

Do circuit relief valve settings meet specification?

Result:

YES:Go to Control Valve Spool Stuck.

NO:Adjust, repair, or replace circuit relief valve. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve
(4-Spool) Disassemble and Assemble . (Group 3360.)
<- Go to Section TOC Section 9025 page 202 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

( 5 ) Control Valve Spool Stuck

Action:

Inspect control valve for stuck spool. See Control Valve Operation . (Group 9025-05.)

Do control valve spools move freely?

Result:

YES:Go to Pump 1 or Pump 2 Flow Rate Pilot Valve Spool Stuck.

NO:Repair or replace control valve components. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve
(4-Spool) Disassemble and Assemble . (Group 3360.)

( 6 ) Pump 1 or Pump 2 Flow Rate Pilot Valve Spool Stuck

Action:

Inspect pump 1 or pump 2 flow rate pilot valves? See Pilot Signal Manifold Operation . (Group 9025-05.)

Do flow rate pilot valve spools move freely?

Result:

YES:Diagnostic checkout complete.

NO:Repair or replace pilot signal manifold flow rate pilot valve spool. See Pilot Signal Manifold Disassemble and Assemble .
(Group 3360.)

<- Go to Section TOC Section 9025 page 203 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Load Drifts Down When Control Lever is in Neutral Position


73

Load Drifts Down When Control Lever is in Neutral Position Diagnostic


Procedure
( 1 ) Cylinder Leakage

Action:

Inspect cylinders for leaks. See Cylinder Drift Test—Boom, Arm, and Bucket . (Group 9025-25.)

Are cylinders free of leaks?

Result:

YES:Go to Circuit Relief Valve Setting Too Low or Malfunctioning.

NO:Repair or replace cylinder. See Boom Cylinder Remove and Install , see Arm Cylinder Remove and Install and see Bucket
Cylinder Remove and Install . (Group 3360.)

( 2 ) Circuit Relief Valve Setting Too Low or Malfunctioning

Action:

Check circuit relief valve setting of slow function. See Circuit Relief Valve Test and Adjustment . (Group 9025-25.)

Do circuit relief valve settings meet specification?

Result:

YES:Go to Boom Manual Lower Screw Loose.

NO:Adjust, repair, or replace circuit relief valve. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve
(4-Spool) Disassemble and Assemble . (Group 3360.)

( 3 ) Boom Manual Lower Screw Loose

Action:

Inspect boom manual lower screw. See Lower Boom with Engine Stopped . (Operator’s Manual.)

Is boom manual lower screw tightened to specification?

Result:

YES:Go to Control Valve Leakage.

NO:Tighten boom manual lower screw to specification.

( 4 ) Control Valve Leakage

Action:

Inspect control valve for leakage. See Travel System Component Location . (Group 9025-15.)

Is control valve free of leaks?

Result:

YES:Diagnostic checkout complete.

<- Go to Section TOC Section 9025 page 204 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

NO:Repair or replace control valve components. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve
(4-Spool) Disassemble and Assemble . (Group 3360.)

Load Falls When Control Valve is Actuated To Raise Load With Engine Running at Slow Idle
73

Load Falls When Control Valve is Actuated To Raise Load With Engine
Running at Slow Idle Diagnostic Procedure
( 1 ) Lift Check Valve Leakage

Action:

Inspect control valve check valves for leakage. See Control Valve Check Valves Identification and Operation and see Control
Valve Operation . (Group 9025-05.)

Are check valves operating correctly?

Result:

YES:Diagnostic checkout complete.

NO:Repair or replace control valve components. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve
(4-Spool) Disassemble and Assemble . (Group 3360.)

<- Go to Section TOC Section 9025 page 205 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal
73

IMPORTANT:

Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will
result in permanent damage to connector. Torque only to specification.

Item Measurement Specification

Cab Harness-to-Machine Harness 100-Pin Connector (X3) Torque 10 N·m

89 lb.-in.

H/P (High Power) Function Does Not Operate, PWR (Power) Mode is
Normal Diagnostic Procedure
( 1 ) Slow Engine Speed

Action:

Check engine speed and power mode setting. See Engine Speed Control System Operation . (Group 9010-05.)

Does engine speed meet specification?

Result:

YES:Go to Pressure Sensor Malfunction.

NO:Select correct engine speed and power mode setting.

( 2 ) Pressure Sensor Malfunction

Action:

Check pressure readings of the following pressure sensors.

Pump 1 Delivery Pressure


Pump 2 Delivery Pressure
Boom Up Pilot Pressure
Arm In Pilot Pressure

Pressure readings can be viewed using the monitor service menu. See Service Menu . (Group 9015-16.)

Actuate arm in or boom up function to view reading. Compare pump 1 and pump 2 pressure readings to main relief and power
dig valve specification. See Main Relief and Power Dig Valve Test and Adjustment and see Power Dig Solenoid Valve Test and
Adjustment . (Group 9025-25.)

Compare boom up and arm in pressure readings to control valve spool actuating pilot pressure specification. See Control Valve
Spool Actuating Pilot Pressure Test . (Group 9025-25.)

Do pressure readings meet specification?

Result:

YES:Go to Power Mode Button Malfunction.

NO:Replace pressure sensors as required.For pump 1 and pump 2 pressure sensor locations, see Pump Harness (W8)
Component Location . (Group 9015-10.) For boom up and arm in pressure sensor locations, see Machine Harness (W2)
Component Location . (Group 9015-10.)

NO:Check wiring harness for pump 1 and pump 2 pressure sensors. See Pump Harness (W8) Component Location . (Group
9015-10.) Check wiring harness for boom up and arm in pressure sensors. See Machine Harness (W2) Component Location .
(Group 9015-10.)
<- Go to Section TOC Section 9025 page 206 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

( 3 ) Power Mode Button Malfunction

Action:

Check power mode button using the monitor service menu. See Service Menu . (Group 9015-16.)

Select power mode to display switch position. Press power mode button to ECO, PWR, and H/P positions. Monitor service display
should correspond with switch position.

Does monitor service menu correspond with switch position?

Result:

YES:Diagnostic checkout complete.

NO:Check wiring harness. See Machine Harness (W2) Component Location . (Group 9015-10.)

<- Go to Section TOC Section 9025 page 207 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Swing Speed Slow in Both Directions


73

Swing Speed Slow in Both Directions Diagnostic Procedure


( 1 ) Slow Engine Speed

Action:

Check engine speed. See Engine Speed Control System Operation . (Group 9010-05.) Also see Main Controller (MCZ) Circuit
Theory of Operation . (Group 9015-15.)

Does engine speed meet specification?

Result:

YES:Go to Swing Motor Crossover Relief Valve Malfunction.

NO:Select correct engine speed.

( 2 ) Swing Motor Crossover Relief Valve Malfunction

Action:

Inspect swing motor crossover relief valve. See Swing Motor Crossover Relief Valve Test and Adjustment . (Group 9025-25.)

Does swing motor crossover relief valve meet specification?

Result:

YES:Go to Control Valve Leakage.

NO:Repair or replace swing motor crossover relief valve. See Crossover Relief Valve and Make-Up Check Valve Remove and
Install . (Group 4360.)

( 3 ) Control Valve Leakage

Action:

Inspect swing valve spool in control valve for leakage. For component location, see Control Valve Operation . (Group 9025-05.)

Is swing valve spool OK?

Result:

YES:Go to Swing Motor Leakage.

NO:Repair or replace control valve components as necessary. See Control Valve (5-Spool) Disassemble and Assemble and see
Control Valve (4-Spool) Disassemble and Assemble . (Group 3360.)

( 4 ) Swing Motor Leakage

Action:

Inspect swing motor for leakage. See Swing Motor Leakage Test . (Group 9025-25.)

Does swing motor meet specification?

Result:

YES:Go to Swing Park Brake Not Fully Released.

NO:Repair or replace swing motor. See Swing Motor and Park Brake Disassemble and see Swing Motor and Park Brake
<- Go to Section TOC Section 9025 page 208 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Assemble . (Group 4360.)

( 5 ) Swing Park Brake Not Fully Released

Action:

Inspect pump 1 or pump 2 flow rate pilot valves. See Pilot Signal Manifold Operation . (Group 9025-05.)

Do flow rate pilot valve spools move freely?

Result:

YES:Go to Pump 2 Worn.

NO:Repair or replace pilot signal manifold flow rate pilot valve spool. See Pilot Signal Manifold Disassemble and Assemble .
(Group 3360.)

( 6 ) Pump 2 Worn

Action:

Slow travel cycle times may indicate worn pump. Check travel cycle times. See Cycle Times Check . (Group 9005-10.)

If travel cycle times do not meet specification, check pump flow. See Pump Flow Test . (Group 9025-25.)

Do travel cycle times and pump flow meet specification?

Result:

YES:Diagnostic checkout complete.

NO:Repair or replace pump. See Pump 1 and 2 Remove and Install . (Group 3360.)

<- Go to Section TOC Section 9025 page 209 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Swing Speed Slow or Does Not Operate in One Direction


73

Swing Speed Slow or Does Not Operate in One Direction Diagnostic


Procedure
( 1 ) Pilot Circuit Malfunction

Action:

Inspect pilot circuit for malfunction. See Pilot System Operation . (Group 9025-05.)

Is pilot circuit OK?

Result:

YES:Go to Swing Motor Make-Up Check Valve Leakage.

NO:Repair or replace pilot circuit malfunction.

( 2 ) Swing Motor Make-Up Check Valve Leakage

Action:

Inspect swing motor make-up check valves. See Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation .
(Group 9025-05.)

Are swing motor make-up check valves OK?

Result:

YES:Go to Swing Motor Crossover Relief Valve Malfunction.

NO:Repair or replace swing motor make-up check valve. See Crossover Relief Valve and Make-Up Check Valve Remove and
Install . (Group 4360.)

( 3 ) Swing Motor Crossover Relief Valve Malfunction

Action:

Inspect swing motor crossover relief valve. See Swing Motor Crossover Relief Valve Test and Adjustment . (Group 9025-25.)

Does swing motor crossover relief valve meet specification?

Result:

YES:Go to Control Valve Sticking.

NO:Repair or replace swing motor crossover relief valve. See Crossover Relief Valve and Make-Up Check Valve Remove and
Install . (Group 4360.)

( 4 ) Control Valve Sticking

Action:

Inspect control valve for sticking spool. For component location, see Control Valve Operation . (Group 9025-05.)

Does control valve spool move freely?

Result:

YES:Diagnostic checkout complete.

<- Go to Section TOC Section 9025 page 210 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

NO:Repair or replace control valve components as necessary. See Control Valve (5-Spool) Disassemble and Assemble and see
Control Valve (4-Spool) Disassemble and Assemble . (Group 3360.)

<- Go to Section TOC Section 9025 page 211 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Upperstructure Drift with Swing Valve in Neutral


73

Upperstructure Drift with Swing Valve in Neutral Diagnostic Procedure


( 1 ) Park brake operation

Action:

Inspect swing motor and park brake for proper application and release. See Swing Motor Park Brake Release Circuit Operation .
(Group 9025-05.)

Does swing continue to drift after releasing controller for 10 seconds?

Result:

YES:Go to Swing park brake not engaging.

NO:Go to Drift direction.

( 2 ) Drift direction

Action:

Operate machine and check for drift in both directions.

Does swing drift occur in both directions?

Result:

YES:Go to Case drain leakage.

NO:Go to Swing motor make-up check valve leakage.

( 3 ) Case drain leakage

Action:

Inspect swing motor for leakage. See Swing Motor Leakage Test . (Group 9025-25.)

Does observed leakage meet specification?

Result:

YES:Go to Damper valve spool sticking.

NO:Repair or replace swing motor and park brake. See Swing Motor and Park Brake Remove and Install , see Swing Motor and
Park Brake Disassemble , and see Swing Motor and Park Brake Assemble . (Group 4360.)

( 4 ) Damper valve spool sticking

Action:

Inspect park brake valve for sticking damper valve spool. See Swing Motor Park Brake Release Circuit Operation (Group
9025-05) for component identification.

Does damper valve spool move freely?

Result:

YES:Diagnostic checkout complete.

NO:Repair or replace damper valve spool. See Crossover Relief Valve and Make-Up Check Valve Remove and Install . (Group
<- Go to Section TOC Section 9025 page 212 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

4360.)

( 5 ) Swing motor make-up check valve leakage

Action:

Inspect swing motor make-up check valves. See Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation .
(Group 9025-05.)

Are swing motor make-up check valves OK?

Result:

YES:Go to Swing motor crossover relief valve malfunction.

NO:Repair or replace swing motor make-up check valves. See Crossover Relief Valve and Make-Up Check Valve Remove and
Install . (Group 4360.)

( 6 ) Swing motor crossover relief valve malfunction

Action:

Remove crossover relief valves and install in opposite ports in park brake housing. See Crossover Relief Valve and Make-Up
Check Valve Remove and Install . (Group 4360.)

Does swing drift change directions?

Result:

YES:Repair or replace crossover relief valves. See Crossover Relief Valve and Make-Up Check Valve Remove and Install .
(Group 4360.)

NO:Diagnostic checkout complete.

( 7 ) Swing park brake not engaging

Action:

Inspect swing motor and park brake. See Swing Motor Park Brake Release Circuit Operation . (Group 9025-05.) See Swing Motor
and Park Brake Inspection . (Group 4360.)

Is swing motor and park brake OK?

Result:

YES:Diagnostic checkout complete.

NO:Repair or replace swing motor and park brake. See Swing Motor and Park Brake Remove and Install , see Swing Motor and
Park Brake Disassemble , and see Swing Motor and Park Brake Assemble . (Group 4360.)

<- Go to Section TOC Section 9025 page 213 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Swing Function Does Not Operate


73

Swing Function Does Not Operate Diagnostic Procedure


( 1 ) Pilot Circuit Malfunction

Action:

Inspect pilot circuit for malfunction. See Pilot System Operation . (Group 9025-05.)

Is pilot circuit OK?

Result:

YES:Go to Swing Park Brake Malfunction.

NO:Repair or replace pilot circuit malfunction.

( 2 ) Swing Park Brake Malfunction

Action:

Inspect pump 1 or pump 2 flow rate pilot valves. See Pilot Signal Manifold Operation . (Group 9025-05.)

Do flow rate pilot valve spools move freely?

Result:

YES:Go to Control Valve Stuck.

NO:Repair or replace pilot signal manifold flow rate pilot valve spool. See Pilot Signal Manifold Disassemble and Assemble .
(Group 3360.)

( 3 ) Control Valve Stuck

Action:

Inspect for stuck swing valve spool in control valve. For component location, see Control Valve Operation . (Group 9025-05.)

Does swing valve spool move freely?

Result:

YES:Go to Mechanical Failure of Swing Motor or Gear Case.

NO:Repair or replace control valve components as necessary. See Control Valve (5-Spool) Disassemble and Assemble and see
Control Valve (4-Spool) Disassemble and Assemble . (Group 3360.)

( 4 ) Mechanical Failure of Swing Motor or Gear Case

Action:

Inspect swing motor and gear case.

Are swing motor and gear case OK?

Result:

YES:Diagnostic checkout complete.

NO:Repair or replace swing motor and gear case. See Swing Gear Case Disassemble and Assemble . (Group 4350.) Also see
Swing Motor and Park Brake Disassemble and see Swing Motor and Park Brake Assemble . (Group 4360.)
<- Go to Section TOC Section 9025 page 214 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Travel Park Brakes Do Not Apply


73

Travel Park Brakes Do Not Apply Diagnostic Procedure


( 1 ) Counterbalance Valve Spool Stuck, Oil Not Releasing From Piston Cavity

Action:

Inspect counterbalance valve. See Park Brake Valve Disassemble and Assemble . (Group 0260.)

Result:

YES:Go to Mechanical Failure of Travel Motor and Gear Case.

NO:Repair or replace counterbalance valve.

( 2 ) Mechanical Failure of Travel Motor and Gear Case

Action:

Inspect travel motor and gear case for mechanical failure. See Travel Motor and Park Brake Disassemble and Assemble .
(Group 0260.) Also see Travel Gear Case Disassemble and Assemble . (Group 0250.)

Is travel motor and gear case OK?

Result:

YES:Diagnostic checkout complete.

NO:Repair or replace travel motor or gear case.

<- Go to Section TOC Section 9025 page 215 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Track Will Not Move in One Direction


73

Track Will Not Move in One Direction Diagnostic Procedure


( 1 ) Pilot Circuit Malfunction

Action:

Inspect pilot circuit for malfunction. See Pilot System Operation . (Group 9025-05.)

Is pilot circuit OK?

Result:

YES:Go to Travel Motor Crossover Relief Valve Malfunction.

NO:Repair or replace pilot circuit malfunction.

( 2 ) Travel Motor Crossover Relief Valve Malfunction

Action:

Inspect travel motor crossover relief valve. See Travel Motor Crossover Relief Valve Test and Adjustment . (Group 9025-25.)

Is travel motor crossover relief valve OK?

Result:

YES:Go to Control Valve Stuck.

NO:Repair or replace travel motor crossover relief valve. See Park Brake Valve Disassemble and Assemble . (Group 0260.)

( 3 ) Control Valve Stuck

Action:

Inspect for stuck travel valve spool in control valve. For component location, see Control Valve Operation . (Group 9025-05.)

Does travel valve spool move freely?

Result:

YES:Go to Counterbalance Valve Spool Stuck.

NO:Repair or replace control valve components as necessary. See Control Valve (5-Spool) Disassemble and Assemble and see
Control Valve (4-Spool) Disassemble and Assemble . (Group 3360.)

( 4 ) Counterbalance Valve Spool Stuck

Action:

Inspect counterbalance valve. See Travel Motor and Park Brake Valve Operation . (Group 9025-05.)

Does counterbalance valve spool move freely?

Result:

YES:Go to Center Joint Leakage.

NO:Repair or replace counterbalance valve. See Park Brake Valve Disassemble and Assemble . (Group 0260.)

( 5 ) Center Joint Leakage

<- Go to Section TOC Section 9025 page 216 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Action:

Inspect center joint for leakage. See Center Joint Air Test . (Group 4360.)

Is center joint OK?

Result:

YES:Diagnostic checkout complete.

NO:Repair or replace center joint. See Center Joint Disassemble and Assemble . (Group 4360.)

<- Go to Section TOC Section 9025 page 217 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Track Will Not Move in Either Direction


73

Track Will Not Move in Either Direction Diagnostic Procedure


( 1 ) Pilot Circuit Malfunction

Action:

Inspect pilot circuit for malfunction. See Pilot System Operation . (Group 9025-05.)

Is pilot circuit OK?

Result:

YES:Go to Travel Motor Crossover Relief Valve Malfunction.

NO:Repair or replace pilot circuit malfunction.

( 2 ) Travel Motor Crossover Relief Valve Malfunction

Action:

Inspect travel motor crossover relief valve. See Travel Motor Crossover Relief Valve Test and Adjustment . (Group 9025-25.)

Is travel motor crossover relief valve OK?

Result:

YES:Go to Control Valve Stuck.

NO:Repair or replace travel motor crossover relief valve. See Park Brake Valve Disassemble and Assemble . (Group 0260.)

( 3 ) Control Valve Stuck

Action:

Inspect for stuck travel valve spool in control valve. For component location, see Control Valve Operation . (Group 9025-05.)

Does travel valve spool move freely?

Result:

YES:Go to Counterbalance Valve Spool Stuck.

NO:Repair or replace control valve components as necessary. See Control Valve (5-Spool) Disassemble and Assemble and see
Control Valve (4-Spool) Disassemble and Assemble . (Group 3360.)

( 4 ) Counterbalance Valve Spool Stuck

Action:

Inspect counterbalance valve.

Does counterbalance valve spool move freely?

Result:

YES:Go to Mechanical Failure of Travel Motor or Gear Case.

NO:Repair or replace counterbalance valve. See Park Brake Valve Disassemble and Assemble . (Group 0260.)

( 5 ) Mechanical Failure of Travel Motor or Gear Case

<- Go to Section TOC Section 9025 page 218 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Action:

Inspect travel motor and gear case for mechanical failure. See Travel Motor and Park Brake Disassemble and Assemble .
(Group 0260.) Also see Travel Gear Case Disassemble and Assemble . (Group 0250.)

Is travel motor and gear case OK?

Result:

YES:Go to Center Joint Leakage.

NO:Repair or replace travel motor or gear case.

( 6 ) Center Joint Leakage

Action:

Inspect center joint for leakage. See Center Joint Air Test . (Group 0260.)

Is center joint OK?

Result:

YES:Diagnostic checkout complete.

NO:Repair or replace center joint. See Center Joint Remove and Install . (Group 4360.)

<- Go to Section TOC Section 9025 page 219 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Machine Mistracks at All Speeds in Both Directions


73

Machine Mistracks at All Speeds in Both Directions Diagnostic


Procedure
( 1 ) Incorrect Track Sag Adjustment

Action:

Check track sag. See Check and Adjust Track Sag . (Operator′s Manual.)

Is track sag within specification?

Result:

YES:Go to Pilot Control Valve Malfunction.

NO:Adjust track sag.

( 2 ) Pilot Control Valve Malfunction

Action:

Check control valve spool actuating pilot pressure. See Control Valve Spool Actuating Pilot Pressure Test . (Group 9025-25.)

Does control valve spool actuating pilot pressure meet specification?

Result:

YES:Go to Travel Motor Crossover Relief Valve.

NO:Inspect and repair or replace pilot control valve. See Pilot Valve (Left and Right) Disassemble and Assemble and see Travel
Pilot Valve Disassemble and Assemble . (Group 3360.)

( 3 ) Travel Motor Crossover Relief Valve

Action:

Inspect travel motor crossover relief valves. See Travel Motor Crossover Relief Valve Test and Adjustment . (Group 9025-25.)

Are travel motor crossover relief valves OK?

Result:

YES:Go to Servo Piston Shuttle Valve Leakage.

NO:Repair or replace travel motor crossover relief valve. See Park Brake Valve Disassemble and Assemble . (Group 0260.)

( 4 ) Servo Piston Shuttle Valve Leakage

Action:

Inspect servo piston shuttle valve. See Travel Motor and Park Brake Disassemble and Assemble . (Group 0260.)

Does shuttle valve operate correctly?

Result:

YES:Go to Travel Motor Leakage.

NO:Repair or replace servo piston shuttle valve.

<- Go to Section TOC Section 9025 page 220 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

( 5 ) Travel Motor Leakage

Action:

Check tracking while descending a hill. If tracking is within specification when descending a hill, but not when on the level or
going up hill, travel motor leakage is indicated. See Travel System Tracking Check . (Group 9005-10.)

If tracking does not meet specification, check travel motor leakage. See Travel Motor Leakage Test . (Group 9025-25.)

Does tracking and motor leakage meet specification?

Result:

YES:Go to Center Joint Leakage.

NO:If travel motor leakage does not meet specification, repair or replace travel motor. See Travel Motor and Park Brake
Disassemble and Assemble . (Group 0260.)

( 6 ) Center Joint Leakage

Action:

Inspect center joint for leakage. See Center Joint Air Test . (Group 0260.)

Is center joint OK?

Result:

YES:Go to Pump 1 or Pump 2 Regulator Malfunction.

NO:Repair or replace center joint. See Center Joint Disassemble and Assemble . (Group 0260.)

( 7 ) Pump 1 or Pump 2 Regulator Malfunction

Action:

Check pump 1 or pump 2 regulator. See Pump Regulator Test and Adjustment—Minimum Flow and see Pump Regulator Test
and Adjustment—Maximum Flow . (Group 9025-25.)

Does pump 1 or pump 2 regulator meet specification?

Result:

YES:Diagnostic checkout complete.

NO:Repair or replace pump 1 or pump 2 regulator. See Pump 1 and 2 Regulator Disassemble and Assemble . (Group 3360.)

<- Go to Section TOC Section 9025 page 221 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Slow Travel Speed or Low Power


73

Slow Travel Speed or Low Power Diagnostic Procedure


( 1 ) Incorrect Track Sag Adjustment

Action:

Check track sag. See Check and Adjust Track Sag . (Operator′s Manual.)

Is track sag within specification?

Result:

YES:Go to Travel Motor Crossover Relief Valve Malfunction.

NO:Adjust track sag.

( 2 ) Travel Motor Crossover Relief Valve Malfunction

Action:

Inspect travel motor crossover relief valve. See Travel Motor Crossover Relief Valve Test and Adjustment . (Group 9025-25.)

Is travel motor crossover relief valve OK?

Result:

YES:Go to Travel Park Brake Not Releasing.

NO:Repair or replace travel motor crossover relief valve. See Park Brake Valve Disassemble and Assemble . (Group 0260.)

( 3 ) Travel Park Brake Not Releasing

Action:

Inspect travel park brake. See Travel Motor and Park Brake Disassemble and Assemble . (Group 0260.)

Is travel park brake OK?

Result:

YES:Go to Travel Motor Leakage.

NO:Repair or replace travel park brake.

( 4 ) Travel Motor Leakage

Action:

Inspect travel motor for leakage. See Travel Motor Leakage Test . (Group 9025-25.)

Does travel motor meet specification?

Result:

YES:Go to Center Joint Leakage.

NO:Repair or replace travel motor. See Travel Motor and Park Brake Disassemble and Assemble . (Group 0260.)

( 5 ) Center Joint Leakage

<- Go to Section TOC Section 9025 page 222 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Action:

Inspect center joint for leakage. See Center Joint Air Test . (Group 0260.)

Is center joint OK?

Result:

YES:Go to Worn Pump.

NO:Repair or replace center joint. See Center Joint Disassemble and Assemble . (Group 0260.)

( 6 ) Worn Pump

Action:

Slow travel cycle times may indicate worn pump. Check travel cycle times. See Cycle Times Check . (Group 9005-10.)

If travel cycle times do not meet specification, check pump flow. See Pump Flow Test . (Group 9025-25.)

Do travel cycle times and pump flow meet specification?

Result:

YES:Go to Engine Performance Low.

NO:Repair or replace pump. See Pump 1 and 2 Remove and Install . (Group 3360.)

( 7 ) Engine Performance Low

Action:

Check engine speed and power mode setting. See Engine Speed Control System Operation . (Group 9010-05.)

Does engine speed meet specification?

Result:

YES:Diagnostic checkout complete.

NO:Select desired engine speed and power mode.

<- Go to Section TOC Section 9025 page 223 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Combined Travel and Dig Functions Slow or No Power


73

Combined Travel and Dig Functions Slow or No Power Diagnostic


Procedure
( 1 ) Travel Flow Combiner Valve Circuit Malfunction

Action:

Inspect travel flow combiner pilot valve (SL) in pilot signal manifold for stuck spool. See Pilot Signal Manifold Disassemble and
Assemble . (Group 3360.)

Inspect travel flow combiner valve. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve (4-Spool)
Disassemble and Assemble . (Group 3360.)

Is travel flow combiner valve circuit OK?

Result:

YES:Go to Control Valve Stuck.

NO:Repair or replace travel flow combiner valve circuit components.

( 2 ) Control Valve Stuck

Action:

Inspect for stuck travel and boom valve spools in control valve. For component location, see Control Valve Operation . (Group
9025-05.)

Does travel and boom valve spools move freely?

Result:

YES:Diagnostic procedure complete.

NO:Repair or replace control valve components as necessary. See Control Valve (5-Spool) Disassemble and Assemble and see
Control Valve (4-Spool) Disassemble and Assemble . (Group 3360.)

<- Go to Section TOC Section 9025 page 224 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Travel is “Jerky”
73

Travel is “Jerky” Diagnostic Procedure


( 1 ) Incorrect Track Sag Adjustment

Action:

Check track sag. See Check and Adjust Track Sag . (Operator′s Manual.)

Is track sag within specification?

Result:

YES:Go to Roller Malfunction.

NO:Adjust track sag.

( 2 ) Roller Malfunction

Action:

Inspect rollers.

Is oil level to specification?

Result:

YES:Go to Travel Park Brake Leakage.

NO:Add oil as required.

( 3 ) Travel Park Brake Leakage

Action:

Inspect travel park brake. See Travel Motor and Park Brake Disassemble and Assemble . (Group 0260.)

Is travel park brake OK?

Result:

YES:Go to Mechanical Failure of Travel Motor or Gear Case.

NO:Repair or replace travel park brake.

( 4 ) Mechanical Failure of Travel Motor or Gear Case

Action:

Inspect travel motor and gear case for mechanical failure. See Travel Motor and Park Brake Disassemble and Assemble .
(Group 0260.) Also see Travel Gear Case Disassemble and Assemble . (Group 0250.)

Is travel motor and gear case OK?

Result:

YES:Go to Undercarriage Components Worn.

NO:Repair or replace travel motor or gear case.

( 5 ) Undercarriage Components Worn

<- Go to Section TOC Section 9025 page 225 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Action:

Inspect undercarriage components. See SP326VOL1 Undercarriage Appraisal Manual for 130G specifications.

Do undercarriage components meet specification?

Result:

YES:Diagnostic checkout complete.

NO:Repair or replace undercarriage components.

Machine Will Not Hold Back and Park Brakes Engage and Disengage When Traveling Down an Incline
73

Machine Will Not Hold Back and Park Brakes Engage and Disengage
When Traveling Down an Incline Diagnostic Procedure
( 1 ) Counterbalance Valve Spool Stuck

Action:

Inspect counterbalance valve. See Park Brake Valve Disassemble and Assemble . (Group 0260.)

Does counterbalance valve spool move freely?

Result:

YES:Diagnostic checkout complete.

NO:Repair or replace counterbalance valve.

Machine Will Not Turn Smoothly in One Direction or Park Brake Grabs
73

Machine Will Not Turn Smoothly in One Direction or Park Brake Grabs
Diagnostic Procedure
( 1 ) Counterbalance Valve Spool Stuck

Action:

Inspect counterbalance valve. See Park Brake Valve Disassemble and Assemble . (Group 0260.)

Does counterbalance valve spool move freely?

Result:

YES:Diagnostic checkout complete.

NO:Repair or replace counterbalance valve.

<- Go to Section TOC Section 9025 page 226 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Pump 1, Pump 2, and Pilot Pump Line Identification

Pump 1, Pump 2, and Pilot Pump Line Identification

LEGEND:
1 Pilot Pump Suction
2 Pilot Signal Manifold (port SB)-to-Pump 2 Regulator
3 Pump 2-to-Control Valve (5 spool)
4 Pilot Signal Manifold (port SA)-to-Pump 1 Regulator
5 Pump 1-to-Control Valve (4 spool)
6 Pilot Filter-to-Return Manifold
7 Pilot Filter-to-Solenoid Valve Manifold (port PD)
8 Pump 1 Attenuator
9 Pump 1, Pump 2 Suction
10 Pilot Pump-to-Pilot Filter
11 Pilot Filter-to-Pump 2 Regulator
12 Pump 2 Attenuator
15 Pump 1 (4-spool)

<- Go to Section TOC Section 9025 page 227 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

16 Pump 2 (5-spool)
17 Regulator Drain Hose to Hydraulic Oil Tank
28 Pilot Pump
29 Pilot Filter and Bypass Valve

<- Go to Section TOC Section 9025 page 228 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Control Valve Line Identification

Control Valve Line Identification—5-Spool Side

LEGEND:
2 Boom Down (pilot)
4 Arm In (pilot)
6 Swing Right (pilot)
7 Bucket Curl (pilot)
10 Left Travel Reverse (pilot)
12 Right Travel Reverse (pilot)
31 To Hydraulic Oil Tank
36 To Hydraulic Oil Cooler
43 From Arm In Flow Rate Pilot Valve (port SE)
51 From Swing Device
52A To Swing Motor (swing left)
52B To Swing Motor (swing right)
63A To Center Joint (left travel forward)

<- Go to Section TOC Section 9025 page 229 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

63B To Center Joint (left travel reverse)


73 4-Spool Control Valve
74 5-Spool Control Valve
127A To Arm Cylinder (rod end)
127B To Arm Cylinder (head end)
144 To Blade Control Valve
155 To Shuttle Valve
157 Auxiliary Function (2 used)
B31 Arm In Pressure Sensor
DE To Solenoid Valve Manifold Port DE
DN To Solenoid Valve Manifold Port DN
DY To Solenoid Valve Manifold Port DY (2 used)
SC To Solenoid Valve Manifold Port SC
SG To Solenoid Valve Manifold Port SG

Control Valve Line Identification—4-Spool Side

LEGEND:
1 Boom Up (pilot)
<- Go to Section TOC Section 9025 page 230 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

3 Arm Out (pilot)


5 Swing Left (pilot)
8 Bucket Dump (pilot)
9 Left Travel Forward (pilot)
11 Right Travel Forward (pilot)
15 From Hydraulic Pump 1
16 From Hydraulic Pump 2
31 To Hydraulic Oil Tank
46 From Bucket Flow Rate Pilot Valve (port SK)
61A To Center Joint (right travel forward)
61B To Center Joint (right travel reverse)
73 4-Spool Control Valve
74 5-Spool Control Valve
83 To Boom Flow Rate Control Valve
87 From Boom Lower Meter-In Cut Valve
125A To Boom Cylinder (head end)
125B To Boom Cylinder (rod end)
126A To Bucket Cylinder (head end)
126B To Bucket Cylinder (rod end)
145 From Travel Flow Combiner Shuttle Valve
155 From Shuttle Valve
B30 Boom Up Pressure Sensor
DD To Solenoid Valve Manifold Port DD
DK To Solenoid Valve Manifold Port DK
DN To Solenoid Valve Manifold Port DN
DZ To Solenoid Valve Manifold Port DZ
SF To Solenoid Valve Manifold Port SF
SI To Solenoid Valve Manifold Port SI

<- Go to Section TOC Section 9025 page 231 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Swing Motor Line Identification

Swing Motor Line Identification

LEGEND:
1 From Control Valve Swing Left
2 From Control Valve Swing Right
3 To Hydraulic Oil Tank Return Manifold
4 To Control Valve
5 From Pilot Signal Manifold (port SH)
6 Case Drain Line
B32 Front Attachment Pressure Sensor

<- Go to Section TOC Section 9025 page 232 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern

Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern

<- Go to Section TOC Section 9025 page 233 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

LEGEND:
1 Port 1
2 Port 2
3 Port 3
4 Port 4
5 Pilot Control Shutoff Valve
6 From Solenoid Valve Manifold (port PE)
39 Left Pilot Control Valve
40 Right Pilot Control Valve
41 Pilot Signal Manifold
A Port A
A1 To Travel Pilot Controller
A2 Port A2
A3 Port A3
A4 Port A4
B Port B
C Port C
D Port D
E Port E
F Port F
G Port G
H Port H
P Port P
PI Port PI
T Port T
T1 From Travel Pilot Controller
T2 Port T2
T3 Port T3

Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern

Excavator Pattern

Pilot Signal Manifold Ports


Functions Pilot Control Valve Ports
Pilot Control Valve Side Control Valve Side

Bucket Dump 1 H 8

Boom Down 2 B 2
Right Pilot Lever
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 Pilot Lever
Arm In 4 D 4

P Pilot Shutoff Valve A3

T Pilot Shutoff Valve T3

NOTE: Letters and numbers are located on housings next to ports.

<- Go to Section TOC Section 9025 page 234 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern

Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern

<- Go to Section TOC Section 9025 page 235 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

LEGEND:
1 Port 1
2 Port 2
3 Port 3
4 Port 4
5 Pilot Control Shutoff Valve
6 From Solenoid Valve Manifold (port PE)
39 Left Pilot Control Valve
40 Right Pilot Control Valve
41 Pilot Signal Manifold
A Port A
A1 To Travel Pilot Controller
A2 Port A2
A3 Port A3
A4 Port A4
B Port B
C Port C
D Port D
E Port E
F Port F
G Port G
H Port H
P Port P
PI Port PI
T Port T
T1 From Travel Pilot Controller
T2 Port T2
T3 Port T3

Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern

Backhoe Pattern

Pilot Signal Manifold Ports


Functions Pilot Control Valve Ports
Pilot Control Valve Side Control Valve Side

Bucket Dump 1 H 8

Arm Out 2 C 3
Right Pilot Lever
Bucket Curl 3 G 7

Arm In 4 D 4

P Pilot Shutoff Valve A2

T Pilot Shutoff Valve T2

Swing Right 1 F 6

Boom Down 2 B 2

Swing Left 3 E 5
Left Pilot Lever
Boom Up 4 A 1

P Pilot Shutoff Valve A3

T Pilot Shutoff Valve T3

NOTE: Letters and numbers are located on housings next to ports.

<- Go to Section TOC Section 9025 page 236 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Pilot Signal Manifold-to-Control Valve Line Connection

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

<- Go to Section TOC Section 9025 page 237 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

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
41 Pilot Signal Manifold
73 Front Control Valve (4-spool)
74 Rear Control Valve (5-spool)

Pilot Signal Manifold-to-Control Valve Line Connection—Bottom

<- Go to Section TOC Section 9025 page 238 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

LEGEND:
1 Port 1 to Boom Up Pilot Cap
3 Port 3 to Arm Out Pilot Cap
5 Port 5 to Swing Left Pilot Cap
8 Port 8 to Bucket Dump Pilot Cap
9 Port 9 to Left Travel Forward Pilot Cap
11 Port 11 to Right Travel Forward Pilot Cap
41 Pilot Signal Manifold
73 Front Control Valve (4-spool)
74 Rear Control Valve (5-spool)
B33 Swing Pressure Sensor
B34 Travel Pressure Sensor

<- Go to Section TOC Section 9025 page 239 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Travel System Component Location

Travel System Component Location

LEGEND:
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
28 Pilot Pump
31 Hydraulic Oil Tank
38 Travel Pilot Control Valve
41 Pilot Signal Manifold

<- Go to Section TOC Section 9025 page 240 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

60 Right Travel Device


62 Left Travel Device
72 Center Joint
75 Right Travel Spool
110 Left Travel Spool
Y10 Pilot Shutoff Solenoid

<- Go to Section TOC Section 9025 page 241 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Travel Hydraulic System Line Connection

Travel Hydraulic System Line Connection

<- Go to Section TOC Section 9025 page 242 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

LEGEND:
9 Left Travel Forward Port (pilot side)
10 Left Travel Reverse Port (pilot side)
11 Right Travel Forward Port (pilot side)
12 Right Travel Reverse Port (pilot side)
37 Solenoid Valve Manifold
38 Travel Pilot Control Valve
41 Pilot Signal Manifold
60 Right Travel Device
62 Left Travel Device
72 Center Joint
73 Right Control Valve (4-spool)
74 Left Control Valve (5-spool)
75 Right Travel Spool (4-spool)
110 Left Travel Spool (5-spool)
160 Left Travel Forward
161 Right Travel Forward
162 Left Travel Reverse
163 Right Travel Reverse
164 Return Line to Hydraulic Oil Tank
I Left Travel Forward Port (control side)
J Left Travel Reverse Port (control side)
K Right Travel Forward Port (control side)
L Right Travel Reverse Port (control side)
PI Pilot Shutoff Solenoid Valve Port
Y10 Pilot Shutoff Solenoid Valve
Y24 Power Dig Solenoid Valve (port SG)

<- Go to Section TOC Section 9025 page 243 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Blade Hydraulic System Component Location

Blade Hydraulic System Component Location

<- Go to Section TOC Section 9025 page 244 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

LEGEND:
1 Center Joint-to-Blade Cylinder Rod End Hose (2 used)
2 Center Joint-to-Blade Cylinder Head End Hose (2 used)
3 Blade Pilot Control Valve-to-Blade Signal Shuttle Valve Hose
4 Blade Pilot Control Valve-to-Blade Signal Shuttle Valve Hose
5 Blade Pilot Control Valve-to-Pilot Shutoff Valve Hose
6 Blade Pilot Control Valve-to-Pilot Shutoff Valve Hose
7 Blade Control Valve-to-Control Valve (5 spool) Hose
8 Blade Control Valve-to-Blade Signal Shuttle Valve Hose
9 Blade Control Valve-to-Blade Signal Shuttle Valve Hose
10 Blade Control Valve-to-Hydraulic Oil Tank Return Manifold Hose
11 Blade Control Valve-to-Hydraulic Oil Tank Return Manifold Hose
12 Blade Control Valve-to-Center Joint Hose
13 Blade Control Valve-to-Blade Main Relief Valve Hose
14 Blade Control Valve-to-Center Joint Hose
15 Blade Signal Shuttle Valve-to-Pilot Signal Manifold Hose
16 Blade Control Valve-to-Swing Parking Brake Shuttle Valve Hose
17 Solenoid Valve Manifold-to-Pilot Shutoff Valve Hose
18 Pump 1 Regulator Valve-to-Pilot Signal Manifold Hose
19 Hydraulic Oil Return-to-Hydraulic Oil Tank Hose
20 Swing Parking Brake Shuttle Valve-to-Swing Park Brake Hose
21 Pilot Pump-to-Solenoid Valve Manifold Hose
22 Blade Pump-to-Blade Main Relief Valve Hose
23 Blade Main Relief Valve-to-Control Valve Hose
28 Pilot Pump
31 Hydraulic Oil Tank
37 Solenoid Valve Manifold
40 Blade Pump Supply Hose
41 Pilot Signal Manifold
52 Swing Motor
72 Center Joint
74 Control Valve (5 spool)
132 Fan Drive Pump
143 Blade Cylinder (2 used)
144 Blade Control Valve
146 Swing Parking Brake Shuttle Valve
148 Blade Signal Shuttle Valve
150 Blade Pilot Control Valve
151 Blade Main Relief Valve
152 Blade Pump
153 Pilot Shutoff Valve

<- Go to Section TOC Section 9025 page 245 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Auxiliary Attachment Schematic

<- Go to Section TOC Section 9025 page 246 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Auxiliary Pilot Control Valve Schematic (auxiliary spool shown shifted)

<- Go to Section TOC Section 9025 page 247 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

LEGEND:
28 Pilot Pump
41 Pilot Signal Manifold
45 Swing Park Brake Release Pilot Valve (port SH)
47 Pump 2 Flow Rate Pilot Valve (port SB)
56 To Swing Park Brake
73 4-Spool Control Valve
74 5-Spool Control Valve
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
90 Arm 2 Spool
93 Bypass Shutoff Valve
95 Swing Spool
97 Arm 1 Spool
104 Boom 2 Spool
107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
110 Left Travel Spool
117 Main Relief and Power Dig Valve
118 Auxiliary Flow Combiner Valve
153 Pilot Shutoff Valve
179 To Pump 2 Flow Rate Solenoid Valve
604 Return Oil
609 Pilot Oil
B60 Attachment Pressure Sensor

<- Go to Section TOC Section 9025 page 248 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Auxiliary Solenoid Valve Operation of Control Valve (auxiliary spool shown shifted)

<- Go to Section TOC Section 9025 page 249 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

LEGEND:
28 Pilot Pump
41 Pilot Signal Manifold
45 Swing Park Brake Release Pilot Valve (port SH)
47 Pump 2 Flow Rate Pilot Valve (port SB)
56 To Swing Park Brake
73 4-Spool Control Valve
74 5-Spool Control Valve
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
90 Arm 2 Spool
93 Bypass Shutoff Valve
95 Swing Spool
97 Arm 1 Spool
104 Boom 2 Spool
107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
110 Left Travel Spool
117 Main Relief and Power Dig Valve
118 Auxiliary Flow Combiner Valve
153 Pilot Shutoff Valve
172 Auxiliary Soleniod Valve
173 Auxiliary Pressure Reducing Valve
179 To Pump 2 Flow Rate Solenoid Valve
604 Return Oil
609 Pilot Oil
B60 Attachment Pressure Sensor

<- Go to Section TOC Section 9025 page 250 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Auxiliary High Flow Line Kit Schematic (auxiliary spool shifted)

<- Go to Section TOC Section 9025 page 251 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

LEGEND:
13 Auxiliary (pilot)
14 Auxiliary (pilot)
15 Pump 1
16 Pump 2
28 Pilot Pump
37 Solenoid Valve Manifold
73 4-Spool Control Valve
74 5-Spool Control Valve
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
90 Arm 2 Spool
93 Bypass Shutoff Valve
95 Swing Spool
97 Arm 1 Spool
104 Boom 2 Spool
107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
110 Left Travel Spool
117 Main Relief and Power Dig Valve
118 Auxiliary Flow Combiner Valve
120 Travel Flow Combiner Valve
174 Auxiliary Attachment
175 Selector Valve Solenoid Valve
176 Selector Valve
600 High-Pressure Oil
604 Return Oil
609 Pilot Oil
Y40 Selector Valve Solenoid Valve

<- Go to Section TOC Section 9025 page 252 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Two Pump Combined Flow Kit Schematic (auxiliary function active, 2-speed activation solenoid valve [Y43] energized)

<- Go to Section TOC Section 9025 page 253 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

LEGEND:
15 Pump 1
16 Pump 2
28 Pilot Pump
41 Pilot Signal Manifold
45 Swing Park Brake Release Pilot Valve (port SH)
47 Pump 2 Flow Rate Pilot Valve (port SB)
48 Pump 1 Flow Rate Pilot Valve (port SA)
56 To Swing Park Brake
73 4-Spool Control Valve
74 5-Spool Control Valve
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
90 Arm 2 Spool
93 Bypass Shutoff Valve
95 Swing Spool
97 Arm 1 Spool
104 Boom 2 Spool
107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
110 Left Travel Spool
117 Main Relief and Power Dig Valve
118 Auxilairy Flow Combiner Valve
119 Check Valve—Flow Combiner Valve Circuit
120 Travel Flow Combiner Valve
155 From Shuttle Valve
170 Auxiliary Shuttle Valve
177 Flow Rate Select Solenoid Valve
178 Flow Rate Select Reducing Valve
179 To Pump 2 Flow Rate Solenoid Valve
180 To Torque Control Solenoid Valve
600 High-Pressure Oil
604 Return Oil
609 Pilot Oil
B60 Attachment Pressure Sensor
B61 Arm Out Pressure Sensor
DP To Solenoid Valve Manifold Port DP
DY To Solenoid Valve Manifold Port DY
Y43 2-Speed Activation Solenoid Valve
Y44 Flow Rate Adjustment Solenoid Valve

<- Go to Section TOC Section 9025 page 254 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Auxiliary System Line Connections

<- Go to Section TOC Section 9025 page 255 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

High Flow Line Connections

<- Go to Section TOC Section 9025 page 256 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

LEGEND:
28 Pilot Pump
29 Pilot Filter and Bypass Valve
31 Hydraulic Oil Tank
37 Solenoid Valve Manifold
73 4-Spool Control Valve
74 5-Spool Control Valve
174 Auxiliary Attachment
175 Selector Valve Solenoid Valve
176 Selector Valve
Y40 Selector Valve Solenoid Valve

<- Go to Section TOC Section 9025 page 257 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Two Pump Combined Flow Kit Line Connections

<- Go to Section TOC Section 9025 page 258 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

LEGEND:
28 Pilot Pump
29 Pilot Filter and Bypass Valve
31 Hydraulic Oil Tank
37 Solenoid Valve Manifold
41 Pilot Signal Manifold
73 4-Spool Control Valve
74 5-Spool Control Valve
155 Shuttle Valve
170 Auxiliary Shuttle Valve
177 Flow Rate Select Solenoid Valve
178 Flow Rate Select Reducing Valve

<- Go to Section TOC Section 9025 page 259 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Hydraulic System Schematic

<- Go to Section TOC Section 9025 page 260 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Pilot Signal Manifold—Excavator Pattern

<- Go to Section TOC Section 9025 page 261 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

LEGEND:
1 Boom Up (pilot)
2 Boom Down (pilot)
3 Arm Out (pilot)
4 Arm In (pilot)
5 Swing Left (pilot) (5-spool)
6 Swing Right (pilot) (5-spool)
7 Bucket Curl (pilot)
8 Bucket Dump (pilot)
9 Left Travel Forward (pilot)
10 Left Travel Reverse (pilot)
11 Right Travel Forward (pilot)
12 Right Travel Reverse (pilot)
17 To Pump 1 Regulator
18 To Pump 2 Regulator
28 Pilot Pump
29 Pilot Filter and Bypass Valve
30 Pilot Pressure Regulating Valve
37 Solenoid Valve Manifold
38 Travel Pilot Control Valve
39 Left Pilot Control Valve
40 Right Pilot Control Valve
41 Pilot Signal Manifold
42 Boom Down Shockless Valve
43 Arm 1 Flow Rate Pilot Valve (port SE)
44 Travel Flow Combiner Pilot Valve (port SL)
45 Swing Park Brake Release Pilot Valve (port SH)
46 Bucket Flow Rate Pilot Valve (port SK)
47 Pump 2 Flow Rate Pilot Valve (port SB)
48 Pump 1 Flow Rate Pilot Valve (port SA)
49 Filter Screen (17 used)
50 Shuttle Valve (17 used)
56 From Swing Park Brake
77 To Bucket Flow Rate Control Valve (valve and poppet)
83 From Boom Flow Rate Control Valve (valve and poppet)
84 From Dig Regenerative Valve (2 used)
91 From Arm 2 Flow Rate Control Valve (valve and poppet) (2 used)
93 To Bypass Shutoff Valve
94 From Arm Regenerative Cut Valve
98 To Arm 1 Flow Rate Control Valve (valve and poppet)
108 From Auxiliary Flow Rate Control Valve (valve and poppet)
118 From Auxiliary Function Flow Combiner Valve
120 To Travel Flow Combiner Valve
129 Orifice
145 Travel Flow Combiner Shuttle Valve
146 Swing Parking Brake Shuttle Valve
147 Blade Signal Selector Valve
148 Blade Signal Shuttle Valve
150 Blade Pilot Control Valve
153 Pilot Shutoff Valve
155 Shuttle Valve
200 From Main Relief and Power Dig Valve and Center Joint
201 To Pump 1 Control Pressure Sensor and Pump 1 Regulator
202 Blade Down (pilot)
203 Blade Up (pilot)
204 From Boom Lower Meter-In Cut Valve and Arm 1 Spool
604 Return Oil
609 Pilot Oil
B32 Front Attachment Pressure Sensor
B33 Swing Pressure Sensor
B34 Travel Pressure Sensor
Y10 Pilot Shutoff Solenoid
Y22 Dig Regenerative Solenoid (SF)
Y23 Arm Regenerative Solenoid (SC)
Y24 Power Dig Solenoid (SG)
Y27 Arm 2 Flow Control Solenoid (SI)

<- Go to Section TOC Section 9025 page 262 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Pilot Signal Manifold—Backhoe Pattern

<- Go to Section TOC Section 9025 page 263 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

LEGEND:
1 Boom Up (pilot)
2 Boom Down (pilot)
3 Arm Out (pilot)
4 Arm In (pilot)
5 Swing Left (pilot) (5-spool)
6 Swing Right (pilot) (5-spool)
7 Bucket Curl (pilot)
8 Bucket Dump (pilot)
9 Left Travel Forward (pilot)
10 Left Travel Reverse (pilot)
11 Right Travel Forward (pilot)
12 Right Travel Reverse (pilot)
17 To Pump 1 Regulator
18 To Pump 2 Regulator
28 Pilot Pump
29 Pilot Filter and Bypass Valve
30 Pilot Pressure Regulating Valve
37 Solenoid Valve Manifold
38 Travel Pilot Control Valve
39 Left Pilot Control Valve
40 Right Pilot Control Valve
41 Pilot Signal Manifold
42 Boom Down Shockless Valve
43 Arm 1 Flow Rate Pilot Valve (port SE)
44 Travel Flow Combiner Pilot Valve (port SL)
45 Swing Park Brake Release Pilot Valve (port SH)
46 Bucket Flow Rate Pilot Valve (port SK)
47 Pump 2 Flow Rate Pilot Valve (port SB)
48 Pump 1 Flow Rate Pilot Valve (port SA)
49 Filter Screen (17 used)
50 Shuttle Valve (17 used)
56 From Swing Park Brake
77 To Bucket Flow Rate Control Valve (valve and poppet)
83 From Boom Flow Rate Control Valve (valve and poppet)
84 From Dig Regenerative Valve (2 used)
91 From Arm 2 Flow Rate Control Valve (valve and poppet) (2 used)
93 To Bypass Shutoff Valve
94 From Arm Regenerative Cut Valve
98 To Arm 1 Flow Rate Control Valve (valve and poppet)
108 From Auxiliary Flow Rate Control Valve (valve and poppet)
118 From Auxiliary Function Flow Combiner Valve
120 To Travel Flow Combiner Valve
129 Orifice
145 Travel Flow Combiner Shuttle Valve
146 Swing Parking Brake Shuttle Valve
147 Blade Signal Selector Valve
148 Blade Signal Shuttle Valve
150 Blade Pilot Control Valve
153 Pilot Shutoff Valve
155 Shuttle Valve
200 From Main Relief and Power Dig Valve and Center Joint
201 To Pump 1 Control Pressure Sensor and Pump 1 Regulator
202 Blade Down (pilot)
203 Blade Up (pilot)
204 From Boom Lower Meter-In Cut Valve and Arm 1 Spool
604 Return Oil
609 Pilot Oil
B32 Front Attachment Pressure Sensor
B33 Swing Pressure Sensor
B34 Travel Pressure Sensor
Y10 Pilot Shutoff Solenoid
Y22 Dig Regenerative Solenoid (SF)
Y23 Arm Regenerative Solenoid (SC)
Y24 Power Dig Solenoid (SG)
Y27 Arm 2 Flow Control Solenoid (SI)

<- Go to Section TOC Section 9025 page 264 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Control Valve Schematic (S.N. —040159)

<- Go to Section TOC Section 9025 page 265 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

LEGEND:
1 Boom Up (pilot)
2 Boom Down (pilot)
3 Arm Out (pilot)
4 Arm In (pilot)
5 Swing Left (pilot) (5-spool)
6 Swing Right (pilot) (5-spool)
7 Bucket Curl (pilot)
8 Bucket Dump (pilot)
9 Left Travel Forward (pilot)
10 Left Travel Reverse (pilot)
11 Right Travel Forward (pilot)
12 Right Travel Reverse (pilot)
13 Plug—Auxiliary (pilot)
14 Plug—Auxiliary (pilot)
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
36 Hydraulic Oil Cooler
43 Arm 1 Flow Rate Pilot Valve (port SE)
46 Bucket Flow Rate Pilot Valve (port SK)
51 From Swing Device
52 Swing Motor
61 Right Travel Motor
63 Left Travel Motor
72 From Center Joint
73 Right Control Valve (4-spool)
74 Left Control Valve (5-spool)
75 Right Travel Spool
76 Bucket Spool
77 Bucket Flow Rate Control Valve (valve and poppet)
78 Bucket Regenerative Valve
79 Bucket Dump Circuit Relief and Anticavitation Valve
80 Bucket Curl Circuit Relief and Anticavitation Valve
81 Boom 1 Spool
82 Boom Regeneration Valve
83 Boom Flow Rate Control Valve (valve and poppet)
84 Dig Regenerative Valve
85 Boom Reduced Leakage Valve (valve and check valve)
86 Orifice
87 Boom Lower Meter-In Cut Valve
88 Boom Up Circuit Relief and Anticavitation Valve
89 Boom Down Circuit Relief and Anticavitation Valve
90 Arm 2 Spool
91 Arm 2 Flow Rate Control Valve (valve and poppet)
92 Check Valve (lift check)—Arm 2 Neutral Passage
93 Bypass Shutoff Valve
94 Arm Regenerative Valve
95 Swing Spool
96 Check Valve (lift check)—Swing Neutral Passage
97 Arm 1 Spool
98 Arm 1 Flow Rate Control Valve (valve and poppet)
100 Check Valve (lift check)—Dig Regenerative Circuit
101 Arm Reduced Leakage Valve (valve and poppet)
102 Arm In Circuit Relief and Anticavitation Valve
103 Arm Out Circuit Relief and Anticavitation Valve
104 Boom 2 Spool
105 Check Valve (lift check)—Boom 2 Power Circuit
107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
109 Plug (2 used)
110 Left Travel Spool
111 Check Valve (lift check)—Left Travel Neutral Passage
112 Check Valve (lift check)—Left Travel Power Passage
113 Orifice—Left Travel Power Passage
114 Orifice—Air Bleed (9 used)
115 Main Relief Valve Isolation Check Valve—5-Spool
116 Main Relief Valve Isolation Check Valve—4-Spool

<- Go to Section TOC Section 9025 page 266 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

117 Main Relief and Power Dig Valve


118 Auxiliary Function Flow Combiner Valve
119 Check Valve—Flow Combiner Valve Circuit
120 Travel Flow Combiner Valve
121 Check Valve—Travel Flow Combiner Valve Circuit
122 Check Valve (lift check)—Bucket
123 Orifice—Bucket Power Circuit
124 Oil Cooler Bypass Valve
125 Boom Cylinder (2 used)
126 Bucket Cylinder
127 Arm Cylinder
128 Check Valve
140 Blade Spool
141 Blade Up Circuit Relief and Anticavitation Valve
142 Blade Down Circuit Relief and Anticavitation Valve
143 Blade Cylinder (2 used)
144 Blade Control Valve
145 From Travel Flow Combiner Shuttle Valve
149 Arm Regenerative Cut Valve
151 Blade Main Relief Valve
152 Blade Pump
155A From Shuttle Valve
155B To Shuttle Valve
166 Bucket Regenerative Cut Valve
202 Blade Down (pilot)
203 Blade Up (pilot)
600 High Pressure Oil
604 Return Oil
606 Trapped Oil
B30 Boom Up Pressure Sensor
B31 Arm In Pressure Sensor
DD To Solenoid Valve Manifold Port DD
DE To Solenoid Valve Manifold Port DE
DK To Solenoid Valve Manifold Port DK
DN To Solenoid Valve Manifold Port DN
DY To Solenoid Valve Manifold Port DY
DZ To Solenoid Valve Manifold Port DZ
SC To Solenoid Valve Manifold Port SC
SF To Solenoid Valve Manifold Port SF
SG To Solenoid Valve Manifold Port SG
SI To Solenoid Valve Manifold Port SI

<- Go to Section TOC Section 9025 page 267 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Control Valve Schematic (S.N. 040160—)

<- Go to Section TOC Section 9025 page 268 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

LEGEND:
1 Boom Up (pilot)
2 Boom Down (pilot)
3 Arm Out (pilot)
4 Arm In (pilot)
5 Swing Left (pilot) (5-spool)
6 Swing Right (pilot) (5-spool)
7 Bucket Curl (pilot)
8 Bucket Dump (pilot)
9 Left Travel Forward (pilot)
10 Left Travel Reverse (pilot)
11 Right Travel Forward (pilot)
12 Right Travel Reverse (pilot)
13 Plug—Auxiliary (pilot)
14 Plug—Auxiliary (pilot)
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
36 Hydraulic Oil Cooler
43 Arm 1 Flow Rate Pilot Valve (port SE)
46 Bucket Flow Rate Pilot Valve (port SK)
51 From Swing Device
52 Swing Motor
61 Right Travel Motor
63 Left Travel Motor
72 From Center Joint
73 Right Control Valve (4-spool)
74 Left Control Valve (5-spool)
75 Right Travel Spool
76 Bucket Spool
77 Bucket Flow Rate Control Valve (valve and poppet)
78 Bucket Regenerative Valve
79 Bucket Dump Circuit Relief and Anticavitation Valve
80 Bucket Curl Circuit Relief and Anticavitation Valve
81 Boom 1 Spool
82 Boom Regeneration Valve
83 Boom Flow Rate Control Valve (valve and poppet)
84 Dig Regenerative Valve
85 Boom Reduced Leakage Valve (valve and check valve)
86 Orifice
87 Boom Lower Meter-In Cut Valve
88 Boom Up Circuit Relief and Anticavitation Valve
89 Boom Down Circuit Relief and Anticavitation Valve
90 Arm 2 Spool
91 Arm 2 Flow Rate Control Valve (valve and poppet)
92 Check Valve (lift check)—Arm 2 Neutral Passage
93 Bypass Shutoff Valve
94 Arm Regenerative Valve
95 Swing Spool
96 Check Valve (lift check)—Swing Neutral Passage
97 Arm 1 Spool
98 Arm 1 Flow Rate Control Valve (valve and poppet)
100 Check Valve (lift check)—Dig Regenerative Circuit
101 Arm Reduced Leakage Valve (valve and poppet)
102 Arm In Circuit Relief and Anticavitation Valve
103 Arm Out Circuit Relief and Anticavitation Valve
104 Boom 2 Spool
105 Check Valve (lift check)—Boom 2 Power Circuit
107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
109 Plug (2 used)
110 Left Travel Spool
111 Check Valve (lift check)—Left Travel Neutral Passage
112 Check Valve (lift check)—Left Travel Power Passage
113 Orifice—Left Travel Power Passage
114 Orifice—Air Bleed (9 used)
115 Main Relief Valve Isolation Check Valve—5-Spool
116 Main Relief Valve Isolation Check Valve—4-Spool

<- Go to Section TOC Section 9025 page 269 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

117 Main Relief and Power Dig Valve


118 Auxiliary Function Flow Combiner Valve
119 Check Valve—Flow Combiner Valve Circuit
120 Travel Flow Combiner Valve
121 Check Valve—Travel Flow Combiner Valve Circuit
122 Check Valve (lift check)—Bucket
123 Orifice—Bucket Power Circuit
124 Oil Cooler Bypass Valve
125 Boom Cylinder (2 used)
126 Bucket Cylinder
127 Arm Cylinder
128 Check Valve
140 Blade Spool
141 Blade Up Circuit Relief and Anticavitation Valve
142 Blade Down Circuit Relief and Anticavitation Valve
143 Blade Cylinder (2 used)
144 Blade Control Valve
145 From Travel Flow Combiner Shuttle Valve
149 Arm Regenerative Cut Valve
151 Blade Main Relief Valve
152 Blade Pump
155A From Shuttle Valve
155B To Shuttle Valve
166 Bucket Regenerative Cut Valve
202 Blade Down (pilot)
203 Blade Up (pilot)
600 High Pressure Oil
604 Return Oil
606 Trapped Oil
B30 Boom Up Pressure Sensor
B31 Arm In Pressure Sensor
DD To Solenoid Valve Manifold Port DD
DE To Solenoid Valve Manifold Port DE
DK To Solenoid Valve Manifold Port DK
DN To Solenoid Valve Manifold Port DN
DY To Solenoid Valve Manifold Port DY
DZ To Solenoid Valve Manifold Port DZ
SC To Solenoid Valve Manifold Port SC
SF To Solenoid Valve Manifold Port SF
SG To Solenoid Valve Manifold Port SG
SI To Solenoid Valve Manifold Port SI

<- Go to Section TOC Section 9025 page 270 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Swing Motor Schematic

LEGEND:
51 Swing Device
52 Swing Motor
53 Swing Motor Make-Up Check Valve (2 used)
54 Swing Crossover Relief Valve (2 used)
55 Swing Damper Valve
56 Swing Park Brake
57 Orifice
58 Check Valve
59 Flow Control Valve
73 To Right Control Valve Return Passage
95A From Swing Spool—Right Swing
95B From Swing Spool—Left Swing
205 To Swing Parking Brake Shuttle Valve and Swing Park Brake Release Pilot Valve (port SH)
604 Return Oil

<- Go to Section TOC Section 9025 page 271 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Travel Motor Schematic

LEGEND:
60 Right Travel Device
61 Right Travel Motor
62 Left Travel Device
63 Left Travel Motor
64 Travel Park Brake (2 used)
65 Travel Speed Servo Piston (2 used)
66 Travel Speed Change Valve (2 used)
67 Shuttle Valve (2 used)
68 Travel Motor Crossover Relief Valve (4 used)
69 Check Valve (4 used)
70 Orifice (4 used)
71 Counterbalance Valve (2 used)
72 Center Joint
75A From Right Travel Spool—Forward
75B From Right Travel Spool—Reverse
<- Go to Section TOC Section 9025 page 272 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

110A From Left Travel Spool—Reverse


110B From Left Travel Spool—Forward
143 Blade Cylinder (2 used)
144A From Blade Control Valve (blade down)
144B From Blade Control Valve (blade up)
207 From Travel Speed Solenoid (SI) and Main Relief and Power Dig Valve (P1, P2)
604 Trapped Oil
606 Return Oil

<- Go to Section TOC Section 9025 page 273 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Hydraulic Pumps and Regulators

<- Go to Section TOC Section 9025 page 274 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

LEGEND:
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
17 Pump 1 Regulator
18 Pump 2 Regulator
27 Attenuator Hose (2 used)
28 Pilot Pump
29 Pilot Filter and Bypass Valve
30 Pilot Pressure Regulating Valve
31 Hydraulic Oil Tank
32 Return Filter
34 Filter Bypass
35 Suction Screen
36 Hydraulic Oil Cooler
37A To Solenoid Valve Manifold
37B From Solenoid Valve Manifold
41 From Pilot Signal Manifold
47 From Pump 2 Flow Rate Pilot Valve (port SB)
52 From Swing Motor
72 From Center Joint
73A To Right Control Valve (4-spool)
73B From Right Control Valve (4-spool)
73C From Right Control Valve (4-spool
74A To Left Control Valve (5-spool)
74B From Left Control Valve (5-spool)
124 Oil Cooler Bypass Valve
128 Check Valve
132 Fan Drive Pump
133 To Fan Drive Motor
144A From Blade Control Valve
144B From Blade Control Valve
151 From Blade Main Relief Valve
152 Blade Pump
153 From Pilot Shutoff Valve
206 To Blade Main Relief Valve and Blade Control Valve
208 From Pump 1 Flow Rate Pilot Valve (port SA)
600 High Pressure Oil
604 Return Oil
609 Pilot Oil
B35 Pump 1 Delivery Pressure Sensor
B36 Pump 1 Control Pressure Sensor
B37 Pump 2 Delivery Pressure Sensor
B38 Pump 2 Control Pressure Sensor
Y20 Pump 2 Flow Rate Limit Solenoid (SB)
Y21 Torque Control Solenoid (ST)

For more information on fan drive, See Fan Drive Hydraulic System Schematic . (Group 9025-15.)

<- Go to Section TOC Section 9025 page 275 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Hydraulic System Component Location

Hydraulic System Component Location

LEGEND:
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
28 Pilot Pump
29 Pilot Filter and Bypass Valve
30 Pilot Pressure Regulating Valve
31 Hydraulic Oil Tank
36 Hydraulic Oil Cooler
37 Solenoid Valve Manifold
38 Travel Pilot Control Valve
39 Left Pilot Control Valve
40 Right Pilot Control Valve
41 Pilot Signal Manifold
51 Swing Device

<- Go to Section TOC Section 9025 page 276 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

60 Right Travel Device


62 Left Travel Device
72 Center Joint
73 Front Control Valve (4-spool)
74 Rear Control Valve (5-spool)
125 Boom Cylinder (2 used)
126 Bucket Cylinder
127 Arm Cylinder
Y10 Pilot Shutoff Solenoid

<- Go to Section TOC Section 9025 page 277 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Hydraulic System Line Connections

Hydraulic System Line Connections

<- Go to Section TOC Section 9025 page 278 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

LEGEND:
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
28 Pilot Pump
29 Pilot Filter and Bypass Valve
30 Pilot Pressure Regulating Valve
31 Hydraulic Oil Tank
36 Hydraulic Oil Cooler
41 Pilot Signal Manifold
51 Swing Device
72 Center Joint
73 Right Control Valve (4-spool)
74 Left Control Valve (5-spool)
125 Boom Cylinder (2 used)
126 Bucket Cylinder
127 Arm Cylinder
SA Pump 1 Flow Rate Pilot Valve Port
SB Pump 2 Flow Rate Pilot Valve Port
SH Swing Park Brake Release Port

<- Go to Section TOC Section 9025 page 279 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Fan Drive System Component Location

Fan Drive Hydraulic System Component Location

<- Go to Section TOC Section 9025 page 280 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

LEGEND:
1 Case Drain Line (fan drive motor to hydraulic oil tank)
2 Supply Line (hydraulic oil tank to fan drive pump)
3 Supply Line (fan drive pump to fan drive motor)
4 Return Line (fan drive motor to hydraulic oil return manifold)
5 Hydraulic Oil Return Manifold
6 Return Line (hydraulic oil cooler to hydraulic oil return manifold)
31 Hydraulic Oil Tank
132 Fan Drive Pump
133 Fan Drive Motor
B53 Fan Speed Sensor
Y9 Reversing Fan Solenoid (if equipped)
Y5005 Variable Speed Fan Solenoid

<- Go to Section TOC Section 9025 page 281 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information

Fan Drive Hydraulic System Schematic

Fan Drive Hydraulic System Schematic

LEGEND:
31 Hydraulic Oil Tank
32 Return Filter
34 Filter Bypass
35 Suction Screen
132 Fan Drive Pump
133 Fan Drive Motor
134 Fan Speed Control Valve
600 High Pressure Oil
604 Return Oil
Y5005 Variable Speed Fan Solenoid

<- Go to Section TOC Section 9025 page 282 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Fan Drive Hydraulic System Schematic—Reversing (if equipped)

LEGEND:
31 Hydraulic Oil Tank
32 Return Filter
34 Filter Bypass
35 Suction Screen
132 Fan Drive Pump
133 Fan Drive Motor
135 Fan Speed and Reversing Control Valve (if equipped)
600 High Pressure Oil
604 Return Oil
Y9 Reversing Fan Solenoid
Y5005 Variable Speed Fan Solenoid

<- Go to Section TOC Section 9025 page 283 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Group 25 - Tests
JT05800 Digital Thermometer Installation
LEGEND:
A Temperature Probe
B Cable
C JT05800 Digital Thermometer

JT05800 Digital Thermometer

Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JT05800 Digital Thermometer

[1] - Fasten temperature probe (A) to a bare metal hydraulic line using a tie band.

Digital Thermometer

JT05800

To measure the temperature of hydraulic oil.

[2] - Wrap temperature probe and line with a shop towel.

<- Go to Section TOC Section 9025 page 284 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

JT02156A Digital Pressure and Temperature Analyzer Kit Installation

JT02156A Digital Pressure and Temperature Analyzer Kit

LEGEND:
A Digital Pressure and Temperature Analyzer
B 3400 kPa (35 bar) (500 psi) Transducer
34 000 kPa (350 bar) (5000 psi) Transducer
70 000 kPa (700 bar) (10 000 psi) Transducer

Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JT02156A Digital Pressure and Temperature Analyzer Kit

JT02158 Digital Pressure and Temperature Analyzer

JT02159 6 m (20 ft.) Cable with Couplers

JT02161 3400 kPa (35 bar) (500 psi) Transducer

JT02162 34 000 kPa (350 bar) (5000 psi) Transducer

JT05969 Thermo-Coupler

312883 Carry Case

JT02160 70 000 kPa (700 bar) (10 000 psi) Transducer (Optional, Order Separately)

Use the digital pressure and temperature analyzer (A) and transducers (B) in place of analog gauges and a separate
temperature reader.

Digital Pressure and Temperature Analyzer Kit

JT02156A

Kit contains the analyzer, cable, two transducers, thermo-coupler, and a carry case.

Digital Pressure and Temperature Analyzer

JT02158

To display digital readings for temperature and single, multiple, or differential hydraulic oil pressure. Also reads vacuum when
used with 500 psi transducer.

6 m (20 ft.) Cable with Couplers

JT02159

To connect tranducers to digital pressure and temperature analyzer.

3400 kPa (35 bar) (500 psi) Transducer

JT02161
<- Go to Section TOC Section 9025 page 285 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

To measure hydraulic oil pressure and vacuum.

34 000 kPa (350 bar) (5000 psi) Transducer

JT02162

To measure hydraulic oil pressure.

Thermo-Coupler

JT05969

To measure hydraulic oil temperature.

Carry Case

312883

Storage for analyzer and components.

70 000 kPa (700 bar) (10 000 psi) Transducer (Optional, Order Separately)

JT02160

To measure hydraulic oil pressure.

Transducers are temperature sensitive. Allow transducer to warm to system temperature. After transducer is warmed and no
pressure applied, push sensor zero button for one second to set the true zero point.

When using for different pressures, turn selector to OFF for two seconds and then to the pressure range. Readings are
inaccurate if proper range for transducer is not used.

<- Go to Section TOC Section 9025 page 286 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Hydraulic Oil Cleanup Procedure


Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JDG10712 Super Caddy

One Suction Hose 4.6 m (15 ft) x 25 mm (1.0 in.) I.D. 100R1 Hose with 1.0 in. M NPT Ends

One Discharge Hose 4.6 m (15 ft) x 19 mm (0.75 in.) I.D. 100R1 Hose with 0.75 in. M NPT Ends

3 Foot Suction Wand 25 mm (1.00 in.) O.D. (with angle cut tip)

3 Foot Discharge Wand 19 mm (0.75 in.) O.D.

This procedure is to be used on machines that have had hydraulic system repair without a catastrophic
component failure. Filter procedure must be done prior to starting machine after a component has been repaired
or replaced.

IMPORTANT:

Intermixing of oils can cause premature hydraulic component damage and oil contamination. Oil types
and filters must not be intermixed. Use filter element in same type oil to avoid intermixing of oils.

Avoid oil contamination. Oil contamination could result if Super Caddy is used in dusty or wet conditions.
Instrument cleanliness and clean work practices are critical when filtering or taking oil samples. Dust,
wind, and moisture, as well as contaminated sample pumps, bottles and tubing can affect results.

Super Caddy requires a 20 amp electric circuit. Use of electrical extension cord is not recommended.

[1] -
LEGEND:
1 Pressure Release Button
2 Cap Screw (6 used)
3 Hydraulic Oil Tank Cover

Hydraulic Oil Tank Pressure Relief Cover

Filter oil at 27°C (80°F) or above for best JDG10712 Super Caddy performance. Reduce flow rate to filter oil below 27°C (80°F).

[2] - Clean surrounding area of hydraulic oil tank cover (3) to prevent hydraulic system contamination.

[3] - Press pressure release button (1) to relief pressure from hydraulic oil tank.

[4] - Remove cap screws (2) and cover.

[5] -

<- Go to Section TOC Section 9025 page 287 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

→NOTE:

Ensure maximum oil movement during cleanup procedure. Orient submerged ends of suction and
discharge wands as far away from each other as possible.

Insert suction and discharge wands from Super Caddy into hydraulic oil tank opening.

Super Caddy

JDG10712

Remove particle contamination and moisture from oil.

One Suction Hose 4.6 m (15 ft) x 25 mm (1.0 in.) I.D. 100R1 Hose with 1.0 in. M NPT Ends

Use with Super Caddy to transfer and clean hydraulic oil.

3 Foot Suction Wand 25 mm (1.00 in.) O.D. (with angle cut tip)

Use with Super Caddy to transfer and clean hydraulic oil.

3 Foot Discharge Wand 19 mm (0.75 in.) O.D.

Use with Super Caddy to transfer and clean hydraulic oil.

[6] -

→NOTE:

Ensure suction and discharge wands maintain position in hydraulic reservoir.

Seal suction and discharge wands in opening of hydraulic oil tank to prevent contamination.

[7] - Use Super Caddy to remove oil contaminants. Refer to operator′s manual included with Super Caddy or see Super Caddy
in Service ADVISOR ™ for operating procedure.

[8] - Install new hydraulic system oil filters for cleanup procedure. See Replace Hydraulic Tank Oil Filter and see Replace Pilot
Oil Filter . (Operator’s Manual.)

[9] - Install hydraulic oil tank cover and cap screws.

[10] -

CAUTION:

Prevent possible personal injury from unexpected machine movement. Clear all persons from area before
operating machine.

CAUTION:

Avoid entanglement and possible electrocution from Super Caddy power cord. DO NOT operate machine
while Super Caddy is connected to machine.

<- Go to Section TOC Section 9025 page 288 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Make sure area is clear and large enough to operate all functions of machine.

[11] - Fill hydraulic oil tank to operating level. See Drain and Refill Hydraulic Tank Oil . (Operator’s Manual.)

[12] -

IMPORTANT:

Avoid hydraulic system damage or further oil contamination. DO NOT force hydraulic system over system
relief or over return filter bypass.

Run machine at slow idle. Operate each circuit a minimum of 3—5 minutes in each direction to flush any remaining
contaminants.

[13] - Stop machine and install suction and discharge wands.

[14] - Repeat Super Caddy operation procedure until contaminant value is at specifications per Super Caddy operation manual.

[15] - When oil reaches acceptable value of cleanliness, remove suction and discharge wands.

[16] - Install new hydraulic system oil filters. See Replace Hydraulic Tank Oil Filter and see Replace Pilot Oil Filter . (Operator’s
Manual.)

[17] - See Check Hydraulic Tank Oil Level . (Operator’s Manual.)

[18] - Return machine to service.

[19] -

→NOTE:

Some hydraulic systems may not be able to maintain correct specification without additional filtration
equipment. Additional filtration equipment is recommended for machines in extreme environments.
Bypass filtration systems are available.

Check and record oil particle counts. After 100 hours of operation check hydraulic oil to confirm system is within specification
according to Super Caddy operation manual.

Auxiliary hydraulic attachments or components can be a point of entry for contamination. Frequent attachment changes also
increase chances for contaminants to enter hydraulic system. Use care when connecting and removing components to prevent
system contamination. Quick couplers must not be connected until they have been cleaned and capped when not in use.

Hydraulic Oil Tank Pressure Release Procedure

<- Go to Section TOC Section 9025 page 289 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Park Machine

[1] - Park machine on level surface.

[2] - Position machine with arm cylinder fully retracted and bucket cylinder fully extended.

[3] - Lower boom until bucket is resting on ground.

[4] - Shut engine off.

[5] -
LEGEND:
1 Pressure Release Button
2 Hydraulic Oil Tank Cover

Hydraulic Oil Tank Cover

Press pressure release button (1) to relieve hydraulic oil tank pressure.

<- Go to Section TOC Section 9025 page 290 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Hydraulic Oil Warm-Up Procedure


Specifications

SPECIFICATIONS

1300—1500 rpm if below -18°C (0°F)


Engine Speed
1750—1850 rpm if above -18°C (0°F)

ECO (economy) Mode if below -18°C (0°F)


Power Mode Button Position
H/P (high power) Mode if above -18°C (0°F)

Work Mode Switch Position Dig Mode

Auto-Idle Switch Position OFF

Travel Speed Switch Position Slow (turtle)

45—55°C
Hydraulic Oil Temperature
110—130°F

IMPORTANT:

If machine temperature is below -18°C (0°F), start procedure in the ECO (economy) mode. Failure to do
this could cause pump cavitation. Once oil temperature is above -18°C (0°F), the power mode can be
switched to H/P (high power) mode.

Below -18°C (0°F) an extended warm-up period may be necessary. Hydraulic functions will move slowly and lubrication of parts
may not be adequate with cold oil. Do not attempt normal machine operation until hydraulic functions move at or close to
normal cycle times.

Operate functions slowly and avoid sudden movements until engine and hydraulic oils are thoroughly warmed. Operate a
function by moving it a short distance in each direction. Continue operating the function increasing the distance traveled in
each cycle until full stroke is reached.

For faster warm-up, restrict air flow through oil cooler using cardboard or other similar material. Use correct viscosity oil to
minimize warm-up period. See Hydraulic Oil . (Operator′s Manual.)

[1] - Connect one of the following test equipment to monitor the coolant temperature, hydraulic oil temperature and actual
engine speed.

Monitor application. See Service Menu for instruction to actuate the service menu on monitor in cab. (Group 9015-16.)
Select the following items from monitoring list:
Coolant Temperature
Hydraulic Oil Temperature
Actual Engine Speed
Service ADVISOR ™ application. See Service ADVISOR™ Connection Procedure for instruction. (Group 9015-20.) Select the
following items from the menu:
Coolant Temperature
Hydraulic Oil Temperature
Actual Engine Speed
MPDr application. See MPDr Connection Procedure for instruction. (Group 9015-20.) Select the following items from the
monitor display:
Coolant Temperature
Hydraulic Oil Temperature
Actual Engine Speed

[2] -

CAUTION:

Avoid possible serious injury from machine movement during warm-up procedure. Clear the area of all
bystanders before doing the warm-up procedure.
<- Go to Section TOC Section 9025 page 291 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Clear the area of all bystanders to allow for machine movement.

[3] - Run machine at specification for approximately 5 minutes before operating any functions.

Item Measurement Specification

Engine Speed 1300—1500 rpm if below -18°C (0°F)

1750—1850 rpm if above -18°C (0°F)

Power Mode Button Position ECO (economy) Mode if below -18°C (0°F)

H/P (high power) Mode if above -18°C (0°F)

Work Mode Switch Position Dig Mode

Auto-Idle Switch Position OFF

Travel Speed Switch Position Slow (turtle)

[4] - Slowly turn upperstructure so boom is to the side.

[5] -

CAUTION:

Avoid possible serious injury from machine sliding backwards. Keep angle between boom and arm at
90—110°.

Keeping the angle between boom and arm at 90—110°, lower boom to raise track off the ground.

[6] - Operate travel function (side with track off ground) for approximately 5 minutes.

[7] - When oil temperature is above -18°C (0°F), increase engine speed to 1750—1850 rpm and press power mode button to
H/P (high power).

[8] -

IMPORTANT:

Holding a function over relief for more than 10 seconds can cause damage due to hot spots in the control
valve.

Operate the travel function (side with track off the ground). Also operate the bucket curl function over relief for 10 seconds and
then stop for 5 seconds. Repeat the cycle until oil is heated to specifications.

[9] - Stop periodically and operate all hydraulic functions to distribute the heated oil.

[10] - Continue procedure until oil temperature is within specifications.

Item Measurement Specification

Hydraulic Oil Temperature 45—55°C

110—130°F

<- Go to Section TOC Section 9025 page 292 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Pilot Pressure Regulating Valve Test and Adjustment


Specifications

SPECIFICATIONS

45—55°C
Hydraulic Oil Temperature
110—130°F

Engine Speed Fast Idle and Slow Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

3.8—4.8 MPa
3805—4805 kPa
Pilot System Pressure (slow idle)
39.0—49.0 bar
552—697 psi

3.5—5.0 MPa
3509—5012 kPa
Pilot System Pressure (fast idle)
36.0—51.0 bar
509—727 psi

0.078 MPa
78 kPa
Pilot Pressure Regulating Valve Shim [approximate per 0.25 mm (0.010 in.) shim]
0.78 bar
11.3 psi

0.157 MPa
157 kPa
Pilot Pressure Regulating Valve Shim [approximate per 0.50 mm (0.020 in.) shim]
1.57 bar
22.8 psi

0.304 MPa
304 kPa
Pilot Pressure Regulating Valve Shim [approximate per 1.00 mm (0.040 in.) shim]
3.04 bar
44.1 psi

25 N˙m
Plug-to-Pilot Pressure Regulating Valve Housing Torque
220 lb.-in.

Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Adapter (1/4 M BSPP ORB x 7/16-20 M 37°)

JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)

JT02156A Digital Pressure/Temperature Analyzer

Gauge 7000 kPa (70 bar) (1000 psi)

The purpose of this test is to check and, if necessary, adjust the pressure setting of the pilot pressure regulating valve. Pilot
pressure is controlled by this valve.

This test is to ensure there is enough pilot pressure to operate all pilot system functions and to adjust pressure as needed. The
pilot pressure regulating valve is used to regulate pilot system pressure.

[1] - Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank
Pressure Release Procedure . (Group 9025-25.)

[2] -

<- Go to Section TOC Section 9025 page 293 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

LEGEND:
1 Test Port
2 Adapter
3 JT02162 Transducer
4 Oil Sample Port (if equipped)
30 Pilot Pressure Regulating Valve

Pilot Pressure Regulating Valve and Test Port

Remove plug from test port (1).

Adapter

1/4 M BSPP ORB x 7/16-20 M 37°

To connect a gauge or transducer to pilot pressure regulating valve

Transducer 35 000 kPa (350 bar) (5000 psi)

JT02162

Used to measure hydraulic pressure.

Digital Pressure/Temperature Analyzer

JT02156A

To display hydraulic pressure readings.

Gauge 7000 kPa (70 bar) (1000 psi)

Used to measure hydraulic pressure.

[3] - Install adapter (2).

[4] - Connect JT02162 Transducer (3) and JT02156A Digital Pressure/Temperature Analyzer or 7000 kPa (70 bar) (1000 psi)
gauge to adapter.

→NOTE:

The monitor can be used to make a quick check of the pilot system pressure using arm in function.
Monitor arm in pilot pressure with engine at fast idle and then actuate arm in function over relief. The
pressure reading displayed is from arm in pressure sensor located on control valve.

Before making any adjustments, check the pilot pressure at the test port using a pressure gauge. For
pilot filter and pressure regulating valve location, see Hydraulic System Component Location . (Group
9025-15.)

<- Go to Section TOC Section 9025 page 294 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Connect one of the following test equipment to monitor hydraulic oil temperature and actual engine speed.

Monitor application. For instruction to actuate the service menu on monitor in cab, see Service Menu . (Group 9015-16.)
Select the following items to display:
Arm Roll-In Pilot Pressure
Hydraulic Oil Temperature
Actual Engine Speed
Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select
the following items to display:
Arm Roll-In Pilot Pressure
Hydraulic Oil Temperature
Actual Engine Speed
MPDr application. For instruction, see MPDr Connection Procedure . (Group 9015-20.) Select the following items to display:
Arm Roll-In Pilot Pressure
Hydraulic Oil Temperature
Actual Engine Speed

[5] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)

[6] - Run machine at specification:

Item Measurement Specification

Hydraulic Oil Temperature 45—55°C

110—130°F

Engine Speed Fast Idle and Slow Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

[7] - Compare pressure readings to specifications. Make adjustments as necessary.

Item Measurement Specification

Pilot System Pressure (slow idle) Pressure 3.8—4.8 MPa

3805—4805

39.0—49.0 bar

552—697 psi

Pilot System Pressure (fast idle) Pressure 3.5—5.0 MPa

3509—5012 kPa

36.0—51.0 bar

509—727 psi

[8] - Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank
Pressure Release Procedure . (Group 9025-25.)

[9] -

<- Go to Section TOC Section 9025 page 295 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

LEGEND:
1 Test Port
2 Adapter
3 JT02162 Transducer
4 Oil Sample Port (if equipped)
30 Pilot Pressure Regulating Valve

Pilot Pressure Regulating Valve and Test Port

Remove pilot pressure regulating valve (30). Add shims to increase pressure. Remove shims to decrease pressure.

Item Measurement Specification

Pilot Pressure Regulating Valve Shim [approximate per 0.25 mm (0.010 in.) shim] Pressure Change 0.078 MPa

78 kPa

0.78 bar

11.3 psi

Pilot Pressure Regulating Valve Shim [approximate per 0.50 mm (0.020 in.) shim] Pressure Change 0.157 MPa

157 kPa

1.57 bar

22.8 psi

Pilot Pressure Regulating Valve Shim [approximate per 1.00 mm (0.040 in.) shim] Pressure 0.304 MPa

304 kPa

3.04 bar

44.1 psi

[10] - Tighten pilot pressure regulating valve plug to specification.

Item Measurement Specification

Plug-to-Pilot Pressure Regulating Valve Housing Torque 25 N˙m

220 lb.-in.

[11] - Check pressure settings again.

<- Go to Section TOC Section 9025 page 296 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Control Valve Spool Actuating Pilot Pressure Test


Specifications

SPECIFICATIONS

45—55°C
Hydraulic Oil Temperature
110—130°F

Engine Speed Fast Idle and Slow Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

Travel Speed Switch Position Fast (rabbit)

3.4—4.0 MPa
3432—4021 kPa
Control Valve Spool Actuating Pressure
34.3—40.2 bar
495—583 psi

Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Adaptor Tee (9/16-18 F Sw 37° x 7/16-20 M 37° x 9/16-18 M 37°)

Gauge 7000 kPa (70 bar) (1000 psi)

JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)

JT02156A Digital Pressure/Temperature Analyzer

Purpose of test is to ensure pilot pressure to the valve spools is adequate to completely shift the spools.

[1] - Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank
Pressure Release Procedure . (Group 9025-25.)

[2] -

→NOTE:

Spool actuating pressure can be checked for each function by installing a tee and gauge in pilot line and
then actuating that function.

LEGEND:
1 Adaptor Tee
2 JT02162 Transducer

Control Valve Spool Actuating Pilot Pressure Test


<- Go to Section TOC Section 9025 page 297 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Install adaptor tee in pilot line for function being tested.

Adaptor Tee

9/16-18 F Sw 37° x 7/16-20 M 37° x 9/16-18 M 37°

To connect a gauge or transducer to pilot line.

Gauge 7000 kPa (70 bar) (1000 psi)

Used to measure hydraulic pressure.

Transducer 35 000 kPa (350 bar) (5000 psi)

JT02162

Used to measure hydraulic pressure.

Digital Pressure/Temperature Analyzer

JT02156A

Used to measure hydraulic pressure and temperature.

[3] - Install JT02162 Transducer and JT02156A Digital Pressure/Temperature Analyzer or 7000 kPa (70 bar) (1000 psi) gauge.

[4] -

→NOTE:

Spool actuating pressure for boom up, arm in, left and right swing, and all travel functions can also be
measured with the monitor.

Connect one of the following test equipment to monitor pressure reading, hydraulic oil temperature and actual engine speed.

Monitor application. For instruction to actuate the service menu on monitor in cab, see Service Menu . (Group 9015-16.)
Select the following items to display:
Arm Roll-In Pilot Pressure
Hydraulic Oil Temperature
Actual Engine Speed
Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select
the following items to display:
Arm Roll-In Pilot Pressure
Hydraulic Oil Temperature
Actual Engine Speed
MPDr application. For instruction, see MPDr Connection Procedure . (Group 9015-20.) Select the following items to display:
Arm Roll-In Pilot Pressure
Hydraulic Oil Temperature
Actual Engine Speed

[5] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)

[6] - Run machine at specifications.

Item Measurement Specification

Hydraulic Oil Temperature 45—55°C

110—130°F

Engine Speed Fast Idle

Work Mode Switch Position Dig Mode

<- Go to Section TOC Section 9025 page 298 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Item Measurement Specification

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

Travel Speed Switch Position Fast (rabbit)

[7] - Actuate the function to be checked to full stroke. Record pressure.

[8] - Compare pressure to specifications.

Item Measurement Specification

Control Valve Spool Actuating Pressure 3.4—4.0 MPa

3432—4021 kPa

34.3—40.2 bar

495—583 psi

If valve spool actuating pressure is not to specification, check pilot system pressure. See Pilot Pressure Regulating Valve Test
and Adjustment . (Group 9025-25.)

If pilot system pressure is to specification, check pressure at the solenoid valve manifold, pilot control shutoff solenoid valve,
pilot controllers, and pilot signal manifold.

<- Go to Section TOC Section 9025 page 299 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Dig Regenerative Solenoid Valve Test and Adjustment


Specifications

SPECIFICATIONS

45—55°C
Hydraulic Oil Temperature
110—130°F

Engine Speed Fast Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

Monitor Reading ± 0.2 MPa


Monitor Reading ± 200 kPa
Dig Regenerative Solenoid (port SF) Pressure Monitor Reading ± 2.0 bar
Monitor Reading ± 29.0 psi
Actual Reading From Gauge Must Be Within Pressure Range of Monitor Reading and Tolerance

0.111 MPa
111 kPa
Solenoid Adjusting Screw Pressure Change (approximate per 1/4 turn)
1.11 bar
16.1 psi

4 mm
End of Adjusting Screw-to-Nut Length (maximum)
0.157 in.

5.0 N˙m
Adjusting Screw-to-Nut Torque
45 lb.-in.

Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Adaptor Tee (1/4 M BSPP ORB x 7/16-20 M 37° x M14-1.5 M 45°)

JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)

JT02156A Digital Pressure/Temperature Analyzer

Gauge 7000 kPa (70 bar) (1000 psi)

Purpose of this test is to check the output pressure for the dig regenerative solenoid (Y22) is within specification.

[1] - Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank
Pressure Release Procedure . (Group 9025-25.)

[2] -

Solenoid Valve Manifold Location

<- Go to Section TOC Section 9025 page 300 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Solenoid Valve Manifold Detail

LEGEND:
1 Power Dig Solenoid Fitting
2 Dig Regenerative Solenoid Fitting
3 Arm Regenerative Solenoid Fitting
4 Arm 2 Flow Control Solenoid Fitting
37 Solenoid Valve Manifold
Y22 Dig Regenerative Solenoid (port SF)
Y23 Arm Regenerative Solenoid (port SC)
Y24 Power Dig Solenoid (port SG)
Y27 Arm 2 Flow Control Solenoid (port SI)
Remove dig regenerative solenoid fitting (2) from dig regenerative solenoid (Y22).

[3] -

(1/4 M BSPP ORB x 7/16-20 M 37° x M14-1.5 M 45°)

Adaptor Tee

Used to connect test gauges.

Transducer 35 000 kPa (350 bar) (5000 psi)

JT02162

Used to measure hydraulic pressure.

Digital Pressure/Temperature Analyzer

JT02156A

Used to measure hydraulic pressure and temperature.

Gauge 7000 kPa (70 bar) (1000 psi)

<- Go to Section TOC Section 9025 page 301 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Used to measure hydraulic pressure.

Install adaptor tee where elbow was. Connect line to adaptor tee.

[4] - Connect JT02162 Transducer and JT02156A Digital Pressure/Temperature Analyzer or 7000 kPa (70 bar) (1000 psi) gauge
to tee.

[5] - Connect one of the following test equipment to monitor the dig regenerative solenoid reading, hydraulic oil temperature,
and actual engine speed.

Monitor application. For instruction to actuate the service menu on monitor in cab, see Service Menu . (Group 9015-16.)
Select the following items to display:
Digging Regen P/S O/P
Hydraulic Oil Temperature
Actual Engine Speed
Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select
the following items to display:
Digging Regen P/S O/P
Hydraulic Oil Temperature
Actual Engine Speed
MPDr application. For instruction, see MPDr Connection Procedure . (Group 9015-20.) Select the following items to display:
Digging Regen P/S O/P
Hydraulic Oil Temperature
Actual Engine Speed

[6] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)

[7] - Run machine at specification.

Item Measurement Specification

Hydraulic Oil Temperature 45—55°C

110—130°F

Engine Speed Fast Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

[8] -

→NOTE:

Pressure reading displayed on the monitor is calculated from an electrical signal in the main controller
(MCZ). The reading does not change when solenoid adjustment is made.

Operate boom up and arm in over relief. Record monitor and gauge pressure readings.

[9] - Calculate pressure range using the calculated reading from monitor and the specific tolerance provided.

[10] - Verify that the actual reading from gauge is within the calculated pressure range from monitor.

Item Measurement Specification

Dig Regenerative Solenoid (port SF) Pressure Monitor Reading ± 0.2 MPa

Monitor Reading ± 200 kPa

Monitor Reading ± 2.0 bar

Monitor Reading ± 29.0 psi

<- Go to Section TOC Section 9025 page 302 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Item Measurement Specification

Actual Reading From Gauge Must Be Within Pressure Range of Monitor Reading and Tolerance

→NOTE:

An example of monitor reading is given in the chart below for the dig regenerative solenoid.

Example of Monitor Calculated Reading

Example of Calculated Reading From Monitor

Actuated Non Actuated

3.19 MPa 0.03 MPa


3190 kPa 30 kPa
Example Monitor Reading
31.9 bar 0.3 bar
463 psi 4 psi

[11] -
LEGEND:
4 Solenoid
5 Nut
6 Adjusting Screw

Solenoid Adjustment

Adjust solenoid (4) being tested as necessary.

IMPORTANT:
Avoid possible O-ring damage. Do not loosen adjusting screw more than two turns. Turning
adjusting screw out too far may cause O-ring damage and leakage.

Loosen nut (5).

b. Turn adjusting screw (6) IN to increase pressure setting; turn adjusting screw OUT to decrease pressure setting. The
length from end of adjusting screw to nut must not exceed 4 mm (0.157 in.).
Item Measurement Specification

Solenoid Adjusting Screw Pressure Change (approximate per 1/4 turn) 0.111 MPa

111 kPa

1.11 bar

16.1 psi

End of Adjusting Screw-to-Nut Length (maximum) 4 mm

0.157 in.

c. Hold adjusting screw and tighten nut to specification.


Item Measurement Specification

Adjusting Screw-to-Nut Torque 5.0 N˙m

45 lb.-in.

<- Go to Section TOC Section 9025 page 303 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

[12] - Check pressure setting again.

<- Go to Section TOC Section 9025 page 304 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Arm Regenerative Solenoid Valve Test and Adjustment


Specifications

SPECIFICATIONS

45—55°C
Hydraulic Oil Temperature
110—130°F

Engine Speed Fast Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

Monitor Reading ± 0.2 MPa


Monitor Reading ± 200 kPa
Arm Regenerative Solenoid (port SC) Pressure Monitor Reading ± 2.0 bar
Monitor Reading ± 29.0 psi
Actual Reading From Gauge Must Be Within Pressure Range of Monitor Reading and Tolerance

0.111 MPa
111 kPa
Solenoid Adjusting Screw Pressure Change (approximate per 1/4 turn)
1.11 bar
16.1 psi

4 mm
End of Adjusting Screw-to-Nut Length (maximum)
0.157 in.

5.0 N˙m
Adjusting Screw-to-Nut Torque
45 lb.-in.

Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Adaptor Tee (1/4 M BSPP ORB x 7/16-20 M 37° x M14-1.5 M 45°)

JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)

JT02156A Digital Pressure/Temperature Analyzer

Gauge 7000 kPa (70 bar) (1000 psi)

Purpose of this test is to check the output pressure for the arm regenerative solenoid (Y23) is within specification.

[1] - Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank
Pressure Release Procedure . (Group 9025-25.)

[2] -

Solenoid Valve Manifold Location

<- Go to Section TOC Section 9025 page 305 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Solenoid Valve Manifold Detail

LEGEND:
1 Power Dig Solenoid Fitting
2 Dig Regenerative Solenoid Fitting
3 Arm Regenerative Solenoid Fitting
4 Arm 2 Flow Control Solenoid Fitting
37 Solenoid Valve Manifold
Y22 Dig Regenerative Solenoid (port SF)
Y23 Arm Regenerative Solenoid (port SC)
Y24 Power Dig Solenoid (port SG)
Y27 Arm 2 Flow Control Solenoid (port SI)
Remove arm regenerative solenoid fitting (3) from arm regenerative solenoid (Y23).

[3] -

(1/4 M BSPP ORB x 7/16-20 M 37° x M14-1.5 M 45°)

Adaptor Tee

Used to connect test gauges.

Transducer 35 000 kPa (350 bar) (5000 psi)

JT02162

Used to measure hydraulic pressure.

Digital Pressure/Temperature Analyzer

JT02156A

Used to measure hydraulic pressure and temperature.

Gauge 7000 kPa (70 bar) (1000 psi)

<- Go to Section TOC Section 9025 page 306 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Used to measure hydraulic pressure.

Install adaptor tee where elbow was. Connect line to adaptor tee.

[4] - Connect JT02162 Transducer and JT02156A Digital Pressure/Temperature Analyzer or 7000 kPa (70 bar) (1000 psi) gauge
to tee.

[5] - Connect one of the following test equipment to monitor the arm regenerative solenoid reading, hydraulic oil temperature,
and actual engine speed.

Monitor application. For instruction to actuate the service menu on monitor in cab, see Service Menu . (Group 9015-16.)
Select the following items to display:
Arm Regen P/S Output
Hydraulic Oil Temperature
Actual Engine Speed
Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select
the following items to display:
Arm Regen P/S Output
Hydraulic Oil Temperature
Actual Engine Speed
MPDr application. For instruction, see MPDr Connection Procedure . (Group 9015-20.) Select the following items to display:
Arm Regen P/S Output
Hydraulic Oil Temperature
Actual Engine Speed

[6] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)

[7] - Run machine at specification.

Item Measurement Specification

Hydraulic Oil Temperature 45—55°C

110—130°F

Engine Speed Fast Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

[8] -

CAUTION:

To avoid personal injury, clear area of all bystanders before doing test. Slowly swing through one
complete revolution to ensure that the area is clear of objects before testing.

→NOTE:

Pressure reading displayed on the monitor is calculated from an electrical signal in the main controller
(MCZ). The reading does not change when solenoid adjustment is made.

Combined operation of swing and arm in functions. Record monitor and gauge pressure readings.

[9] - Calculate pressure range using the calculated reading from monitor and the specific tolerance provided.

<- Go to Section TOC Section 9025 page 307 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

[10] - Verify that the actual reading from gauge is within the calculated pressure range from monitor.

Item Measurement Specification

Arm Regenerative Solenoid (port SC) Pressure Monitor Reading ± 0.2 MPa

Monitor Reading ± 200 kPa

Monitor Reading ± 2.0 bar

Monitor Reading ± 29.0 psi

Actual Reading From Gauge Must Be Within Pressure Range of Monitor Reading and Tolerance

→NOTE:

An example of monitor reading is given in the chart below for the arm regenerative solenoid.

Example of Monitor Calculated Reading

Example of Calculated Reading From Monitor

Actuated Non Actuated

3.19 MPa 0.03 MPa


3190 kPa 30 kPa
Example Monitor Reading
31.9 bar 0.3 bar
463 psi 4 psi

[11] -
LEGEND:
4 Solenoid
5 Nut
6 Adjusting Screw

Solenoid Adjustment

Adjust solenoid (4) being tested as necessary.

IMPORTANT:
Avoid possible O-ring damage. Do not loosen adjusting screw more than two turns. Turning
adjusting screw out too far may cause O-ring damage and leakage.

Loosen nut (5).

b. Turn adjusting screw (6) IN to increase pressure setting; turn adjusting screw OUT to decrease pressure setting. The
length from end of adjusting screw to nut must not exceed 4 mm (0.157 in.).
Item Measurement Specification

Solenoid Adjusting Screw Pressure Change (approximate per 1/4 turn) 0.111 MPa

111 kPa

1.11 bar

16.1 psi

End of Adjusting Screw-to-Nut Length (maximum) 4 mm

0.157 in.

<- Go to Section TOC Section 9025 page 308 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

c. Hold adjusting screw and tighten nut to specification.


Item Measurement Specification

Adjusting Screw-to-Nut Torque 5.0 N˙m

45 lb.-in.

[12] - Check pressure setting again.

<- Go to Section TOC Section 9025 page 309 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Power Dig Solenoid Valve Test and Adjustment


Specifications

SPECIFICATIONS

45—55°C
Hydraulic Oil Temperature
110—130°F

Engine Speed Fast Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

Monitor Reading ± 0.2 MPa


Monitor Reading ± 200 kPa
Power Dig Solenoid (port SG) Pressure Monitor Reading ± 2.0 bar
Monitor Reading ± 29.0 psi
Actual Reading From Gauge Must Be Within Pressure Range of Monitor Reading and Tolerance

0.111 MPa
111 kPa
Solenoid Adjusting Screw Pressure Change (approximate per 1/4 turn)
1.11 bar
16.1 psi

4 mm
End of Adjusting Screw-to-Nut Length (maximum)
0.157 in.

5.0 N˙m
Adjusting Screw-to-Nut Torque
45 lb.-in.

Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Adaptor Tee (1/4 M BSPP ORB x 7/16-20 M 37° x M14-1.5 M 45°)

JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)

JT02156A Digital Pressure/Temperature Analyzer

Gauge 7000 kPa (70 bar) (1000 psi)

Purpose of this test is to check the output pressure for the power dig solenoid (Y24) is within specification.

[1] - Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank
Pressure Release Procedure . (Group 9025-25.)

[2] -

Solenoid Valve Manifold Location

<- Go to Section TOC Section 9025 page 310 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Solenoid Valve Manifold Detail

LEGEND:
1 Power Dig Solenoid Fitting
2 Dig Regenerative Solenoid Fitting
3 Arm Regenerative Solenoid Fitting
4 Arm 2 Flow Control Solenoid Fitting
37 Solenoid Valve Manifold
Y22 Dig Regenerative Solenoid (port SF)
Y23 Arm Regenerative Solenoid (port SC)
Y24 Power Dig Solenoid (port SG)
Y27 Arm 2 Flow Control Solenoid (port SI)
Remove power dig solenoid fitting (1) from power dig solenoid (Y24).

[3] -

(1/4 M BSPP ORB x 7/16-20 M 37° x M14-1.5 M 45°)

Adaptor Tee

Used to connect test gauges.

Transducer 35 000 kPa (350 bar) (5000 psi)

JT02162

Used to measure hydraulic pressure.

Digital Pressure/Temperature Analyzer

JT02156A

Used to measure hydraulic pressure and temperature.

Gauge 7000 kPa (70 bar) (1000 psi)

<- Go to Section TOC Section 9025 page 311 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Used to measure hydraulic pressure.

Install adaptor tee where elbow was. Connect line to adaptor tee.

[4] - Connect JT02162 Transducer and JT02156A Digital Pressure/Temperature Analyzer or 7000 kPa (70 bar) (1000 psi) gauge
to tee.

[5] - Connect one of the following test equipment to monitor the power dig solenoid reading, hydraulic oil temperature, and
actual engine speed.

Monitor application. For instruction to actuate the service menu on monitor in cab, see Service Menu . (Group 9015-16.)
Select the following items to display:
Pressure Boost P/S Output
Hydraulic Oil Temperature
Actual Engine Speed
Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select
the following items to display:
Pressure Boost P/S Output
Hydraulic Oil Temperature
Actual Engine Speed
MPDr application. For instruction, see MPDr Connection Procedure . (Group 9015-20.) Select the following items to display:
Pressure Boost P/S Output
Hydraulic Oil Temperature
Actual Engine Speed

[6] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)

[7] - Run machine at specification.

Item Measurement Specification

Hydraulic Oil Temperature 45—55°C

110—130°F

Engine Speed Fast Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

[8] -

→NOTE:

Pressure reading displayed on the monitor is calculated from an electrical signal in the main controller
(MCZ). The reading does not change when solenoid adjustment is made.

Press power dig switch to turn function on. Record monitor and gauge pressure readings.

[9] - Calculate pressure range using the calculated reading from monitor and the specific tolerance provided.

[10] - Verify actual pressure reading at gauge is within the calculated pressure range from monitor.

Item Measurement Specification

Power Dig Solenoid (port SG) Pressure Monitor Reading ± 0.2 MPa

Monitor Reading ± 200 kPa

Monitor Reading ± 2.0 bar

Monitor Reading ± 29.0 psi

<- Go to Section TOC Section 9025 page 312 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Item Measurement Specification

Actual Reading From Gauge Must Be Within Pressure Range of Monitor Reading and Tolerance

→NOTE:

An example of monitor reading is given in the chart below for the power dig solenoid.

Example of Monitor Calculated Reading

Example of Calculated Reading From Monitor

Actuated Non Actuated

3.19 MPa 0.03 MPa


3190 kPa 30 kPa
Example Monitor Reading
31.9 bar 0.3 bar
463 psi 4 psi

[11] -
LEGEND:
4 Solenoid
5 Nut
6 Adjusting Screw

Solenoid Adjustment

Adjust solenoid (4) being tested as necessary.

IMPORTANT:
Avoid possible O-ring damage. Do not loosen adjusting screw more than two turns. Turning
adjusting screw out too far may cause O-ring damage and leakage.

Loosen nut (5).

b. Turn adjusting screw (6) IN to increase pressure setting; turn adjusting screw OUT to decrease pressure setting. The
length from end of adjusting screw to nut must not exceed 4 mm (0.157 in.).
Item Measurement Specification

Solenoid Adjusting Screw Pressure Change (approximate per 1/4 turn) 0.111 MPa

111 kPa

1.11 bar

16.1 psi

End of Adjusting Screw-to-Nut Length (maximum) 4 mm

0.157 in.

c. Hold adjusting screw and tighten nut to specification.


Item Measurement Specification

Adjusting Screw-to-Nut Torque 5.0 N˙m

45 lb.-in.

<- Go to Section TOC Section 9025 page 313 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

[12] - Check pressure setting again.

<- Go to Section TOC Section 9025 page 314 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Arm 2 Flow Control Solenoid Valve Test and Adjustment


Specifications

SPECIFICATIONS

45—55°C
Hydraulic Oil Temperature
110—130°F

Engine Speed Fast Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

Monitor Reading ± 0.2 MPa


Monitor Reading ± 200 kPa
Arm 2 Flow Control Solenoid (port SI) Pressure Monitor Reading ± 2.0 bar
Monitor Reading ± 29.0 psi
Actual Reading From Gauge Must Be Within Pressure Range of Monitor Reading and Tolerance

0.111 MPa
111 kPa
Solenoid Adjusting Screw Pressure Change (approximate per 1/4 turn)
1.11 bar
16.1 psi

4 mm
End of Adjusting Screw-to-Nut Length (maximum)
0.157 in.

5.0 N˙m
Adjusting Screw-to-Nut Torque
45 lb.-in.

Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Adaptor Tee (1/4 M BSPP ORB x 7/16-20 M 37° x M14-1.5 M 45°)

JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)

JT02156A Digital Pressure/Temperature Analyzer

Gauge 7000 kPa (70 bar) (1000 psi)

Purpose of this test is to check output pressure for the arm 2 flow control solenoid (Y27) is within specification.

[1] - Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank
Pressure Release Procedure . (Group 9025-25.)

[2] -

Solenoid Valve Manifold Location

<- Go to Section TOC Section 9025 page 315 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Solenoid Valve Manifold Detail

LEGEND:
1 Power Dig Solenoid Fitting
2 Dig Regenerative Solenoid Fitting
3 Arm Regenerative Solenoid Fitting
4 Arm 2 Flow Control Solenoid Fitting
37 Solenoid Valve Manifold
Y22 Dig Regenerative Solenoid (port SF)
Y23 Arm Regenerative Solenoid (port SC)
Y24 Power Dig Solenoid (port SG)
Y27 Arm 2 Flow Control Solenoid (port SI)
Remove arm 2 flow control solenoid fitting (4) from arm 2 flow control solenoid (Y27).

[3] -

(1/4 M BSPP ORB x 7/16-20 M 37° x M14-1.5 M 45°)

Adaptor Tee

Used to connect test gauges.

Transducer 35 000 kPa (350 bar) (5000 psi)

JT02162

Used to measure hydraulic pressure.

Digital Pressure/Temperature Analyzer

JT02156A

Used to measure hydraulic pressure and temperature.

Gauge 7000 kPa (70 bar) (1000 psi)

<- Go to Section TOC Section 9025 page 316 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Used to measure hydraulic pressure.

Install adaptor tee where elbow was. Connect line to adaptor tee.

[4] - Connect JT02162 Transducer and JT02156A Digital Pressure/Temperature Analyzer or 7000 kPa (70 bar) (1000 psi) gauge
to tee.

[5] - Connect one of the following test equipment to monitor the dig regenerative solenoid reading, hydraulic oil temperature,
and actual engine speed.

Monitor application. For instruction to actuate the service menu on monitor in cab, see Service Menu . (Group 9015-16.)
Select the following items to display:
Arm 2 Flw Cont P/S Output
Hydraulic Oil Temperature
Actual Engine Speed
Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select
the following items to display:
Arm 2 Flw Cont P/S Output
Hydraulic Oil Temperature
Actual Engine Speed
MPDr application. For instruction, see MPDr Connection Procedure . (Group 9015-20.) Select the following items to display:
Arm 2 Flw Cont P/S Output
Hydraulic Oil Temperature
Actual Engine Speed

[6] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)

[7] - Run machine at specification.

Item Measurement Specification

Hydraulic Oil Temperature 45—55°C

110—130°F

Engine Speed Fast Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

[8] -

→NOTE:

Pressure reading displayed on the monitor is calculated from an electrical signal in the main controller
(MCZ). The reading does not change when solenoid adjustment is made.

Combined operation of boom up and arm in. Record monitor and gauge pressure readings.

[9] - Calculate pressure range using the calculated reading from monitor and the specific tolerance provided.

[10] - Verify that the actual reading from gauge is within the calculated pressure range from monitor.

Item Measurement Specification

Arm 2 Flow Control Solenoid (port SI) Pressure Monitor Reading ± 0.2 MPa

Monitor Reading ± 200 kPa

Monitor Reading ± 2.0 bar

Monitor Reading ± 29.0 psi

<- Go to Section TOC Section 9025 page 317 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Item Measurement Specification

Actual Reading From Gauge Must Be Within Pressure Range of Monitor Reading and Tolerance

→NOTE:

An example of monitor reading is given in the chart below for the arm 2 flow control solenoid.

Example of Monitor Calculated Reading

Example of Calculated Reading From Monitor

Actuated Non Actuated

3.19 MPa 0.03 MPa


3190 kPa 30 kPa
Example Monitor Reading
31.9 bar 0.3 bar
463 psi 4 psi

[11] -
LEGEND:
4 Solenoid
5 Nut
6 Adjusting Screw

Solenoid Adjustment

Adjust solenoid (4) being tested as necessary.

IMPORTANT:
Avoid possible O-ring damage. Do not loosen adjusting screw more than two turns. Turning
adjusting screw out too far may cause O-ring damage and leakage.

Loosen nut (5).

b. Turn adjusting screw (6) IN to increase pressure setting; turn adjusting screw OUT to decrease pressure setting. The
length from end of adjusting screw to nut must not exceed 4 mm (0.157 in.).
Item Measurement Specification

Solenoid Adjusting Screw Pressure Change (approximate per 1/4 turn) 0.111 MPa

111 kPa

1.11 bar

16.1 psi

End of Adjusting Screw-to-Nut Length (maximum) 4 mm

0.157 in.

c. Hold adjusting screw and tighten nut to specification.


Item Measurement Specification

Adjusting Screw-to-Nut Torque 5.0 N˙m

45 lb.-in.

<- Go to Section TOC Section 9025 page 318 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

[12] - Check pressure setting again.

<- Go to Section TOC Section 9025 page 319 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Torque Control Solenoid Valve Test and Adjustment


Specifications

SPECIFICATIONS

45—55°C
Hydraulic Oil Temperature
110—130°F

Engine Speed Fast Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

Monitor Reading ± 0.2 MPa


Monitor Reading ± 200 kPa
Torque Control Solenoid Valve Pressure Monitor Reading ± 2.0 bar
Monitor Reading ± 29.0 psi
Actual Reading From Gauge Must Be Within Pressure Range of Monitor Reading and Tolerance

0.111 MPa
111 kPa
Adjusting Screw Pressure Change (approximate per 1/4 turn)
1.11 bar
16.1 psi

4 mm
End of Adjusting Screw-to-Nut Length (maximum)
0.157 in.

5.0 N˙m
Adjusting Screw-to-Housing Nut Torque
45 lb.-in.

Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Adapter (1/4 M BSPP ORB x 7/16-20 M 37°)

JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)

JT02156A Digital Pressure/Temperature Analyzer

Gauge 7000 kPa (70 bar) (1000 psi)

Purpose of this test is to check that the output pressure from the torque control solenoid valve (4) is within specification.

[1] - Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank
Pressure Release Procedure . (Group 9025-25.)

[2] -
LEGEND:
1 Pump 1 Regulator
2 Test Port
3 Pump 2 Regulator
4 Torque Control Solenoid Valve

Torque Control Test Port

<- Go to Section TOC Section 9025 page 320 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Remove plug from torque control solenoid valve test port (2) in pump 1 regulator (1).

[3] -

Adapter

(1/4 M BSPP ORB x 7/16-20 M 37°)

To connect to the test port of pump 1 and pump 2.

Transducer 35 000 kPa (350 bar) (5000 psi)

JT02162

Used to measure hydraulic pressure.

Digital Pressure/Temperature Analyzer

JT02156A

Used to measure hydraulic pressure and temperature.

Gauge 7000 kPa (70 bar) (1000 psi)

To measure hydraulic pressure.

Install adapter.

[4] - Connect JT02162 Transducer and JT02156A Digital Pressure/Temperature Analyzer or 7000 kPa (70 bar) (1000 psi) gauge
to adapter.

[5] - Connect one of the following test equipment to monitor the pump torque proportional valve pressure reading, hydraulic
oil temperature, and actual engine speed.

Monitor application. For instruction to actuate the service menu on monitor in cab, see Service Menu . (Group 9015-16.)
Select the following items to display:
Pumps 1&2 Torque P/S O/P
Hydraulic Oil Temperature
Actual Engine Speed
Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select
the following items to display:
Pumps 1&2 Torque P/S O/P
Hydraulic Oil Temperature
Actual Engine Speed
MPDr application. For instruction, see MPDr Connection Procedure . (Group 9015-20.) Select the following items to display:
Pumps 1&2 Torque P/S O/P
Hydraulic Oil Temperature
Actual Engine Speed

[6] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)

[7] - Run machine at specification.

Item Measurement Specification

Hydraulic Oil Temperature 45—55°C

110—130°F

Engine Speed Fast Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

<- Go to Section TOC Section 9025 page 321 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

[8] -

→NOTE:

Pressure reading displayed on the monitor is calculated from an electrical signal in the main controller
(MCZ). The reading does not change when valve adjustment is made.

Place all pilot control levers and pedals in the neutral position. Record the pressure readings from monitor and gauge.

[9] - Calculate pressure range using the calculated reading from monitor and the specific tolerance provided.

[10] - Verify actual reading from gauge is within the calculated pressure range from monitor.

Item Measurement Specification

Torque Control Solenoid Valve Pressure Monitor Reading ± 0.2 MPa

Monitor Reading ± 200 kPa

Monitor Reading ± 2.0 bar

Monitor Reading ± 29.0 psi

Actual Reading From Gauge Must Be Within Pressure Range of Monitor Reading and Tolerance

→NOTE:

An example of monitor reading is given in chart below for the torque control solenoid valve.

When a function is actuated, readings start to decrease. The reading will vary depending on the load on
the function.

Example of Monitor Calculated Reading

Example of Calculated Reading From Monitor

Neutral (Non Actuated) Actuated

3.79 MPa 0.33 MPa


3850 kPa 330 kPa
Example Monitor Reading
38.5 bar 3.3 bar
558 psi 48 psi

[11] - Adjust torque control solenoid valve as needed.


LEGEND:
4 Torque Control Solenoid Valve
5 Nut
6 Adjusting Screw

<- Go to Section TOC Section 9025 page 322 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Solenoid Valve Adjustment

IMPORTANT:
Avoid possible O-ring damage. Do not loosen adjusting screw more than two turns. Turning
adjusting screw out too far may cause O-ring damage and leakage.

Loosen nut (5).

b. Turn adjusting screw (6) in to increase pressure setting or turn adjusting screw out to decrease pressure setting. The
length from end of adjusting screw to nut must not exceed specification.
Item Measurement Specification

Adjusting Screw Pressure Change (approximate per 1/4 turn) 0.111 MPa

111 kPa

1.11 bar

16.1 psi

End of Adjusting Screw-to-Nut Length (maximum) 4 mm

0.157 in.

c. Hold adjusting screw. Tighten nut to specification.


Item Measurement Specification

Adjusting Screw-to-Housing Nut Torque 5.0 N˙m

45 lb.-in.

[12] - Check pressure setting again.

<- Go to Section TOC Section 9025 page 323 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Pump Control Pilot Pressure Signal Test


Specifications

SPECIFICATIONS

45—55°C
Hydraulic Oil Temperature
110—130°F

Engine Speed Fast Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

1.03 MPa
1030 kPa
Pump 1 and Pump 2 Pump Control Pressure in Neutral Pressure (approximate)
10.3 bar
149 psi

3.70 MPa
3700 kPa
Pump 1 and Pump 2 Pump Control Pressure at Full Actuation Pressure (approximate)
37.0 bar
537 psi

The function of the pump 1 and pump 2 flow rate pilot valves (port SA and SB), is to send a regulated pilot control pressure
signal to its respective pump regulator to change pump flow in response to the actuation of pilot control valves to shift the
control valve spools.

Purpose of this test is to check regulated pump control pilot pressure signal from flow rate pilot valves to remote control spool
in pump 1 and pump 2 regulators. Pressure increases as a function is actuated and decreases when function is returned to
neutral. The pressure signals are checked by monitoring the pump 1 and pump 2 control pressure sensors.

For the flow rate pilot valves, see Pilot Signal Manifold Operation . (Group 9025-05.)

For the remote control spools, see Pump 1 and Pump 2 Regulator Operation . (Group 9025-05.)

[1] - Connect one of the following test equipment to monitor pump 1 and pump 2 control pressure, hydraulic oil temperature,
and actual engine speed.

Monitor application. For instruction to actuate the service menu on monitor in cab, see Service Menu . (Group 9015-16.)
Select the following items to display:
Pump 1 Pump Control Pressure
Pump 2 Pump Control Pressure
Hydraulic Oil Temperature
Actual Engine Speed
Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select
the following items to display:
Pump 1 Pump Control Pressure
Pump 2 Pump Control Pressure
Hydraulic Oil Temperature
Actual Engine Speed
MPDr application. For instruction, see MPDr Connection Procedure . (Group 9015-20.) Select the following items to display:
Pump 1 Pump Control Pressure
Pump 2 Pump Control Pressure
Hydraulic Oil Temperature
Actual Engine Speed

[2] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)

[3] - Run machine at specification.

Item Measurement Specification

Hydraulic Oil Temperature 45—55°C

<- Go to Section TOC Section 9025 page 324 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Item Measurement Specification

110—130°F

Engine Speed Fast Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

[4] - Return all control levers and pedals to neutral position. Place pilot shutoff lever in the unlock (DOWN) position.

[5] - Record pressure readings from monitor.

Item Measurement Specification

Pump 1 and Pump 2 Pump Control Pressure in Neutral Pressure (approximate) 1.03 MPa

1030 kPa

10.3 bar

149 psi

[6] -

CAUTION:

Prevent possible injury from machine movement. Ensure that area is clear of bystanders and large
enough to operate all machine functions.

Slowly actuate control lever for boom up to full stroke while observing the monitor.

The pressures must increase smoothly and evenly as function is actuated to full stroke.

[7] - Hold control lever at full stroke. Record pressure readings from monitor.

Item Measurement Specification

Pump 1 and Pump 2 Pump Control Pressure at Full Actuation Pressure (approximate) 3.70 MPa

3700 kPa

37.0 bar

537 psi

[8] - Check the following if the pressure signal does not increase smoothly and evenly or is not to specification.

Check hoses from pilot signal manifold to pump 1 and pump 2 regulators for damage.
Check pump 1 and pump 2 control pressure sensors, Perform Pressure Sensor Test . (Group 9015-20.)
To remove and inspect pump 1 and pump 2 flow rate pilot valves, See Pilot Signal Manifold Disassemble and Assemble .
(Group 3360.)

<- Go to Section TOC Section 9025 page 325 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Main Relief and Power Dig Valve Test and Adjustment


Specifications

SPECIFICATIONS

45—55°C
Hydraulic Oil Temperature
110—130°F

Engine Speed Fast Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

34.0—36.5 MPa
34 000—36 500 kPa
Main Relief Valve Pressure
340—365 bar
4931—5294 psi

35.3—38.3 MPa
35 300—38 300 kPa
Power Dig Valve Pressure
353—383 bar
5120—5555 psi

2.95 MPa
2950 kPa
First Adjusting Plug Pressure Change (approximate per 1/4 turn)
29.5 bar
427 psi

49—55 N·m
24 mm Nut Torque
36—41 lb.-ft.

2.95 MPa
2950 kPa
Second Adjusting Plug Pressure Change (approximate per 1/4 turn)
29.5 bar
427 psi

59—69 N·m
27 mm Nut Torque
44—50 lb.-ft.

Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Pump 1 Adapter (1/4 M BSPP ORB x 7/16-20 M 37°)

Pump 2 Adapter (-8 ORFS)

Gauge 70 000 kPa (700 bar) (10 000 psi)

JT02156A Digital Pressure/Temperature Analyzer

JT02160 Transducer 70 000 kPa (700 bar) (10 000 psi)

Combination Wrenches 24 and 27 mm

Purpose of main relief valve is to limit the maximum hydraulic system pressure. Power dig is a temporary increase of the
system pressure. The valve is checked and adjusted to protect components from damage caused by excessive pressures.

[1] -

<- Go to Section TOC Section 9025 page 326 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Pump 1 and Pump 2 Test Ports

Pump 1 and Pump 2 Test Ports

LEGEND:
1 Pump 1 Test Port
2 Pump 1 Adapter
3 Pump 2 Test Port
4 Pump 2 Adapter
5 JT02160 Transducer
Connect one of the following test equipment to monitor pump 1 and 2 delivery pressure, hydraulic oil temperature, and actual
engine speed.

Monitor application. For instruction to actuate the service menu on monitor in cab, see Service Menu . (Group 9015-16.)
Select the following items to display:
Pump 1 Delivery Pressure
Pump 2 Delivery Pressure

<- Go to Section TOC Section 9025 page 327 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Hydraulic Oil Temperature


Actual Engine Speed
Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select
the following items to display:
Pump 1 Delivery Pressure
Pump 2 Delivery Pressure
Hydraulic Oil Temperature
Actual Engine Speed
MPDr application. For instruction, see MPDr Connection Procedure . (Group 9015-20.) Select the following items to display:
Pump 1 Delivery Pressure
Pump 2 Delivery Pressure
Hydraulic Oil Temperature
Actual Engine Speed

Pump 1 Adapter

1/4 M BSPP ORB x 7/16-20 M 37°

To connect to the test port of pump 1

Pump 2 Adapter

-8 ORFS

To connect to the test port of pump 2.

Gauge 70 000 kPa (700 bar) (10 000 psi)

To measure hydraulic pressure.

Digital Pressure/Temperature Analyzer

JT02156A

To display hydraulic pressure readings.

Transducer 70 000 kPa (700 bar) (10 000 psi)

JT02160

To measure hydraulic pressure.

[2] - Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank
Pressure Release Procedure . (Group 9025-25.)

[3] - Remove plug from pump 1 test port (1) or pump 2 test port (3).

[4] - Install pump 1 adapter (2) or pump 2 adaptor (4).

[5] - Connect JT02156A Digital Pressure/Temperature Analyzer and JT02160 Transducer (5) or 70 000 kPa (700 bar) (10 000
psi) gauge to adapter.

[6] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)

[7] - Run machine at specification.

Item Measurement Specification

Hydraulic Oil Temperature 45—55°C

<- Go to Section TOC Section 9025 page 328 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Item Measurement Specification

110—130°F

Engine Speed Fast Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

[8] - Actuate arm in function over relief. Record main relief pressure reading.

[9] - Actuate arm in function over relief while pressing power dig switch. Record power dig pressure reading.

[10] - Adjust main relief and power dig valve (117) pressure as needed.
LEGEND:
6 First Adjusting Plug
7 24 mm Nut
8 Second Adjusting Plug
9 27 mm Nut
10 Piston
73 Right Control Valve (4-spool)
74 Left Control Valve (5-spool)
117 Main Relief and Power Dig Valve

Main Relief and Power Dig Valve Location

<- Go to Section TOC Section 9025 page 329 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Main Relief and Power Dig Valve

→NOTE:

If pressure setting cannot be raised by adjusting main relief and power dig valve, arm in circuit relief
valve pressure setting may be low. Before continuing, see Circuit Relief Valve Test and Adjustment .
(Group 9025-25.)

Item Measurement Specification

Main Relief Valve Pressure 34.0—36.5 MPa

34 000—36 500 kPa

340—365 bar

4931—5294 psi

Power Dig Valve Pressure 35.3—38.3 MPa

35 300—38 300 kPa

353—383 bar

5120—5555 psi

[11] - Loosen 24 mm nut (7).

24 and 27mm Combination Wrenches

To loosen and tighten adjusting plugs and nuts.

[12] - Turn first adjusting plug (6) in until piston (10) is against bottom of bore in second adjusting plug (8). Tighten nut finger
tight.

<- Go to Section TOC Section 9025 page 330 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

[13] - Loosen 27 mm nut (9).

[14] - Start engine.

[15] - Actuate arm in function over relief.

[16] - Turn second adjusting plug (8) IN to increase power dig relief pressure or turn adjusting plug OUT to decrease pressure.

Item Measurement Specification

Second Adjusting Plug Pressure Change (approximate per 1/4 turn) 2.95 MPa

2950 kPa

29.5 bar

427 psi

[17] - Hold second adjusting plug (8). Tighten 27 mm nut (9) to specification.

Item Measurement Specification

27 mm Nut Torque 59—69 N·m

44—51 lb.-ft.

[18] - Loosen 24 mm nut (7).

[19] - Actuate arm in function over relief.

[20] - Turn first adjusting plug (6) OUT to decrease pressure within specified pressure for main relief valve.

Item Measurement Specification

First Adjusting Plug Pressure Change (approximate per 1/4 turn) 2.95 MPa

2950 kPa

29.5 bar

427 psi

[21] - Hold first adjusting plug (6). Tighten 24 mm nut (7) to specification.

Item Measurement Specification

24 mm Nut Torque 49—55 N·m

36—41 lb.-ft.

[22] - Repeat test procedure and compare pressures to specification.

<- Go to Section TOC Section 9025 page 331 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Circuit Relief Valve Test and Adjustment


Specifications

SPECIFICATIONS

45—55°C
Hydraulic Oil Temperature
110—130°F

Engine Speed (approximate) 1300 rpm

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

37.3—38.3 MPa
37 300—38 300 kPa
Bucket Curl Pressure
373—383 bar
5410—5555 psi

39.2—40.2 MPa
39 200—40 200 kPa
Bucket Dump Pressure
392—402 bar
5685—5831 psi

37.3—38.3 MPa
37 300—38 300 kPa
Arm In Pressure
373—383 bar
5410—5555 psi

39.2—40.2 MPa
39 200—40 200 kPa
Arm Out Pressure
392—402 bar
5685—5831 psi

39.2—40.2 MPa
39 200—40 200 kPa
Boom Up Pressure
392—402 bar
5685—5831 psi

37.3—38.3 MPa
37 300—38 300 kPa
Boom Down Pressure
373—383 bar
5410—5555 psi

2.65 MPa
2650 kPa
Circuit Relief Valve Pressure Change (approximate per 1/4 turn)
26.5 bar
385 psi

20 N·m
Circuit Relief Valve Adjusting Screw-to-Plug Nut Torque
177 lb.-in.

Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Pump 1 Adapter (1/4 M BSPP ORB x 7/16-20 M 37°)

Pump 2 Adapter (-8 ORFS)

Gauge 70 000 kPa (700 bar) (10 000 psi)

JT02156A Digital Pressure/Temperature Analyzer

JT02160 Transducer 70 000 kPa (700 bar) (10 000 psi)

Purpose of this test is to verify the front attachment circuit relief valve pressures are within specification.

Circuit relief valves limit high pressure spikes caused by external forces when functions are in neutral. Valves are checked and
adjusted to specification to protect components from damage.

[1] -

<- Go to Section TOC Section 9025 page 332 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Pump 1 and Pump 2 Test Ports

Pump 1 and Pump 2 Test Ports

LEGEND:
1 Pump 1 Test Port
2 Pump 1 Adapter
3 Pump 2 Test Port
4 Pump 2 Adapter
5 JT02160 Transducer
Connect one of the following test equipment to monitor pump 1 and 2 delivery pressure, hydraulic oil temperature, and actual
engine speed.

Monitor application. See Service Menu for instruction to actuate the service menu on monitor in cab. (Group 9015-16.)
Select the following items to display:
Pump 1 Delivery Pressure
Pump 2 Delivery Pressure

<- Go to Section TOC Section 9025 page 333 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Hydraulic Oil Temperature


Actual Engine Speed
Service ADVISOR ™ application. See Service ADVISOR™ Connection Procedure for instruction. (Group 9015-20.) Select the
following items to display:
Pump 1 Delivery Pressure
Pump 2 Delivery Pressure
Hydraulic Oil Temperature
Actual Engine Speed
MPDr application. See MPDr Connection Procedure for instruction. (Group 9015-20.) Select the following items to display:
Pump 1 Delivery Pressure
Pump 2 Delivery Pressure
Hydraulic Oil Temperature
Actual Engine Speed

Pump 1 Adapter

(1/4 M BSPP ORB x 7/16-20 M 37°)

To connect to the test port of pump 1 and pump 2.

Pump 2 Adapter

(-8 ORFS)

To connect to the test port of pump 2.

Gauge 70 000 kPa (700 bar) (10 000 psi)

To measure hydraulic pressure.

Digital Pressure/Temperature Analyzer

JT02156A

To display hydraulic pressure readings.

Transducer 70 000 kPa (700 bar) (10 000 psi)

JT02160

To measure hydraulic pressure.

[2] - Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank
Pressure Release Procedure . (Group 9025-25.)

[3] - Remove plug from pump 1 test port (1) and pump 2 test port (3).

[4] - Install pump 1 adapter (2) and pump 2 adapter (4).

[5] - Connect JT02156A Digital Pressure/Temperature Analyzer and JT02160 Transducer (5) or 70 000 kPa (700 bar) (10 000
psi) gauge to adapter.

[6] - Turn second adjusting plug of main relief and power dig valve in 1/2 turn to increase pressure setting. See Main Relief and
Power Dig Valve Test and Adjustment for adjustment procedure. (Group 9025-25.)

[7] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)

<- Go to Section TOC Section 9025 page 334 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

[8] - Run machine at specification.

Item Measurement Specification

Hydraulic Oil Temperature 45—55°C

110—130°F

Engine Speed (approximate) 1300 rpm

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

[9] -

Control Valve (top view)

<- Go to Section TOC Section 9025 page 335 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Control Valve (bottom view)

LEGEND:
73 Front Control Valve (4-spool)
74 Rear Control Valve (5-spool)
79 Bucket Dump Circuit Relief and Anticavitation Valve
80 Bucket Curl Circuit Relief and Anticavitation Valve
88 Boom Up Circuit Relief and Anticavitation Valve
89 Boom Down Circuit Relief and Anticavitation Valve
102 Arm In Circuit Relief and Anticavitation Valve
103 Arm Out Circuit Relief and Anticavitation Valve
117 Main Relief and Power Dig Valve
Actuate the function over relief for circuit relief valve (79, 80, 88, 89, 102, and 103) being checked. Record pressure reading.

Item Measurement Specification

Bucket Curl Pressure 37.3—38.3 MPa

37 300—38 300 kPa

373—383 bar

5410—5555 psi

Bucket Dump Pressure 39.2—40.2 MPa

39 200—40 200 kPa

392—402 bar

5685—5831 psi

Arm In Pressure 37.3—38.3 MPa

37 300—38 300 kPa

373—383 bar

5410—5555 psi

Arm Out Pressure 39.2—40.2 MPa

39 200—40 200 kPa

392—402 bar

5685—5831 psi

Boom Up Pressure 39.2—40.2 MPa

<- Go to Section TOC Section 9025 page 336 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Item Measurement Specification

39 200—40 200 kPa

392—402 bar

5685—5831 psi

Boom Down Pressure 37.3—38.3 MPa

37 300—38 300 kPa

373—383 bar

5410—5555 psi

[10] - Adjust the circuit relief valve as needed. Turn adjusting screw in to increase pressure setting; turn adjusting screw out to
decrease pressure setting. Hold screw and tighten nut to specification.

Item Measurement Specification

Circuit Relief Valve Pressure Change (approximate per 1/4 turn) 2.65 MPa

2650 kPa

26.5 bar

385 psi

Circuit Relief Valve Adjusting Screw-to-Plug Nut Torque 20 N·m

177 lb.-in.

[11] - Check pressures again.

[12] - Turn second adjusting plug of main relief and power dig valve out to its original setting. Check main pressure setting.
See Main Relief and Power Dig Valve Test and Adjustment for adjustment procedure. (Group 9025-25.)

<- Go to Section TOC Section 9025 page 337 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Blade Main Relief Valve Test and Adjustment

IMPORTANT:

Relief pressure setting is higher when operating blade down function. The blade down circuit relief and
anticavitation valve is set higher than blade up circuit relief and anticavitation valve. The difference is
noticed when checking both blade up and blade down circuits over relief.

Specifications

SPECIFICATIONS

45—55°C
Hydraulic Oil Temperature
110—130°F

Engine Speed Dial Position 1650—1750 rpm

Work Mode Switch Preload Dig Mode

Power Mode Switch Position PWR (power) Mode

Auto-Idle Switch Position OFF

27.5 MPa
27 500 kPa
Blade Up Relief Valve (approximate)
275 bar
3989 psi

39.2 MPa
39 200 kPa
Blade Down Relief Valve (approximate)
392 bar
5685 psi

3.8 MPa
3378 kPa
Blade Main Relief Valve Pressure Change (approximate per 1/4 turn)
34 bar
490 psi

9.82 N·m
24 mm Lock Nut Torque
7.2 lb·ft

Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Adapter Tee (9/16-18 F Sw 37° x 7/16-20 M 37° x 9/16-18 M 37°)

Gauge 70 000 kPa (700 bar) (10 000 psi)

JT02156A Digital Pressure/Temperature Analyzer

JT02160 Transducer, 70 000 kPa (700 bar) (10 000 psi)

Combination Wrench 24 mm

The purpose of blade main relief valve is to limit the maximum hydraulic system pressure in the blade circuit. The valve is
checked and adjusted, to protect components from damage caused by excessive pressures.

[1] -

CAUTION:

Avoid injury from escaping fluid under pressure. The hydraulic oil tank is pressurized. Stop engine and
relieve pressure in the system before disconnecting hydraulic lines.

Stop engine and release hydraulic oil tank pressure, by pushing pressure release valve at top of hydraulic oil tank.

[2] -

<- Go to Section TOC Section 9025 page 338 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Blade Pump Pressure Test

LEGEND:
1 Test Port
2 Adapter Tee
3 JT02160 Transducer
132 Fan Drive/Blade Pump
Disconnect delivery line from fan drive/blade pump (132). For blade and line connection location, see Blade Hydraulic System
Component Location . (Group 9025-15.)

[3] - Install adapter tee (2) and connect delivery line to test port (1).

[4] - Install JT02156A Digital Pressure/Temperature Analyzer and JT02160 Transducer or 70 000 kPa (700 bar) (10 000 psi)
gauge.

Adapter Tee

9/16-18 F Sw 37° x 7/16-20 M 37° x 9/16-18 M 37°

To connect gauge or transducer in blade pump delivery line.

Gauge 70 000 kPa (700 bar) (10 000 psi)

To measure hydraulic pressure.

Digital Pressure/Temperature Analyzer

JT02156A

<- Go to Section TOC Section 9025 page 339 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

To display hydraulic pressure readings.

Transducer, 70 000 kPa (700 bar) (10 000 psi)

Transducer, 70 000 kPa (700 bar) (10 000 psi)

To measure hydraulic pressure.

[5] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)

[6] - Run machine at following specifications:

Item Measurement Specification

Hydraulic Oil Temperature 45—55°C

110—130°F

Engine Speed 1650—1750 rpm

Work Mode Switch Position Dig Mode

Power Mode Switch Position PWR (power) Mode

Auto-Idle Switch Position OFF

[7] - Slowly operate blade function over relief. Record blade main relief valve pressure reading.

[8] -

→NOTE:

If blade circuit main relief valve does not meet specification, adjustment can be made.

Adjust blade main relief valve pressure as needed.

Item Measurement Specification

Blade Up Relief Valve Pressure (approximate) 20.6 MPa

20 600 kPa

206 bar

2990 psi

Blade Down Relief Valve Pressure (approximate) 39.2 MPa

39 200 kPa

392 bar

5685 psi

[9] -

<- Go to Section TOC Section 9025 page 340 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

LEGEND:
1 24 mm Lock Nut
2 Adjusting Screw
136 Blade Main Relief Valve

Blade Main Relief Valve

Loosen 24 mm lock nut (1).

Combination Wrench 24 mm

To loosen and tighten adjusting lock nut.

[10] - Turn adjusting screw (2) to change blade main relief valve setting. Turn clockwise to increase pressure; turn counter
clockwise to decrease pressure.

Item Measurement Specification

Blade Main Relief Valve Pressure Change (approximate per 1/4 turn) 3.8 MPa

3378 kPa

34 bar

490 psi

[11] - Hold adjusting screw. Tighten 24 mm lock nut to specification.

Item Measurement Specification

24 mm Nut Torque 9.82 N·m

7.2 lb·ft

[12] - Check pressure again.

[13] -

→NOTE:

Adjustments to circuit relief valves should not be attempted. Replace circuit relief valves as necessary.

<- Go to Section TOC Section 9025 page 341 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

LEGEND:
137 Blade Control Valve
141 Blade Up Circuit Relief and Anticavitation Valve
142 Blade Down Circuit Relief and Anticavitation Valve

Blade Control Valve Circuit Relief and Anticavitation


Valves

If pressure specification cannot be achieved by adjusting blade main relief valve replace circuit relief and anticavitation valves
(141 and 142).

[14] - Check pressure again.

<- Go to Section TOC Section 9025 page 342 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Swing Motor Crossover Relief Valve Test and Adjustment


Specifications

SPECIFICATIONS

45—55°C
Hydraulic Oil Temperature
110—130°F

Engine Speed (approximate) 1300 rpm

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

33.0—35.5 MPa
33 000—35 500 kPa
Swing Motor Crossover Relief Valve Pressure
330—355 bar
4787—5150 psi

1.0 MPa
1000 kPa
Swing Motor Crossover Relief Adjusting Screw Pressure Change (approximate per 1/4 turn)
10 bar
142 psi

49 N·m
Swing Motor Crossover Relief Valve Lock Nut
36 lb.-ft.

Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Pump 1 Adapter (1/4 M BSPP ORB x 7/16-20 M 37°)

Pump 2 Adapter (-8 ORFS)

Gauge 70 000 kPa (700 bar) (10 000 psi)

JT02156A Digital Pressure/Temperature Analyzer

JT02160 Transducer 70 000 kPa (700 bar) (10 000 psi)

Purpose of this test is to verify the swing motor crossover relief valve pressures are within specification.

Swing motor crossover relief valves limit system pressure in the swing circuit. They protect swing components from high
stresses generated during the starting and stopping of the upperstructure. They also protect components against pressure
spikes from external forces when the control valve is in neutral.

[1] -

<- Go to Section TOC Section 9025 page 343 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Pump 1 and Pump 2 Test Ports

Pump 1 and Pump 2 Test Ports

LEGEND:
1 Pump 1 Test Port
2 Pump 1 Adapter
3 Pump 2 Test Port
4 Pump 2 Adapter
5 JT02160 Transducer
Connect one of the following test equipment to monitor pump 2 delivery pressure, hydraulic oil temperature, and actual engine
speed.

Monitor application. For instruction to actuate the service menu on monitor in cab, see Service Menu . (Group 9015-16.)
Select the following items to display:
Pump 1 Delivery Pressure
Pump 2 Delivery Pressure

<- Go to Section TOC Section 9025 page 344 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Hydraulic Oil Temperature


Actual Engine Speed
Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select
the following items to display:
Pump 1 Delivery Pressure
Pump 2 Delivery Pressure
Hydraulic Oil Temperature
Actual Engine Speed
MPDr application. For instruction, See MPDr Connection Procedure . (Group 9015-20.) Select the following items to
display:
Pump 1 Delivery Pressure
Pump 2 Delivery Pressure
Hydraulic Oil Temperature
Actual Engine Speed

Adapter

1/4 M BSPP ORB x 7/16-20 M 37°

To connect to the test port of pump 1 and pump 2.

Pump 2 Adapter

-8 ORFS

To connect to the test port of pump 2.

Gauge 70 000 kPa (700 bar) (10 000 psi)

To measure hydraulic pressure.

Digital Pressure/Temperature Analyzer

JT02156A

To display hydraulic pressure readings.

Transducer 70 000 kPa (700 bar) (10 000 psi)

JT02160

To measure hydraulic pressure.

[2] - Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank
Pressure Release Procedure . (Group 9025-25.)

[3] - Remove plug from pump 2 test port (3).

[4] - Install adapter (4).

[5] - Connect JT02156A Digital Pressure/Temperature Analyzer and JT02160 Transducer (5) or 70 000 kPa (700 bar) (10 000
psi) gauge to adapter.

[6] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)

[7] - Run machine at specification.

<- Go to Section TOC Section 9025 page 345 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Item Measurement Specification

Hydraulic Oil Temperature 45—55°C

110—130°F

Engine Speed (approximate) 1300 rpm

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

[8] - Actuate swing function over relief. Record pressure reading. Repeat for opposite direction.

Compare recorded pressures to specification.

Item Measurement Specification

Swing Motor Crossover Relief Valve Pressure 33.0—35.5 MPa

33 000—35 500 kPa

330—355 bar

4787—5150 psi

[9] -

Swing Motor Crossover Relief Valve Location

<- Go to Section TOC Section 9025 page 346 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Swing Motor Crossover Relief Valve

LEGEND:
6 Poppet
7 Spring
8 Lock Nut
9 Adjusting Screw
52 Swing Motor
54 Swing Crossover Relief Valve (2 used)
59 Swing Gear Case
Stop machine before making adjustments. Loosen lock nut (8). Turn adjusting screw (9) IN to increase pressure; OUT to
decrease pressure.

Item Measurement Specification

Swing Motor Crossover Relief Adjusting Screw Pressure Change Pressure Change (approximate per 1/4 turn) 1.00 MPa

1000 kPa

10 bar

142 psi

[10] - Tighten lock nut to specification.

Item Measurement Specification

Swing Motor Crossover Relief Valve lock nut Torque 49 N·m

36 lb.-ft.

[11] - Actuate swing function over relief to check adjustment.

<- Go to Section TOC Section 9025 page 347 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Travel Motor Crossover Relief Valve Test and Adjustment


Specifications

SPECIFICATIONS

45—55°C
Hydraulic Oil Temperature
110—130°F

Engine Speed (approximate) 1300 rpm

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

34.0—36.5 MPa
34 000—36 500 kPa
Travel Motor Crossover Relief Valve Pressure
344—3650 bar
4931—5294 psi

0.9 MPa
900 kPa
Crossover Relief Valve Shim Pressure Change [per 0.5 mm (0.02 in.)]
9 bar
130 psi

310 N˙m
Crossover Relief Valve Torque
230 lb.-ft.

Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Pump 1 Adapter (1/4 M BSPP ORB x 7/16-20 M 37°)

Pump 2 Adapter (-8 ORFS)

Gauge 70 000 kPa (700 bar) (10 000 psi)

JT02156A Digital Pressure/Temperature Analyzer

JT02160 Transducer 70 000 kPa (700 bar) (10 000 psi)

76.2 mm (3 in.) OD Pin or Round Bar Stock (2 used)

Purpose of test is to check that the travel motor crossover relief valve pressure is within specification.

[1] -

<- Go to Section TOC Section 9025 page 348 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Pump 1 and Pump 2 Test Ports

Pump 1 and Pump 2 Test Ports

LEGEND:
1 Pump 1 Test Port
2 Pump 1 Adapter
3 Pump 2 Test Port
4 Pump 2 Adapter
5 JT02160 Transducer
Connect one of the following test equipment to monitor pump 1 and 2 delivery pressure, hydraulic oil temperature, and actual
engine speed.

Monitor application. For instruction to actuate the service menu on monitor in cab, see Service Menu . (Group 9015-16.)
Select the following items to display:
Pump 1 Delivery Pressure
Pump 2 Delivery Pressure

<- Go to Section TOC Section 9025 page 349 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Hydraulic Oil Temperature


Actual Engine Speed
Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select
the following items to display:
Pump 1 Delivery Pressure
Pump 2 Delivery Pressure
Hydraulic Oil Temperature
Actual Engine Speed
MPDr application. For instruction, see MPDr Application . (Group 9015-20.) Select the following items to display:
Pump 1 Delivery Pressure
Pump 2 Delivery Pressure
Hydraulic Oil Temperature
Actual Engine Speed

Adapter

(1/4 M BSPP ORB x 7/16-20 M 37°)

To connect to the test port of pump 1 and pump 2.

Pump 2 Adapter

-8 ORFS

To connect to the test port of pump 2.

Gauge 70 000 kPa (700 bar) (10 000 psi)

To measure hydraulic pressure.

Digital Pressure/Temperature Analyzer

JT02156A

To display hydraulic pressure readings.

Transducer 70 000 kPa (700 bar) (10 000 psi)

JT02160

To measure hydraulic pressure.

[2] - Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank
Pressure Release Procedure . (Group 9025-25.)

[3] - Remove the plug from pump 1 and pump 2 test port (1 and 3).

[4] - Install adapters (2 and 4).

[5] - Install JT02156A Digital Pressure/Temperature Analyzer and JT02160 Transducer (5) or 70 000 kPa (700 bar) (10 000 psi)
gauge.

[6] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)

[7] -

<- Go to Section TOC Section 9025 page 350 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

LEGEND:
6 76.2 mm (3 in.) OD Pin

Travel Motor Stalled Using Pin

Install 76.2 mm (3 in.) OD pin (6) or round bar stock between sprocket and track frame to stall travel motor.

76.2 mm (3 in.) OD Pin or Round Bar Stock (2 used)

To put between sprocket and track frame to stall travel motor.

[8] - Run machine at specification.

Item Measurement Specification

Hydraulic Oil Temperature 45—55°C

110—130°F

Engine Speed (approximate) 1300 rpm

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

[9] -
LEGEND:
68 Travel Motor Crossover Relief Valve (2 used)

Travel Motor Crossover Relief Valve Location


<- Go to Section TOC Section 9025 page 351 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Hold power dig switch. Slowly actuate the travel function for the crossover relief valve (68) being checked.

Record pressure reading. Make adjustments as necessary.

Item Measurement Specification

Travel Motor Crossover Relief Valve Pressure 34.0—36.5 MPa

34 000—36 500 kPa

340—365 bar

4931—5294 psi

[10] - Stop engine. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank.

[11] -

Travel Motor Crossover Relief Valve Shims

LEGEND:
22 Poppet
23 Spring Seat
24 Shim
25 Spring
Remove crossover relief valve. Add or remove shims (24) to adjust pressure.

Item Measurement Specification

Crossover Relief Valve Shim Pressure Change [per 0.5 mm (0.02 in.)] 0.9 MPa

900 kPa

9 bar

130 psi

[12] - Install crossover relief valve. Tighten to specification.

Item Measurement Specification

Crossover Relief Valve Torque 310 N˙m

<- Go to Section TOC Section 9025 page 352 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Item Measurement Specification

230 lb.-ft.

[13] - Hold power dig switch. Actuate travel function at stall to check adjustment.

<- Go to Section TOC Section 9025 page 353 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Pump Regulator Test and Adjustment—Minimum Flow


Specifications

SPECIFICATIONS

45—55°C
Hydraulic Oil Temperature
110—130°F

Engine Speed Fast Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

Travel Speed Switch Position Slow (turtle)

One Revolution of Raised Track Cycle Time (with pump regulator pilot line disconnected) 24.4—26.4 seconds

Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Plug 7/16-20 M 37°

Stop Watch

Combination Wrench 17 mm

Flat Blade Screwdriver

Purpose of this test is to check and adjust the minimum flow rate of pump 1 and 2 using the cycle time for travel as an
indicator of pump flow rate.

[1] - Check and adjust track sag. See Check and Adjust Track Sag . (Operator′s Manual.)

[2] - Connect one of the following test equipment to monitor hydraulic oil temperature and actual engine speed.

Monitor application. For instruction to actuate the service menu on monitor in cab, see Service Menu . (Group 9015-16.)
Select the following items to display:
Hydraulic Oil Temperature
Actual Engine Speed
Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select
the following items to display:
Hydraulic Oil Temperature
Actual Engine Speed
MPDr application. For instruction, see MPDr Connection Procedure . (Group 9015-20.) Select the following items to display:
Hydraulic Oil Temperature
Actual Engine Speed

[3] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)

Item Measurement Specification

Hydraulic Oil Temperature 45—55°C

110—130°F

[4] - Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank
Pressure Release Procedure . (Group 9025-25.)

[5] -

<- Go to Section TOC Section 9025 page 354 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

LEGEND:
1 Hydraulic Pump 1 Pilot Line
2 Hydraulic Pump 2 Pilot Line
17 Hydraulic Pump 1 Regulator
18 Hydraulic Pump 2 Regulator

Hydraulic Pump Regulator Pilot Lines

Disconnect pump regulator pilot lines (1 and 2) from pump 1 and 2 regulators (17 and 18). Install plugs in pilot lines.

Plug

7/16-20 M 37°

To plug pump control valve pilot lines.

Leave fittings on regulator open. Lay a shop towel over the fittings.

[6] - Raise right track off ground for pump 1 testing or left track for pump 2.

[7] - Run machine at specifications:

Item Measurement Specification

Engine Speed Fast Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

Travel Speed Switch Position Slow (turtle)

[8] - Actuate travel function to full speed. Record cycle time for one revolution.

Stop Watch

To time test.

[9] -

<- Go to Section TOC Section 9025 page 355 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

LEGEND:
5 Minimum Flow Adjusting Screw
6 17 mm Nut

Minimum Flow Adjusting Screw

Adjust minimum flow adjusting screw (5) as needed to obtain specified cycle time. Turn screw in to decrease cycle time (flow
rate increases); turn screw out to increase cycle time (flow rate decreases). Hold screw and tighten 17 mm nut (6).

Combination Wrench 17 mm

To loosen and tighten nut

Flat Blade Screwdriver

To turn adjusting screw

Item Measurement Specification

One Revolution of Raised Track (with pump regulator pilot line disconnected) Cycle Time 24.4—26.4 seconds

[10] - Repeat procedure for other pump.

Adjust regulators so cycle times are approximately the same for each track.

<- Go to Section TOC Section 9025 page 356 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Pump Regulator Test and Adjustment—Maximum Flow


Specifications

SPECIFICATIONS

45—55°C
Hydraulic Oil Temperature
110—130°F

3 mm
End of Maximum Flow Adjusting Screw to 13 mm Nut Distance
0.125 in. (1/8 in.)

Engine Speed Fast Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

Travel Speed Switch Position Slow (turtle)

Track Raised—3 Revolutions 23.4—27.4 sec.

Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Combination Wrench 13 mm

Flat Blade Screwdriver

Stop Watch

Combination Wrench 30 mm

Purpose of this test is to check and adjust the maximum flow rate of pump 1 and 2 using the cycle times for travel. Travel
times for each side need to be the same.

Maximum flow rate cannot be significantly increased by turning out the flow adjusting cartridge.

[1] - Check and adjust track sag. See Check and Adjust Track Sag . (Operator′s Manual.)

[2] - Connect one of the following test equipment to monitor hydraulic oil temperature and actual engine speed.

Monitor application. For instruction to actuate the service menu on monitor in cab, see Service Menu . (Group 9015-16.)
Select the following items to display:
Hydraulic Oil Temperature
Actual Engine Speed
Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select
the following items to display:
Hydraulic Oil Temperature
Actual Engine Speed
MPDr application. For instruction, see MPDr Connection Procedure . (Group 9015-20.) Select the following items to display:
Hydraulic Oil Temperature
Actual Engine Speed

[3] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)

Item Measurement Specification

Hydraulic Oil Temperature 45—55°C

110—130°F

[4] -

<- Go to Section TOC Section 9025 page 357 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

LEGEND:
1 Distance
2 Maximum Flow Adjusting Screw
3 13 mm Nut
4 Flow Adjusting Cartridge (track cycle time)
5 30 mm Nut

Flow Adjusting Cartridge and Maximum Flow Adjusting


Screw

Check distance from end of maximum flow adjusting screw (2) to 13 mm nut (3) for both pump 1 and pump 2 regulators. Adjust
screw to specification as needed.

Combination Wrench 13 mm

To loosen and tighten nut and adjust cartridge.

Flat Blade Screwdriver

To turn adjusting screw.

Item Measurement Specification

End of Maximum Flow Adjusting Screw to 13 mm Nut Distance 3 mm

0.125 in. (1/8 in.)

[5] - Run machine at specifications.

Item Measurement Specification

Engine Speed Fast Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

Travel Speed Switch Position Slow (turtle)

[6] - Raise the right track off ground to test pump 1 or left track for pump 2.

[7] - Actuate travel function to full speed with raised track. Record track cycle time for three revolutions.

<- Go to Section TOC Section 9025 page 358 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Repeat procedure for the other pump.

Stop Watch

To time test.

[8] - Adjust flow adjusting cartridge (track cycle time) (4) on pump 1 and pump 2 regulators so track cycle times are within
specification and approximately the same.

Item Measurement Specification

Track Raised—3 Revolutions Cycle Time 23.4—27.4 sec.

Loosen 30 mm nut (5). Turn flow adjusting cartridge in for a slower track cycle time (decrease flow rate), turn flow adjusting
cartridge out for a faster track cycle time (increase flow rate). Tighten 30 mm nut after adjustment.

Combination Wrench 30 mm

To loosen and tighten nut.

<- Go to Section TOC Section 9025 page 359 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Pump Flow Test


Specifications

SPECIFICATIONS

45—55°C
Hydraulic Oil Temperature
110—130°F

Engine Speed Fast Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

59—67 L/min. at 27 MPa


59—67 L/min. at 27 000 kPa
Pump 1 or Pump 2 Flow Rate
59—67 L/min. at 270 bar
15.5—17.7 gpm at 3930 psi

100—106 L/min. at 14.7 MPa


100—106 L/min. at 14 700 kPa
Pump 1 or Pump 2 Flow Rate
100—106 L/min. at 147 bar
26.4—28.0 gpm at 2130 psi

Specifications

SPECIFICATIONS (continued)

1/4 turn clockwise increases minimum pump flow rate approximately 6.2
L/min.
Minimum Flow Adjusting Screw Turn
1/4 turn clockwise increases minimum pump flow rate approximately 1.7
gpm

20 N·m
Minimum Flow Rate Adjusting Screw 17 mm Nut Torque
180 lb.-in.

1/4 turn clockwise decreases maximum pump flow rate approximately


5.2 L/min.
Maximum Flow Adjusting Screw Turn
1/4 turn clockwise decreases maximum pump flow rate approximately
1.4 gpm

10 N·m
Maximum Flow Rate Adjusting Screw 13 mm Nut Torque
89 lb.-in.

1/4 turn clockwise decreases flow rate approximately 10.4 L/min.


Flow Adjusting Cartridge (track cycle time) Turn
1/4 turn clockwise decreases flow rate approximately 2.8 gpm

30 N·m
Flow Adjusting Cartridge (track cycle time) 30 mm Nut Torque
22 lb.-ft.

1/4 turn clockwise increases flow rate approximately 10.4 L/min.


Load Adjusting Cartridge (outer spring) (pressure to flow control-torque adjustment) Turn
1/4 turn clockwise increases flow rate approximately 2.8 gpm

30 N·m
Load Adjusting Cartridge (outer spring) (pressure to flow control-torque adjustment) Torque
22 lb.-ft.

1/4 turn clockwise increases flow rate approximately 2.3 L/min.


Load Adjusting Screw (inner spring) (pressure to flow control-torque adjustment) Turn
1/4 turn clockwise increases flow rate approximately 0.6 gpm

10 N·m
Load Adjusting Screw (inner spring) (pressure to flow control-torque adjustment) Torque
89 lb.-in.

Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Vacuum Pump

JT03452 Split Flange Connector Plate Kit

Flowmeter

T107068 Flange Fitting Split Clamp Half (Code 62)

1020 mm (40 in.) x 1 in. Hose with 90° flange fitting end (Code 62)

Adapter (1/4 M BSPP ORB x 7/16-20 M 37°)

Gauge 70 000 kPa (700 bar) (10 000 psi)

JT02156A Digital Pressure/Temperature Analyzer

JT02160 Transducer 70 000 kPa (700 bar) (10 000 psi)

Purpose of this test is to determine pump condition, and should be performed only if a comparison of actual machine cycle

<- Go to Section TOC Section 9025 page 360 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

times to specified cycle times indicates low pump flow. Do the following appropriate procedures before continuing test:

See Pump Regulator Test and Adjustment—Minimum Flow . (Group 9025-25.)


See Pump Regulator Test and Adjustment—Maximum Flow . (Group 9025-25.)
See Pump 1 and Pump 2 Regulator Operation for information on pump control pressure operation. (Group 9025-05.)
See Torque Control Solenoid Valve Test and Adjustment . (Group 9025-25.)
See Pump Control Pilot Pressure Signal Test . (Group 9025-25.)

[1] -

Pump Flow Test

LEGEND:
1 Pump 1 Delivery Port
2 Pump 2 Delivery Port
3 Pump 1 and Pump 2 Regulator
73 Front Control Valve (4-spool)
74 Rear Control Valve (5-spool)
<- Go to Section TOC Section 9025 page 361 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank
Pressure Release Procedure . (Group 9025-25.)

[2] - Apply vacuum or drain hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank . (Group 3360.) See Drain and Refill
Hydraulic Tank Oil . (Operator’s Manual.)

Vacuum Pump

To minimize oil loss.

[3] - Disconnect pump-to-control valve line from pump 1 delivery port (1) and/or pump 2 delivery port (2).

For instruction, see DFT1218 Split Flange Hose Cap . (Group 9900.)

Split Flange Hose Cap

DFT1218

Close split flange style hose ends.

[4] -

→NOTE:

Both pumps can be connected as shown, but only one pump at a time can be checked when only one
return line is used.

An alternate method is to connect pump-to-control valve lines to outlet of flowmeters. Return oil then
flows through the control valve and hydraulic oil cooler to the hydraulic oil tank.

Connect flowmeter. If available, connect flowmeters to both pumps as shown.

Elbow Fitting

(-16 M BSPP ORB x -16 M ORFS)

To connect return hose from flowmeter to return manifold.

Flowmeter

To measure pump flow.

Flange Fitting Split Clamp Half (Code 62)

T107068

Hold hose with flange fittings in place.

1020 mm (40 in.) x 1 in. hose with 90° flange fitting end (Code 62)

Connect flowmeter to pump.

[5] -

<- Go to Section TOC Section 9025 page 362 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

LEGEND:
6 Arm In Pilot Line
41 Pilot Signal Manifold

Arm In Pilot Line

Disconnect arm in pilot line (6). Install cap on pilot signal manifold (41) and tighten. Install plug in pilot line loose and cover
with shop towel to avoid contamination.

→NOTE:

Pilot line is disconnected so arm in function can be used to put pump 1 and pump 2 into stroke and not
move arm.

[6] - Remove vacuum.

[7] - Open flowmeter loading valve completely.

[8] - Connect one of the following test equipment to monitor pump 1 and 2 delivery pressure, hydraulic oil temperature, and
actual engine speed.

Monitor application. For instruction to actuate the service menu on monitor in cab, see Service Menu . (Group 9015-16.)
Select the following items to display:
Pump 1 Delivery Pressure
Pump 2 Delivery Pressure
Hydraulic Oil Temperature
Actual Engine Speed
Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select
the following items to display:
Pump 1 Delivery Pressure
Pump 2 Delivery Pressure
Hydraulic Oil Temperature
Actual Engine Speed
MPDr application. For instruction, see MPDr Connection Procedure . (Group 9015-20.) Select the following items to display:
Pump 1 Delivery Pressure
Pump 2 Delivery Pressure
Hydraulic Oil Temperature
Actual Engine Speed

Adapter

(1/4 M BSPP ORB x 7/16-20 M 37°)

To connect to the test port of pump 1 and pump 2.

Gauge 70 000 kPa (700 bar) (10 000 psi)

<- Go to Section TOC Section 9025 page 363 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

To measure hydraulic pressure.

Digital Pressure/Temperature Analyzer

JT02156A

To display hydraulic pressure readings.

Transducer, 70 000 kPa (700 bar) (10 000 psi)

JT02160

To measure hydraulic pressure.

[9] - Warm hydraulic oil to specification by closing flowmeter loading valve to increase pressure.

[10] - Operate machine at specification.

Item Measurement Specification

Hydraulic Oil Temperature 45—55°C

110—130°F

Engine Speed Fast Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

[11] - Actuate arm in for pump 1 and pump 2 to full actuation and hold throughout test.

[12] - Slowly close loading valve on flowmeter to obtain specified pressures. Record flow rate at each pressure.

[13] - Open loading valve. Stop engine.

[14] - Compare flow rates to specifications.

Item Measurement Specification

Pump 1 or Pump 2
Pump 1 or Pump 2 Flow Rate 59—67 L/min. at 27 MPa

59—67 L/min. at 27 000 kPa

59—67 L/min. at 270 bar

15.5—17.7 gpm at 3930 psi

Pump 1 or Pump 2 Flow Rate 100—106 L/min. at 14.7 MPa

100—106 L/min. at 14 700 kPa

100—106 L/min. at 147 bar

26.4—28.0 gpm at 2130 psi

[15] - Pump flow rate can be increased by adjusting pump 1 and/or pump 2 regulators.

IMPORTANT:

Avoid possible pump damage. Do not turn minimum flow adjusting screw more than two turns.

<- Go to Section TOC Section 9025 page 364 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Pump 1 and Pump 2 Regulator Adjustment

LEGEND:
8 17 mm Nut
9 Minimum Flow Adjusting Screw
10 13 mm Nut
11 Load Adjusting Screw (inner spring) (pressure to flow control-torque adjustment)
12 Load Adjusting Cartridge (outer spring) (pressure to flow control-torque adjustment)
13 30 mm Nut
14 13 mm Nut
15 Maximum Flow Adjusting Screw
16 Flow Adjusting Cartridge (track cycle time)
17 30 mm Nut
18 Hydraulic Oil Pressure
19 Hydraulic Oil Flow Rate
Minimum flow rate:

a. Loosen 17 mm nut (8).


b. Turn minimum flow adjusting screw (9) clockwise 1/4 turn to increase minimum pump flow.
Item Measurement Specification

Minimum Flow Adjusting Screw Turn 1/4 turn clockwise increases minimum pump flow rate approximately 6.2 L/min.

1/4 turn clockwise increases minimum pump flow rate approximately 1.7 gpm

c. Hold minimum flow adjusting screw. Tighten 17 mm nut to specification.


Item Measurement Specification

Minimum Flow Rate Adjusting Screw 17 mm Nut Torque 20 N·m

180 lb.-in.

[16] -

<- Go to Section TOC Section 9025 page 365 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

IMPORTANT:

Avoid possible pump damage. Do not increase the maximum pump flow rate over maximum flow
specifications.

Do not turn maximum flow adjusting screw more than two turns.

Maximum flow rate:

a. Loosen 13 mm nut (14).


b. Turn maximum flow adjusting screw (15) clockwise 1/4 turn to decrease maximum pump flow.
Item Measurement Specification

Maximum Flow Adjusting Screw Turn 1/4 turn clockwise decreases maximum pump flow rate approximately 5.2 L/min.

1/4 turn clockwise decreases maximum pump flow rate approximately 1.4 gpm

c. Hold maximum flow adjusting screw. Tighten 13 mm nut to specification.


Item Measurement Specification

Maximum Flow Rate Adjusting Screw 13 mm Nut Torque 10 N·m

89 lb.-in.

[17] -

IMPORTANT:

Avoid possible pump damage. Do not turn flow adjusting cartridge more than one turn.

Flow adjusting cartridge (track cycle time):

a. Loosen 30 mm nut (17).


b. Turn flow adjusting cartridge (16) clockwise 1/4 turn to decrease flow rate.
Item Measurement Specification

Flow Adjusting Cartridge (track cycle time) Turn 1/4 turn clockwise decreases flow rate approximately 10.4 L/min.

1/4 turn clockwise decreases flow rate approximately 2.8 gpm

c. When flow adjusting cartridge (16) is turned clockwise, the maximum flow rate also decreases. To maintain the maximum
flow rate unchanged, turn adjusting screw (15) counterclockwise twice as much as adjusting cartridge was turned
clockwise.
d. Hold flow adjusting cartridge. Tighten 30 mm nut to specification.
Item Measurement Specification

Flow Adjusting Cartridge (track cycle time) 30 mm Nut Torque 30 N·m

22 lb.-ft.

[18] -

IMPORTANT:

Avoid possible pump damage. Do not turn load adjusting cartridge more than one turn.

Load adjusting cartridge (outer spring) (pressure to flow control-torque adjustment):

a. Loosen 30 mm nut (13).

<- Go to Section TOC Section 9025 page 366 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

b. Turn load adjusting cartridge (12) clockwise 1/4 turn to increase flow rate.
Item Measurement Specification

Load Adjusting Cartridge (outer spring) (pressure to flow control-torque


Turn 1/4 turn clockwise increases flow rate approximately 10.4 L/min.
adjustment)

1/4 turn clockwise increases flow rate approximately 2.8 gpm

c. Hold load adjusting cartridge. Tighten 30 mm nut to specification.


Item Measurement Specification

Load Adjusting Cartridge (outer spring) (pressure to flow control-torque adjustment) Torque 30 N·m

22 lb.-ft.

[19] -

IMPORTANT:

Avoid possible pump damage. Do not turn load adjusting screw more than one turn.

Load adjusting screw (inner spring) (pressure to flow control-torque adjustment):

a. Loosen 13 mm nut (10).


b. Turn load adjusting screw (11) clockwise 1/4 turn to increase flow rate.
Item Measurement Specification

Load Adjusting Screw (inner spring) (pressure to flow control-torque


Turn 1/4 turn clockwise increases flow rate approximately 1.3 L/min.
adjustment)

1/4 turn clockwise increases flow rate approximately 0.6 gpm

c. Hold load adjusting screw. Tighten 13 mm nut to specification.


Item Measurement Specification

Load adjusting screw (inner spring) (pressure to flow control-torque adjustment) Torque 10 N·m

89 lb.-in.

<- Go to Section TOC Section 9025 page 367 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Swing Motor Leakage Test


Specifications

SPECIFICATIONS

45—55°C
Hydraulic Oil Temperature
110—130°F

Engine Speed Fast Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

0.4 L/min. or less


0.11 gpm of less
Swing Motor Swinging Leakage
0.6 L/min. (maximum allowable)
0.16 gpm (maximum allowable)

1.6 L/min. or less


0.42 gpm or less
Swing Motor Stalled Leakage
2.0 L/min. (maximum allowable)
0.53 gpm (maximum allowable)

Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Cap (9/16-18 F 37°)

Calibrated Container

[1] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)

Item Measurement Specification

Hydraulic Oil Temperature 45—55°C

110—130°F

[2] - Release hydraulic oil tank pressure by pressing pressure release button on top of hydraulic oil tank. See Hydraulic Oil
Tank Pressure Release Procedure . (Group 9025-25.)

[3] -
LEGEND:
Return Line (swing motor to hydraulic oil tank return
1
manifold)
2 Hydraulic Oil Tank Return Manifold
3 Calibrated Container

Return Line

Disconnect return line (1) from hydraulic oil tank return manifold (2). Place return line in calibrated container (3). Install cap on
return manifold fitting.

<- Go to Section TOC Section 9025 page 368 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Cap

9/16-18 F 37°

Cap elbow while return line is disconnected.

Calibrated Container

To measure amount of fluid leakage.

[4] - Run machine at specification.

Item Measurement Specification

Engine Speed Fast Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

[5] -

CAUTION:

To avoid personal injury, clear area of all bystanders before doing test. Slowly swing through one
complete revolution to ensure that the area is clear of objects before testing.

Raise and lower boom to pressurize hydraulic oil tank.

[6] - Operate swing function for 1 minute. Record amount of leakage.

Repeat procedure in opposite swing direction. Record amount of leakage.

Compare amount of leakage for each direction to specification.

Item Measurement Specification

Swing Motor Swinging Leakage 0.4 L/min. or less

0.11 gpm of less

0.6 L/min. (maximum allowable)

0.16 gpm (maximum allowable)

[7] - Stall swing function for 1 minute. Record the amount of leakage.

Repeat procedure by stalling the motor in several different positions. Record the amount of leakage for each position.

Repeat procedure in opposite direction.

Take an average of the readings. Compare amount of leakage to specification.

Item Measurement Specification

Swing Motor Stalled Leakage 1.6 L/min. or less

0.42 gpm or less

2.0 L/min. (maximum allowable)

0.53 gpm (maximum allowable)

[8] - Remove cap and connect return line to hydraulic oil tank return manifold.

[9] - Swing motor leakage over specified allowable amount can be caused by a malfunction in the swing motor crossover relief

<- Go to Section TOC Section 9025 page 369 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

valves.

See Swing Motor Crossover Relief Valve Test and Adjustment . (Group 9025-25.)

[10] - Repair or replace swing motor if the leakage is over specified amount and crossover relief valves are OK.

See Swing Motor and Park Brake Remove and Install . (Group 4360.)

<- Go to Section TOC Section 9025 page 370 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Travel Motor Leakage Test


Specifications

SPECIFICATIONS

45—55°C
Hydraulic Oil Temperature
110—130°F

Engine Speed Fast Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Position OFF

Travel Speed Switch Position Fast (rabbit)

0.3—1.2 L/min
0.08—0.32 gpm
Travel Motor with Track Raised Leakage
1.8 L/min (maximum allowable)
0.48 gpm (maximum allowable)

0.3—1.9 L/min
0.08—0.50 gpm
Travel Motor Stalled Leakage
2.5 L/min (maximum allowable)
0.66 gpm (maximum allowable)

Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Cap (3/4-16 F 37°)

Calibrated Container

76.2 mm (3 in.) Outside Diameter Pin or Round Bar Stock

Plug (3/4-16 M 37°)

[1] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)

Item Measurement Specification

Hydraulic Oil Temperature 45—55°C

110—130°F

[2] - Release hydraulic oil tank pressure by pressing pressure release button on top of hydraulic oil tank. See Hydraulic Oil
Tank Pressure Release Procedure . (Group 9025-25.)

[3] -
LEGEND:
Return Line (center joint to hydraulic oil tank return
1
manifold)
2 Hydraulic Oil Tank Return Manifold
3 Calibrated Container

Center Joint Return Line


<- Go to Section TOC Section 9025 page 371 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Disconnect return line (1) from hydraulic oil tank return manifold (2). Place return line in a calibrated container (3). Install cap
on hydraulic oil tank return manifold fitting.

Cap

3/4-16 F 37°

To cap fitting after disconnecting return line.

Calibrated Container

To measure fluid leakage.

[4] - Raise track off the ground for side being tested.

[5] - Run machine at specification.

Item Measurement Specification

Engine Speed Fast Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Position OFF

Travel Speed Switch Position Fast (rabbit)

[6] - For travel motor being tested, actuate travel forward function at full speed for 1 minute. Record amount of fluid leakage.
Repeat procedure for reverse travel.

Compare leakage to specification. Repair or replace travel motor as necessary. See Travel Motor and Park Brake Remove and
Install . (Group 0260.)

Item Measurement Specification

Travel Motor with Track Raised Leakage 0.3—1.2 L/min

0.08—0.32 gpm

1.8 L/min (maximum allowable)

0.48 gpm (maximum allowable)

[7] -
LEGEND:
4 76.2 mm (3 in.) Outside Diameter Pin

Travel Motor Stalled Using Pin

<- Go to Section TOC Section 9025 page 372 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

To test travel motor for leakage at stall, install pin (4) or round bar stock between the sprocket and track frame on the side
being tested.

76.2 mm (3 in.) Outside Diameter Pin or Round Bar Stock

Put between sprocket and track frame to stall travel motor.

[8] - Actuate the forward travel function being tested to full stroke for 1 minute. Record the amount of fluid leakage.

Repeat procedure by stalling the motor in several different positions and then take an average of readings. Repeat procedure
for reverse travel.

Item Measurement Specification

Travel Motor Stalled Leakage 0.3—1.9 L/min

0.08—0.50 gpm

2.5 L/min (maximum allowable)

0.66 gpm (maximum allowable)

[9] - Remove cap and connect return line to hydraulic oil tank return manifold.

[10] -

Travel Motor Drain Line

LEGEND:
6 Travel Motor Drain Line
7 Test Hose
8 Calibrated Container
For leakage that is substantially more in one direction than the other, a seal in the center joint may be leaking. To isolate
leakage in travel motor or center joint, check leakage at the travel motor.

[11] - Release hydraulic oil tank pressure by pressing pressure release button on top of hydraulic oil tank. See Hydraulic Oil
Tank Pressure Release Procedure . (Group 9025-25.)

[12] - Disconnect travel motor drain line (6) at travel motor. Install plug in the line.

Connect a test hose (7) to fitting on travel motor. Put line in a calibrated container (8).

Plug

3/4-16 M 37°
<- Go to Section TOC Section 9025 page 373 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

To close drain line after disconnected at travel motor.

[13] - Repeat test procedure. Record and compare results.

[14] - Remove test hose and plug. Connect travel motor drain line to travel motor.

[15] - Travel motor leakage over specified allowable amount can be caused by a malfunction in travel motor crossover relief
valve.

See Travel Motor Crossover Relief Valve Test and Adjustment . (Group 9025-25.)

[16] - Repair or replace travel motor if leakage is over specified amount and the crossover relief valves are OK.

See Travel Motor and Park Brake Remove and Install . (Group 0260.)

<- Go to Section TOC Section 9025 page 374 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Cylinder Drift Test—Boom, Arm, and Bucket


Specifications

SPECIFICATIONS

45—55°C
Hydraulic Oil Temperature
110—130°F

750 kg
Bucket Load Weight (approximate)
1654 lb.

10 mm
Boom Cylinder Drift (maximum allowable for 5 minutes)
0.39 in.

20 mm
Arm Cylinder Drift (maximum allowable for 5 minutes)
0.79 in.

15 mm
Bucket Cylinder Drift (maximum allowable for 5 minutes)
0.59 in.

110 mm
Bottom of Bucket-to-Ground Drift (maximum allowable for 5 minutes)
4.33 in.

5 mm
Boom Cylinder—Bucket Empty Drift (maximum allowable for 5 minutes)
0.20 in.

15 mm
Arm Cylinder—Bucket Empty Drift (maximum allowable for 5 minutes)
0.59 in.

10 mm
Bucket Cylinder—Bucket Empty Drift (maximum allowable for 5 minutes)
0.39 in.

100 mm
Arm Tip-to-Ground—Bucket Empty Drift (maximum allowable for 5 minutes)
3.94 in.

Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Tape Measure

Procedure is used to check leakage past the cylinder piston seals, control valve spools, circuit relief valves, boom reduced
leakage valve, and arm reduced leakage valve.

Drift Test—Bucket Filled

[1] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)

Item Measurement Specification

Hydraulic Oil Temperature 45—55°C

110—130°F

[2] - Fill bucket with material to specification.

Item Measurement Specification

Loaded Bucket Weight (approximate) 750 kg

1654 lb.

[3] -

<- Go to Section TOC Section 9025 page 375 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Machine Position—Bucket Loaded

Position arm cylinder so rod is extended approximately 50 mm (2 in.) from retracted position.

[4] - Position bucket cylinder so rod is retracted 50 mm (2 in.) from extended position.

[5] - Position boom cylinders so bucket pivot pin is at the same height as the boom-to-main frame pin.

[6] - After 5 minutes, measure amount of movement for boom, arm, and bucket cylinders and bottom of bucket to the ground.

Item Measurement Specification

Boom Cylinder Drift (maximum allowable for 5 minutes) 10 mm

0.39 in.

Arm Cylinder Drift (maximum allowable for 5 minutes) 20 mm

0.79 in.

Bucket Cylinder Drift (maximum allowable for 5 minutes) 15 mm

0.59 in.

Bottom of Bucket-to-Ground Drift (maximum allowable for 5 minutes) 110 mm

4.33 in.

Tape Measure

Used to measure drift.

<- Go to Section TOC Section 9025 page 376 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Machine Position—Bucket Empty

LEGEND:
1 Arm Tip Position Above Ground
Drift Test—Bucket Empty

[1] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)

[2] - Empty bucket of material.

[3] - Position arm and bucket so rod is fully extended.

[4] - Lower boom until arm tip position above ground (1) is 1 m (40 in.).

[5] - Position bucket cylinder so rod is retracted 50 mm (2 in.) from extended position.

[6] - After 5 minutes, measure amount of movement for boom, arm, and bucket cylinders and arm tip to ground.

Item Measurement Specification

Boom Cylinder—Bucket Empty Drift (maximum allowable for 5 minutes) 5 mm

0.20 in.

Arm Cylinder—Bucket Empty Drift (maximum allowable for 5 minutes) 15 mm

0.59 in.

Bucket Cylinder—Bucket Empty Drift (maximum allowable for 5 minutes) 10 mm

0.39 in.

Arm Tip-to-Ground—Bucket Empty Drift (maximum allowable for 5 minutes) 100 mm

3.94 in.

<- Go to Section TOC Section 9025 page 377 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Fan Drive Pump Flow Test


Specifications

SPECIFICATIONS

45—55°C
Hydraulic Oil Temperature
110—130°F

Engine Speed Fast Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

47 L/min.
New, Typical Flow Rate
12.4 gpm

40 L/min.
Used, Minimum Flow Rate
10.6 gpm

24.8—25.2 MPa
24 800—25 200 kPa
Fan Drive Circuit Pressure
248—252 bar
3600—3650 psi

Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JT05984 Flowmeter

Female End Test Hose -10 ORFS

Use this procedure when diagnosing system overheating problems. See Fan Drive Hydraulic System Operation . (Group
9025-05.)

[1] - Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank
Pressure Release Procedure . (Group 9025-25.)

[2] - Remove cooling package guard from under the machine.

[3] -
LEGEND:
1 Pressure Line (fan drive pump to fan drive motor)
133 Fan Drive Motor
Y5005 Variable Speed Fan Solenoid

Fan Drive Motor

Disconnect pressure line (1) coming from fan drive pump and connect JT05984 Flowmeter in-line using hose containing -10
ORFS female ends.

Flowmeter

JT05984

<- Go to Section TOC Section 9025 page 378 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Used to determine fan drive pump flow

Test Hose

-10 ORFS Female Ends

Connect Flow Meter-to-Fan Drive Motor

[4] - Connect one of the following test equipment to display hydraulic oil temperature and actual engine speed.

Monitor application. For instruction to actuate the service menu on monitor in cab, see Service Menu . (Group 9015-16.)
Select the following items to display:
Hydraulic Oil Temperature
Actual Engine Speed
Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select
the following items to display:
Hydraulic Oil Temperature
Actual Engine Speed
MPDr application. For instruction, see MPDr Connection Procedure . (Group 9015-20.) Select the following items to display:
Hydraulic Oil Temperature
Actual Engine Speed

[5] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)

Item Measurement Specification

Hydraulic Oil Temperature 45—55°C

110—130°F

[6] -

→NOTE:

When the variable speed fan solenoid is disconnected, all hydraulic oil is forced through fan drive motor
(133) with the exception of a small portion is sent over circuit relief to tank. This non adjustable circuit
relief valve is built into the variable speed fan solenoid.

Disconnect variable speed fan solenoid (Y5005). See Engine Interface Harness (W5) Component Location . (Group 9015-10.) Be
aware that the hydraulic oil temperature will cool rapidly due to high fan speed, so it is important to have this test done quickly
and with proper hydraulic oil temperatures.

[7] - Run engine at specification.

Item Measurement Specification

Engine Speed Fast Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

[8] - Record fan drive pump flow and compare to specification.

Item Measurement Specification

New, Typical Flow Rate 47 L/min.

12.4 gpm

Used, Minimum Flow Rate 40 L/min.

10.6 gpm

Fan Drive Circuit Pressure 24.8—25.2 MPa

24 800—25 200 kPa

<- Go to Section TOC Section 9025 page 379 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Item Measurement Specification

248—252 bar

3600—3650 psi

[9] - If fan drive circuit testing pressure is not to specification, change variable speed fan solenoid which contains a built in
relief valve.

If pump flow is below minimum specification, replace cooling fan drive pump. See Fan Drive Pump Remove and Install . (Group
3360.)

If pump flow is within specification and overheating persists, perform the following:

Check hydraulic lines to and from fan drive motor.


Check variable speed fan solenoid. See Proportional Solenoid Test . (Group 9015-20.)
Replace fan drive motor. See Fan Drive Motor Remove and Install . (Group 3360.)

[10] - Connect variable speed fan solenoid. See Engine Interface Harness (W5) Component Location . (Group 9015-10.)

[11] - Install cooling package guard.

<- Go to Section TOC Section 9025 page 380 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests

Fan Speed Test


Specifications

SPECIFICATIONS

50—60°C
Hydraulic Oil Temperature
122—140°F

Engine Speed Fast Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

Cooling Fan Speed 1300—1500 rpm

Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JT05709 Reflective Tape

JT05719 Handheld Digital Tachometer

Use this procedure when diagnosing system overheating problems. See Fan Drive Hydraulic System Operation . (Group
9025-05.)

[1] -
LEGEND:
1 Fan Blade
2 JT05709 Reflective Tape
133 Fan Drive Motor
Y5005 Variable Speed Fan Solenoid

Fan Drive Motor

Remove cooling package guard from under the machine.

[2] - Install JT05709 Reflective Tape (2) on one fan blade (1).

Reflective Tape

JT05709

Mark Fan Blade

Handheld Digital Tachometer

JT05719

Measuring Fan Speed

<- Go to Section TOC Section 9025 page 381 130G Excavator Diagnostic
HEATING AND AIR CONDITIONING (g) by Belgreen v2.0

[3] - Use one of the following to display hydraulic oil temperature and actual engine speed.

Monitor application. For instruction to actuate service menu on monitor in cab, see Service Menu . (Group 9015-16.)
Select the following items to display:
Hydraulic Oil Temperature
Actual Engine Speed
Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select
the following items to display:
Hydraulic Oil Temperature
Actual Engine Speed
MPDr application. For instruction, see MPDr Connection Procedure . (Group 9015-20.) Select the following items to display:
Hydraulic Oil Temperature
Actual Engine Speed

[4] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)

Item Measurement Specification

Hydraulic Oil Temperature 50—60°C

122—140°F

[5] - Disconnect engine coolant temperature sensor (B5208). See Engine Harness (W4) Component Location . (Group 9015-10.)
This will allow maximum oil flow allowed by engine control unit (ECU) through fan drive motor (133).

[6] - Operate engine at specification.

Item Measurement Specification

Engine Speed Fast Idle

Work Mode Switch Position Dig Mode

Power Mode Button Position PWR (power) Mode

Auto-Idle Switch Position OFF

[7] - Measure fan speed with JT05719 Handheld Digital Tachometer. Record result.

[8] - Compare reading to specification.

Item Measurement Specification

Cooling Fan Speed 1300—1500 rpm

[9] - If fan speed is below specification, test fan drive pump. See Fan Drive Pump Flow Test . (Group 9025-25.)

If fan drive pump flow is in specification, check variable speed fan solenoid. See Proportional Solenoid Test . (Group 9015-20.)

[10] - Connect engine coolant temperature sensor (B5208). See Engine Harness (W4) Component Location . (Group 9015-10.)

[11] - Install cooling package guard.

<- Go to Section TOC Section 9031 page 382 130G Excavator Diagnostic
130G Excavator Diagnostic (g) by Belgreen v2.1

Section 9031 - HEATING AND AIR CONDITIONING


Table of contents
Group 05 - Theory of Operation ............................................................................................................. 1
Air Conditioning System Cycle of Operation ......................................................................................... 1
Group 15 - Diagnostic Information ........................................................................................................ 3
Air Conditioning System Does Not Operate Diagnostic Procedure ....................................................... 3
Air Conditioning Does Not Cool Interior of Cab Diagnostic Procedure .................................................. 5
Air Conditioning Runs Constantly, Too Cold Diagnostic Procedure ....................................................... 7
Interior Windows Continue to Fog Using Air Conditioner Diagnostics Procedure .................................. 9
Heater System Does Not Operate Diagnostic Procedure .................................................................... 11
Heater Does Not Warm Interior of Cab Diagnostic Procedure ............................................................ 16
Interior Windows Continue to Fog Using Heater Diagnostic Procedure .............................................. 18
Heater and Air Conditioner Diagnostic Trouble Code Check ............................................................... 19
Heater and Air Conditioner Component Location ............................................................................... 20
Group 25 - Tests ..................................................................................................................................... 22
Refrigerant Cautions and Proper Handling ......................................................................................... 22
Visual Inspection of Components ....................................................................................................... 23
Air Conditioner Compressor Clutch Test ............................................................................................. 25
Refrigerant Leak Test ......................................................................................................................... 26
Refrigerant Hoses and Tubing Inspection ........................................................................................... 26
Air Conditioner Compressor Belt Check and Adjustment .................................................................... 26
R134a Air Conditioning System Test .................................................................................................. 27
Operating Pressure Diagnostic Chart .................................................................................................. 30

<- Go to Global Table of contents 130G Excavator Diagnostic


Section 9031 - HEATING AND AIR CONDITIONING Group 05: Theory of Operation

Group 05 - Theory of Operation


Air Conditioning System Cycle of Operation

Refrigerant System Cycle of Operation

LEGEND:
1 Evaporator
2 Compressor
3 Condenser
4 Circulation Blower Motor
5 Expansion Valve
6 Receiver-Dryer
7 High Pressure Liquid
8 High Pressure Gas
9 Low Pressure Liquid
10 Low Pressure Gas
11 Air Flow

The compressor (2) is belt driven and engaged by an electromagnetic clutch. The air conditioner circuit automatically controls
compressor engagement or disengagement when system is in operation.

The compressor draws low pressure gas (10) from evaporator (1) and compresses it into high pressure gas (8). High pressure
gas causes temperature of refrigerant to rise higher than outside air temperature.

High pressure gas leaves compressor and flows through condenser (3). Inside condenser, heat is removed and transferred to
outside air that is drawn through condenser core by the fan. Cooling refrigerant causes it to condense, and refrigerant leaves
condenser as high pressure liquid (7).

<- Go to Section TOC Section 9031 page 1 130G Excavator Diagnostic


Section 9031 - HEATING AND AIR CONDITIONING Group 15: Diagnostic Information

High pressure liquid flows into receiver-dryer (6), where moisture and contaminants (acid, solids, etc.) are removed. The
receiver-dryer contains a color moisture indicator. (Blue) indicates no moisture is present. (Pink) indicates moisture is present.
Should moisture be combined with refrigerant, hydrofluoric and hydrochloric acids are formed. These acids are corrosive to
metal surfaces, and leakage will eventually develop. The receiver-dryer also stores refrigerant, allowing a longer period of time
before additional refrigerant is needed. Refrigerant hoses allow a small amount of refrigerant to migrate through their walls.

Refrigerant flows from receiver-dryer through expansion valve (5) to the evaporator. The expansion valve senses refrigerant
temperature and pressure to modulate refrigerant flow, which then changes refrigerant to low pressure liquid (9) entering
evaporator. Actual cooling and drying of cab air takes place at evaporator. Heat absorbed by evaporator and transferred to
refrigerant causes refrigerant to vaporize into low pressure gas. Low pressure gas is drawn from evaporator by compressor and
cycle is repeated.

A freeze control switch senses temperature of evaporator coil through a capillary tube. This prevents the evaporator from
becoming cold enough to freeze moisture that condenses on the evaporator coil. Condensed moisture is drained away through
drain tubes connected to a drain pan under evaporator.

System pressure is monitored by a high/low pressure switch, located on high pressure side of expansion valve. If pressure
becomes too high or too low, the switch opens and stops the compressor, interrupting the cycle.

The engine cooling fan increases to 1200 rpm for increased flow across the condenser when ambient air is over 15°C (60°F)
and air conditioner is on.

For location of machine heater and air conditioner components, see Heater and Air Conditioner Component Location . (Group
9031-15.)

<- Go to Section TOC Section 9031 page 2 130G Excavator Diagnostic


Section 9031 - HEATING AND AIR CONDITIONING Group 15: Diagnostic Information

Group 15 - Diagnostic Information


Air Conditioning System Does Not Operate
188

Air Conditioning System Does Not Operate Diagnostic Procedure


( 1 ) Diagnostic Trouble Code Check

Action:

Check air conditioner controller (ACF) for diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Monitor Display
. (Group 9015-20.)

Are diagnostic trouble codes displayed in the air conditioner controller (ACF)?

Result:

YES:Follow diagnostic procedure for trouble code displayed. See Air Conditioner Controller (ACF) Diagnostic Trouble Codes .
(Group 9001-40.)

NO:Go to Monitor Settings Check.

( 2 ) Monitor Settings Check

Action:

Check machine settings in the monitor for proper air conditioner control mode setting. See Machine Setting . (Group 9015-16.)

Is the correct setting selected?

Result:

YES:Go to Fuse Check.

NO:Select the correct setting.

( 3 ) Fuse Check

Action:

Remove air conditioner and heater 20 amp fuse (F3) (marked HEATER). See Fuse and Relay Specifications . (Group 9015-10.)

Check continuity of air conditioner and heater 20 amp fuse (F3). See Fuse Test . (Group 9015-20.)

Is continuity indicated?

Result:

YES:Go to Air Conditioner Compressor Belt Check.

NO:Replace air conditioner and heater 20 amp fuse (F3) (marked HEATER).

( 4 ) Air Conditioner Compressor Belt Check

Action:

Check air conditioner compressor belt for proper pulley alignment and damage. See Inspect Serpentine Belt . (Operator′s
Manual.)

Is the belt properly aligned and in good condition?

<- Go to Section TOC Section 9031 page 3 130G Excavator Diagnostic


Section 9031 - HEATING AND AIR CONDITIONING Group 15: Diagnostic Information

Result:

YES:Go to Vent Air Flow Check.

NO:Replace belt. See Serpentine Belt Remove and Install . (Group 0510.)

( 5 ) Vent Air Flow Check

Action:

Turn key switch to ON position. Turn fan speed switch to maximum speed.

Is cool air coming from vents?

Result:

YES:Checks complete.

NO: See Air Conditioning Does Not Cool Interior of Cab . (Group 9031-15.)

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Section 9031 - HEATING AND AIR CONDITIONING Group 15: Diagnostic Information

Air Conditioning Does Not Cool Interior of Cab


188

Air Conditioning Does Not Cool Interior of Cab Diagnostic Procedure


( 1 ) Cab Fresh Air Filter Restriction Check

Action:

Check cab fresh air filter for debris or air flow restrictions.

Is cab fresh air filter dirty or clogged with debris?

Result:

YES:Clean or replace cab fresh air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters . (Operator’s Manual.)

NO:Go to Cab Recirculating Air Filter Restriction Check.

( 2 ) Cab Recirculating Air Filter Restriction Check

Action:

Check cab recirculating air filter for debris or air flow restrictions.

Is cab recirculating air filter dirty or clogged with debris?

Result:

YES:Clean or replace cab recirculating air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters . (Operator’s Manual.)

NO:Go to Cab Seals Check.

( 3 ) Cab Seals Check

Action:

Check windows and doors to make sure seals are in good condition.

Are seals on all windows and doors in good condition?

Result:

YES:Go to Refrigerant Hose Restriction Check.

NO:Repair or replace damaged or malfunctioning seals.

( 4 ) Refrigerant Hose Restriction Check

Action:

Check refrigerant hoses. See Refrigerant Hoses and Tubing Inspection . (Group 9031-25.)

Are any hoses kinked, pinched or collapsed?

Result:

YES:Reroute or re-index hoses. Replace kinked or collapsed hoses. See Heater and Air Conditioner Component Location .
(Group 9031-15.)

NO:Go to Condenser Air Flow Restriction Check.

( 5 ) Condenser Air Flow Restriction Check

<- Go to Section TOC Section 9031 page 5 130G Excavator Diagnostic


Section 9031 - HEATING AND AIR CONDITIONING Group 15: Diagnostic Information

Action:

Check condenser fins for air flow restrictions.

Are condenser fins clogged with debris?

Result:

YES:Clean condenser fins.

NO:Go to Evaporator Core Air Flow Restriction Check.

( 6 ) Evaporator Core Air Flow Restriction Check

Action:

Check evaporator core fins for restrictions.

Are the evaporator core fins clogged with debris?

Result:

YES:Clean evaporator fins.

NO:Go to Evaporator Core Fins Check.

( 7 ) Evaporator Core Fins Check

Action:

Check evaporator core fins for frosting or freezing.

Is there any ice or frost on evaporator core fins?

Result:

YES:Air conditioner freeze control switch not positioned correctly on evaporator core. Reposition air conditioner freeze control
switch.

NO:Go to System Operating Pressures Check.

( 8 ) System Operating Pressures Check

Action:

Check air conditioner system operating pressures. See R134a Air Conditioning System Test . (Group 9031-25.)

Are air conditioner system operating pressures within range?

Result:

YES:Checks complete.

NO:Check conditions. See Operating Pressure Diagnostic Chart . (Group 9031-25.)

<- Go to Section TOC Section 9031 page 6 130G Excavator Diagnostic


Section 9031 - HEATING AND AIR CONDITIONING Group 15: Diagnostic Information

Air Conditioning Runs Constantly, Too Cold


188

Air Conditioning Runs Constantly, Too Cold Diagnostic Procedure


( 1 ) Air Conditioning System Check

Action:

Check air conditioning system for proper operation. See Heater and Air Conditioner Operational Checks . (Group 9031-25.)

Is the air conditioning system operating correctly?

Result:

YES:Go to Evaporator Core Component Check.

NO: Go to Air Conditioning System Does Not Operate . (Group 9031-15.)

( 2 ) Evaporator Core Component Check

Action:

Check evaporator core fins for frosting or freezing.

Is there any ice or frost on evaporator core fins?

Result:

YES:Air conditioner freeze control switch not positioned correctly on evaporator core. Reposition air conditioner freeze control
switch.

NO:Go to Air Conditioner Compressor Clutch Relay Check.

( 3 ) Air Conditioner Compressor Clutch Relay Check

Action:

Remove air conditioner compressor clutch relay (K18). See Cab Harness (W1) Component Location . (Group 9015-10.)

Test air conditioner compressor clutch relay (K18). See Relay Test . (Group 9015-20.)

Does air conditioner compressor clutch relay test good?

Result:

YES:Go to Wiring Harness Check.

NO:Replace air conditioner compressor clutch relay (K18).

( 4 ) Wiring Harness Check

Action:

Check heater and air conditioner harness (W41) for open and short circuits. See Heater and Air Conditioner Harness (W41)
Component Location . (Group 9015-10.)

Is heater and air conditioner harness in good condition?

Result:

YES:Checks complete.

<- Go to Section TOC Section 9031 page 7 130G Excavator Diagnostic


Section 9031 - HEATING AND AIR CONDITIONING Group 15: Diagnostic Information

NO:Repair or replace heater and air conditioner harness (W41).

<- Go to Section TOC Section 9031 page 8 130G Excavator Diagnostic


Section 9031 - HEATING AND AIR CONDITIONING Group 15: Diagnostic Information

Interior Windows Continue to Fog Using Air Conditioner


188

Interior Windows Continue to Fog Using Air Conditioner Diagnostics


Procedure
( 1 ) Air Conditioning System Check

Action:

Check air conditioning system for proper operation. See Heater and Air Conditioner Operational Checks . (Group 9031-25.)

Is the air conditioning system operating correctly?

Result:

YES:Go to Cab Fresh Air Filter Restriction Check.

NO: Go to Air Conditioning System Does Not Operate . (Group 9031-15.)

( 2 ) Cab Fresh Air Filter Restriction Check

Action:

Check cab fresh air filter for debris or air flow restrictions.

Is cab fresh air filter dirty or clogged with debris?

Result:

YES:Clean or replace cab fresh air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters . (Operator’s Manual.)

NO:Go to Cab Recirculating Air Filter Restriction Check.

( 3 ) Cab Recirculating Air Filter Restriction Check

Action:

Check cab recirculating air filter for debris or air flow restrictions.

Is cab recirculating air filter dirty or clogged with debris?

Result:

YES:Clean or replace cab recirculating air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters . (Operator’s Manual.)

NO:Go to Check Air Conditioner Drain Hoses.

( 4 ) Check Air Conditioner Drain Hoses

Action:

See Heater and Air Conditioner Component Location . (Group 9031-15.)

Are the hoses plugged or pinched?

Result:

YES:Unplug or replace hoses.

NO:Go to Heater Core Check.

<- Go to Section TOC Section 9031 page 9 130G Excavator Diagnostic


Section 9031 - HEATING AND AIR CONDITIONING Group 15: Diagnostic Information

( 5 ) Heater Core Check

Action:

Check to see if heater core is leaking engine coolant. See Heater and Air Conditioner Component Location . (Group 9031-15.)

Is heater core leaking engine coolant?

Result:

YES:Replace heater core.

NO:Checks complete.

<- Go to Section TOC Section 9031 page 10 130G Excavator Diagnostic


Section 9031 - HEATING AND AIR CONDITIONING Group 15: Diagnostic Information

Heater System Does Not Operate


188

Heater System Does Not Operate Diagnostic Procedure


( 1 ) Diagnostic Trouble Code Check

Action:

Check air conditioner controller (ACF) for diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Monitor Display
. (Group 9015-20.)

Are diagnostic trouble codes displayed in the air conditioner controller (ACF)?

Result:

YES:Follow diagnostic procedure for trouble code displayed. See Air Conditioner Controller (ACF) Diagnostic Trouble Codes .
(Group 9001-30.)

NO:Go to Monitor Settings Check.

( 2 ) Monitor Settings Check

Action:

Check machine settings in the monitor for proper air conditioner control mode setting. See Machine Setting . (Group 9015-16.)

Is the correct setting selected?

Result:

YES:Go to Fuse Check.

NO:Select the correct setting.

( 3 ) Fuse Check

Action:

Remove heater and air conditioner 20 amp fuse (F3) (marked HEATER). See Fuse and Relay Specifications . (Group 9015-10.)

Check continuity of heater and air conditioner 20 amp fuse (F3). See Fuse Test . (Group 9015-20.)

Is continuity indicated?

Result:

YES:Go to Cab Fresh Air Filter Restriction Check.

NO:Replace heater and air conditioner 20 amp fuse (F3).

( 4 ) Cab Fresh Air Filter Restriction Check

Action:

Check cab fresh air filter for debris or air flow restrictions.

Is cab fresh air filter dirty or clogged with debris?

Result:

YES:Clean or replace cab fresh air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters . (Operator’s Manual.)

<- Go to Section TOC Section 9031 page 11 130G Excavator Diagnostic


Section 9031 - HEATING AND AIR CONDITIONING Group 15: Diagnostic Information

NO:Go to Cab Recirculating Air Filter Restriction Check.

( 5 ) Cab Recirculating Air Filter Restriction Check

Action:

Check cab recirculating air filter for debris or air flow restrictions.

Is cab recirculating air filter dirty or clogged with debris?

Result:

YES:Clean or replace cab recirculating air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters . (Operator’s Manual.)

NO:Go to Air Conditioner and Heater Blower Motor Operation Check.

( 6 ) Air Conditioner and Heater Blower Motor Operation Check

Action:

Operate the blower speed switch in low, medium, and high speed modes. See Switch Panel Functions . (Operator’s Manual.)

Does the air conditioner and heater blower motor work at any speed?

Result:

YES:Go to Air Conditioner and Heater Blower Motor Low Speed Check.

NO: Go to Air Conditioner and Heater Blower Motor Check .

( 7 ) Air Conditioner and Heater Blower Motor Low Speed Check

Action:

Operate air conditioner and heater blower motor at low speed.

Does air conditioner and heater blower motor operate?

Result:

YES:Go to Air Conditioner and Heater Blower Motor Medium Speed Check.

NO:Replace blower motor resistor (R17). See Heater and Air Conditioner Harness (W41) Component Location . (Group
9015-10.)

( 8 ) Air Conditioner and Heater Blower Motor Medium Speed Check

Action:

Operate air conditioner and heater blower motor at medium speed.

Does air conditioner and heater blower motor speed increase?

Result:

YES:Go to Air Conditioner and Heater Blower Motor High Speed Check.

NO:Replace blower motor transistor (R16). See Heater and Air Conditioner Harness (W41) Component Location . (Group
9015-10.)

( 9 ) Air Conditioner and Heater Blower Motor High Speed Check

<- Go to Section TOC Section 9031 page 12 130G Excavator Diagnostic


Section 9031 - HEATING AND AIR CONDITIONING Group 15: Diagnostic Information

Action:

Operate air conditioner and heater blower motor at high speed.

Does air conditioner and heater blower motor speed increase?

Result:

YES:Checks complete.

NO:Replace max hi relay (K17). See Cab Harness (W1) Component Location . (Group 9015-10.)

( 10 ) Air Conditioner and Heater Blower Motor Check

Action:

Disconnect air conditioner and heater blower motor (M7). See Heater and Air Conditioner Harness (W41) Component Location .
(Group 9015-10.)

Supply 24 volts and ground to air conditioner and heater blower motor (M7). See Heater and Air Conditioner Harness (W41)
Wiring Diagram . (Group 9015-10.)

Does air conditioner and heater blower motor run?

Result:

YES:Go to Air Conditioner and Heater Blower Motor Circuit Check.

NO:Replace air conditioner and heater blower motor. See Heater and Air Conditioner Harness (W41) Component Location .
(Group 9015-10.)

( 11 ) Air Conditioner and Heater Blower Motor Circuit Check

Action:

Disconnect air conditioner blower motor (M7). See Heater and Air Conditioner Harness (W41) Component Location . (Group
9015-10.)

Turn key switch to ON position, check for voltage between terminal 2 and ground. See Heater and Air Conditioner Harness
(W41) Wiring Diagram . (Group 9015-10.)

Is 24 volts present?

Result:

YES:Go to Blower Motor Resistor (R17) Ground Circuit Check.

NO: Go to Air Conditioner Blower Motor Relay Check .

( 12 ) Blower Motor Resistor (R17) Ground Circuit Check

Action:

Disconnect blower motor resistor (R17). See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)

Disconnect air conditioner 4-pin connector (X51).

Check for continuity between blower motor resistor (R17) connector pin 4 and air conditioner 4-pin connector (X51) pin 1.

Is continuity indicated?

<- Go to Section TOC Section 9031 page 13 130G Excavator Diagnostic


Section 9031 - HEATING AND AIR CONDITIONING Group 15: Diagnostic Information

Result:

YES:Go to Air Conditioner Controller (ACF) Ground Circuit Check.

NO:Open in heater and air conditioner harness (W41) ground circuit. Repair or replace harness.

( 13 ) Air Conditioner Controller (ACF) Ground Circuit Check

Action:

Disconnect air conditioner controller (A7) connector. See Heater and Air Conditioner Harness (W41) Component Location .
(Group 9015-10.)

Disconnect air conditioner 4-pin connector (X51).

Check for continuity between air conditioner controller (A7) connector pins 4 and 9 and air conditioner 4-pin connector (X51)
pin 1.

Is continuity indicated at both pins?

Result:

YES:Go to Cab Harness (W1) Ground Circuit Check.

NO:Open in heater and air conditioner harness (W41) ground circuit. Repair or replace harness.

( 14 ) Cab Harness (W1) Ground Circuit Check

Action:

Check for continuity between air conditioner 4-pin connector (X51) pin 1 and ground. See Cab Harness (W1) Wiring Diagram .
(Group 9015-10.)

Is continuity indicated?

Result:

YES:Go to Air Conditioner Blower Motor Relay Check.

NO:Open in cab harness (W1) ground circuit. Repair or replace harness. See Cab Harness (W1) Component Location . (Group
9015-10.)

( 15 ) Air Conditioner Blower Motor Relay Check

Action:

Remove air conditioner blower motor relay (K15). See Cab Harness (W1) Component Location . (Group 9015-10.)

Test air conditioner blower motor relay. See Relay Test . (Group 9015-20.)

Does air conditioner blower motor relay test OK?

Result:

YES:Go to Power Check.

NO:Replace air conditioner blower motor relay.

( 16 ) Power Check

<- Go to Section TOC Section 9031 page 14 130G Excavator Diagnostic


Section 9031 - HEATING AND AIR CONDITIONING Group 15: Diagnostic Information

Action:

Disconnect air conditioner blower motor relay (K15).

Disconnect air conditioner controller (ACF) connector.

Check for voltage between air conditioner blower motor relay (K15) connector pin 1 and ground, and between air conditioner
controller (ACF) connector pin 7 and ground.

See Cab Harness (W1) Component Location and see Heater and Air Conditioner Harness (W41) Component Location . (Group
9015-10.)

Is 24 volts present at both locations?

Result:

YES:Go to Air Conditioner Controller (ACF) Signal Check.

NO:Repair or replace cab harness (W1) or heater and air conditioner harness (W41).

( 17 ) Air Conditioner Controller (ACF) Signal Check

Action:

Turn key switch to ON position. Set blower speed switch to maximum speed. See Switch Panel Functions . (Operator’s Manual.)

Check for continuity between air conditioner 10-pin connector (X52) pins 1 and 2 and ground. See Heater and Air Conditioner
Harness (W41) Wiring Diagram . (Group 9015-10.)

Is continuity indicated at both pins?

Result:

YES:Checks complete.

NO:Replace air conditioner controller (ACF). See Air Conditioner Controller (ACF) Remove and Install . (Group 9015-20.)

<- Go to Section TOC Section 9031 page 15 130G Excavator Diagnostic


Section 9031 - HEATING AND AIR CONDITIONING Group 15: Diagnostic Information

Heater Does Not Warm Interior of Cab


188

Heater Does Not Warm Interior of Cab Diagnostic Procedure


( 1 ) Heater Check

Action:

Check heater system for proper operation. See Heater and Air Conditioner Operational Checks . (Group 9031-25.)

Is the heater system operating correctly?

Result:

YES:Go to Coolant Check.

NO: Go to Heater System Does Not Operate . (Group 9031-15.)

( 2 ) Coolant Check

Action:

Check engine coolant level. See Check Engine Coolant Level . (Operator’s Manual.)

Is engine coolant full?

Result:

YES:Go to Cab Fresh Air Filter Restriction Check.

NO:Fill with proper coolant to specification. See Check Engine Coolant Level . (Operator’s Manual.)

( 3 ) Cab Fresh Air Filter Restriction Check

Action:

Check cab fresh air filter for debris or air flow restrictions.

Is cab fresh air filter dirty or clogged with debris?

Result:

YES:Clean or replace cab fresh air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters . (Operator’s Manual.)

NO:Go to Cab Recirculating Air Filter Restriction Check.

( 4 ) Cab Recirculating Air Filter Restriction Check

Action:

Check cab recirculating air filter for debris or air flow restrictions.

Is cab recirculating air filter dirty or clogged with debris?

Result:

YES:Clean or replace cab recirculating air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters . (Operator’s Manual.)

NO:Go to Heater Hose Restriction Check.

( 5 ) Heater Hose Restriction Check

<- Go to Section TOC Section 9031 page 16 130G Excavator Diagnostic


Section 9031 - HEATING AND AIR CONDITIONING Group 15: Diagnostic Information

Action:

Check heater hoses. See Heater and Air Conditioner Component Location . (Group 9031-15.)

Are any hoses kinked, pinched or collapsed?

Result:

YES:Reroute or re-index hoses. Replace kinked or collapsed hoses.

NO:Go to Heater Door Servo Motor Check.

( 6 ) Heater Door Servo Motor Check

Action:

Inspect heater servo motor and door.

Is the servo motor and door working correctly?

Result:

YES:Go to Heater Core Air Flow Restriction Check.

NO:Repair or replace servo motor or door.

( 7 ) Heater Core Air Flow Restriction Check

Action:

Check heater core fins for debris.

Are the heater core fins clogged with debris?

Result:

YES:Clean heater core fins.

NO:Checks complete.

<- Go to Section TOC Section 9031 page 17 130G Excavator Diagnostic


Section 9031 - HEATING AND AIR CONDITIONING Group 15: Diagnostic Information

Interior Windows Continue to Fog Using Heater


188

Interior Windows Continue to Fog Using Heater Diagnostic Procedure


( 1 ) Cab Fresh Air Filter Restriction Check

Action:

Check cab fresh air filter for debris or air flow restrictions.

Is cab fresh air filter dirty or clogged with debris?

Result:

YES:Clean or replace cab fresh air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters . (Operator’s Manual.)

NO:Go to Heater Core Leak Check.

( 2 ) Heater Core Leak Check

Action:

Check to see if the heater core is leaking coolant. See Heater and Air Conditioner Component Location . (Group 9031-15.)

Is the heater core leaking coolant?

Result:

YES:Replace heater core.

NO:Go to Cab Seals Check.

( 3 ) Cab Seals Check

Action:

Check windows and doors to make sure seals are good.

Are seals on all windows and doors functioning properly?

Result:

YES:Go to Air Conditioner Check.

NO:Repair or replace malfunctioning seals.

( 4 ) Air Conditioner Check

Action:

Check to see if the air conditioner is working properly.

Is air conditioner working properly?

Result:

YES:Go to Door Servo Motor Check.

NO:Correct air conditioner problem. See Air Conditioning System Does Not Operate . (Group 9031-15.)

( 5 ) Door Servo Motor Check

<- Go to Section TOC Section 9031 page 18 130G Excavator Diagnostic


Section 9031 - HEATING AND AIR CONDITIONING Group 15: Diagnostic Information

Action:

Check to make sure the servo motor(s) are opening doors correctly.

Are the servo motor(s) operating correctly?

Result:

YES:Checks complete.

NO:Repair or replace servo motor(s).

Heater and Air Conditioner Diagnostic Trouble Code Check


Air conditioner controller (ACF) diagnostic trouble codes (DTCs) can be displayed on the monitor, connection with Service
ADVISOR ™ , or by connection with MPDr.

See Reading Diagnostic Trouble Codes With Monitor Display . (Group 9015-20.)
See Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application . (Group 9015-20.)
See MPDr Application . (Group 9015-20.)

<- Go to Section TOC Section 9031 page 19 130G Excavator Diagnostic


Section 9031 - HEATING AND AIR CONDITIONING Group 15: Diagnostic Information

Heater and Air Conditioner Component Location

Heater and Air Conditioner Component Location

LEGEND:
1 Heater and Air Conditioner Unit
2 Heater Return Line
3 Heater Supply Line

<- Go to Section TOC Section 9031 page 20 130G Excavator Diagnostic


Section 9031 - HEATING AND AIR CONDITIONING Group 25: Tests

4 Evaporator-to-Compressor Low Pressure Line


5 Condenser
6 Receiver-Dryer
7 Condenser-to-Receiver-Dryer High Pressure Line
8 Compressor-to-Condenser Line
9 Evaporator-to-Receiver-Dryer Line
A7 Air Conditioner Controller (ACF)
B20 Air Conditioner High/Low Pressure Switch
M7 Air Conditioner and Heater Blower Motor
Y11 Air Conditioner Compressor Clutch

<- Go to Section TOC Section 9031 page 21 130G Excavator Diagnostic


Section 9031 - HEATING AND AIR CONDITIONING Group 25: Tests

Group 25 - Tests
Refrigerant Cautions and Proper Handling
Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JT02167A Prism Pro Refrigerant Identification Instrument

CAUTION:

DO NOT allow liquid refrigerant to 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 air conditioning systems.

<- Go to Section TOC Section 9031 page 22 130G Excavator Diagnostic


Section 9031 - HEATING AND AIR CONDITIONING Group 25: Tests

Heater and Air Conditioner Operational Checks


Visual Inspection of Components
( 1 ) Lines and Hoses Check

Action:

Inspect all lines and hoses.

sss:

Are all lines and hoses straight and in good condition, not kinked, worn from rubbing, or weather checked?

sss:

Are hose and line connections clean and not showing signs of leakage, such as dirt, oil, or refrigerant dye?

sss:

Are all hose and line clamps in place and tight, with cushions or rubber inserts in place to prevent damage to hoses or lines?

Result:

YES:Go to Air Conditioner Compressor Check.

NO:Reposition hoses and lines as necessary. Replace, adjust, and tighten clamps as necessary. Note any hoses or lines that
will require replacement.

( 2 ) Air Conditioner Compressor Check

Action:

Inspect air conditioner compressor.

sss:

Is belt in good condition, not frayed, worn, or glazed?

sss:

Is belt properly tensioned?

sss:

Is belt tensioner in good condition, not worn or damaged?

sss:

Is compressor pulley in good condition and properly aligned with belt drive pulley on engine?

sss:

Are compressor mounting brackets in good condition, and is mounting hardware properly tightened?

sss:

Are electrical connections to compressor clean and tight? Is wiring in good condition?

Result:

YES:Go to Condenser Check.

NO:Repair or replace components as necessary.

<- Go to Section TOC Section 9031 page 23 130G Excavator Diagnostic


Section 9031 - HEATING AND AIR CONDITIONING Group 25: Tests

( 3 ) Condenser Check

Action:

Inspect condenser core.

sss:

Is core free of dirt and debris?

sss:

Is core not showing signs of leakage, such as dirt, oil, or refrigerant dye?

sss:

Are fins of core straight, not bent or damaged?

Result:

YES:Go to Engine Fan Check.

NO:Clean and straighten fins if necessary. Repair or replace components as necessary.

( 4 ) Engine Fan Check

Action:

Inspect engine fan.

sss:

Are fan blades in good condition, not worn, bent, broken, or missing?

sss:

Is fan securely installed?

Result:

YES:Go to Heater/Evaporator Core Check.

NO:Repair or replace components as necessary.

( 5 ) Heater/Evaporator Core Check

Action:

Inspect heater/evaporator core.

sss:

Is core free of dirt and debris?

sss:

Is core not showing signs of leakage, such as dirt, oil, or refrigerant dye?

sss:

Are fins of core straight, not bent or damaged?

sss:

<- Go to Section TOC Section 9031 page 24 130G Excavator Diagnostic


Section 9031 - HEATING AND AIR CONDITIONING Group 25: Tests

Is condensation drain hose attached and in good condition, not kinked, damaged, or clogged?

Result:

YES:Go to Cab Air Filter Check.

NO:Clean and straighten fins if necessary. Repair or replace components as necessary.

( 6 ) Cab Air Filter Check

Action:

Inspect cab air filter.

sss:

Is cab air filter clean and free of debris?

Result:

YES:Go to Cab Door and Windows Check.

NO:Replace cab air filter.

( 7 ) Cab Door and Windows Check

Action:

Open and close cab door and windows. Inspect seals.

sss:

Are seals present, properly installed, and in good condition?

sss:

Do door and windows contact seals evenly?

Result:

YES:Checks complete.

NO:Adjust door and windows if necessary. Repair or replace components as necessary.

Air Conditioner Compressor Clutch Test


[1] - Disconnect machine harness (W2) from air conditioner compressor clutch (Y11). See Machine Harness (W2) Component
Location . (Group 9015-10.)

[2] - Connect battery voltage to air conditioner compressor clutch (Y11).

[3] - Clutch solenoid will engage and click will be heard.

[4] - If clutch solenoid does not engage, replace air conditioner compressor clutch. See Air Conditioner Compressor Remove
and Install . (Group 1830.)

[5] - If clutch solenoid engages but the air conditioning system does not cool, see Air Conditioning System Does Not Operate .
(Group 9031-15.)

<- Go to Section TOC Section 9031 page 25 130G Excavator Diagnostic


Section 9031 - HEATING AND AIR CONDITIONING Group 25: Tests

Refrigerant Leak Test


Specifications

SPECIFICATIONS

25 mm per second
Leak Detector Probe Speed
1 in. per second

[1] - Inspect all lines, fittings, and components for oily or dusty conditions. When refrigerant leaks from the system, a small
amount of oil is carried out with it.

[2] - A soap and water solution can be applied on components in the system, this forms bubbles at the source of a leak.

[3] - If a leak detector is used, move leak detector probe under hoses and around connections at a rate of 25 mm (1 in.) per
second.

Item Measurement Specification

Leak Detector Probe Speed Speed 25 mm per second

1 in. per second

[4] - Some refrigerant manufacturers add dye to refrigerant to aid in leak detection.

[5] - Repair or replace components as necessary to correct identified leaks.

Refrigerant Hoses and Tubing Inspection

IMPORTANT:

Prevent refrigerant gas leakage. Do not use hydraulic hoses as replacement hoses in the air conditioning
system. Only use certified hoses meeting SAE J2064 Type C requirements. Hoses used for air conditioning
systems contain special barriers in their walls to prevent migration of refrigerant gas.

When a component is disconnected from the system, special care should be given to inspecting hoses and tubing for moisture,
grease, dirt, rust, or other foreign material. If such contamination is present in hoses, tubing, or fittings and cannot be removed
by cleaning, then replace parts.

IMPORTANT:

Chlorinated solvents (such as trichloroethylene) are contaminants, and must not be used for cleaning.
The use of these solvents will cause deterioration of hoses.

Fittings that have grease or dirt on them should be wiped clean with a cloth dampened with alcohol.

To assist in making leak proof 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.

Air Conditioner Compressor Belt Check and Adjustment


Inspect condition and tension of air conditioner belt. See Inspect Serpentine Belt . (Operator′s Manual.)

<- Go to Section TOC Section 9031 page 26 130G Excavator Diagnostic


Section 9031 - HEATING AND AIR CONDITIONING Group 25: Tests

R134a Air Conditioning System Test


Specifications

SPECIFICATIONS

Engine Speed Dial Fast Idle

Auto-Idle Switch A/I OFF

Power Mode Button PWR (power) Mode

Temperature Control/Mode Switch Maximum Cooling

Blower Motor Speed Switch High Speed

Service Equipment And Tools

SERVICE EQUIPMENT AND TOOLS

JT02045 R134a Deluxe Recovery/Recycling and Charging Station

JT02167A Prism Pro Refrigerant Identification Instrument

Thermometer

CAUTION:

Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing.

See Refrigerant Cautions and Proper Handling . (Group 9031-25.)

IMPORTANT:

Use correct refrigerant recovery, recycling, and charging stations. Do not mix refrigerant, hoses, fittings,
components, or refrigerant oils to avoid air conditioning system contamination. Identify refrigerant
before recovering, recycling, and charging system.

[1] - Prepare machine for service. See Park and Prepare for Service Safely . (Group 9000-01).

[2] - Clean the cooling package compartment access door, and fins of hydraulic oil cooler, radiator, condenser, and evaporator
to ensure proper air flow.

[3] - Clean and inspect cab fresh air filter. Replace if necessary. See Clean Cab Fresh Air and Cab Recirculating Air Filters .
(Operator’s Manual.)

[4] - Identify refrigerant type using JT02167A Prism Pro Refrigerant Identification Instrument.

Prism Pro Refrigerant Identification Instrument

JT02167A

To safely identify type and check purity of refrigerant prior to recovery, recycling and recharging of A/C systems.

[5] -

→NOTE:

Follow manufacturer′s instructions when operating refrigerant recovery, recycling, and charging station.

Connect refrigerant recovery, recycling, and charging station. See R134a Refrigerant Recovery, Recycling, and Charging

<- Go to Section TOC Section 9031 page 27 130G Excavator Diagnostic


Section 9031 - HEATING AND AIR CONDITIONING Group 25: Tests

Station Installation Procedure . (Group 1830.)

[6] - Open both low and high pressure valves on refrigerant recovery, recycling, and charging station.

[7] - Open cab door and windows.

[8] - Start engine and run at specification.

Item Measurement Specification

R134a Air Conditioning System Test


Engine Speed Dial Position Fast Idle

Auto-Idle Switch Position A/I OFF

Power Mode Button Setting PWR (power) Mode

[9] - Press the blower motor speed switch to turn the air conditioner ON. See Cab Heater and Air Conditioner . (Operator′s
Manual.)

[10] - Turn the temperature control/mode switch to maximum cooling position.

[11] - Turn blower motor speed switch to high.

[12] - Run machine for at least 5 minutes.

[13] - Measure and record air temperature at condenser air inlet and at air ducts in cab.

Thermometer

Used to measure air temperature at condenser air inlet and air ducts in air conditioning unit.

[14] - Observe low side pressure and high side pressure on gauges.

[15] - Compare pressures and air duct temperature readings to specifications shown.

Low And High Pressures At Various Temperatures

Ambient Air Expected Air Duct Low Side High Side


Temperature Temperature Pressure Pressure

140—169 kPa 595—721 kPa


18—21°C 9—15°C
1.40—1.69 bar 5.95—7.21 bar
65—70°F 48—59°F
20—25 psi 86—104 psi

131—158 kPa 689—835 kPa


22—24°C 9—15°C
1.31—1.58 bar 6.89—8.35 bar
72—76°F 48—59°F
19—23 psi 100—121 psi

122—148 kPa 766—927 kPa


25—26°C 10—16°C
1.22—1.48 bar 7.66—9.27 bar
77—79°F 50—61°F
18—21 psi 111—134 psi

111—134 kPa 843—1020 kPa


27—29°C 10—16°C
1.11—1.34 bar 8.43—10.20 bar
81—85°F 50—61°F
16—19 psi 122—148 psi

94—113 kPa 975—1181 kPa


30—32°C 10—16°C
0.94—1.13 bar 9.75—11.81 bar
86—90°F 50—61°F
14—16 psi 141—171 psi

77—93 kPa 1125—1361 kPa


33—35°C 10—16°C
0.77—0.93 bar 11.25—13.61 bar
92—95°F 50—61°F
11—14 psi 163—197 psi

<- Go to Section TOC Section 9031 page 28 130G Excavator Diagnostic


Section 9031 - HEATING AND AIR CONDITIONING Group 25: Tests

Ambient Air Expected Air Duct Low Side High Side


Temperature Temperature Pressure Pressure

72—87 kPa 1265—1531 kPa


36—38°C 10—16°C
0.72—0.87 bar 12.65—15.31 bar
97—101°F 50—61°F
10—13 psi 183—222 psi

79—96 kPa 1360—1646 kPa


39—40°C 11—17°C
0.79—0.96 bar 13.60—16.46 bar
103—104°F 52—63°F
11—14 psi 197—239 psi

91—110 kPa 1495—1810 kPa


41—43°C 13—20°C
0.91—1.10 bar 14.95—18.10 bar
106—110°F 55—68°F
13—16 psi 217—262 psi

108—131 kPa 1669—2020 kPa


44—47°C 16—23°C
1.08—1.31 bar 16.69—20.20 bar
112—117°F 61—73°F
16—19 psi 242—293 psi

108—131 kPa 1669—2020 kPa


48—51°C 16—23°C
1.08—1.31 bar 16.69—20.20 bar
119—124°F 61—73°F
16—19 psi 242—293 psi

[16] - If measurements do not meet specifications, diagnose malfunction. See Operating Pressure Diagnostic Chart . (Group
9031-25.)

<- Go to Section TOC Section 9031 page 29 130G Excavator Diagnostic


DEALER FABRICATED TOOLS (g) by Belgreen v2.0

Operating Pressure Diagnostic Chart


Pressure Diagnostic Chart

Low Side High Side


Condition kPa (bar) kPa (bar) Suction Line Receiver-Dryer Liquid Line Discharge Line Discharge Air
(psi) (psi)

Lack of Refrigerant Very Low Very Low Slightly Cool Slightly Warm Slightly Warm Slightly Warm Warm

Loss of Refrigerant Low Low Cool Warm to Hot Warm Warm to Hot Slightly Cool

Cool, Sweating, or Cool, Sweating, Hot to Point of


High Side Restriction Low Low Cool Slightly Cool
Frosting or Frosting Restriction

Cold, Sweating, or
Expansion Valve Closed Low Low Frosting Heavily at Warm Warm Hot Slightly Cool
Valve Outlet

Loose Belt or Compressor


High Low Cool Warm Warm Warm Slightly Cool
Malfunction

Slightly Cool to
Condenser Malfunction High High Hot Hot Hot Warm
Warm

Refrigerant Contaminated and


High High Warm to Hot Warm Warm Hot Warm
Air in System

Cold, Sweating, or
Expansion Valve Open High High Warm Warm Hot Slightly Cool
Frosting Heavily

Plugged Condenser,
Normal High Cool Warm Warm Hot Slightly Cool
Overcharge of Refrigerant

Normal (may Normal (may


Moisture in System Cool Warm Warm Hot Cool to Warm
drop) drop)

Heater Valve Stuck Open Normal Normal Cool Warm Warm Hot Warm

Lack of Refrigerant and Air in Normal (no


Normal Warm to Hot Warm Warm Warm Slightly Cool
System drop)

<- Go to Section TOC Section 9900 page 30 130G Excavator Diagnostic


130G Excavator Diagnostic (g) by Belgreen v2.1

Section 9900 - DEALER FABRICATED TOOLS


Table of contents
Group 99 - Dealer Fabricated Tools ...................................................................................................... 1
DFT1218 Split Flange Hose Cap ........................................................................................................... 1

<- Go to Global Table of contents 130G Excavator Diagnostic


Section 9900 - DEALER FABRICATED TOOLS Group 99: Dealer Fabricated Tools

Group 99 - Dealer Fabricated Tools


DFT1218 Split Flange Hose Cap

Split Flange Hose Cap

Split Flange Hose Cap is used with split clamp halves to close 1 in. split flange.

Material required is 9.5 mm (3/8 in.) steel plate.

<- Go to Global Table of contents 130G Excavator Diagnostic

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