Description of Problems E n gi n e oi l p re ss u er i s t oo l o w. Enginecoolanttemperatureistoohi u reistoohigh. Hydraulicoiltemperatureistoohigh. A i r if l e t r i s cl o gg ed . Batteryvo e ryvoltageisnotnorm al. Governoractuatorfeedbacksensorcircuitisopenor orcircuitisopenor shortedtobatteryvoltage. Governoractuatorfeedbacksensorcirc o rcircuitisshortedtobodyground. Governoractuatorfeedbacksignalisnotstable. Governoractuatorfeedbacksignaldeviates. Governoractuatordoesnotmove. C al i br at i on d aat e r or r . M on iot r R AM i s n ot n o m r al . Electricpowersupplytothecontrolleristoohigh(43volts). Over-currentinproportionalreducingvalve. Proportionalreducingval i ngvalvecircuitisopen. Sparesolenoid1(digitaloutput)overcu ) overcurrent. Over-currentindigitaloutput(trenchingsolenoid). Over-currentindigitaloutput(finecontrolsolenoid). Over-currentindigitaloutput(travelspeedchangesolenoid). Over-currentindigitaloutput(travelalarm). m ). S pare. Over-currentindigitaloutput(swingbrakesolenoid). S p ar e s ol e no i d 2. E n gi n e sp ee d i s no t n or ma l . Enginecoolanttemperaturesensorisshor o risshortedtobodyground. Hydraulicoiltemperaturesensorisshortedtobodygroun o und. PWMsensorofpumpdeliverypres y pressureisshortedtobodygroun o und. SparePWMsensor1isshortedtobodyground. SparePWMsensor2isshortedtobodyground. PWMsensorofpumpdeliverypress y pressureisope u reisopenincircuit. SparePWMsensor1circuitisopen. SparePWMsensor2circuitisopen. Fuelsensorisshortedtobod e dtobodyground. Fuelsensorisopenorshortedtobatteryvoltage. Electricpowersupplyistoolow(below23volts). Electricpowersupplyistoohigh(above32volts). Enginespeeddialisnotinoneofthe10specifiedpositions. Datamismatch1betweenalternatorandspeedsensor(alternatorisabnormal). Datamismatch2betweenalternatorandspeedsensor(speedsensorisabnormal). orisabnormal). E ng n i e st al ls . Monitorcommunicationisnotnormal. Monitortakestoomuchtimetorespondtocontroller'ssignal. Communicationisabnormalincontroller.
EngSpeed(-)
Starter Relay No. 1O 1Output
A768
BU
Pump Control Valve #1 (+)
Part No.
GN
St art er Rel ay Coi lT oN oNeut St Star tS tSW
A7 69
GY
P ump Co ntro lVa vl e# 2(- )
307
4I-5394 102-8016 111-9916
Sender: Resistor: Solenoid:
121-1490
Solenoid:
121-1491
Solenoid:
163-6616
Resistor:
OR
Ke yS WT oNe ut St St art SW SW
A7 70
308
YL
Main Power Relay Coil /
A771
PU
Float SW
309
GY
Alt Regulator Term.
F771
OR
Backup SW
310
PU
Start Aid SW To Start Aid Sol
F772
WH
Backup SW
320
OR
Horn Relay Coil To SW
F773
OR
Governor Accel
321
BR
322
GY
323
WH
325
PK
330
YL
E el ct or ni cP cP ump Co ntr ol By Bypas sSW To To Resi st or
Bckp Alarm Lamp Travel Alarm
F774
WH
Governor Decel
Warni ng Horn (F or ward)
J7 03
PK
A tl Pul se Si gT oA oAn it S - at r tR tRel ay (wa sD sD746 PK )
Fuel Pump Power
K785
GN
Quick Coupler Sw to Quick Coupler Solenoid 2
Fuel Pump Relay Cut-Out
877
YL
Glow Plug Magnetic SW To Glow Plug
Neut Start Relay Coil
954
GN
Hammer SW A
365
YL
F uel Pu Pump Rel ay To To Sw ti ch
4 03
GN
E ng n i e/ Pu mp C nt rl T o Al e t rn at or ( P) T er m.
G 97 5
YL
C ru sh P e r ss S Wt o De mo il ti on Re a l y
4 05
GY
E ng ni e/ Pu mp Cn Cn rt lT oO oO li Pr es su e r Sw Sw
K 90 4
G973
GN
P um pD si ch ar ge - Si gn al
4 12
BU
E ng ni e/ Pu mp Cn rt l To Co Co ol an tL tL ev el S w
K 90 5
BU
P um pD si ch ar ge - +B +B
MonitoringCircuits
OR
G 97 4
430
BU
Eng ni e/P ump Cntr Tl o Ai rF rFi tl er Sw
4 87
OR
E ng n i e/ Pu mp C nt rl T o Hy d Oi l Fi lt er I nd ci at or
Harness And Wire Electrical Schematic Symbols Component Location
E ng ni e/ Pu mp Co Co nt o r lT o Tr av el Pr Pr es su er Sw Sw
BR
Radio Speaker -R -Right
L972
BU
Engine/Pump Control To Low d I le SW
5 12
GN
R ad oi Sp Sp ea ke rr- Ri Ri gh t(t( Co m m on )
L 97 4
GN
E ng ni e/ Pu mp Cn Cn rt lT o Bo om Ra si eP e r ss Sw Sw
5 13
OR
Component
RelatedElectricalServiceManuals Title
Form Number
AC / C om pr es so /r Re rf g i er an t Pr es su re S W
L 97 5
PK
E ng n i e/ Pu mp C on rt ol T o AI H n I di ca o t r
5 19
PK
T he m r os a t tT tT o Re rf g i er an tP tP e r ss .S .S W
L 97 6
GN
E xc av at or Fu Fu el P ump Sw Sw ti ch
Engine/PumpControl:
RENR1998
530
OR
Washer Sw To Wiper Control
L977
YL
Trenching Sol
StartingandCharging:
RENR1007
575
YL
Wiper - Aux (Park)
L978
GY
Level Finish Sol
5 76
PK
W pi er - Au x( x( Lo w)
Actuator-EngGovernor
A 1 22 21
Service Connector
CONN 3 CONN 4
35
24
4
Schematic Location
Machine Location
H-9
D
G-8
D
G-8 G-8
E
26 38
36
40
41
37
31 34 23
19
30 7
D D
6
11
2
Sensor-FuelLevel
A-2
23
Sensor-PumpDischargePress
A-2
24
Alternator
C-9
4
Sensor-Speed
28
17
13
G
B-8
25
Battery
F-9
6
Socket - 12V 5A
H-5
Block - Terminal
G-7
D
Solenoid - Air Conditioner Clutch
B-9
26
Breaker - Alt
G-9
D
Solenoid - Eng/Pump Cont
A-7
F
H-9
H-2
A
D
Solenoid - Hydraulic Lock
B-4, C-4
7
Solenoid - Level Finish
A-7
F
Control -Power Window
B-6
15
Solenoid - Quick Coupler #1
C-2, H-2
32
Control - Wiper
E-2
A
Solenoid - Quick Coupler #2
C-2, H-2
32
Converter
J-2
8
Solenoid - Swing brake
A-2
32
Converter - 12V 5A
H-5
9
Solenoid - Travel Speed
A-7
F
Meter - Service 27
C
B
Machine Location 21
3
Lighter - Cigar
18
10
F 3 16
Sensor-AIHCoolantTemp
Schematic Location C-9
C-8
Indicator - Hydraulic Oil Filter
20
Component
D-9
Fuse - Block
8
D
25
14 39
12
9
29
32
Connector Location ConnectorNumber
2
Machine Location 1
Alarm- Travel
Breaker - Main
5
Schematic Location A-9
AirHeater
Control - Eng/Pump 15
CONN 2
J-4, 5, 6
C
Solenoid - Trenching
A-7
F
B-7
E
Switch -Q -Quick Coupler
E-5
B
E-2
A
F-2
A
Switch - Air Cleaner Switch - Aux Hyd Pressure Switch - Backup EPR Valve
F-8 G-2 D-4
A
F-9
40
Switch - Backup Gov
D-5
C
Motor - Lower Wiper
G-2
G
Switch - Boom Raise Press
C-7
34
D-8
D
Motor - Starter
A-9
14
Switch - Coolant Level
E-9
36
D-8 D-8
D D
Motor - Washer
F-9
41
Switch - Disconnect
G-9
Motor - Wiper
E-2
A
Switch - Engine Oil Level
B-9
Switch - Engine Oil Pressure
B-9
38
G-2
G
D-8
D
Panel - A/C Switch
H-6
C
D D
Pump - Auto Lubrication
E-9
16
CONN 11
G-7
D
17
CONN 12 CONN 13
G-7 F-6
D G
Switch - Hammer Press Switch - Horn
H-2
B-2 H-7
D
Switch - Hydraulic Oil Level
B-7
E
Relay - Boom Lamp
J-8
D
Switch - Implement Swing Press
B-7
32
CONN 14
E-6
G
Relay - Chassis/Cab Lamp
J-9
D
Switch - Key
E-6 E-6
G G
Relay - Demolition
H-8
D
Switch - Lower Washer
Relay - Fan
J-7
D
Switch - Lower Wiper
E-4
B
CONN 17
D-6
G
Relay - Horn
J-9
D
Switch - Neutral Start Limit
H-2
C
CONN 18 CONN 19
B-6 B-6
Relay -H -Hydraulic Lock Solenoid
J-8
D
Switch -O -One Touch Low d I le
CONN 20
B-5
A
Relay - Main
H-8
CONN 21 CONN 22
B-5 B-5
A G
CONN 24 CONN 25
B-5
G
C-5 C-5
G 11
CONN 26
E-5
B
CONN 27 1 2V 5A Socket CONN 28
H-5 H-5
A 30
CONN 29
H-5
G
CONN 30
H-4
G
CONN 31 CONN 32
H-4 H-4
G G
CONN 33 CONN 34 CONN 35
4041
39
36
8
35
16
D
30
A
G 20
11
26
15
21
3
7 B
5 4 22
34
12
31
A-3
23
H-2, H-3 J-2
G 30
14
CONN 36
C-2
12
1
B-2 B-2
17 28
Switch - Panel
D
Switch - Power Window
E-4
B
18
Switch - Power Wi W indow Limit
A-6, G-2
A
Relay - Refueling 2
B-2
19
Switch - Refrigerant Low Press
E-9
39
Relay - Start
H-7
D
Switch - Refueling Level
A-2
29
Relay - Start Cont
J-7
D
Switch - Refueling Start
B-2
27
Relay - Timer
J-7
D
Switch - Refueling Stop
B-3
28
25
E
23
10 13 19
18 27
29 24
F
J-9
D D
Switch - Seat Heater
E-5
AA 1
9X-1123 325-PK-14
Wire Color
Socket
2
200-BK-14
Circuit Number Identification
Wire Gauge
Electrical Schematic Symbols And Definitions FUSE - A componentin an electrical circuitthat will open the circuitif toomuch current flows through it. REEDSWITCH - Aswitchwhose contactsare controlled bya magnet. Amagne tcloses the contacts ofa normallyopen reedswitch; it opens the contactsofa normally closedreed switch.
E ng ni e/ Pu mp Cn rt l To Hy d Oi l Te m p S en de r E ng n i e/ Pu mp C nt lr T o Co ol an t Te mp S en de r
R ad oi Sp Sp ea ke rr- Le Le tf (C (C om mo n)
Normally open switch that will close with an increase of a specific condition (temp-press-etc.).
Compone nt De scription
S wi ng B ra ke S ol - + B
PK GY
BU
Flow Symbol
Level Symbol
C r us h S ol t o D em ol i it on R eal y
4 91
L 90 9
Temperature Symbol
B oom R ai se Pr ess SW ot Cr ush Pr ess SW
4 92
AccessoryCircuits
T
Resistor, Sender and Solenoid Specifications
WH
Electrical Schematic Symbols And Definitions
Pressure Symbol
Gov ernor Ac Act uato rF eed back To To E/ PE PEC M
304 306
PK
SENR9236-01 April 2000
T
SENDER -A component thatisusedwitha temperature a ture orpressure gauge. The sender measures the temperature orpressure. Itsresistance changesto givea n indicationto the gauge ofthe temperature orpressure.
RELAY (MagneticSwitch)-A (MagneticSwitch) -A relay is an electrical component that is activatedby electricity. Ithas a coilthat makes anelectromagnetwhen currentflows through it. The electromagnet romagnet can openor close theswitch part of the relay. CIRCUITBREAKER (C/B) (C/B)-A -A component in an electricalcircuit thatwill openthe circuit iftoo much current flowsthroughit. This does notdestroythe circuit breakerand it canbe reset to becomepartofthecircuitagain.
A= Locatedinsideofcab. 17
28
B =Locatedinsideofrightconsole. C= Locatedinsideofleftconsole. D= Locatedaroundrelaypanel. E= Locatedaroundhydraulicoiltank.
Machine Harness And Component Locations
F = Locatedaroundpilotmanifold. G = Locatedunderplatform.
SOLENOID -A solenoidis an electrical componentthat isactivated byelectricity.It has a coil that makesanelectromagnet whencurrent flows through ough it. The electromagnet romagnet canopen or close a valveor move a pieceof metal that can dowork. MAGNETICLATCH SOLENOID SOLENOID-A -A magneticlatch solenoidis anelectricalcomponent thatis activatedby electricity and held latchby a permanent magnet.It has two coils (latchand unlatch) thatmake electromagnetwhen currentflows throughthem. Italso has an internalswitch that places the latchcoil circuitopenat the timethe coil latches.
