13 Electrical System

Service Manual
Chapter 13 - Electric systems

Electrical system.......................................................................................................................................... 13-3
1 Main components location ........................................................................................................... 13-4
2 Cabin electric ............................................................................................................................... 13-6
2.1 Control and cab instrumentation........................................................................................ 13-6
2.2 Switching box E1005 ......................................................................................................... 13-7
2.3 Washer / wipers................................................................................................................. 13-12
2.4 Analog monitoring.............................................................................................................. 13-16
3 Lighting ........................................................................................................................................ 13-24
3.1 Attachment ........................................................................................................................ 13-26
3.2 Uppercarriage.................................................................................................................... 13-32
3.3 Access ladder lighting, engine and control valve............................................................... 13-38
3.4 Cabin lighting - dome light ................................................................................................. 13-48
3.5 Electric box lighting............................................................................................................ 13-50
3.6 Travel alarm....................................................................................................................... 13-53
4 Power pack .................................................................................................................................. 13-56
4.1 Engine ............................................................................................................................... 13-56
4.2 The sensors....................................................................................................................... 13-70
4.3 Emergency stop................................................................................................................. 13-75
4.4 Solenoid valves ................................................................................................................. 13-82
5 Alternator - battery ....................................................................................................................... 13-87
5.1 Schematic.......................................................................................................................... 13-88
5.2 Components location......................................................................................................... 13-90
5.3 Function............................................................................................................................. 13-93
6 Display / sensors ......................................................................................................................... 13-94
6.1 Electric schematic.............................................................................................................. 13-94
6.2 Principle schematic............................................................................................................ 13-95
6.3 Component location........................................................................................................... 13-96
6.4 Display............................................................................................................................... 13-99
6.5 The BST ............................................................................................................................ 13-117
6.6 The CAN BUS ................................................................................................................... 13-118
6.7 The BBT ............................................................................................................................ 13-119
7 Components ................................................................................................................................ 13-122
7.1 Alternator ........................................................................................................................... 13-122
7.2 Batteries ............................................................................................................................ 13-129
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13.1Electrical system
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13.1.1Main components location
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A1001 Printed circuit board ESP01

E1003 Power connection box
E1005 Cabin connection box
E1006 Cabin connection box / air conditioned
E1010 Cabin connection box / greasing
E1022_1 Connection box / principal ladder control
E1022_2 Control box / trap door control
H1 Monitoring display
S2 Control unit
S9_1 Engine battery switch
S100_1 Emergency stop cabin
S100_2 Emergency stop pump
S100_3 Emergency stop engine
S100_4 Emergency stop counterweight
S100_5 Emergency stop control valve
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13.1.2Cabin electric
13.1.2.1Control and cab instrumentation
15 Control board for safety operation of engine and hydraulic pumps, controls of floodlights, ...
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A2 Radio S6 Switch / float position

A1001 Printed circuit board ESP01 S7
Switch / safety lever
E14 Cigarette lighter S57
E1010 Switching box central lubrication S120 Switch / swing brake
E1031 Central lubrication unit T1
Central lubrication control unit
H1 Monitoring display U16
H7 Buzzer U20 Voltage transformer
P5 Hourmeter U21
Electronic box BST
S1 «Contact» key U22
S4 Switch / horn U23 Pedal for shovel flap
U24
Left joystick
Right joystick
Pedal for right travel gear
Pedal for left travel gear
13.1.2.2Switching box E1005

This box is located behing the driver seat.
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Plates
Component Designation Function
A1008_1 Plate relay E1005 • Contain the relays for the control of windshield water and
wiper, horns, air seat compressor, safety for ladder and
trap
A1014 Current regulation plate For pontoon
A1016 Interface plate • Interface between S2 and A1019 for engine revolution va-
lue setting
• Interface between XT 103, XT 104 (test pumps settings)
and S2
• Interface between Quantum U18 (oil pressure and coolant
temperature) and S2
A1019 Regulation plate • Interface between A1016 and Quantum U18 for engine re-
volution value setting
• Interface between board (button R6) and Quantum U18 for
engine revolution value setting in safety mode
• Converts the PWM signal issued from the Quantum U18 in
a proportional signal current sent to BST U16
• Contains the relays for changing the supplying of the sole-
noid valves for pumps regulation and for fans speed regu-
lation in safety mode
• Interface between the BST U16 and the solenoid valves for
pumps regulation and for fans speed
• Interface between the engine speed transmitter Liebherr
(B12) and the BST U16
• A1014
A1020 FSG plate • Converts the signal of commands (joysticks and pedals)
and supplies the solenoid valves for the movements
• Supplies the solenoid valve Y136 (pressure cut off)
• Converts the current issued from A1001 (button S21) and
supplies the solenoid valve Y94 (high speed)
• Interface between the proximity switches and the solenoid
valves for attenuation of the movements (cylinder end stro-
ke)
• Send the status of the solenoid valves of the excavator mo-
vements to the keyboard S2
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Fuses and relays
F29 8A Fuse / Reserve cameras

F30 8A Fuse / Attenuation plate supply reserve
F31 15A Fuse / A1020 Boom / Shovel tilt
F32 15A Fuse / A1020 Stick / Swing
F33 15A Fuse / A1020 Travel / Trap door
F34 15A Fuse / A1020 FSG
F35 15A Fuse / A1020 controler FSG
F124 15A Fuse / S7, A1001
F125 15A Fuse / A1019, U16
F126 15A Fuse / A1001
F127 15A Fuse / Greasing
F128 15A Fuse / Board
F129 15A Fuse / Cabin
F130 8A Fuse / A1001
F148 15A Fuse / A1019
F161 15A Fuse / A1036
K22.1 Relay option windshield wiper
K22.2 Relay option windshield wiper
K23 Relay second air conditionned
K98 Relay travel alarm
K99 Relay supply A1020
K139 Relay fire alarm
K183 Relay engine stop
K184 Relay power reduced
KT10 Relay timer emergency stop
KT17 Relay timer fire alarm
KT51 Relay timer engine stop
Connectors
Name Designation Mounted Connected with

on
X70 Connector 8 poles A1019 A1016
X71 Connector 24 poles A1019 Board and BST
X72 Connector 3 poles A1019 Board


X76 Connector 2 poles A1019 F148
X77 Connector 4 poles A1019 E1038
X78 Connector 12 poles A1019 E1038
X79 Connector 2 poles A1019 F125

X80 Connector 3 poles A1019
X81 Connector 7 poles A1019 Quantum
X82 Connector 16 poles A1020 A1001 and Y94, S122, input for proximity transmitters
X83 Connector 8 poles A1020 B75
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X84 Connector 16 poles A1020 /
X85 Connector 18 poles A1020 Outputs for solenoid valves for boom movements
X86 Connector 18 poles A1020 Outputs for solenoid valves for bucket movements
X87 Connector 18 poles A1020 Outputs for solenoid valves for stick / crowd movements
X88 Connector 18 poles A1020 Outputs for solenoid valves for swing movements
X89_1 Connector 4 poles A1020 Ground
X89_2 Connector 4 poles A1020 Program
X90 Connector 6 poles A1020 K98 travel alarm
X91 Connector 8 poles A1020 Pressure cut off / float position

X92 Connector 14 poles A1020 Output for proximity transmitters
X93 Connector 4 poles A1020 Protected supplies to outside
X94 Connector 18 poles A1020 Outputs for solenoid valves for travel and shovel flap move-
ments
X95 Connector 3 poles A1020 Supply A1020
X95_1 Connector 4 poles A1014 /

X96 Connector 4 poles A1020 Joystick U21, swing and stick (crowd) movement
X97_1 Connector 6 poles A1020 Joystick U21, horn

X97_2 Connector 6 poles A1020 A1008_1, horn
X97_2 Connector 2 poles A1014 A1019, Y4

X97_4 Connector 2 poles A1014 A1019, Y3.3
X98 Connector 4 poles A1020 Joystick U22, boom and shovel tilt movement
X98 Connector 4 poles A1014 A1019, Y3.1
X99_1 Connector 6 poles A1020 Joystick U22
X99_2 Connector 6 poles A1020 X83 for float position and A1001 for swing brake
X100 Connector 3 poles A1020 Pedal U24 for travel left
X101 Connector 3 poles A1020 Pedal U23 for travel right
X102 Connector 4 poles A1020 Pedal U20 for shovel flap
X103 Connector 8 poles A1020 A1001 for shield
X104 Connector 3 poles A1020 /
X300 Electronic ground E1005
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X330 Service ground E1005
X500 Terminal block E1005
X517_1 Connector 3 poles CAN1 From A1020 (X103)
X517_2 Connector 3 poles CAN1 From E1036 (X122)
X517_3 Connector 3 poles CAN1 To A1001 (X1)
X560 Connector 6 poles E1005 Diagnostic from Quantum U18 (X845)
X561 Connector 3 poles E1005 Diagnostic from Cense (X849)
XT103 Connector 3 poles E1005 Test pumps setting
XT104 Connector 3 poles E1005 Test pumps setting
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13.1.2.3Washer / wipers
The hydraulic excavator is provided like any other vehicle with a washer and a wiper to clean the cab’s
windshield.
Electric schematic
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A1001 Printed circuit board ESP01 K1 Relay on A1001 / windshield wiper

A1008_1 Plate relay A1008_1 M3
Washer motor
B01 Relay on A1008_1 / windshield washer M4
B03 Relay on A1008_1 / windshield wiper M20 Wiper motor
E1005 Cabin connection box S2
Washer motor (reserve)
F124 15A Fuse / A1001 V7
F128 15A Fuse / M3, M4, M20 Y32 Control unit
Diode
Solenoid valve / windshield washer
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Components location
Prinplate ESP01
A1008_1
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Wiper motor location
Functional description
Windshield wiper
To use the wiper, depress the switch S14 on the switching unit. Depressing the button S14 activates the relay
K1 on A1001 and the relay B03 on A1008_1 and finally the motor M4.
Depressing the button S14 will successively :
• Turn on the windshield wiper in intermittent mode (the light diode I is on).
• Turn on the windshield wiper in continuous mode (the light diode C is on).
• Turn off the windshield wiper (the both light diodes are off).
In addition, the pause time for the intermittent mode can be adjusted by using the button S14 :
• Select the intermittent mode and keep the button S14 depressed; after a few seconds, the light diode I
will blink rapidly.
• Release the button S14 when the blinking duration has reached the desired pause time. Adjustment is
possible between 2 and 9 seconds.
Winshield water
To wash the windshield depress the button S11 on the switching unit. The button S11 switches the relay B01
of the plate A1008_1. The windshield water motor M3 is then supplied.
The washing liquid is charged via the service trap.
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Troubleshooting
Before any electrical measurement, be sure that all the components are under current.
Problem : the wiper is out of order.

Are the elements under 24V?
Y N
Supply properly the different elements.
Is the relay OK?
Y N
Change the relay.
Does the motor function?
Y N
Change / repair the motor.

Check the mechanical part between the motor and the washer.
Problem : the washer is out of order.

Is there enough liquid in the tank?
Y N
Fill the tank.
Are the element supplied properly?

Y N
Supply properly the different element.
Are the signal transmitted?

Y N
Check the signals after A1001, A1008_1.
Check the motor. Replace if faulty.
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13.1.2.4Analog monitoring
Components location
H6 Clock P9 Principal battery voltmeter^

H38 Indicator grease alarm P10
Control unit air conditioning
H38_1 Indicator empty level P2 R6
H60 Indicator / control E52 S23 Potentiometer speed control
H61 Indicator / Quantum warning S73
Switch revolution
H62 Indicator / Quantum protection S74
H81 Indicator / supervision hydraulic valve S82_1 Switch control E52 not used
H91 Not used S82_2
Safety switch engine flow
H92 Indicator / fire alarm S84_2
H94 Indicator / fuel valve S85 Diagnostic switch idle increment
H122 Indicator no movement ladder / trap door S100_1
Diagnostic switch idle decrement
down S126
H126 Indicator alarm driveway S149 Switch centralized lubrification
P4 Indicator engine RPM
Switch Quantum error code in / out
P8 Service battery voltmeter
Emergency stop cabin
Switch board top of cabin lightening
Switch ladder lightening
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H9 Buzzer, it gives an acoustic signal for several errors.

H38 Lights up if a failure appears in central lubrication (cf. grease systems).
H38_1 Lights up if the engine coolant temperature is overheating and the buzzer in the cab sounds.
H60 Lights up if a fault, which could cause serious engine damages, is detected.
H61 Lights up if another fault, which does not necessitate an immediate engine shut down, is detec-
ted.
H62 Lights up if any parameter supervised by the system has come out of its normal operation
range.
H81 Lights up if the hydraulic tank valve is closed.
H92 Lights up if there is a fire and the buzzer in the cab sounds.
H94 Lights up if the fuel tank valve is closed.
H122 (Cf. ladder / service trap systems) : for safety reasons, the swing and travel movements remain
locked if the access ladder and the service flap are not locked in the uppermost position.
This safety measure can be bypassed for as long as the button H122 is depressed.
H126 Indicator alarm driveway
P4 Engine RPM gauge.
P5 Operating hours engine
P8 System voltage / service batteries.
P9 System voltage / main batteries.
P10 Control of the aire conditioner unit (cf. heater / air conditioning).
R6 Throttle control knob (cf. Electrical systems / engine) : in emergency operation of diesel engine,
the knob R6 is used for the RPM adjustment.
S23 Use this button to switch the diesel engine operation in emergency control function (cf. electrical
systems / engine). When the emergency control is turned on, the indicator light in the but-
ton is on.
S74 During safety operation, the pres-set value for the flow of the hydraulic pumps is activated by
pushing this button.
S82_1 Push this button to see the code of the next error detected by the Quantum system.
S82_2 Push this button to see the code of the previous error detected by the Quantum system.
S84_2 Switch centralized lubrification.
S85 On / off switch of the Quantum system.
S100_1 (Emergency stop) : using the emergency switch will shut down the diesel engine and disconnect
the electrical system (cf. electrical systems / engine / emergency stop). Use this shut off
method only for emergencies.
S126 Additional floodlights.
S149 Additional floodlights ladder.
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As the majority of switches and buttons are fully described in their own section, we just mention the following :
– clock;
– voltmeter;
– buzzer;
– hourmeter.
Clock and volmeter
Electric schematic :
F128 15A fuse / board P8 Service battery voltmeter

F140 15A fuse / board P9
Principal battery voltmeter
H6 Clock X320
X330 Kl31 service ground E1003
Kl31 service ground E1005
The voltmeters indicate the voltage in the electrical circuits (main circuit and service circuit). It is useful to see
if the batteries are charged, if the alternator works properly, if there are some unusual voltage variations and
so on.
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Component location :
Fuse F128 in box E1005 Fuse F140 in box E1003

The others components are representing on the figure control board.
The hour meter
Electric schematic :
P5 Operating hours on Power Pack X330 Kl31 service ground E1005
The hour meter indicates the running time of the power pack. The information is also transmitted to the control
unit (cf. electrical systems / display-sensors).
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Component location :
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The buzzer
The buzzer H9 warns when there are problems with :

• the engine oil pressure
• the coolant level
• the coolant temperature
• the hydraulic oil level
• the coolant pressure
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The cigarette lighter
E14 Cigarette lighter X320 Kl31 service ground E1005

F141 15A fuse
The radio
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A2 Radio F140 15A fuse

B50 FR/FL Speaker front left / right T1
Voltage transformer
B50 RR/RL Speaker rear left / right X320
13.1.3Lighting
This section describes the different lighting systems existing on the R 9250 hydraulic excavator : lighting used
the site or the excavator itself, as well as the service lighting.
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13.1.3.1Attachment
Electric schematic
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E2_1 Floodlight 70W / 24V attachment S10 Switch attachment floodlight

E2_2 Floodlight 70W / 24V attachment (option) U11
Floodlight elec. box E1003
E3_1 Floodlight 70W / 24V attachment X118
E3_2 Floodlight 70W / 24V attachment (option) X125 Connector 40 poles / E1003
E4_1 Floodlight 70W / 24V attachment
Connector 12 poles / elevation-attach-
E4_2 Floodlight 70W / 24V attachment (option) X354
ment
E5_1 Floodlight 70W / 24V attachment X500
E5_2 Floodlight 70W / 24V attachment (option) X621_1 Kl30 supply E1003
E1003 Power connection box X621_2
Terminal block E1005
E1005 Cabin connection box X621_3
F12_1 25A fuse / attachment floodlight X621_4 Connector 2 poles / E2_1
F12_2 25A fuse / attachment floodlight X622_1
Connector 2 poles / E4_1
F20_6 100A fuse / engine X622_2
K20_1 Relay attachment floodlight X622_3 Connector 2 poles / E2_2
K20_2 Relay attachment floodlight X622_4
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Component location
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The optional attachment lights E4 and E5 are situated just up the floodlight E2 and E3.
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To switch on the attachment lights E2, E3 (and in option E4, E5), press the switch S10. When the switch S10
is actuating, the relays K20_1 and K20_2 are activated. So the floodlight E2 (and E4) is supplying in current
by the fuse F12_2, and the floodlight E3 (and E5) is supplying in current by the fuse F12_1.
Troubleshooting
Problem 1 : all the attachment floodlights aren’t lighting.
Verify if the tension, which is coming from the fuse F12_1 and F12_2 is equal to 24V. Is it equal to 24V?
Y N
Have the fuses blown out?
Y N
Change the faulty fuses.
Put on the fuses.
Check if the bulbs are in order to work?
Y N
Change the faulty bulbs?
Check the relays K20_1 and K20_2, are they running?
Y N
Change the faulty relay
The problem is coming from the switch S10, change or repair it.
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Problem 2 : the floodlight E2 or E3 isn’t in order to work.
Verify if the tension, which is coming from the fuse F12_1 (when E3 isn’t in order to work) or F12_2 (when
E2 isn’t in order to work), is equal to 24V. Is it equal to 24V?
Y N
Has the fuse F12_1 or F12_2 blown out?
Y N

Put on the fuse, which has blown out.
Check the relays K20_1 (when E3 isn’t in order to work) or K20_2 (when E2 isn’t in order to work), is it run-
ning?
Y N
The bulb is broken, change it.
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13.1.3.2Uppercarriage
Electric schematic
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A1008_1 Plate relay E1005 X113 Connector 24 poles / E1003 ground

E1_1 Floodlight 70W / 24V fuel tank X116
Connector 70 poles / E1003
E1_2 Floodlight 70W / 24V fuel tank reserve X118
E1_3 Floodlight 70W / 24V fuel tank X121 Connector 40 poles / E1003
E1_4 Floodlight 70W / 24V fuel tank reserve X310
Connector 40 poles / E1003 elevation
E6_1 Floodlight 70W / 24V front catwalk X330
E6_2 Floodlight 70W / 24V front catwalk reser. X354 Kl31 principal ground E1003
E6_3 Floodlight 70W / 24V front catwalk X500
E6_4 Floodlight 70W / 24V front catwalk reser. X535_1
E18_1 Floodlight 70W / 24V counterweight res. X535_2 Kl30 supply E1003
E18_2 Floodlight 70W / 24V counterweight res. X620_1
E18_3 Floodlight 70W / 24V counterweight res. X620_2
E18_4 Floodlight 70W / 24V counterweight res. X620_3 Connector 2 poles / 58_1
E58_1 Floodlight 70W / 24V top of cabin X620_4
Connector 2 poles / 58_2
E58_2 Floodlight 70W / 24V top of cabin X623_1
E1003 Power connection box X623_2 Connector 2 poles / E1_1
E1005 Cabin connection box X623_3
F12_3 35A fuse / fuel tank floodlight X623_4
F12_4 35A fuse / hydraulic tank floodlight X662 Connector 2 poles / E1_3
F12_5 25A fuse / counterweight floodlight X672
F12_6 25A fuse / counterweight floodlight X721
F20_6 100A fuse / engine X834 Connector 2 poles / E6_1
K20_3 Relay fuel tank floodlight X835
K20_4 Relay hydraulic tank floodlight X841_1
K20_5 Relay counterweight floodlight X841_2 Connector 2 poles / E6_3
K20_6 Relay counterweight floodlight X842_1
S10 Switch attachment floodlight X842_2
S22 Switch counterweight floodlight X860 Connector 40 poles fuel tank
U10 Floodlight elec. box control valves
Connector 12 poles U10
Connector 24 poles / hyd. tank ground
Connector 12 poles / counterweight
Connector 12 poles / ground engine
Connector 24 poles / engine
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To switch the uppercarriage floodlights E1_1, E1_2, E6_1, E6_2, E58_1 and E58_2 (and in option E1_3, E1_4,
E6_3 and E6_4), press the switch S10. When the switch S10 is actuating the relays K20_3 and K20_4 are
activated. The floodlights E1_1, E1_2, E6_1, E6_2, E58_1 and E58_2 (and in option E1_3, E1_4, E6_3 and
E6_4) light up. E1_1, E1_2 and E58_2 (and in option E1_3 and E1_4) are supplying in current by the fuse
F12_4. E6_1, E6_2 and E58_1 (and in option E6_3 and E6_4) are supplying in current by the fuse F12_3.
To switch up the counterweight floodlights E18_1, E18_2, E18_3 and E18_4, press the switch S22. When the
switch is actuating the relays ST2 of the relay plate A1008_5 is activated, this relay activates the relays K20_5
and K20_6. The floodlights E18_1, E18_2, E18_3 and E18_4 light up. E18_1 and E18_2 are supplying in cur-
rent by the fuse F12_5, and the floodlights E18_3 and E18_4 are supplying in current by the fuse F12_6.
Troubleshooting
Problem 1 : all the uppercarriage floodlights aren’t lighting.
Y N
Y N
Put on the fuses.
Y N

Check the relays K20_3 and K20_4, are they running?
Y N
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Problem 2 : all the counterweight floodlights aren’t lighting.
Y N
Y N
Put on the fuses.

Y N
Check the relays ST2, K20_5 and K20_6, are they running?
Y N

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13.1.3.3Access ladder lighting, engine and control valve
Schematic
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A1008_1 Plate relay E1005 S125 Switch top of cabin lightening

E15_1 Service lightening 18W elevation S126
Switch board top of cabin lightening
E16_1 Service lightening 18W engine S139
E16_5 Service lightening 18W batteries S141 Switch engine lightening
E17_1 Service lightening 18W control valve X113
Switch elevation lightening
E19 Floodlight 70W/24V catwalk X116
E21 Service floodlight 70W top of cabin X118 Connector 24 poles / E1003 ground
E31 Board lightening 8W/24V X121
E59 Floodlight 70W/24V top of cabin X128
E1003 Power connection box X134 Connector 40 poles / E1003
E1005 Cabin connection box X320
Connector 40 poles / E1003 - elevation
E1022_1 Connection box principal ladder control X353
E1039_1 Emergency stop box control valve X500 Connector 70 poles / elevation-ladder
F138 100A fuse / service circuit supply X529
terminal block E1003
F140 15A fuse / board X533
F142 15A fuse / lightening X534 Kl31 service ground E1003
F143 24A fuse / lightening X536
Kl30 service supply E1003
H6 Clock X648
K11 Relais current charging X649_1 Terminal block E1005
K113 Relay lightening X835
Terminal block 24V T1
K133 Relay lightening X852
KT9 Relay timer lightening X860 Connector 2 poles / E31
S116 Switch control valve lightening X890
Connector 12 poles / ladder
Connector 24 poles / engine ground
Connector 40 poles
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Component location
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To switch on the access ladder lighting E19, E21 and E59, press the switch S126, or S127 for limited time li-
ghting and S125 for an unlimited time lighting. The floodlights E21 and E59 are situated at the top of the cabin,
and the service light E19 is in the left catwalk box. When S126 or S127 has been pressed, the relay KT9 is
activated for some time (this time is adjustable). When the relay KT9 is actuated, the relay K113 is activated.
So the floodlight E19, E21 and E59 are supplied in current.
The part where is situated the engine can be lightened, to switch on the service lightening engine E16_1 and
E16_5, press the switch S139. When the switch is activated the lights E16_1 and E16_5 are supplied in current
by the fuse F143.
The control valve installation can be lightened too. For this operation press the switch S116. So the service
lightening control valve E17_1 lights up. When the switch is activated the light E17_1 is supplied in current by
the fuse F143.
To switch the service lightening elevation E15_1, press the switch S141. When S141 is pressed, the relay K133
is activated. So the light E15_1 is supplied in current by the fuse F142.
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Troubleshooting
Problem 1 : all the access ladder lights aren’t working.
Verify if the tension, which is coming from the fuse F138 and F143 is equal to 24V. Is it equal to 24V?
Y N
Y N

Put on the fuses.
Y N

Check the relays KT9 and K113, are they running?
Y N
The problem is coming from the switch S125, S126 or S127, change or repair the faulty one.
Problem 2 : one access ladder light isn’t in order to work.
The bulb of the light which isn’t in order to work is broken, change it.
Problem 3 : the service lightening elevation isn’t in order to work.
Verify if bulb is in order to work?

Y N
Check the relay K133, is it running?
Y N
Change the relay.
Verify if the tension, which is coming from the fuse F138 or F142, is equal to 24V. is it equal to
24V?.
Y N
Y N
Change the fuses.
Put on the fuses.
The bulb is broken, change it.

The elevation light switch is broken, change it.
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Problem 4 : all the lights of the service engine lighting don’t work.
Verify if the tension, which is coming from the fuse F138 and F143 is equal to 24V. Is it equal to 24V?
Y N
Y N
Put on the fuses.

Y N
The problem is coming from the switch S139, change or repair the switch.
Problem 5 : one light of the service engine lighting doesn’t work.

Problem 6 : all the lights of the service control lighting don’t work.
Verify if the tension, which is coming from the fuse F138 and F143, is equal to 24V. Is it equal to 24V?
Y N
Y N
Put on the fuses.
Y N
Change the faulty bulbs.

The problem is coming from the switch S116, change or repair the relay.
Problem 7 : one light of the service control valve lighting doesn’t work.
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13.1.3.4Cabin lighting - dome light
Electric schematic
E7 Dome light S41 Dome light switch
Component location
To light up the dome lights E7, press the switch S41.
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Troubleshooting
Problem 1 : all the dome lights aren’t in order to work.
Check the bulb, are they in order to work?
Y N
Change the bulbs.
Problem 2 : one dome light isn’t lighting up.
Change the bulb, which isn’t in order to work.
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13.1.3.5Electric box lighting
Electric schematic
E8 E1005 lightening F119 Dome light switch

E44 E1003 lightening F167
25A fuse / elevation pressure fan
M15
Elevation pressure fan
Components location
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To switch on the electric box lighting E8, press the switch, which is on the light E8. This switch is feeding in
voltage by the fuse F119.
To light up the electric box lighting E44, press the switch, which is on the light E44. This switch is feeding in
voltage by the fuse F167.*
Troubleshooting
Problem 1 : the neon E8 doesn’t light up.
Verify if the tension, which is coming from the fuse, is equal to 24V. Is it equal to 24V?
Y N
Have the fuse blown out?
Y N
Change the fuse.
Put on the fuse.
Check if the neon tube is in order to work?
Y N
Change to neon tube.
The problem is coming from the switch, change or repair it.
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Problem 2 : the neon E44 doesn’t light up.
Verify if the tension, which is coming from the fuse, is equal to 24V. Is it equal to 24V?
Y N
Have the fuse blown out?
Y N
Change the fuse.
Put on the fuse.
Check if the neon tube is in order to work?

Y N
Change to neon tube.
The problem is coming from the switch, change or repair it.
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13.1.3.6Travel alarm
Electric schematic
A1020 FSG plate H15_1 Horn travel alarm top of cabin

E22_1 Warm light travel alarm top of cabin H15_2
Horn travel alarm counterweight right
E22_2 Warm light travel alarm counterweight right H15_3
E22_3 Warm light travel alarm counterweight left K98 Horn travel alarm counterweight left
F129 15A fuse / cabin
Relay travel alarm
Component location
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When the excavator is in motion, the FSG plate A1020 sends an electrical signal to the relay K98. So the relay
is activated and the horn travel alarms H15_1, H15_2, H15_3, the warm light E22_1, E22_2 and E22_3 are
actuated. So the travel alarm system is a safety element which warms (noise and light) people when the exca-
vator is in motion.
13.1.4Power pack
13.1.4.1Engine
Start and prelub system
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Schematic
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A1001 ESP01 plate P4 Indicator engine RPM

A1008_2 Plate relay E1003 R17
Resistance 25W / 150 Ohms
B73 Proximity switch / hydr. valve supervi- S1
sion S9_1 Starting switch
B74 Proximity switch / hydr. valve supervi- S149
Engine battery switch
sion U27
B87 Pressure switch / prelub V50 Switch start pilot
E1003 Power connection box V51
Relay start prelub
E1005 Cabin connection box V53
F20_2 100A fuse / supply E1005 Kl15 V54 Diode bridge
F20_3 100A fuse / charging current V55
Diode bridge
F20_6 100A fuse / engine V56
F21 200A fuse / supply X60_1 Diode bridge
F37 25A fuse / ether X60_2
Diode bridge
F38 400A fuse / prelub X115
F119 8A fuse / S1/Kl30 X118 Diode bridge
F126 15A fuse / A1001 X120
Diode bridge
F138 100A fuse / service circuit supply X121
F153 400A fuse X122 Connector 1 pole / battery
F154 400A fuse X134
Connector 1 pole / battery
F155 100A fuse X310
F169 15A fuse / charging X330 Connector 6 poles / U27 prelub
G1 Battery X350
G2 Battery X351
G3 Battery X352 Connector 9 poles / elevation
G4 Battery X353
Connector 40 poles / E1003-elevation
G5 Generator X354
G6 Service battery X356 Connector 70 poles / E1005-elevation
G7 Service battery X358
H81 Indicator / supervision hyd valve X500
K11 Relais current charging X526 Kl31 principal ground E1003
K16_1 Startrelay E1003 X726
K16_2 Startrelay E1003 X835
K19_2 Relay Kl15 X840 Kl30 principal supply
K19_3 Relay Kl15 X852
Kl31 principal ground
K19_4 Relay Kl15 X861
M1 Starter X877 Kl30 service supply
M2 Starter X890
Kl30 service supply E1003
M14 Preheating engine Y128
Kl30 supply E1003
Rod copper S9_1
Rod copper MP80
Connector 3 poles / P4
Connector 3 poles / B73-B74
Connector 2 poles / Y128
Connector 24 poles / engine ground
Connector 2 poles / B87
Connector 40 poles
Solenoid valve ether
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Component location
Batteries G1, G2, G3 and G4
Pressure switch / prelub B87 and generator G5 Solenoid ether valve Y128
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E1003 under the cab
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Start system components G5, M14, U27
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Start system components M1, M2
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Function
Kl30 : pole direct from battery plus
Kl15 : pole + when the key is in contact position
Kl50 : pole + when the key is in start position
Kl61 : charging current
Kl31 : ground
• Start
When turning the key in contact position, it is necessary that the emergency stops are not switched in order to
have the current Kl15.
The current Kl15 issued from the fuse F137 supplies the «key switch input» of the QUANTUM U18 (the switch
QUANTUM S9.1 must be closed). The engine is ready to start.
To start the engine, turn the key in position 3.
If the hydraulic valve is opened (contacts in B73 and B74 are closed), the current Kl50 supplied the first relay
start prelub U27 via the time lag relay TS2 (0 - 10 sec.) in A1008_2. The prelub procedure begins. The prelub
system establishes the correct lub oil pressure in the engine.
The relay U27 is actuated and allows to the prelub motor M14 to be supplied. When the pressure in the engine
has reached the prescribed value, the pressure switch B87 is switched and send a signal to the relay U27. The
prelub motor M14 is no more supplied. After 3 seconds, the prelub relay U27 actuates the relays K16_1 and
K16_2, so the starter motors M1 and M2 are supplied and are both running.
As soon as the engine is running, it drives the alternator G5. The charging current Kl61 actuates the relay BO2
on the printplate A1008_2 and so the relay TS2. The current Kl50 can no longer supply the relay U27. No ad-
ditional lubrication and starting procedures can be triggered.
• Cold start
A cold start system is standard equipment; which makes it easier to start the engine at low temperatures. If the
engine does not start, or at the beginning of the starting procedure, use this procedure to spray starter fluid
(ether) into the intake manifold.
To use the cold start, press the switch S36. It actuates the relay ST2 on the printplate A1008_2. The current
«Kl50 / start» coming from U27, which also supplies the starter motors M1 and M2, actuates the relay BO3
which engages the ether solenoid valve Y128 for engine cold starting.
As soon as the engine is running, it drives the alternator G5. It actuates the relay BO2 and so the relay TS2 on
the printplate A1008_2. The current Kl50 can no longer supply the relay U27. No additional lubrication and star-
ting procedures can be triggered and the cold starting stops.
• Stop
To stop the engine of the hydraulic excavator, reduce the engines RPM to low idle via the arrow key S70, and
continue to run the engine for 3-5 minutes to lower the temperature. Then turn the ignition key to turn the engine
off. The current Kl15 issued from the fuse F137 no longer supplies the «key switch input» of the QUANTUM
U18. The engine shuts down.
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RPM control
Schematic
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A1001 ESP01 plate R6 Potentiometer speed control

A1016 Interface plate S2
Keyboard
A1019 Regulation plate S23
E1005 Cabin connection box U18 Safety operation for diesel engine
QUANTUM
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Component location
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Function
The LED indicator displays the engine RPM. It divides the completes RPM range into 10 stages. The engine
RPM can be set either using the arrow keys S228 and S229, or the mode key S86. For the use, see the Ope-
ration and Maintenance Manual.
• Mode automatic
The signal goes from the keyboard S2 to the interface plate A1016. The signal is then sent to the regulation
plate A1019.
This signal is a current of 24V, which frequency varies between 160 and 370 Hz (1 Hz corresponds to 5 RPM).
The signal is then sent to the QUANTUM U18 threw the wire «Vehicle speed VSS+» and the QUANTUM U18
adjusts the RPM.
• Mode manual
If the engine can not be started, monitored or operated safety, due to a functional problem in the electronic
control of the excavator, the engine operation can be continued by using the manual mode.
The RPM control becomes manual by pushing the button S23. The relay K6 of the plate A1019 is actuated and
the wire «Remote throttle select» coming from the QUANTUM U18 is connected to the ground X300.
To adjust the RPM value, the QUANTUM will now take the signal coming from the throttle R6 threw the wire
«Remote throttle signal».
The throttle R6 transforms the signal (+5V) coming from the QUANTUM U18 (wire «Remote throttle supply»)
into a signal, which varies between 0,8V and 2,5V depending on the position of the throttle R6.
13.1.4.2The sensors
The engine
The engine CUMMINS QSK 45 mounted on the excavator R9250 is equipped with the Electronic Control Mo-
dule QUANTUM. This system analyses the data provided by the sensors mounted on the engine. All the trou-
bles appearing on the engine are centrally indicated on the control board (see Operation and Maintenance
Manual). This system also controls the engine speed and the fuel pressure in order to optimise the exhaust
emissions.
The option CENSE can be installed. It provides more information thanks to several sensors. This option allows
a better control of the engine.
As the engine cooling system is specific to LIEBHERR France, the sensors concerning the coolant level and
the coolant temperature are mounted by LIEBHERR France.
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Engine sensors location
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Splitterbox and pumps

The excavator R9250 is equipped with several sensors (pressure, temperature, clogging), which allow to su-
pervise serveral parameters. When a parameter is not in its normal range, a symbol appears on the display
and an error code is stored in the display.
This system allows to detect the eventual troubles and to prevent any damages to the excavator. The details
of the connection between sensors and the display, the symbols and the error codes are described in the chap-
ter «display».
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Sensors on the splitterbox and on the pumps and connection box E1036
Pressure sensors B84
B15 Transmitter / splitterbox temperature

B63-1 Transmitter / pump clogging engine
B63-7/1 Transmitter / pump clogging engine
B63-7/2 Transmitter / pump clogging engine
B64-1 Transmitter / pump overheating engine
B64-7/1 Transmitter / pump overheating engine
B64-7/2 Transmitter / pump overheating engine
B72 Transmitter / splittebox pressure
B84 Transmitter / control pressure
E1036 Connection box pump transmitters
13.1.4.3Emergency stop
The excavator is equipped with five emergency off switches in order to make the engine shut down quickly.
This section describes the function and the location of these switches.
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Schematic
Pos. Description Pos. Description
A1008_2 Plate relay E1003 S100_3 Emergency stop engine

E8 E1005 lightening S100_4 Emergency stop counterweight
E1003 Power connection box S178 Switch reset shutdown timer
E1005 Cabin connection box X122 Connector 70 poles / E1005-elevation
E1039_1 Emergency stop box control valve X127 Connector 24 poles / elevation-greasing
F119 8A fuse / S1 / Kl30 X330 Kl31 service ground E1005
H92 Indicator / fire alarm X500 Terminal block E1005
K19_1 Relay Kl15 X528 Connector 70 poles / board
K139 Realy fire alarm X538 Connector 2 poles / E8
K183 Relay engine stop X662 Connector 40 poles fuel tank
KT10 Relay timer emergency stop X721 Connector 24 poles / hydraulic tank ground
KT17 Relay timer fire alarm X760 Connector 2 poles / H13
KT51 Relay timer engine stop X860 Connector 24 poles / engine
S1 Starting switch X861 Connector 24 poles / engine
S100_1 Emergency stop cabin Y13 Solenoid valve cut off
S100_2 Emergency stop pump
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Function
The emergency stops are used to stop the engine instantaneously during operation or to prevent the engine to
be started. The five emergency stops are mounted in line.
In normal conditions, the emergency stops are not locked. The key of the starting switch S1 turning on the po-
sition 1 allows the current to supply the engine via S100_1, S100_2, S100_3, S100_4 and S100_5.
If one of the emergency stops is pushed, the engine is no longer supplied and shut down. In the same time,
the relay timer KT10 is actuated and supplies the shut off valve Y13. The opening of this valve depressurise
the hydraulic tank in order to prevent any injuries due to leaks from a hose and mechanical damages. This valve
is automatically closed again after 10 minutes.
In addition a fire alarm can be installed. The relay K139 is then mounted in line with the emergency stops. When
a fire is detected, the relay K139 is actuated and prevents the engine to be supplied during one hour. In the
same time, the relay KT10 is actuated and supplies the shut off valve Y13. After the fire system has been ac-
tuated, the operator must wait 1 hour before attempting to restart.
For a pontoon excavator, an additional emergency stop has to be mounted. Its function is the same as the other
emergency stops.
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13.1.4.4Solenoid valves
The schematic and the function of the solenoid valves are described in the chapter «Attachment travel sys-
tems».
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Pos. Description
SU1 Servo unit
VB1 Valve block 1
VB2 Valve block 2
VB3 Valve block 3
VB4 Valve block 4
Y3_1 Solenoid valve servo pressure
Y3_2 Solenoid valve servo pressure
Y4_1 Solenoid valve pump regulation
Y7 Solenoid valve swing brake
Y94 Solenoid valve high speed
Y100 Solenoid valve boom extend 1
Yr100 Adjustment solenoid valve extend 1
Yr101 Adjsutement solenoid valve extend 2
Yr102 Adjustment solenoid valve extend 3
Y105 Solenoid valve boom retract 1
Yr105 Adjustment solenoid valve boom retract 1
Y110 Solenoid valve crowd extend 1
Yr110 Adjustment solenoid valve crowd extend 1
Y115 Solenoid valve crowd retract 1
Yr115 Adjustment solenoid valve crowd retract 1
Y116 Solenoid valve crowd retract 2
Yr116 Adjustment solenoid valve crowd retract 2
Y120 Solenoid valve shovel tilt extend 1
Yr120 Adjustment solenoid valve shovel tilt extend 1
Y125 Solenoid valve shovel tilt retract 1
Yr125 Adjustment solenoid valve shovel tilt retract 1
Y130 Solenoid valve shovel flap in
Yr130 Adjustment solenoid valve shovel flap in
Y132 Solenoid valve shovel flap out
Yr132 Adjustment solenoid valve shovel flap out
Y140 Solenoid valve travel right backward
Yr140 Adjustment solenoid valve travel right backward
Y141 Solenoid valve travel right forward
Yr141 Adjustment solenoid valve travel right forward
Y142 Solenoid valve travel left backward
Yr142 Adjustment solenoid valve travel left backward
Y143 Solenoid valve travel left forward
Yr143 Adjustment solenoid valve travel left forward
Y144 Solenoid valve sum travel forward
Yr144 Adjustment solenoid valve sum travel forward
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13.1.5Alternator - battery
This section describes the different tension sources, and the electrical grounding on the hydraulic excavator.
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13.1.5.1Schematic
Pos. Description Pos. Description
A1008_2 Plate relay E1003 M1 Starter

E1003 Power connection box M2 Starter
F21 200A fuse / supply R17 Resistance 25W / 150 Ohms
F119 8A fuse / S1 / Kl30 S9_1 Engine battery switch
F138 100A fuse / service circuit supply X60_1 Connector 1 pole / battery
F153 500A fuse X60_2 Connector 1 pole / battery
F154 500A fuse X121 Connector 40 poles / E1003 - elevation
F155 100A fuse X310 Kl31 principal ground E1003
F169 15A fuse / charging X350 Kl30 principal supply
G1 Battery X351 Kl31 principal ground
G2 Battery X352 Kl30 service supply
G3 Battery X353 Kl30 service supply E1003
G4 Battery X354 Kl30 supply E1003
G5 Generator X356 Rod copper S9_1
G6 Battery X358 Rod copper MP80
G7 Battery X861 Connector 24 poles / engine
K11 Relais current charging
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Ground scheme
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13.1.5.2Components location
Batteries and batteries connector X60-1
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Switch battery
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E1003
Generator G5 and starter M1 and M2
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13.1.5.3Function
Batteries
The excavator R9250 is equipped with 6 batteries : 4 principal batteries and 2 service batteries.
The four principal batteries G1, G2, G3 and G4 supply :
– The starter motors M1 and M2.
– The principal circuit Kl30 in E1003.
The two service batteries G6 and G7 supply :
– The motor M10 for ladder and service trap depending on fuse F139.
– Service lighting depending on fuse F138 : access ladder, engine, control valve (see § lighting).
– Control board depending on fuse F138.
When the batteries are discharged, it is possible to supply the electrical circuits of the excavator with external
sources (24V) thanks to the connectors X60-1 and X60-2.
Alternator
The engine thanks to a belt drives the alternator G5.
As soon as the alternator runs, it sends a current via its pole B+. This current charges the principal batteries
(G1, G2, G3 and G4) and supplies the principal circuit via the fuses F21_1 and F21_2 and via the connector
X354.
In the same time, the alternator sends a current via its pole D+. The relay B02 in the plate A1008_2 is then
actuated. It allows the current Kl15 to actuate the relay K11. The current Kl30 issued from the connector X354
can then supply the service circuit and charge the service batteries.
Ground
The electrical system of the hydraulic excavator R9250 is an important part. So for more safety the ground of
every electrical circuits have been regrouped on the rotating deck.
The cut off switches

To protect the electrival systems, you can isolate electrically every circuit. The switch S9_1 permits to isolate
the batteries. This operation allows to repair the hydraulic excavator in safety conditions.
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13.1.6Display / sensors
13.1.6.1Electric schematic
A1001 ESP01 plate H1 Display

A1016 Interface plate
A1020 FSG plate S2 Keyboard / BBT
CAN1 Controller area network 1 SAE 1587 Engine information data reader
CAN2 Controller area network 2
U16 Electronic box BST
E1036 Connection box pump transmitters U35 Cense system (optional)
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13.1.6.2Principle schematic
Numerical information are transmitted via the CAN (Controller Area Network) between the different terminals
(the display, the BBT, the BST, etc.).
• Information between the BBT (S2) and the ESP01 (A1001).
The information circulating between the two terminals, is about :
– The swing brake.
– The windshield.
– The warning beacon.
– The splash water.
– The working floodlight.
– The heating.
– The travel floodlight.
– The overdrive.
• Information between the BBT (S2) and the ESP01 (A1001).
– The boom.
– The shovel tilt.
– The crowd.
– The swing.
– The travel.
– The trap door.
– The transmitter B30.
– The attachment.
– The swing (ASW).
– The travel (AFA).
– The crows pressure fall.
– The boom pressure fall.
• Information between the BBT (S2) and the connection box pump transmitters (E1036).
– The clogging.
– The overheating.
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– The gearing level Min. / Max.

– The gearing pressure.
– The gearing temperature.
– The tank pressure.
– The control pressure.
• Information between the BBT (S2) and the BST (U18).
The information which are circulated between the two terminals are about.
– The pump angle mini.
– The attachment.
– The travel.
– The swing.
– The transmitter B30.
– The engine speed.
– The current regulation Y4.
– The current rate control Y3_1, Y3_2, Y3_3.
– The error code.
– The bottom dump shovel attachment.
– The hydraulic oil.
– The water.
13.1.6.3Component location
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13.1.6.4Display
Electric schematic
A1001 ESP01 plate E1005 Cabin connection box

A1016 Interface plate E1020 Buzzer pontoon
A1019 Regulation plate
H1 Display
CAN1 Controller area network 1 H9 Buzzer
CAN2 Controller area network 2
S2 Keyboard BBT
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A Analog indicator H24 No function

B Check display P2 Coolant temperature display
C Main screen P2.1 Coolant temperature display red area
D Menu control, screen P3 Fuel level display
H2 Indicator light, engine oil pressure P3.1 Fuel level display red area
H12 Indicator light, battery S349 Back button
H19 No function S350 Down button
H20 No function S351 Up button
H23 No function S352 Menu button
Area A : Diesel engine monitoring
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P2 –Diesel engine coolant temperature display

The display must be in the green area when operating the machine.
In the event of overheating (over 98 ºC = 204°F), the red LEDs P2.1 at the end of indicator P2 will
flash.
The buzzer in the cab also sounds.
When this Indicator light illuminates, the error will be saved as error code E 503.
The red indicator protection H62 on the control board will light up.
The Quantum system will cause an engine shutdown.
Find and rectify the cause of the problem.
P3 – Fuel gauge
The LED indicator lights show the fuel level. When the both red light P3.1 light up, about 10% to
20% fuel are left in the tank as reserves.
Area B : Indicator lights
H2 –Indicator light, low engine oil pressure

The Indicator light illuminates if the engine oil pressure drops below a given value when the machine
is operating.
The buzzer in the cab also sounds.
When this Indicator light illuminates, the error will be saved as error code E 501.
The red indicator protection H62 on the control board will light up.
The Quantum system will cause an engine shutdown.
Find and rectify the cause of the problem.
H12 –Indicator light, battery charge
The Indicator light illuminates if the ignition key is placed in the contact position.
The Indicator light goes out as soon as the engine is started.
When the machine is operating, this Indicator light illuminates if the V-belt alternators or the electri-
cal charging system are defective.
Bring the engine to a low idle immediately.
Allow the engine to idle for approximately 5 seconds.
Switch off the engine.
Rectify the error.
H19 – No function
H20 –No function
H23 – No function
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H24 – No function
Area D : Screen menu control
The screen can be operated using the following 4 buttons :

– S349: Back button
– S350: Down button
– S351: Up button
– S352: Menu* button
* = Change from main to submenus
These buttons can be used to jump from the operator’s menu to the submenus or to move from page to page.
Area C : Screen
To change the screen contrast:
Press button Menu and arrow button Up (higher contrast) or Down (lower contrast) simultaneously.
The value set will be saved.
To alter the brightness of the main screen :
Press button Back and arrow button Up (brighter) or Down (darker) simultaneously.
The value set will be saved.
Note!
A light sensor built in to the top left of the monitoring screen controls the illumination on the
main screen, dependent on the brightness of the environment. Tracking is carried out using the
buttons and originating from the basic setting. Illumination will be automatically reduced in con-
ditions of low environmental brightness.
To change the brightness and the contrast setting to the works setting:
Turn off the ignition.
Press and hold the Up and Down buttons simultaneously.
Turn on the ignition again.
Release the buttons once the automatic check is completed.
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Main screen
The main screen appears when the machine has been switched on and remains on display until the screen is
changed over to the menu selection screen using the Menu button.
EC Cable error display SY Symbols

INF Information TI Time
Main screen design

SY field
The uper field of the monitor shows, on the one hand warning and indicator symbols, on the other hand a clock,
if no more than 4 warning symbols are shown. Should more than two symbols be shown, so the clock is no
more displayed and up to four symbols can be diplayed simultaneously in the field SY
If more than 4 symbols must be displayed, the symbols will be shift to the left by one symbol every 10 seconds.
EC field
The EC window displays the error codes for electrical faults which occur in the excavator's electronics system
(line errors, sensor errors etc.). A maximum of 7 error codes are displayed simultaneously. If there are more
than these 7 errors present, an arrow which points to where the other error codes are located will be displayed
next to the error code window.
Press the Up or Down button.
The error code window will be shifted in the direction selected in the error code list.
INF field
The INF field displays information temporarily, in both text and graphic form.
If more than 3 symbols are to be displayed, the symbols will shift one symbol to the left approx. every
10 seconds.
The information is displayed in graphic or text form and indicates specific operating states on the machine.
TI field
The machine operating hours and the daily operating hours counter are displayed bottom right in this field.
The ® symbol indicates that a quantity limitation is active for the pumps.
Menu navigation in the event of an error display
If an error is recognized as “new” in the SY field, the user is returned to the main screen. The relevant error
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display is activated.
Depending on the error (level of urgency), the buzzer will sound either continuously or in short consecutive
bursts. This symbol will be displayed in the INF field.
Danger!
If the error displayed is not rectified immediately, this could lead to persons sustaining injury or
the machine being damaged.
Rectify / have the error rectified immediately.
To switch off the buzzer, press the Back button.
The error will be acknowledged and stored.
Warning symbols in the SY field

Each of the symbols which follow will be assigned an error code in the form “E 5xx”. Each error which occurs
will be stored via the relevant error code.
E 501–Low engine oil pressure
E 502–Coolant low
This symbol appears if the coolant level drops below the minimum level.
The buzzer sounds simultaneously.
Bring the engine to a low idle immediately.
Switch the engine off as quickly as possible.
Localise the leak and carry out repairs.
Caution!
This monitoring device acts as an increased level of security in case of larger amounts of wa-
ter loss (eg. hose rupture). It does not relieve the operator or maintenance personnel from
the responsibility of regularly checking the coolant level in the equalizing reservoir.
E 503 –Engine coolant overheat
This symbol appears simultaneously with the P2 coolant temperature display.
E 540 –Engine coolant pressure

This symbol appears simultaneously with the red indicator protection H62 if the coolant pres-
sure is too low.
See Cummins Operation Maintenance Manual.
Locate the reason for the trouble and get it repaired.
E 597 –Manifold overheat
This symbol appears simultaneously with the red indicator protection H62 if the manifold tem-
perature is too high (above 104°C=220°F).
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E 506 –Oil in splitterbox is overheating

This symbol appears if the oil temperature in the splittebox exceeds 85°C (185°F)
Turn the engine off.
Find and correct the problem (splitterbox cooler dirty, ...).
E 562 –Low oil level in splitterbox
This symbol appears if the oil level drops below the minimum level.
Find and repair a possible leak.
Add oil until the level is correct.
E 564 –High oil level in splitterbox
This symbol appears if the oil level in the splitterbox is above the maximum level.
Find and repair the problem.
It is possible that too much oil has been added, or the oil level might have increased due to
hydraulic oil entering via a defective pump shaft seal.
E 591 –Splitterbox oil pressure low
This symbol appears if the splitterbox oil pressure drops below 0.2 bar.
Stop operation and turn the engine off.
Find and correct the problem.
E 504 –Low hydraulic oil level
This symbol appears if the oil level in the hydraulic tank drops below the minimum level. At
the same time, the pump are automatically returned to minimum flow.
Find and repair the cause of the oil loss.
Add hydraulic oil via the service flap or via one of the return filters.
E 505 –High hydraulic oil temperature
This symbol appears if the hydraulic oil temperature in the tank exceeds 98°C (208°F).
Stop operation.
Continue to let the engine run in high idle and wait until the symbol disappears.
If necessary.
Find and correct the problem (oil cooler dirty, blower or thermostat defective, ...).
E 566 - E 567 - E 568 – Main pumps are contaminated
This symbol appears if metallic particles have been deposited on the contamination switch of
one of the main pumps (the pump number appears in the top corner of the symbol).
Notify the maintenance personnel.
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E 572 - E 573 –Swing pumps are contaminated

This symbol appears if metallic particles have been deposited on the contamination switch of
one of the swing pumps (the pump number appears in the top corner of the symbol).
Notify the maintenance personnel.
E 578 - E 579 - E 580 – Main pumps overheat
This symbol appears if the temperature on one of the main pumps increases above 92°C
(198°F) (the pump number appears in the top corner of the symbol).
E 584 - E 585 –Swing pumps overheat
This symbol appears if the temperature on one of the swing pumps increases above 92°C
(198°F) (the pump number appears in the top corner of the symbol).
E 592 –Low oil level in the Centinel System (optional)
This symbol appears if the oil level in the Centinal tank drops below the minimum level.
Full the Centinel tank as soon as possible.
E 593 –High fuel temperature
This symbol appears simultaneously with the red indicator protection H62 if the fuel tempe-
rature is too high (above 104°C=220°F).
E 594 –High fuel rail pressure
This symbol appears simultaneously with the red indicator protection H62 if the fuel rail pres-
sure exceeds a normal limit .
E 595 –High blow-by pressure
This symbol appears simultaneously with the red indicator protection H62 if the blow-by pres-
sure exceeds a normal limit .
E 596 –Low engine oil level
This symbol appears simultaneously with the red indicator protection H62 if the engine oil le-
vel drops below the minimum level.
Full the engine oil tank.
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E 598 –Oil change required

This symbol appears simultaneously with the red indicator protection H62 if an engine oil
change is required.
Do it as soon as possible.
Information symbols in the INF field
Service due
This symbol appears if a service interval is due.
Switch on the ignition.
The service interval to be carried out will be displayed for approx. 10 seconds in place
of the overall operating hours.
Acknowledge error
This symbol appears if a machine error (E5xx) has occurred and the buzzer sounds simulta-
neously.
Getting information from the operator’s menu on the main screen

Main screen menu selection
To change to the operator’s menu, the main screen must be visible.

Press the Menu button on the main screen.
The list of accessible menus is displayed.
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To select the operator’s menu:

Press arrow key Down or Up.
The following or previous operator’s menu will be displayed on screen with a black background.
The selected menu is displayed with a black background, the Reset daily operating hours menu is used
here as an example.
Press the Menu button again.
The submenu for the function selected is displayed.
Press the Back button again.
The submenu will be aborted.
Symbol Description
Reset daily operating hours counter
Confirm service interval
Select quantity limitation relating to attachments (eg. hammer)
Operating hours and device data
Status of hydraulic pumps and electrical inputs and outputs
Recorded and stored errors
Immobilizer
(must be activated by LIEBHERR customer service using a service connector)
Reset daily operating hours counter menu

The daily operating hours counter can be reset to 0 using this menu.
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To set the daily operating hours counter to 0:

Press the Up arrow key.
The OK which is not crossed out will be displayed with a black background.
Press the Menu* button.
The operating hours will be reset to 0.
The arrow key symbols Up and Down and the Menu symbol will no longer be displayed.
To exit the menu:

Press the Back button.
To set the work speed:

Press switch S354.
Press the Up or Down arrow key.
Set the desired work speed. The quantity can be limited to up to 50 % of the maximum capacity.
The selected work speed is activated.
LED 1 in switch S354 illuminates.
The symbol ® appears in the S1 field on the main screen.
Press switch S354.
Quantity reduction is deactivated.
LED 1 in the switch goes out.
The symbol turns black = 100%.
Confirm service interval menu
This menu is used for information on service intervals and to confirm service work which has been
carried out.
The operating hours of the next service interval (in this example, “500 Hrs”) and the current operating hours
(“478 Hrs”) are displayed in the menu.
A pending service interval can be confirmed a maximum of 50 operating hours before the service interval is
due.
When this time period has been reached a query will appear to ask whether the service work has been carried
out.
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Service work carried out.

Press the Up arrow key.
The OK which is not crossed out will be displayed with a black background.
Press the Menu button.
The current operating hour will be confirmed as the last service interval carried out.
Service work not carried out.
Allocation of quantity limitation options to external input I1 menu
(Kit input; for example, activation of the hammer pedal)
Predefined quantity limitations have been assigned in this menu.
The arrow opposite the symbol represents the current selection.
In the example, quantity 2 is active if the specified attachment is serviced.
Press the Up or Down arrow key.

A different, predefined quantity (1-4) can be assigned (e g. when work equipment is changed).
The selection is confirmed. The arrow displays the current selection.
To exit the menu:

Operating hours menu
Pages 1 to 2 provide an overview of the operating hours of individual units, processes and operating types.
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Page 1 provides the service life in hours for:

– Diesel engine
– Diesel engine in P mode (RPM stage 10)
– Diesel engine in E mode (RPM stage 8)
– Hydraulic operation
– Swing movements
– Travel movements
– Diesel at low idle

Page 2 is displayed.
The screen (page 2/3) indicates the operating hours for :
– Pontoon operation
– Safety operation for pump power control
– Safety operation for pump flow control
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The technical data menu, page 3, provides information on :
– The excavator type, including type and serial number (type, series)
– The design condition of the control which is currently built in (ver)
– The current operating voltage (volt)
To exit the menu:

Status of hydraulic pumps and electrical inputs and outputs menu
Page 1 provides information from the Quantum system of the engine.
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This screen gives information about the operating position of the hydraulic pumps. It gives the following indi-
cations for each working pumps :
If the flow limitation is activated for the pump. If it occurs, the symbol "R" is displayed in the field TI, see main
screen. The screen 2/7 shows an example with the flow limitation M1 activated, which limits the pump P2
to 34% of the maximum flow. Should several flow limitations be actuated at the same time, so the one with
the smallest flow value has priority.
The graphic bar with electric current value indicates for the pump the amount of the momentary flow control
signal.

The present LR solenoid current (current value for power control) is showed on screen 3.
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The screen 4 indicates for the fan pumps the amount of the momentary flow control signal.

Pages 5, 6 and 7 provide an overview of the status of different electrical inputs.
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A“ ” means "Input not active".

A“ ”means "Input active".
An “NC” beneath the terminal designation means that the software for the relevant input has been deactivated.
The status of the inputs can be changed using the menu "set data" - "set E-code".
The screen 5 indicates the status of the inputs for the different movements.
The screen 6 indicates the status of the flow limitation. M1, M2, ... correspond to machine specific (internal) oil
flow limitations. I1, I2, ... correspond to predefined oil flow limitations (see also menu "set option").
The screen 7 indicates the status other inputs. For the frequency inputs B53 and B12, the signs “ ” means
that a significant frequency is recognised by the system.
B12 Engine RPM sensor B53 Swing motor sensor

S7 Safety lever servo control S57 Swing brake
To exit the menu:

Error menu (operating errors and electrical system errors)
There are 3 selection options in this menu:

– By selecting list Exxx, machine errors recorded by the sensors are listed.
– By selecting list E-elec, all main screen cable errors stored when operating are listed.
– By selecting list S-Exxx, all errors which appeared when the service connector was connected are listed.
To select the desired error type :

Press the Down or Up arrow key.
The following or preceding error type will be displayed with a black background.
The submenu on a black background will be displayed.
If more than 6 error codes are present, arrow key Down or Up can be used to scroll to the next page.
Machine error list Exxx :
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Select list Exxx.

The first page of the submenu appears.
All errors and their error codes are listed on the first page.
Use the Down or Up arrow key to select the error code desired.
The second page of the submenu appears.
Operating hours and the duration of the first and last ten occurrences of the error selected will be listed on the
second page.
The first page of the submenu appears.
Press the Back button again to select another error type or press the Down or Up arrow key to select a new
error code.
s*: Error was indicated by a buzzer and was acknowledged using the Back button. The duration is given in
seconds.
m*: Error was indicated by a buzzer and was acknowledged using the Back button. The duration is given in
minutes.
Note!
Only operating errors with an error code E 5xx will be displayed in the list Exxx menu.
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Cable error list E-elec. :
Select Cable error list E-elec.:

The submenu appears.
The column "Sum" shows the number of all errors that were ever noted.
The column "Test" shows the number of errors occurred since the last deletion of this test error memory listing.
The operating hours above the test column show the operating hour when the last test memory was deleted
(reset).
A different error type may be selected.
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Selecting "list S-Exxx" also shows the errors according to the list, but this time only the errors that occurred
during "service operation".
For each error, an overview can be shown and paged in just like for the "list-Exxx" selection. The column "Sum"
shows the number of all errors that were ever noted.
13.1.6.5The BST
The Litronic excavators are equipped with an electronical command system, the BST (from the German word
: Baggersteuerung).
This system manages the hydraulic pumps and the diesel motor. That means :
• Motor speed adjusting.
• Motor speed storage.
• Hydraulic pumps management.
• Power regulation.
• Hydraulic installation ventilator regulation.
• Hydraulic installation supervision (oil level and temperature).
• Diesel engine management.
• Coolant liquid temperature supervision.
• Motor oil pressure supervision.
Informations, which arrive or go out from the BST, are transmitted and stored via the BUS CAN 1 and are me-
morised in the BST RAM. Informations, which arrive or go out from the display and from the PCB ESP01, are
transmitted via the second bus, CAN2. The BUS CAN 2 transports the information coming from and going to
the display and the PCB ESP01.
13.1.6.6The CAN BUS
Definition
A BUS is a wiring system connecting several terminals in the same way. The CAN (Controller Area Network)
protocol is associated with a chip (5 x 5 mm) which is fast (100 KBD to 1 Mbd) and can be used in severe con-
ditions (vibrations, variable temperatures, ...) as it is the case with the LIEBHERR’s hydraulic excavators.
Principle
The BUS is used to transmit, via a two cables system, numerical information between terminals. Several ter-
minals can send out a message at the same time : there is no «master / slave» relationship. The messages
are processed using an established priority order.
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When a message is send, all terminals receive it but only the concerned terminal takes the message into ac-
count and processes it.
The high data transfer rate produces some signal distortion corrected at reception by the CAN processor. This
processor allows each terminal to control the messages on the bus stopping those containing an error and sen-
ding an acknowledgement message when the message is correct. This system enables the detection of faulty
terminals and minimises the perturbation generated by them to the detriment of the other terminal transmis-
sions.
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13.1.6.7The BBT
Function
The BBT (Baggerbedientastatur in German) is the information dealer between the BST and the display. The
BBT allows the modification of the diesel motor states, the hydraulic pumps, the washer and the wiper, the hea-
ting, the lighting, the orientation and the translation brakes.
An essential function of the BBT is that the BST error signals and the error messages from the sensors are
stored and can be transmitted on a laptop. The error messages from the sensors are stored at the time when
the incident occurred during the working time, the duration of the error and its frequency.
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S86 Operation mode selection Control for engine

61 LED for mode selection indication P4 LED indicator for engine RPM
S10 Attachment floodlight
S11 Windshield washer
S12 Heater blower
S14 Windshield wiper
S17 Swing brake
S18 Not used
S19 Not used
S20 Not used
S21 Travel speed increase
S22 Not used
S36 Cold start system
S41 Dome light
S56 Not used
S87 Not used
S228 Engine RPM increase
S229 Engine RPM reduce
S354 Not used
S10 - Floodlight / Equipment headlight

Press the switch.
Driving light is activated.
LED 1 in the switch illuminates.
Press switch again.
Driving light is deactivated.
Equipment headlight is activated.
Press switch again.
Driving light and equipment headlight are switched on.
LEDs 1 and 2 in the switch illuminate.
Press switch again.
Driving light and equipment headlight are switched off.
LEDs 1 and 2 in the switch go out.
S11 – Windshield washer installation
Press and hold button.
Washing water will be sprayed onto the windscreen through the outlet nozzles.
The windscreen washer runs continuously.
Release the button.
Washing water will be stopped.
Windshield washer will run continuously for approx. another 3 seconds.
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S12 – Heater
Press switch.
Heater fan will be switched to stage 1.
LED L in the switch illuminates.
Press switch again.
Heater fan will be switched to stage 2.
LED H in the switch illuminates.
LED L in the switch goes out.
Press switch again.
Heater fan will be turned off.
LED H in the switch goes out.
S14 – Windscreen washer
Press switch.
Intermittent setting is activated.
LED I in the switch illuminates.
Press switch again.
Continuous operation is activated.
LED C in the switch illuminates.
LED I in the switch goes out.
Press switch again.
Windscreen washer is switched off.
LED C in the switch goes out.
S17 – Swing gear brake
Press switch.
Slewing gear brake is engaged.
Upper carriage is locked.
LED in the switch illuminates.
Press switch again.
Slewing gear brake is released.
LED in the switch goes out.
S21 - High speed gear
Press the switch.
Transfer from normal drive to fast drive is activated.
While driving, the machine will automatically transfer from normal drive to fast drive.
LED 2 illuminates after transfer to fast drive.
Press switch again.
Transfer from normal drive to fast drive is deactivated.
S36 – Special function 1 (optional extra)
Configuration and activation according to kit.
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S86– Mode selection, speed adjustment

Four different modes can be selected by pressing the switch. The currently active
mode will be displayed under the letter on the LED.
– L: LIFT mode (speed level 5)
– F: FINE mode (speed level 10)
– E: ECO mode (speed level 8)
– P: POWER mode (speed level 10)
13.1.7Components
13.1.7.1Alternator
• Niehoff, model C653 A2-211 including A6-141 fan guard
• Specifications
260 Amperes, 28 Volts negative ground alternator system
Brushless phase self energizing and self rectifying
Uses external solid state voltage regulator
Ambient operating temperature-54°C / -65°F to 93°C / 200°F
Bi-directional rotation
Sealed bearing :Front - 306 (Ball)
Rear - 206 (Ball)
Unit weight :29,3 kg / 65 LB
Rotor inertia with fan :175 kg.cm² / 60 LB.IN²
Recommended speed :8000 Rpm
Peak torque at34,2 Nm / 25.2 LB FT at 2400 RPM and a 232 Ampere
22°C / 72°F machine temperatureload at 28 Volts
Peak drive requirements at13,3 kW / 17,9 HP at 8000 RPM and a 314 Ampere load
22°C / 72°C machine temperatureat 28 Volts
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Hazard definitions
These terms are used to bring attention to presence of hazards of various risk levels or to important information
concerning product life.
CAUTION
Indicates presence of hazards that will or can cause minor personal injury or property damage.
NOTICE
indicates special instructions on installation, operation or maintenance that are important but not related to per-
sonal injury hazards.
Table of contents
Section 1 : Wiring Diagram
Section 2 : Basic Troubleshooting
Section 3 : Advanced Troubleshooting
Battery Conditions
NOTICE
Until temperatures of electrical system components stabilize, these conditions may be observed during cold
start voltage tests.
• Maintenance / low maintenance battery :
– Immediately after engine starts, system volts are lower than regulator setpoint with medium amps.
– 3 - 5 minutes into charge cycle, higher system volts and reduced amps.
– 5 - 10 minutes into charge cycle, system volts are at, or nearly at, regulator setpoint, and amps are reduced
to a minimum.
– Low maintenance battery has same characteristics with slightly longer recharge times.
• Maintenance-free battery :
– Immediately after engine start, system volts are lower than regulator setpoint with low amps.
– 15 - 30 minutes into charge cycle, still low volts and low amps.
– 15 - 30 minutes into charge cycle, volts increase several tenths. Amps increase gradually, then quickly to
medium to high amps.
– 20 - 35 minutes into charge cycle, volts increase to setpoint and amps decrease.
• High-cycle maintenance-free battery :
– These batteries respond better than standard maintenance-free. Charge acceptance of these batteries may
display characteristics similar to maintenance batteries.
Charge Volt and Amp Values

The volt and amp levels are a function of the battery state of charge. If batteries are in state of discharge, as
after extended cranking time to start the engine, the system volts, when measured after the engine is started
will be lower than the regulator set point and the system amps will be high. This is a normal condition for char-
ging system. The measured values of system volts and amps will depend on the level of battery discharge. In
other words, the greater the battery discharge level the lower the system volts and higher the system amps will
be. The volt and amp readings will change, system volts reading will increase up to regulator set point and the
system amps will decrease to low level (depending on the other loads) as the batteries recover and become
fully charged.
• Low Amps : a minimum or lowest charging system amp value required to maintain battery state of char-
ge, obtained when testing the charging system with a fully charged battery and no other loads applied.
This value will vary with battery type.
• Medium Amps : a system amps value which can cause the battery temperature to rise above the ade-
quate charging temperature within 4 - 8 hours of charge time. To prevent battery damage the charge amps
should be reduced when battery temperature rises. Check battery manufacturer’s recommendations for
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proper rates of charge amps.

• High Amps : a system amps value which can cause the battery temperature to rise above adequate char-
ging temperature within 2 - 3 hours. To prevent battery damage the charge amps should be reduced when
the battery temperature rises. Check battery manufacturer’s recommendations for proper rates of charge
amps.
• Battery Voltage : steady-state voltage value as measured with battery in open circuit with no battery load.
This value relates to battery state of charge.
• Charge Voltage : a voltage value obtained when the charging system is operating. This value will be hi-
gher than battery voltage and must never exceed the regulator voltage set point.
• B+ Voltage : a voltage value obtained when measuring voltage at battery positive terminal or alternator
B+ terminal.
• Surface Charge : a higher than normal battery voltage occurring when the battery is removed from a bat-
tery charger. The surface charge must be removed to determine true battery voltage and state of charge.
• Significant Magnetism : a change in the strength or intensity of a magnetic field present in the alternator
rotor shaft when the field coil is energized. The magnetic field strength when the field coll is energized
should feel stronger than when the field is not energized.
• Voltage Droop or Sag : a normal condition which occurs when the load demand on the alternator is grea-
ter than rated alternator output at given rotor shaft RPM.
CEN C653A alternator description and operation

C653A alternator is self-rectifying. All windings and current-transmitting components are non-moving, so there
are no brushes or slip rings to wear out.
Controlled by the A2-211 regulator, this alternator is externally energized through the E terminal, connected to
a switched power source to turn on regulator. See wiring diagram on this page.
A2-211 regulator has :
• D+ terminal to provide signal to vehicle electrical system, confirming alternator operation.
• R terminal to provide an optional AC voltage tap.
• Overvoltage cutout (OVCO). Regulators with OVCO (overvoltage cutout) will trip at vehicle electrical sys-
tem voltages above 33 volts that exist longer than 3 seconds. OVCO feature detects high voltage and
reacts by signaling relay in F+ alternator circuit to open. This turns off alternator. Restarting engine resets
OVCO circuit. Regulator regains control of alternator output voltage.
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MJFCIFSS
Service Manual
Electrical system
Basic troubleshooting
Tools and Equipment for Job
– Digital Multimeter (DMM)
– Ampmeter (digital, inductive)
– Jumper wires
Preliminary Check-out
Check symptons in table 1 and correct if necessary.
TABLE 1 System conditions
SYMPTOM ACTION
Low Voltage Output Check : loose drive belt ; low battery state of charge.
Check : current load on system is greater than alternator can produce.
Check : defective wiring or poor ground path ; low regulator setpoint.
Check : defective alternator and / or regulator.
High Voltage Output Check : wrong regulator.

Check : high regulator setpoint.
Check : defective regulator.
Check : alternator.
No Voltage Output Check : broken drive belt.
Check : battery voltage at alternator output terminal.
Check : defective alternator and / or regulator.
Check : lost residual magnetism in self-energizing alternator. Go to the first chart
«NO OUTPUT» in section advanced troubleshooting.
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Electrical system
Basic troubleshooting
• Inspect charging system components for damage
Check connections at B- cable, B+ cable, and alternator-to-regulator harness. Repair or replace any damaged
component before troubleshooting.
• Inspect all vehicle battery connections
Connections must be clean and tight.
• Determine batteries voltages and states of charge
If batteries are discharged, recharge or replace batteries as necessary. Electrical system cannot be properly
tested unless batteries are charged 95% or higher. In addition, open circuit voltages must be within ± 0.2 V.
• Connect meters to alternator
Connect red lead of DMM to alternator B+ terminal and black lead to alternator B- terminal. Clamp inductive
ammeter on B+ cable.
• Operate vehicle
Observe charge voltage.
CAUTIONIf charge voltage is above 33 volts, immediately shut down system.
Electrical system damage may occur if charging system is allowed to operate at high voltage.
If voltage is at or below regulator setpoint, let charging system operate for several minutes to normalize ope-
rating temperature.
• Observe charge volts and amps
Charge voltage should increase and charge amps should decrease. If charge voltage does not increase within
ten minutes, continue to next step.
• Batteries are considered fully charged if charge voltage is at regulator setpoint and charge amps remain
at lowest valur for 10 minutes.
• If charging system is not performing properly, go to second chart (test OVCO circuit) on the last page.
• Check OVCO circuit
Shut down vehicle and restart engine. If alternator functions normally after restart, a «no output condition» was
a normal response of voltage regulator to «high voltage» condition. Inspect condition of electrical system, in-
cluding loose battery cables, both positive and negative. If battery disconnects from system, it could cause «hi-
gh voltage» condition in electrical system, causing OVCO circuit to trip.
If you have reset alternator once, and electrical system returns to normal charge voltage condition, there may
have been a one time, high voltage spike, causing OVCO circuit to trip.
If OVCO circuit repeats cutcout a second time in short succession and shuts off alternator F+ circuit, try third
restart. If OVCO circuit repeats cutout, go to second chart (test OVCO circuit) on the last page.
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MJFCIFSS
Service Manual
Electrical system
Advanced troubleshooting
Trouble : NO OUTPUT
Self-energized alternator may have lost magnetism. Touch steel tool to shaft to detect any magnetism. Is
shaft magnetized?
Yes No
Install a jumper from B+ terminal on alternator to E Install a jumper from B terminal on alternator to
terminal on regulator. Momentarily (1 sec.) E terminal on regulator. Momentarilly (1
jumper E terminal on regulator to D+ terminal sec.) jumper E terminal on regulator to
on regulator. Touch shaft with steel tool to D+ terminal on regulator. Touch shaft
detect significant magnetism. Is shaft magneti- with steel tool to detect significant
zed? magnetism. Is shaft magnetized?
Yes No Yes No
Unplug alternator-to-regulator harness. Connect Retest alternator

DMM across pin D and pin C in harness
plug. Does battery voltage exist?
Yes No Unplug alternator-to-regulator harness. Con-
nect DMM across pin D and pin C in har-
ness plug. Does battery voltage exist?
Alternator is defective Yes No
Connect black lead of DMM to pin E in harness Alternator is defective

plug. Connect red lead to B terminal or
alternator. DMM should read voltage drop.
Reverse leads. DMM should read OL. Connect black lead of DMM to pin E in harness
plug. Connect red lead to B terminal or
Yes No alternator. DMM should read voltage
drop. Reverse leads. DMM should read
OL.
Alternator is defective Yes No
Repair vehicle circuit to E terminal. Vehicle char- Alternator is defective

ging circuit test is complete.
Install a jumper from pin F in harness plug to

Unplug alternator-to-regulator harness. Connect B+ terminal on alternator. Momentarily
DMM across pin D and pin C in harness plug. (1 sec.) jumper pin A in harness plug to
Does battery voltage exist? alternator B terminal. Touch shaft with
steel tool to detect significant magne-
tism. Is shaft magnetized?
Yes No Yes No
Alternator is defective Regulator is defec- Alternator is defective

tive
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MJFCIFSS
Service Manual
Electrical system
Install a jumper from pin F in harness plug to B+ ter- PIN CONNECTIONS

minal on alternator. Momentarily (1 sec.) jum- Pin A : F-
per pin A in harness plug to alternator B Pin B : Phase
terminal. Touch shaft with steel tool to detect Pin C : B-
significant magnetism. Is shaft magnetized? Pin D : B+
Yes No Pin E : D+
Pin F : F+
Regulator is defective Alternator is defective
Alternator-and Regulator Harness plug
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MJFCIFSS
Service Manual
Electrical system
Trouble : ALTERNATOR OUTPUT - TEST OVCO CIRCUIT
With engine off, unplug alternator-to-regulator harness. Connect DMM red lead to pin A on harness plug.
Connect black lead to pin F on same plug. Does resistance measure about 1.2 (- 0.2) ohms?
Yes No
Connect DMM red lead to pin A on alternator-to- Alternator is defective

regulator harness plug. Connect black lead
to alternator B- terminal. Does continuity
exist?
Yes No
Alternator is defective. Regulator is defective.
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MJFCIFSS
Service Manual
Electrical system
13.1.7.2Batteries
Technical data
Nominal voltage : 12V.
Nominal capacity : 170 Ah.
DIN : 72 311.
Maximal dimensions : 514*218*210 mm.
Housing material : Polypropylene.
Battery maintenance
Important : before repair on the electrical system, or before using an arc welder on the machine, the negative
battery terminal should be disconnected first and reconnected last.
In order for the batteries to function properly, it is important to keep them clean at all time.
The battery poles and cable clamps in particular should be cleaned regularly and then coated with acid resis-
tant grease.
To check the electrolyte level, open battery compartment door, lift up rubber cover and remove caps. The elec-
trolyte level should be ½´´ (10 - 15 mm) above the plates. If the electrolyte level is low, add distilled water.
Regularly check the specific gravity with hydrometer. A fully charged battery should have a value of 1.28 kg/l
(31,5°). Batteries with a lower value should be recharged. Reinstall caps, check if battery is mounted securely
and close the battery compartment door.
Danger
Wear protective gloves and safety glasses when handling batteries!
Keep sparks and open flame away from battery. Battery fumes are highly flammable and explosive. Batteries
contain acid, which should not be touched. In case of contact, flush with water and get medical attention.
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Service Manual
Electrical system
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MJFCIFSS

13 Electrical System

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Service Manual

Chapter 13 - Electric systems

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13.1.1Main components location

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A1001 Printed circuit board ESP01

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13.1.2.1Control and cab instrumentation

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A2 Radio S6 Switch / float position

13.1.2.2Switching box E1005

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Component Designation Function

A1014 Current regulation plate For pontoon

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Fuses and relays

F29 8A Fuse / Reserve cameras

Name Designation Mounted Connected with

X71 Connector 24 poles A1019 Board and BST

X72 Connector 3 poles A1019 Board

X74 Connector 5 poles A1019 A1014

X76 Connector 2 poles A1019 F148

X77 Connector 4 poles A1019 E1038

X78 Connector 12 poles A1019 E1038

X79 Connector 2 poles A1019 F125

X81 Connector 7 poles A1019 Quantum

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X84 Connector 16 poles A1020 /

X89_1 Connector 4 poles A1020 Ground

X89_2 Connector 4 poles A1020 Program

X90 Connector 6 poles A1020 K98 travel alarm

X91 Connector 8 poles A1020 Pressure cut off / float position

X93 Connector 4 poles A1020 Protected supplies to outside

X95 Connector 3 poles A1020 Supply A1020

X95_1 Connector 4 poles A1014 /

X95_2 Connector 4 poles A1014 /

X95_4 Connector 4 poles A1014 /

X97_1 Connector 6 poles A1020 Joystick U21, horn

X97_2 Connector 6 poles A1020 A1008_1, horn

X97_2 Connector 2 poles A1014 A1019, Y4

X97_4 Connector 2 poles A1014 A1019, Y3.3

X99_1 Connector 6 poles A1020 Joystick U22

X101 Connector 3 poles A1020 Pedal U23 for travel right

X102 Connector 4 poles A1020 Pedal U20 for shovel flap

X103 Connector 8 poles A1020 A1001 for shield

X104 Connector 3 poles A1020 /

X300 Electronic ground E1005

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X330 Service ground E1005

X500 Terminal block E1005

X517_1 Connector 3 poles CAN1 From A1020 (X103)

X517_2 Connector 3 poles CAN1 From E1036 (X122)

X517_3 Connector 3 poles CAN1 To A1001 (X1)

X560 Connector 6 poles E1005 Diagnostic from Quantum U18 (X845)

X561 Connector 3 poles E1005 Diagnostic from Cense (X849)

XT103 Connector 3 poles E1005 Test pumps setting

XT104 Connector 3 poles E1005 Test pumps setting

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A1001 Printed circuit board ESP01 K1 Relay on A1001 / windshield wiper

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