SM Cat 320d2 Full

320D2 Excavator DFM00001-UP (MACHINE) POWERED BY C7.1 Engine(SEBP6240...
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Product: EXCAVATOR
Model: 320D2 EXCAVATOR DFM
Configuration: 320D2 Excavator DFM00001-UP (MACHINE) POWERED BY C7.1 Engine
Specifications
320D, 320D2, 323D and 323D2 Excavators Machine System Specifications
Media Number -RENR7293-18 Publication Date -01/07/2014 Date Updated -21/07/2014
i04461741
Accumulator (Pilot)
SMCS - 5077-PS
S/N - A6F1-UP
S/N - A8F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... 7/21/2017
320D2 Excavator DFM00001-UP (MACHINE) POWERED BY C7.1 Engine(SEBP6240... Page 2 of 4
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TMF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Illustration 1 g02646982
Table 1
Specification for 087-4454 Hydraulic Accumulator Gp
Item Qty Part Specification Description
1 1 087-4576 Cap Torque to 3.0 ± 0.3 N·m (26.6 ± 2.7 lb in).
Copyright 1993 - 2017 Caterpillar Inc. Fri Jul 21 11:13:27 UTC+0700 2017
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Specifications
i05027549
Accumulator (Pilot)
SMCS - 5077-PS
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TMF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 087-4456 Hydraulic Accumulator Gp
1 1 - Tighten the cap to 2.9 ± 0.2 N·m (26 ± 1.7 lb in).
Final installation torque is
2 1 -
30 ± 5 N·m (266 ± 44 lb in).
Charge pressure of nitrogen gas should be within
- - -
1760 ± 100 kPa (255 ± 15 psi).
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Specifications
i05856130
Air Cleaner
SMCS - 1051
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - KBS1-UP
S/N - KHR1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Table 1
Specification for 450-5325 Air Cleaner Gp
Tighten the clamp to

1 - -
7.5 ± 1.0 N·m (66.4 ± 8.9 lb in).
Tighten the mounting hardware to
2 - -
18 ± 3 N·m (159 ± 27 lb in).
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Testing and Adjusting

C7.1 (Mech) Engines for Caterpillar Built Machines
Media Number -UENR0673-02 Publication Date -01/07/2014 Date Updated -09/07/2014
i05367478
Air in Fuel - Test

SMCS - 1280-081
Introduction
This procedure checks for air in the fuel system. This procedure also assists in finding the source of
the air.
Required Tools
Table 1
Required Tools
Part Number Part Description Qty
2P-8278 Tube As (Sight Gauge) 1
Test Procedure
Work carefully around an engine that is running. Engine parts that are
hot, or parts that are moving, can cause personal injury.
1. Examine the fuel system for leaks. Ensure that the fuel line fittings are properly tightened.
Check the fuel level in the fuel tank. Air can enter the fuel system on the suction side between
the fuel transfer pump and the fuel tank.
2. Install a 2P-8278 Tube As (Sight Gauge) in the fuel return line. When possible, install the sight
gauge in a straight section of the fuel line that is at least 304.8 mm (12 inch) long. Do not install
the sight gauge near the following devices that create turbulence:
◦ Elbows
◦ Relief valves
◦ Check valves
Observe the fuel flow during engine cranking. Look for air bubbles in the fuel. If there is no
fuel that is present in the sight gauge, prime the fuel system. Refer to Testing and Adjusting,
"Fuel System - Prime" for more information. If the engine starts, check for air in the fuel at
varying engine speeds. When possible, operate the engine under the conditions which have
been suspect.
2P-8278 Tube As (Sight Gauge)
(1) A steady stream of small bubbles with a diameter of approximately 1.60 mm (0.063 inch) is an acceptable
amount of air in the fuel.
(2) Bubbles with a diameter of approximately 6.35 mm (0.250 inch) are also acceptable if there are 2 seconds to 3
seconds intervals between bubbles.
(3) Excessive air bubbles in the fuel are not acceptable.
3. If excessive air is seen in the sight gauge in the fuel return line, install a second sight gauge at
the inlet to the fuel transfer pump. If a second sight gauge is not available, move the sight gauge
from the fuel return line and install the sight gauge at the inlet to the fuel transfer pump.
Observe the fuel flow during engine cranking. Look for air bubbles in the fuel. If there is no
fuel that is present in the sight gauge, prime the fuel system. Refer to Testing and Adjusting,
"Fuel System - Prime" for more information. If the engine starts, check for air in the fuel at
varying engine speeds.
If excessive air is not seen at the inlet to the fuel transfer pump, the air is entering the system
after the fuel transfer pump. Refer to the Testing and Adjusting, "Fuel System - Prime".
If excessive air is seen at the inlet to the fuel transfer pump, air is entering through the suction
side of the fuel system.
To avoid personal injury, always wear eye and face protection when
using pressurized air.
NOTICE
To avoid damage, do not use more than 55 kPa (8 psi) to pressurize the
fuel tank.
4. Pressurize the fuel tank to 35 kPa (5 psi). Do not use more than 55 kPa (8 psi) in order to avoid
damage to the fuel tank. Check for leaks in the fuel lines between the fuel tank and the fuel
transfer pump. Repair any leaks that are found. Check the fuel pressure in order to ensure that
the fuel transfer pump is operating properly. For information about checking the fuel pressure,
see Testing and Adjusting, "Fuel System Pressure - Test"
5. If the source of the air is not found, disconnect the supply line from the fuel tank and connect
an external fuel supply to the inlet of the fuel transfer pump. If this corrects the problem, repair
the fuel tank or the stand pipe in the fuel tank.
Copyright 1993 - 2017 Caterpillar Inc. Sat Jul 22 09:21:27 UTC+0700 2017
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i02281171
Air Inlet and Exhaust System - Inspect

SMCS - 1050-040
Do a general visual inspection of the air inlet and exhaust system. Make sure that there are no signs of
leaks in the system.
There will be a reduction in the performance of the engine if there is a restriction or there is a leak in
the air inlet system or the exhaust system.
Hot engine components can cause injury from burns. Before

performing maintenance on the engine, allow the engine and the
components to cool.
Making contact with a running engine can cause burns from hot parts
and can cause injury from rotating parts.
When working on an engine that is running, avoid contact with hot

parts and rotating parts.
1. Inspect the engine air cleaner inlet and ducting in order to ensure that the passageway is not
blocked or collapsed.
2. Inspect the engine air cleaner element. Replace a dirty element with a clean element.
3. Check for dirt tracks on the clean side of the engine air cleaner element. If dirt tracks are
observed, contaminants are flowing past the element.
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i02418531
Alternator - Test
SMCS - 1405-081
1. Put the positive lead "+" of a suitable multimeter on the "B+" terminal of the alternator. Put the
negative "-" lead on the ground terminal or on the frame of the alternator. Put a suitable
ammeter around the positive output wire of the alternator.
2. Turn off all electrical accessories. Turn off the fuel to the engine. Crank the engine for 30
seconds. Wait for two minutes in order to cool the starting motor. If the electrical system
appears to operate correctly, crank the engine again for 30 seconds.
Note: Cranking the engine for 30 seconds partially discharges the batteries in order to do a
charging test. If the battery has a low charge, do not perform this step. Jump start the engine or
charge the battery before the engine is started.
3. Start the engine and run the engine at full throttle.
4. Check the output current of the alternator. The initial charging current should be equal to the
minimum full load current or greater than the minimum full load current. Refer to
Specifications, "Alternator and Regulator" for the correct minimum full load current.
Table 1
Fault Conditions And Possible Causes
Current At Start- The Voltage Is The Voltage Is Within The Voltage Is
up Below Specifications After 10 Above
Specifications Minutes. Specifications
After 10 Minutes. After 10 Minutes.
Less than the Replace the Turn on all accessories. If -

specifications alternator. Check the voltage decreases below
the circuit of the the specifications, replace
ignition switch. the alternator.
Decreases after Replace the The alternator and the Replace the
matching alternator. battery match the alternator.
specifications specifications. Turn on all
accessories in order to
verify that the voltage stays
within specifications.
The voltage Test the battery. The alternator operates Replace the
consistently Test the alternator within the specifications. alternator. Inspect
exceeds again. Test the battery. the battery for
specifications. damage.
5. After approximately ten minutes of operating the engine at full throttle, the output voltage of
the alternator should be 14.0 ± 0.5 volts for a 12 volt system and 28.0 ± 1 volts for a 24 volt
system. Refer to the Fault Conditions And Possible Causes in Table 1.
6. After ten minutes of engine operation, the charging current should decrease to approximately
10 amperes. The actual length of time for the decrease to 10 amperes depends on the following
conditions:
◦ The battery charge
◦ The ambient temperature
◦ The speed of the engine
Refer to the Fault Conditions And Possible Causes in Table 1.
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Specifications
C7.1 (Mech) Engines For Caterpillar Built Machines
i02661857
Alternator and Regulator

SMCS - 1405; 1410
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - KBS1-UP
S/N - KHR1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
12 Volt and 24 Volt Alternator
A typical alternator
(1) Tighten terminal nut "W" to the following torque. ... 3.7 N·m (33 lb in)
(2) Tighten terminal nut "D+" to the following torque. ... 3.7 N·m (33 lb in)
(3) Tighten terminal nut "B+" to the following torque. ... 7 N·m (62 lb in)
Tighten the pulley nut (not shown) to the following torque. ... 80 N·m (59 lb ft)
Alignment of the alternator pulley to the crankshaft pulley ... ± 2.4 mm ( ± 0.0945 inch)
Rotation ... clockwise
Polarity ... Negative earth
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i01126605
Battery - Test
SMCS - 1401-081
Most of the tests of the electrical system can be done on the engine. The wiring insulation must be in
good condition. The wire and cable connections must be clean, and both components must be tight.
Never disconnect any charging unit circuit or battery circuit cable from
the battery when the charging unit is operated. A spark can cause an
explosion from the flammable vapor mixture of hydrogen and oxygen
that is released from the electrolyte through the battery outlets. Injury
to personnel can be the result.
The battery circuit is an electrical load on the charging unit. The load is variable because of the
condition of the charge in the battery.
NOTICE
The charging unit will be damaged if the connections between the

battery and the charging unit are broken while the battery is being
charged. Damage occurs because the load from the battery is lost and
because there is an increase in charging voltage. High voltage will
damage the charging unit, the regulator, and other electrical
components.
See Special Instruction, SEHS7633, "Battery Test Procedure" for the correct procedures to use to test
the battery. This publication also contains the specifications to use when you test the battery.
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Specifications
i04605590
Boom - 5.675 m (18.6188 ft)

SMCS - 6501
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - FAL1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - RAR1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
(1) Stick cylinder group
(2) Stick group
(3) Boom cylinder group
Table 1
Specification for 241-7282 Boom , 290-9192 Boom , 241-7287 Boom , 290-9195 Boom , 294-
1480 Boom , 282-4533 Boom , 315-1064 Boom , and 315-1049 Boom
Item Qty
Part Specification description
All bores must be free of paint. Use 5P-0960 Grease Cartridge to coat all bores for the pins, the
stick, the upper frame, the bushing, and the cylinder pin bores.
4I-4809 Pin Diameter is
4 1
As 79.850 ± 0.025 mm (3.1437 ± 0.0010 inch).
176-2278 Diameter is
5 1
Pin 79.850 ± 0.025 mm (3.1437 ± 0.0010 inch).
Install the bushing (6) in the bore so that the part number of the bushing is facing outward.
The bushing is one of the following part numbers:
Bore of the bushing before installation is
244-4277 90.16 ± 0.02 mm (3.550 ± 0.001 inch).
2
Bushing Installation depth is
6
9.5 ± 0.8 mm (0.37 ± 0.03 inch).
Bore of the bushing before installation is
228-5615 90.25 ± 0.04 mm (3.553 ± 0.002 inch).
2
9.5 ± 0.8 mm (0.37 ± 0.03 inch).
Lubricate the sealing lip of the lip type seals lightly with the lubricant
166-1495
that is being sealed. Install the dust seal so that the lip faces outside,
7 2 Lip Type
as shown. Install the lip type seals so that the lip type seals do not
Seal
extend beyond the face of the boss.
8 1
Pin As 89.850 ± 0.025 mm (3.5374 ± 0.0010 inch).
As required, use the following shims in order to adjust the maximum lateral clearance.
Mount the steel shim in order to be located at the boom side.
Maximum lateral clearance except for Gosselies facility is
1.6 mm (0.06 inch).
Maximum lateral clearance for Gosselies facility is
9 1.0 mm (0.04 inch).
113-2127 Thickness of one shim is
1
Shim 0.5 mm (0.02 inch).
093-0084 Thickness of one shim is
2
Shim 1.0 mm (0.04 inch).
Optional Design
Section D-D
Table 2
Specification for 241-7282 Boom , 290-9192 Boom , 241-7287 Boom , 290-9195 Boom , 294-
1480 Boom , 282-4533 Boom , 315-1064 Boom , and 315-1049 Boom
Item Qty Part Specification description
As required, use the following shims in order to adjust the maximum lateral clearance:
Maximum lateral clearance except for Gosselies facility is
1.6 mm (0.06 inch).
10 Maximum lateral clearance for Gosselies facility is
1.0 mm (0.04 inch).
Thickness of one shim is
2 093-0116 Shim
2.0 mm (0.08 inch).
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Specifications
i04589310
Boom Cylinder Lines

SMCS - 5057-BCD
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - FAL1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBT1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAR1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Typical example
Table 1
Specification for 242-6732 Boom Cylinder Lines Gp , 331-9284 Boom Cylinder Lines Gp ,
331-9286 Boom Cylinder Lines Gp , 266-8023 Boom Cylinder Lines Gp and 242-6737 Boom
Cylinder Lines Gp
8T-3653 Bolt
1 1 Torque to 62.6 ± 11.7 N·m (46.2 ± 8.6 lb ft).
Distance from the centerline of the mounting pin to the center

A - - of the support assembly is
418.0 mm (16.46 inch).
9X-6032 Torque to
2 8
Bolt 51.20 ± 9.61 N·m (37.76 ± 7.09 lb ft).
8T-4196 Bolt Torque to
3 2
31.50 ± 5.88 N·m (278.80 ± 52.04 lb in).
C - - Orient the support assemblies to (50 degrees).
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Specifications
i05492810
Boom Cylinder Lines

SMCS - 5057-BCD
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CXY1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - FAL1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PCM1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Top view
Table 1
Specification for 239-1699 Boom Cylinder Lines Gp
1 4 124-1047 Hose As Torque to 160 ± 16 N·m (118 ± 12 lb ft).
Right side view
Table 2
Specification for 239-1699 Boom Cylinder Lines Gp
Torque to
2 1 9F-2167 Purge Screw
18.0 ± 2.5 N·m (159.3 ± 22.1 lb in).
Torque to
3 1 108-7354 Hose As
76 ± 4 N·m (56 ± 3 lb ft).
Torque to
4 1 148-8444 Swivel Tee As
76 ± 4 N·m (56 ± 3 lb ft).
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Product: EXCAVATOR
Specifications
i05857079
Boom Cylinder
SMCS - 5456
S/N - BZP1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - FAL1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MZD1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAR1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
Table 1
Specification for 341-2790 Boom Cylinder and Seal Gp
Item Qty
Part Specification Description
Bore before assembly is

80.20 ± 0.04 mm (3.157 ± 0.002 inch).
1 1 240-2913 Bushing
Installation depth is
10 mm (0.4 inch).
Torque to
2 12 8T-1447 Bolt
267 ± 40 N·m (197 ± 30 lb ft).
352-1096 Boom Bore is
A 1
Cylinder As 120 mm (4.7 inch).
Diameter is
B 1 352-1102 Rod As
85 mm (3.3 inch).
Bore before assembly is

80.36 ± 0.03 mm (3.164 ± 0.001 inch).
3 1 357-5717 Bushing
10 mm (0.4 inch).
3B-8489 Grease Fitting Torque to
4 1
9.32 ± 0.49 N·m (82.49 ± 4.34 lb in).
Outside diameter before assembly is
90 mm (3.5 inch).
5 1 096-4402 Bushing
Thickness is
2.47 mm (0.097 inch).
Torque to
6 1 247-8864 Piston
5460 ± 260 N·m (4027 ± 192 lb ft).
Torque to
096-3216 Socket 56.9 ± 10.7 N·m (42.0 ± 7.9 lb ft).
7 1
Setscrew After tightening the socket setscrew, stake the socket
setscrew in two places.
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Product: EXCAVATOR
Specifications
i04586315
Boom Lines
SMCS - 5057-BM
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - RAR1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Top view
Table 1
Specification for 260-8010 Boom Lines Gp
Item Qty
202-6996 Hose Torque to

1 1
As 160 ± 16 N·m (118 ± 12 lb ft).
202-3856 Tube Torque to
2 1
As 160 ± 16 N·m (118 ± 12 lb ft).
202-3858 Tube Torque to
3 1
As 160 ± 16 N·m (118 ± 12 lb ft).
Distance between the center of the mounting bolts and the

C - - centerline of boom foot pin is
275.0 mm (10.83 inch).
Distance between the end of the tube assemblies and the
D - - centerline of boom foot pin is
125.0 ± 5.0 mm (4.92 ± 0.20 inch).
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Specifications
i04573598
Bucket Adjuster
SMCS - 6513; 6523
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - RAR1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Right side view
Table 1
Specification for 7Y-2219 Bucket Adjuster Gp
Item
Qty Part Specification Description
As required, use shims (1) to adjust the clearance (B) of 0.5 to 1.0 mm (0.02 to 0.04 inch).
Use minimum three 086-0321 Shims .
1 4 086-0321 Shim
0.5 mm (0.02 inch).
6 086-0322 Shim
1.0 mm (0.04 inch).
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Specifications
i04629865
Bucket Cylinder Lines

SMCS - 5057-G1
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - FAL1-UP
S/N - GTF1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LFL1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - RAC1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TMF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - YSD1-UP
S/N - ZMF1-UP
Table 1
Specification for 248-9926 Bucket Cylinder Lines Gp
Item Qty
Distance from the centerline of the mounting pin to the support

A - - assemblies is
218.0 ± 5.0 mm (8.58 ± 0.20 inch).
C - - Orient the support assemblies to the angle of 30 ± 3 degrees.
1 4
39 ± 8 N·m (29 ± 6 lb ft).
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Product: EXCAVATOR
Specifications
i05237993

SMCS - 5057-G1
S/N - CWG1-UP
S/N - CXY1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - FAL1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Item Qty
9X-6032 Bolt Torque to

1 4
51.20 ± 9.61 N·m (37.76 ± 7.09 lb ft).
B - - assemblies is
212 mm (8.3 inch).
C - - Orient the support assemblies to the angle of 42 degrees.
2 2
31.50 ± 5.88 N·m (278.80 ± 52.04 lb in).
3 1
56.9 ± 10.7 N·m (42.0 ± 7.9 lb ft).
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Specifications
i05393669

SMCS - 5057-G1
S/N - DFM1-UP
S/N - FAL1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - MZD1-UP
S/N - NBT1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PJP1-UP
S/N - RAR1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WGC1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
Table 1
Item Qty
5I-4216 Hose As Torque to

1 1
160 ± 16 N·m (118 ± 12 lb ft).
4I-8785 Hose As Torque to
2 1
160 ± 16 N·m (118 ± 12 lb ft).
Orient the hose assemblies to the angle of 30 ± 3 degrees.
A - -
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Specifications
i05707696
Bucket Cylinder
SMCS - 5457
S/N - DFM1-UP
S/N - FAL1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - PJP1-UP
S/N - RAR1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
Table 1
Specification for 341-2814 Bucket Cylinder and Seal Gp
Item Qty
Inside diameter before assembly 80.20 ± 0.04 mm (3.157

± 0.002 inch).
1 1 241-7382 Bushing
10 mm (0.4 inch).
Torque to
2 12 8T-1447 Bolt
267 ± 40 N·m (197 ± 30 lb ft).
352-1100 Cylinder As Bore is
A 1
120 mm (4.7 inch).
Diameter is
B 1 352-1106 Rod As
85 mm (3.3 inch).
During press fit, insert the bushing with the taper side
first.
Inside diameter before assembly
3 1 357-5712 Bushing
70.35 ± 0.03 mm (2.770 ± 0.001 inch).
10 mm (0.4 inch).
3B-8489 Grease Torque to

4 2
Fitting 9.32 ± 4.90 N·m (82.49 ± 43.37 lb in).
90 mm (3.5 inch).
5 1 096-4402 Bushing
Thickness is
2.47 mm (0.097 inch).
Torque to
6 1 247-8885 Piston
6840 ± 340 N·m (5045 ± 251 lb ft).
Torque to
096-3216 Socket 56.9 ± 10.7 N·m (42.0 ± 7.9 lb ft).
7 1
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Specifications
i05864749
Bucket Linkage - B1 Family

SMCS - 6513
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - FAL1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - JEG1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - RAC1-UP
S/N - RAR1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TMF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Typical example
Table 1
Specification for 260-2288 Bucket Linkage Gp
Item Qty
All bores must be free of paint. Use 5P-0960 Grease Cartridge in order to coat all the pin bores and
the bushings before assembly. After you assemble the bushings coat all the bores and the bushings
with 5P-0960 Grease Cartridge .
Lubricate the sealing lip of lip type seals lightly with the lubricant
166-1494
1 6 Lip Type
as shown. Install lip type seals so that lip of the lip type seals do not
Seal
Install the bush in the bore so that the part number of each bush is
facing outward.
244-4360
2 2 Inside diameter is 80.20 ± 0.04 mm (3.157 ± 0.002 inch).
Bushing
9.5 ± 0.8 mm (0.37 ± 0.03 inch).
Install the bush in the bore so that the part number of each bush is
facing outward.
240-2912 Inside diameter is
3 2
Bushing 80.20 ± 0.04 mm (3.157 ± 0.002 inch).
9.5 ± 0.2 mm (0.37 ± 0.01 inch).
451-2183 Torque to
4 8
Nut 175 ± 30 N·m (129 ± 22 lb ft).
5 1
Pin 79.85 ± 0.04 mm (3.144 ± 0.002 inch).
6 1
Pin 69.85 ± 0.04 mm (2.750 ± 0.002 inch).
7 2
Pin 79.85 ± 0.04 mm (3.144 ± 0.002 inch).
Position the nut (8) to the distance of
- - - 0.5 ± 0.5 mm (0.02 ± 0.02 inch) past the end of the bolts (11) . For
locking, tighten the nut (9) against the nut (8) .
During assembly of linkage group on the machine, rotate the rod end
10 - - of the bucket cylinder to position the grease fitting away from the
stick.
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Specifications
i04633249
Bucket Sidecutter
SMCS - 6813
S/N - A9F1-UP
S/N - CWG1-UP
S/N - DFM1-UP
S/N - FAL1-UP
S/N - GTF1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JZA1-UP
S/N - KGF1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - PBE1-UP
S/N - PCM1-UP
S/N - PHX1-UP
S/N - TDH1-UP
S/N - WGC1-UP
S/N - YSD1-UP
Table 1
Specification for 7Y-0729 Sidecutter Gp
Item Qty
8T-0380
1 8 Apply 4C-9506 Retaining Compound to the threads of the bolts.
Bolt
Before tightening the full nuts (2), push the bucket sidecutter until the
- - -
shear ledge (3) contacts the bucket sidebar (4).
7X-0851 Torque for the full nuts to
2 8
Nut 845 ± 85 N·m (623 ± 63 lb ft).
Distance between the shear ledge and the bucket sidebar should be
C - -
zero.
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Product: EXCAVATOR

320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
340D, 340D2 and 340D2 Excavators, 324D FM Forest Machine and 323D MHPU, 324D
MHPU, 325D MHPU, 329D MHPU, 330D MHPU and 336D MHPU Mobile Hydraulic Power
Units Machine Electronic Control System
i02415546
Calibration
SMCS - 7610-524-MCH
Using Caterpillar Electronic Technician

The Caterpillar Electronic Technician service tool is used in order to access the calibration
procedures. For more information, refer to the manual that was provided with the ET.
Similar procedures for calibration may also be performed through the Monitoring System. See
Systems Operation, RENR8068, "Calibration Mode".
The calibration menu is used in order to compensate for the differences in the mechanical components
and the electrical components. The calibration should be performed if the ECM has been replaced or
the ECM was removed. The calibration should be performed if components have been replaced or
removed. Perform all calibrations that are applicable.
Note: Be sure the hydraulic oil temperature is at least 50 °C (122 °F) before performing calibrations.
Accessing Calibrations
Connect the ET to the machine. See Illustration 1. After communication has been established, the ET
will list the electronic control modules that are on the machine.
Location of the ET Connector
(Behind Operator Seat, Below Right Console)
(1) ET Connector
(2) Right Console
(3) Back of Operator Seat (Shifted Forward for access)
(4) Backup Control Switches
Note: The ECM must detect specific set-up conditions before beginning the calibration procedure. If
a set-up step is not met, the calibration procedure is aborted.
1. Select the Machine ECM.
Typical screen for accessing calibrations
2. Select "Service" from the main menu.
3. Select "Calibrations" from the "Service" drop-down menu.
The following is a list of all possible calibrations from the "Calibrations" drop-down menu. The
specific calibrations will differ across sales models.
◦ "PRV - Main Pump Flow Limitation Pressure Calibration"
◦ "PRV - Power Shift Pressure Calibration"
◦ "Modulation Input Calibration"
◦ "PRV - Variable Relief Pressure Calibration"
◦ "PRV - Attachment Valves Pressure Calibration"
◦ "Engine Speed Calibrations"
4. From the "Calibrations" drop-down menu, select the desired calibration procedure.
5. Follow the instructions that are provided on the screen.
Note: Additional screens will be displayed to notify the operator of the status of the calibration
procedure.
Typical Calibration Screens
Note: Some calibration procedures require additional equipment.
Typical screen for performing calibrations with multiple selections
Typical screen for performing calibrations
Shutdown SIS
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Product: EXCAVATOR
Specifications
i04538709
Camshaft Bearings
SMCS - 1211
S/N - -
Typical example
(1) The diameter of the installed camshaft bearing ... 50.787 to 50.848 mm (1.9995 to 2.0019 inch)
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Specifications
i02772012
Camshaft
SMCS - 1210
S/N - -
Checking the end play of the camshaft
(1) End play of a camshaft ... 0.126 to 0.558 mm (0.0050 to 0.0220 inch)
Maximum permissible end play of a worn camshaft ... 0.62 mm (0.0244 inch)
Typical example
(2) Bolt
Tighten the bolt to the following torque. ... 95 N·m (70 lb ft)
(3) The diameters of the camshaft journals are given in the following tables.
Table 1
Camshaft Journals Standard Diameter
1
50.711 to 50.737 mm (1.9965 to 1.9975 inch)
2
50.457 to 50.483 mm (1.9865 to 1.9875 inch)
3
50.203 to 50.229 mm (1.9765 to 1.9775 inch)
4
49.949 to 49.975 mm (1.9665 to 1.9675 inch)
Maximum wear on the camshaft journals ... 0.05 mm (0.0021 inch)
Check the camshaft lobes for visible damage. If a new camshaft is installed you must install new
lifters.
340D2 L Excavator HHK00001-UP (MACHINE) POWERED BY C9 Engine(SEBP6533... Page 1 of 2
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Model: 340D2 L EXCAVATOR HHK
Configuration: 340D2 L Excavator HHK00001-UP (MACHINE) POWERED BY C9 Engine
Operation and Maintenance Manual

336D2 and 340D2 Excavators
Media Number -SEBU9168-04 Publication Date -01/06/2014 Date Updated -23/06/2014
i05808002
Capacities (Refill)
SMCS - 1000; 7000
Table 1
Approximate Refill Capacities
Component or System Liters US gal
Recommended Type
Cooling System 40 10.5

Caterpillar Extended Life Coolant (ELC)
Coolant Reservoir 1.5 0.4
Fuel Tank 620 163 No. 1 Diesel Fuel or No. 2 Diesel Fuel
Engine Crankcase with
40.5 10.5
Filter
Hydraulic System (1) 194 51 Refer to Operation and Maintenance Manual,
"Lubricant Viscosities".
Swing Drive 19 5.0
Each Final Drive 8 2.1
kg lb
kg lbs
Refer to Operation and Maintenance Manual,
Swing Gear 26.1 57.5
Refrigerant (2) 0.9 2.0 R-134a
(1)
The amount of hydraulic fluid that is needed to refill the hydraulic system after performing Operation and
Maintenance Manual, "Hydraulic System Oil - Change"
(2)
Refer to Service Manual, "Air Conditioning and Heating R-134a for All Caterpillar Machines" for additional
information
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Model: 340D2 L EXCAVATOR HHK
Configuration: 340D2 L Excavator HHK00001-UP (MACHINE) POWERED BY C9 Engine
Operation and Maintenance Manual

336D2 and 340D2 Excavators
Media Number -SEBU9168-04 Publication Date -01/06/2014 Date Updated -23/06/2014
i05808002
Capacities (Refill)
SMCS - 1000; 7000
Table 1
Approximate Refill Capacities
Component or System Liters US gal
Recommended Type
Cooling System 40 10.5

Caterpillar Extended Life Coolant (ELC)
Coolant Reservoir 1.5 0.4
Fuel Tank 620 163 No. 1 Diesel Fuel or No. 2 Diesel Fuel
Engine Crankcase with
40.5 10.5
Filter
Hydraulic System (1) 194 51 Refer to Operation and Maintenance Manual,
Swing Drive 19 5.0
Each Final Drive 8 2.1
kg lb
kg lbs
Refer to Operation and Maintenance Manual,
Swing Gear 26.1 57.5
Refrigerant (2) 0.9 2.0 R-134a
(1)
The amount of hydraulic fluid that is needed to refill the hydraulic system after performing Operation and
Maintenance Manual, "Hydraulic System Oil - Change"
(2)
Refer to Service Manual, "Air Conditioning and Heating R-134a for All Caterpillar Machines" for additional
information
INTERACTIVE SCHEMATIC
Bookmarks X
*This document is best viewed at a
Options
screen resolution of 1024 X 768.
Features
Cover Page
To set your screen resolution do the following:
Tables RIGHT CLICK on the DESKTOP.
Component Select PROPERTIES.
Connector
CLICK the SETTINGS TAB.
Schematic
Machine Views
MOVE THE SLIDER under SCREEN RESOLUTION
Chassis View until it shows 1024 X 768.
Cab View CLICK OK to apply the resolution.
Engine View
*Due to different monitor sizes and PDF reader preferences
The Bookmarks panel will allow you to there may be some variance in linked schematic locations
quickly navigate to points of interest.
Click here to save a copy of

EC-C2 E-C60 this interactive schematic
EC-C3
to your desktop
E-C61
VIEW ALL CALLOUTS
EC-C1
When only one callout is showing on a
machine view, clicking on this button will
Click on any text that is BLUE and make all of the callouts visible. This
underlined. These are hyperlinks button is located in the top right corner
that can be used to navigate the of every machine view page.
schematic and machine views.
ELECTRICAL SYMBOLS BASIC HYDRAULIC

HOTKEYS (Keyboard Shortcuts) COMPONENT SYMBOLS
T
Pressure Temperature Level Flow

Switch Circuit Breaker Pump
FUNCTION KEYS
Switch Switch Switch
or Motor Variability
Click here to view the

Zoom In “CTRL” / “+” Schematic Symbols
Fluid
Conditioner
Spring
(Adjustable)
Zoom Out “CTRL” / “-” and Definitions page
Fit to Page “CTRL” / “0” (zero)

Hand Tool “SPACEBAR” (hold down)
Find “CTRL” / “F”
SCHEMATIC SYMBOLS AND DEFINITIONS
VALVES INTERNAL PASSAGEWAYS PUMPS BASIC HYDRAULIC

ENVELOPES FLOW IN ONE
DIRECTION
FLOW ALLOWED IN
EITHER DIRECTION
PARALLEL
FLOW
CROSS
FLOW
FIXED DISPLACEMENT
COMPONENT SYMBOLS
One Position Two Position Three Position Unidirectional Bidirectional Pump

Infinite Two Three Variability
Positioning Position Position or Motor
PORTS VARIABLE DISPLACEMENT
NON- COMPENSATED
Spring
CYLINDERS Fluid
(Adjustable)
Two-way Three-Way Four-Way Conditioner
Unidirectional Bidirectional
CONTROL
AB AB
Single Acting Double Acting
MOTORS Pressure
FIXED DISPLACEMENT Spring
P T P T Compensation
Normal Position Shifted Position Infinite Position
CHECK
Control Line Restriction
ACCUMULATORS Unidirectional Bidirectional
Valves (Variable)
VARIABLE DISPLACEMENT
Basic Spring Shuttle Pilot NON- COMPENSATED
Symbol Loaded Controlled Spring Loaded Gas Charged Line Restriction
Restriction
(Fixed)
MAIN AUX.
Line Restriction
PILOT CONTROL Variable and Pressure
2-Section
RELEASED PRESSURE ROTATING SHAFTS Compensated
Pump
External Return Internal Return
Attachment Pump: Variable and
REMOTE SUPPLY PRESSURE Pressure Compensated
Internal Hydraulic Pneumatic

Simplified Complete Supply Pressure Energy Triangles
COMBINATION CONTROLS
LINES MEASUREMENT
Solenoid Solenoid Solenoid Solenoid and Servo Thermal Detent Crossing Joining
or Manual and Pilot Pilot or Manual Pressure Temperature Flow
MANUAL CONTROL FLUID STORAGE RESERVOIRS
Push-pull Lever Manual Shutoff General Manual Push Button Pedal Spring Vented Pressurized Return Above Fluid Level Return Below Fluid Level
HYDRAULIC SYMBOLS - ELECTRICAL ELECTRICAL SYMBOLS

G
M T

Transducer Transducer Generator Electric Pressure Pressure Switch Temperature Electrical
Switch Switch Switch Switch Circuit Breaker
(Fluid) (Gas / Air) Motor Switch (Adjustable) Switch Wire
BASIC ELECTRICAL COMPONENT SYMBOLS HARNESS AND WIRE SYMBOLS

Wire, Cable, or Harness Assembly Identification:
Fuse: A component in an electrical circuit that will open the circuit if too much current flows through it. Includes Harness Identification Letters and Harness
Connector Serialization Codes (see sample).
Switch (Normally Open): A switch that will close at a specified point (temp, press, etc.). The circle indicates
that the component has screw terminals and a wire can be disconnected from it.
AG-C4 L-C12
Switch (Normally Closed): A switch that will open at a specified point (temp, press, etc.). 111-7898 3E-5179
No circle indicates that the wire cannot be disconnected from the component. Part Number: for 1
Connector Plug
Ground (Wired): This indicates that the component is connected to a grounded wire. 2
The grounded wire is fastened to the machine.
Plug Receptacle
Pin or Socket Number
Ground (Case): This indicates that the component does not have a wire connected to ground.
It is grounded by being fastened to the machine. Harness Identification Letter(s): (A, B, C, AA, AB, AC, ...)
Reed Switch: A switch whose contacts are controlled by a magnet. A magnet closes the contacts of Harness Connector Serialization Code: The "C" stands for
"Connector" and the number indicates which connector in the
a normally open reed switch; it opens the contacts of a normally closed reed switch.
harness (C1, C2, C3, ...)
L-C12
Sender: A component that is used with a temperature or pressure gauge. 3E-5179
The sender measures the temperature or pressure.
T Its resistance changes to give an indication to the gauge of the temperature or pressure. 5A
Component
Relay (Magnetic Switch): A relay is an electrical component that is activated by electricity. Fuse (5 Amps) 9X-1123 Part Number
It has a coil that makes an electromagnet when current flows through it.
The electromagnet can open or close the switch part of the relay. 325-AG135 PK-14
Harness identification code:
This example indicates wire group 325, Wire Gauge
Solenoid: A solenoid is an electrical component that is activated by electricity. wire 135 in harness "AG". Wire Color
The electromagnet can open or close a valve or move a piece of metal that can do work. 1 Deutsch connector: Typical representation
of a Deutsch connector. The plug contains all
2 sockets and the receptacle contains all pins.
Magnetic Latch Solenoid: An electrical component that is activated by electricity and held latched by a
permanent magnet. It has two coils (latch and unlatch) that make electromagnet 1 Sure-Seal connector: Typical representation
when current flows through them. It also has an internal switch that places of a Sure-Seal connector. The plug and receptacle
2 contain both pins and sockets.
the latch coil circuit open at the time the coil latches.
UENR3604-03
July 2013
320D2 Excavator
Electrical System
GBA1-UP
LMA1-UP
YEA1-UP
XBB1-UP
TMF1-UP
FKK1-UP
DFM1-UP
HDM1-UP
JFM1-UP
DNP1-UP
KHR1-UP
ZCS1-UP
NBT1-UP
© 2013 Caterpillar, All Rights Reserved Printed in U.S.A.

COMPONENT TABLE
Component Location
Schematic Machine Schematic Machine
Component Component
Location Location Location Location
Alarm - Action E-2 1 Sender - Hydraulic Temperature A-14 79
Alarm - Travel Atch A-14 2 Sensor - Atmosphere I-12 80
Alternator E-16 3 Sensor - Coolant Temperature F-16 81
Assembly - Block G-11 4 Sensor - Engine Oil Pressure D-16 82
Assembly - Holder F-10 5 Sensor - Engine Speed Pickup D-16 83
Bar - Bus G-10 6 Sensor - Fuel Level A-14 84
Base - Fuse E-7 7 Sensor - Fuel Plugged B-16 85
Battery - Front F-15 8 Sensor - Pump 1 Pressure A-16 86
Battery - Front Atch F-15 9 Sensor - Pump 2 Pressure A-16 87
Battery - Rear F-16 10 Socket - 12V/10A A Atch D-6 88
Battery - Rear Atch F-16 11 Socket - 12V/10A B Atch D-6 89
Breaker - Alternator G-10 12 Solenoid - 1P 2P Change 1 Atch B-16 90
Breaker - Glow G-10 13 Solenoid - 1P 2P Change 2 Atch C-16 91
Breaker - Main G-10 14 Solenoid - A/C Clutch F-16 92
Coil - Exciter Atch H-1 15 Solenoid - Double Action Atch B-16 93
Control - Wiper C-2 16 Solenoid - Engine Shut Off D-16 94
Converter - 12V 10A Atch I-3 17 Solenoid - Fine Swing A-8 95
Converter - 12V Power C-6 18 Solenoid - Flow Limit Atch A-16 96
Converter - 12V Radio Atch B-5 19 Solenoid - Heavy Lift Atch A-11 97
Converter - Radio C-7 20 Solenoid - Hydraulic Lock A-11 98
Diode - Alternator F-5 21 Solenoid - Power Shift Pressure A-16 99
Diode - Lamp F-8 22 Solenoid - Quick Coupler Atch H-13 100
Diode - Main Relay C-8 23 Solenoid - Relief 1 Atch C-9 101
Diode - Power Relay Atch B-5 24 Solenoid - Relief 2 Atch B-9 102
Diode - Start Relay C-11 25 Solenoid - Single Action 1 Atch B-9 103
ECM - Machine E-10 26 Solenoid - Single Action 2 Atch B-9 104
ECM - Product Link (Basic) J-15 27 Solenoid - Stem 1 Extend Atch C-14 105
ECM - Product Link (PL300) J-14 28 Solenoid - Stem 1 Extend Atch B-11 106
Governor D-16 29 Solenoid - Stem 1 Retract Atch B-11 107
Ground - Cab 1 D-4 30 Solenoid - Stem 2 Extend Atch C-14 108
Ground - Cab 2 C-6 31 Solenoid - Stem 2 Extend Atch B-11 109
Ground - Cab 3 E-4 32 Solenoid - Stem 2 Retract Atch B-11 110
Ground - Chassis 1 C-16 33 Solenoid - Stem 3 Extend Atch D-14 111
Ground - Chassis 2 C-16 34 Solenoid - Stem 3 Retract Atch D-14 112
Ground - Chassis 3 A-10 35 Solenoid - Swing Brake A-11 113
Ground - Chassis 4 J-10 36 Solenoid - Travel Speed A-11 114
Ground - Chassis 5 F-11 37 Solenoid - Travel Straight A-11 115
Ground - Disconnect Strap F-11 38 Solenoid - Universal QC High Atch A-9 116
Ground - Engine Strap E-16 39 Solenoid - Universal QC Low Atch A-9 117
Ground - Platform J-7 40 Suspension - Air Atch J-4 118
Ground - Platform Chassis Strap J-8 41 Switch - Air Cleaner J-12 119
Heater - Seat Atch H-3 42 Switch - Aux Pump Pressure (Step 4) Atch J-1 120
Horn - Forward Warning LH B-7 43 Switch - Boom Raise Pressure Atch B-10 121
Horn - Forward Warning RH B-7 44 Switch - Cold Start Advance E-16 122
Joystick - LH (3 Switch) Atch J-3 45 Switch - Disconnect F-11 123
Joystick - LH Atch J-3 46 Switch - Engine Oil Level D-16 124
Joystick - RH (3 Switch) Atch I-2 47 Switch - Fine Swing Control Atch B-1 125
Joystick - RH Atch I-1 48 Switch - Foot Atch J-1 126
Keyreader - MSS Atch H-2 49 Switch - Hammer Return Filter Atch G-13 127
Lighter - Cigar D-3 50 Switch - High Pressure (Stem 1) Atch I-1 128
Meter - Service E-2 51 Switch - Horn J-3 129
Monitor F-1 52 Switch - Hydraulic Oil Filter A-14 130
Motor - Lower Washer Atch F-10 53 Switch - Implement Pressure I-4 131
Motor - Lower Wiper Atch J-1 54 Switch - Key H-1 132
Motor - Starting E-16 55 Switch - Lower Washer Atch B-3 133
Motor - Washer F-10 56 Switch - Lower Wiper Atch B-2 134
Motor - Wiper D-2 57 Switch - Medium Pressure (Step 3) Atch J-1 135
Pedal - Aux LH Atch J-1 58 Switch - Neutral Start Limit J-3 136
Plugs - Glow E-16 59 Switch - One Touch Low Idle E-2 137
Pump - Lifting B-16 60 Switch - Panel D-2 138
Pump - Refueling Atch B-5 61 Switch - Quick Coupler Atch D-1 139
Radio - Product Link 2nd Generation H-14 62 Switch - Radio Mute Atch B-2 140
Relay - Glow F-10 63 Switch - Refueling Level Atch A-14 141
Relay - LH Speaker (-) Atch G-9 64 Switch - Refueling Start (NO) Atch A-5 142
Relay - LH Speaker (+) Atch G-9 65 Switch - Refueling Stop (NC) Atch A-5 143
Relay - Main C-9 66 Switch - Seat Heater Atch B-3 144
Relay - QC Hydraulic Lock On Atch D-9 67 Switch - Secondary Shutdown G-9 145
Relay - QC Hydraulic Lock Priority Atch E-9 68 Switch - Speaker Exchange Atch B-4 146
Relay - QC Hydraulic Lock Relay 1 Atch D-9 69 Switch - Throttle Position H-1 147
Relay - QC Hydraulic Lock Relay 2 Atch D-9 70 Switch - Travel Left Pressure I-1 148
Relay - Refueling Power Atch B-6 71 Switch - Travel Right Pressure I-1 149
Relay - Refueling Start Atch A-5 72 Switch - Travel Straight Pressure Atch I-1 150
Relay - Refueling Stop Atch B-5 73 Switch - Under Window Limit Atch D-2 151
Relay - RH Speaker (-) Atch G-9 74 Switch - Universal QC Atch D-1 152
Relay - RH Speaker (+) Atch H-9 75 Switch - Water Separator Level B-16 153
Relay - Single Atch E-9 76 Switch - Window Limit F-2 154
Resistor - Machine CAN 1 C-11 77 Timer - Lamp Delay Atch C-9 155
Resistor - Machine CAN 2 C-3 78 Unit - A/C I-8 156
CONNECTOR TABLE
Connector Location
Schematic
Connector Number
Location
CONN 1 J-16
CONN 2 I-16, J-16
CONN 3 I-16, J-16
CONN 4 H-14
CONN 5 H-14
CONN 6 D-13
CONN 7 C-13
CONN 8 B-13, C-13
CONN 9 A-12
CONN 10 A-11
CONN 11 G-11
CONN 12 G-11
CONN 13 H-11
CONN 14 I-11
CONN 15 I-10
CONN 16 I-10
CONN 17 H-10
CONN 18 A-9
CONN 19 G-8
CONN 20 G-8
CONN 21 C-7
CONN 22 B-7
CONN 23 A-8
CONN 24 A-7
CONN 25 A-7
CONN 26 A-6
CONN 27 A-6
CONN 28 C-6
CONN 29 C-6
CONN 30 C-6
CONN 31 C-6
CONN 32 G-7
CONN 33 G-6
CONN 34 G-6
CONN 35 J-5
CONN 36 J-5
CONN 37 G-3, G-4, H-4, H-5
CONN 38 G-5
CONN 39 B-5
CONN 40 H-4
CONN 41 H-4
CONN 42 H-4
CONN 43 I-4
CONN 44 B-3
CONN 45 C-2
CONN 46 F-2
CONN 47 F-2
CONN 48 F-2
CONN 49 G-2
CONN 50 H-2
CONN 51 C-1
The connectors shown in this chart are for harness to harness
connectors. Connectors that join a harness to a component are
generally located at or near the component.
See the Component Location Chart.
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
CAP6 1 C-C18
3422974 2305010
CONN 1 1
2
172-C2
308-C140
RD-18
YL-16
C-C1
1636637
A-C16
1532620
3 403-C141 GN-18
CONNECTS TO EK-C1 4 892-C143 BR-18 1 (41) PLATFORM CHASSIS STRAP GROUND
2 7G1060 A-C28 A-C48
LOC J-16 5 893-C142 GN-18 172-C2 RD-18 172-C2 RD-18 172-A9 RD-18 1
3E3364 1552269
6 235-C159 BK-18 403-C14 GN-18 L973-C80 GN-16 3 L973-A114 GN-16 2
OR A588-C3 GN-18 4 A588-A12 GN-18 A-C30 H-C2 H-C9 H-C8 3 SW-4 N793-A85 GN-18 1 1 (126) FOOT SWITCH ATCH
2434508 2305010 2304011 2434505
CONNECTS TO GN-C1 430-C18 BU-18 492-C291 GY-18 5 492-A156 GY-18
H-C6
4 SW-COM 235-A152 BK-18 2 2 2051339
892-C48 BR-18 308-C4 YL-16 6 308-A80 YL-16 E472-A72 GN-18 1 E472-H1 GN-18 127-H15 OR-16 1 + B 5 SW-1
LOC J-16 (28) PRODUCT LINK ECM (PL300) 892-GN5 BR-18 893-C47 GN-18 184-C5 RD-14 7 184-A11 RD-14 E474-A79 OR-18 2 E474-H2 OR-18 200-H14 BK-16 2 GROUND
1552267 6 SW-2 A-C36 CAP6 4
893-GN6 GN-18 322-C6 GY-16 8 322-A15 GY-16 127-A124 OR-16 K844-A46 GY-18 3 K844-H3 GY-18 154-H10 RD-18 A 2397352 3422974
2399954
GN-C2 N959-GN16 PK-18 128-C296 PK-16 607-C7 PK-16 9 607-A81 PK-16 154-A23 RD-18 K848-A36 WH-18 4 K848-H4 WH-18 (118) AIR SUSPENSION ATCH A588-H11 GN-18 B E472-A133 GN-18 1 1 +8V
(NOTE W)
GN-C1 1607690 N963-GN18 OR-18 147-C10 PU-16 780-C8 PU-16 10 780-A83 PU-16 200-A82 BK-16 235-A76 BK-18 5 235-H5 BK-18 2405063 189-H12 RD-18 C 1 235-A136 BK-18 2 2 GROUND (58) AUXILIARY PEDAL LH ATCH
2434508 1 N981-GN22 GN-18 C-C14 168-C51 RD-10 616-C9 BU-16 11 616-A13 BU-16 200-A7 BK-14 235-A76 BK-18 6 SW-3 N794-A129 GY-18 3 3 PWM OUT 2475276
J J
7Y3967
172-GN1
308-GN3
RD-18
YL-16
1
2 CONN 1 (27) PRODUCT LINK ECM (BASIC)
2
3
172-GN1
172-GN8
RD-18
RD-18 430-C18 BU-18 1
184-C5
186-C288
RD-14
WH-18
147-C10
E554-C11
PU-16
PK-18
12
13
147-A58
E554-A4
PU-16
PK-18 (36) CHASSIS 4 GROUND
200-A8
200-A29
BK-14
BK-14
235-A76
235-A88
BK-18
BK-18
320-A14
A588-A12
RD-18
GN-18 CONN 35 (136) NEUTRAL START LIMIT SWITCH
1114799
1 4
5
4
5 CALIBRATION
403-GN4 GN-18 3 3402413 EK-C2 4 172-GN7 RD-18 C-C15 235-C42 BK-18 14 309-A153 GY-18 200-A51 BK-14 235-A132 BK-18 E472-A72 GN-18 6 6 CALIBRATION
CONNECTS TO C-C18 (NOTE Y) 1607690 7Y3966 15 (45) JOYSTICK LH (3 SWITCH) ATCH
892-GN5 BR-18 4 5 172-GN7 RD-18 (119) AIR CLEANER SWITCH 235-C43 BK-18 318-C274 BR-18 318-A20 BR-18 200-A53 BK-16 235-A137 BK-18 200-A82 BK-16 E474-A79 OR-18 200-H14 BK-16
893-GN6 GN-18 5 1 6 308-GN3 YL-16 235-C158 BK-18 1 2552966 403-C14 GN-18 16 403-A52 GN-18 200-A93 BK-14 235-A143 BK-18 200-A94 BK-16 E997-A154 RD-18 A588-H11 GN-18 2602128 A-C31 A-C32
LOC J-16 17 H-C3 H-C7 1552269 3E3364
235-GN2 BK-18 6 2 7 308-GN10 YL-16 235-C290 BK-18 186-C288 WH-18 186-A157 WH-18 A588-A12 GN-18 200-A102 BK-18 K844-A46 GY-18 154-H10 RD-18
3 CAT DATA LINK + 8 893-GN6 GN-18 308-GN9 YL-16 128-C296 PK-16 18 128-A158 PK-16 128-A158 PK-16 A755-A100 PK-18 200-A110 BK-18 K848-A36 WH-18 189-H12 RD-18 2397352 2472693 1 +B K852-A105 GN-18 1 1 (120) AUX PUMP PRESSURE SWITCH (STEM 4) ATCH
A-C19 H-C1
GN-C5 4 CAT DATA LINK - 9 892-GN5 BR-18 308-GN9 YL-16 235-C314 BK-18 235-C314 BK-18 19 405-A75 GY-18 147-A58 PU-16 A756-A99 BU-18 200-A111 BK-16 320-H8 RD-18 E472-H1 GN-18 1 2 GROUND 235-A104 BK-18 2 2 1673466
2305010 2434508
2305010 5 10 403-GN4 GN-18 235-C315 BK-18 235-C317 BK-18 20 412-A60 BU-18 168-A70 RD-10 A757-A98 GY-18 200-A110 BK-18 E472-H1 GN-18 235-H6 BK-18 2 3 PWM OUT
320-A14 RD-18 1 320-H8 RD-18
21
N963-GN18 OR-18
N959-GN16 PK-18
1
2 CONN 2 6
7
11
12
403-GN12
403-GN11
GN-18
GN-18
235-C317 BK-18 430-C18
487-C19
BU-18
OR-18 22
430-A42
487-A43
BU-18
OR-18
172-A9
177-A71
RD-18
RD-6
A758-A97
E472-A72
BR-18
GN-18
235-A76
235-A88
BK-18
BK-18
235-A37
235-A132
BK-18
BK-18
200-A82
154-A23
BK-16
RD-18
2
3
200-H13 BK-16
154-H10 RD-18
E474-H2 OR-18
K844-H3 GY-18
E474-H2
235-H7
OR-18
BK-18
3
4
4
5
SW-COM
SW-1 A-C25
1552269
A-C45
3E3364
N981-GN22 GN-18 3 CAT DATA LINK + 8 893-EK6 GN-18 RS-232 PORT #1-TXD 13 N957-GN15 PK-18 403-GN11 GN-18 251-C49 YL-18 491-C20 PK-18 23 491-A56 PK-18 184-A11 RD-14 E472-A84 GN-18 235-A132 BK-18 235-A132 BK-18 K848-H4 WH-18 K844-H3 GY-18 5 6 SW-2
4 CONNECTS TO GL-C1 CAT DATA LINK - 9 892-EK5 BR-18 14 235-GN2 BK-18 261-C50 GN-18 F716-C208 WH-18 24 F716-A115 WH-18 186-A157 WH-18 E472-A133 GN-18 235-A137 BK-18 235-A37 BK-18
E997-A154 RD-18 4 189-H12 RD-18
235-H5 BK-18 K848-H4 WH-18 6 K851-A142 BU-18 1 1 (135) MEDIUM PRESSURE SWITCH (STEM 3) ATCH
A588-A12 GN-18 5 A588-H11 GN-18
5 LOC I-16 10 15 235-GN14 BK-18 308-C4 YL-16 495-C22 GN-18 25 495-A54 GN-18 235-A113 BK-18 E473-A50 GY-18 235-A143 BK-18 235-A136 BK-18
127-A124 OR-16 6 127-H15 OR-16
235-H5 BK-18
H-C4
235-A144 BK-18 2 2 1673466
6 11 16 235-GN23 BK-18 318-C274 BR-18 235-C315 BK-18 26 496-A61 WH-18 235-A113 BK-18 E474-A79 OR-18 A588-A12 GN-18 235-A152 BK-18 235-H6 BK-18 1
12 17 235-GN13 BK-18 321-C40 BR-18 A755-C24 PK-18 27 A755-A100 PK-18 235-A76 BK-18 E997-A154 RD-18 A755-A100 PK-18 235-A104 BK-18 235-H7 BK-18 7Y3967 SW-3
RS-232 PORT #1-TXD 13
14
18
19
235-GN13
235-GN23
BK-18
BK-18
322-C6
487-C19
GY-16
OR-18
A756-C25
A757-C26
BU-18
GY-18
28
29
A756-A99
A757-A98
BU-18
GY-18
235-A132
235-A18
BK-18
BK-18
H473-A38
H474-A147
BR-18
GN-18
(40) PLATFORM GROUND A756-A99
A757-A98
BU-18
GY-18
235-A144
235-A149
BK-18
BK-18
CONN 36 200-H13 BK-16
200-H13 BK-16
320-H8 RD-18
H-C5
1 1 A-C7
1552272
A-C8
3E3376
15 20 235-GN14 BK-18 491-C20 PK-18 A758-C27 BR-18 30 A758-A97 BR-18 235-A18 BK-18 H475-A146 BU-18 A758-A97 BR-18 235-A130 BK-18 200-H14 BK-16 7Y3967 (129) HORN SWITCH 576-A40 PK-18 3 3
EK-C1 (46) JOYSTICK LH ATCH
16 21 403-GN12 GN-18 492-C291 GY-18 C468-C28 BU-18 31 C468-A62 BU-18 235-A33 BK-18 H476-A145 WH-18 E472-A72 GN-18 235-A130 BK-18 200-H9 BK-18 200-H9 BK-18 1 2220225 535-A65 BU-16 1 1 (54) LOWER WIPER MOTOR ATCH
2434508 2277617
17 RS-232 PORT #1-RXD 22 N960-GN17 OR-18 308-GN10 YL-16 495-C22 GN-18 E472-C29 GN-18 32 E472-A116 GN-18 235-A88 BK-18 K843-A57 GN-18 E472-A84 GN-18 235-A118 BK-18 575-A39 YL-18 4 4 1677079
172-EK1 RD-18 1 18 RS-232 PORT #1-DTR 23 N970-GN19 YL-18 172-GN8 RD-18 506-C45 PU-18 H476-C30 WH-18 33 H476-A145 WH-18 235-A137 BK-18 K844-A46 GY-18 E472-A133 GN-18 235-A148 BK-18 CONSOLE (LH) 200-A110 BK-18 2 2 +
308-EK3
403-EK4
YL-16
GN-18
2
3
CONN 1 19
20
24
25
172-GN8
308-GN10
RD-18
YL-16
578-C46
607-C7
BU-16
PK-16
H473-C31
G976-C32
BR-18
BU-18
34
35
H473-A38
G976-A45
BR-18
BU-18
235-A143
251-A47
BK-18
YL-18
K847-A22
K848-A36
PU-18
WH-18
E473-A50
E474-A79
GY-18
OR-18
235-A135
235-A135
BK-18
BK-18
S +1
H23 -
892-EK5 BR-18 4 CONNECTS TO C-C18 21 26 403-GN12 GN-18 616-C9 BU-16 L972-C33 BU-18 36 L972-A96 BU-18 261-A48 GN-18 K849-A150 YL-18 E997-A154 RD-18 235-A151 BK-18 A-C10 CAP6 3
893-EK6 GN-18 5 RS-232 PORT #1-RXD 22 27 235-GN14 BK-18 A588-C3 GN-18 H474-C34 GN-18 37 H474-A147 GN-18 308-A80 YL-16 K851-A142 BU-18 H473-A38 BR-18 235-A143 BK-18 A-C40
235-EK2 BK-18 6
LOC J-16 RS-232 PORT #1-DTR 23 28 N957-GN15 PK-18 A755-C24 PK-18 H475-C35 BU-18 38 H475-A146 BU-18 309-A153 GY-18 K852-A105 GN-18 H474-A147 GN-18 235-A143 BK-18
2305010 3422974 1552269
24 29 N960-GN17 OR-18 A756-C25 BU-18 K849-C36 YL-18 39 K849-A150 YL-18 318-A20 BR-18 L972-A96 BU-18 H475-A146 BU-18 535-A65 BU-16 1 1 +12V MEMORY OUT H475-A146 BU-18 1 (148) TRAVEL LEFT PRESSURE SWITCH
235-EK8 BK-18 25 RS-232 PORT #1-CDC 30 N973-GN20 BR-18 N970-GN19 YL-18 A757-C26 GY-18 E997-C84 RD-18 40 E997-A154 RD-18 321-A122 BR-18 N793-A85 GN-18 H476-A145 WH-18 575-A39 YL-18 135-A25 BU-16 2 2 +12V SWITCHED OUT 235-A148 BK-18 2 1673466
235-EK7 BK-18 26 RS-232 PORT #1-GROUND 31 N979-GN21 GN-18 N973-GN20 BR-18 A758-C27 BR-18 K851-C37 BU-18 41 K851-A142 BU-18 322-A15 GY-16 N794-A129 GY-18 K843-A57 GN-18 576-A40 PK-18 210-A26 BK-16 3 3 GROUND (12V) (17) 12V 10A CONVERTER ATCH
235-EK7 BK-18 27 32 N979-GN21 GN-18 C468-C28 BU-18 K852-C38 GN-18 42 K852-A105 GN-18 403-A52 GN-18 K844-A46 GY-18 E472-A133 GN-18 200-A111 BK-16 4 4 GROUND (24V) 3245770 A-C35
235-EK8 BK-18 28 33 E472-C29 GN-18 X738-C316 PK-18 43 X738-A159 PK-18 405-A75 GY-18 128-A158 PK-16 K847-A22 PU-18 H473-A38 BR-18 120-A119 YL-16 5 5 +24V BATTERY IN 1552269
29 J1939 LOW 34 E473-C55 GY-18 321-C40 BR-18 44 321-A122 BR-18 412-A60 BU-18 147-A58 PU-16 K848-A36 WH-18 H474-A147 GN-18 120-A109 YL-16 6 6 +24V SWITCHED IN H474-A147 GN-18 1 (149) TRAVEL RIGHT PRESSURE SWITCH
RS-232 PORT #1-CDC 30 35 E474-C52 OR-18 45 430-A42 BU-18 168-A70 RD-10 K849-A150 YL-18 H475-A146 BU-18 235-A149 BK-18 2 1673466
RS-232 PORT #1-GROUND 31 36 E554-C11 PK-18 235-C42 BK-18 46 235-A113 BK-18 487-A43 OR-18 172-A9 RD-18 K851-A142 BU-18 K849-A150 YL-18
32 37 E997-C84 RD-18 235-C43 BK-18 47 235-A143 BK-18 491-A56 PK-18 177-A71 RD-6 K852-A105 GN-18 K851-A142 BU-18
A-C43 A-C12 A-C44
33 38 F716-C208 WH-18 48 492-A156 GY-18 184-A11 RD-14 L972-A96 BU-18 K852-A105 GN-18
1552269 1552269 3E3364
J1939 LOW 34 39 G976-C32 BU-18 506-C45 PU-18 49 506-A35 PU-18 495-A54 GN-18 186-A157 WH-18 N793-A85 GN-18 N793-A85 GN-18
GL-C1 35 40 H473-C31 BR-18 578-C46 BU-16 50 578-A34 BU-16 496-A61 WH-18 200-A7 BK-14 (156) A/C UNIT N794-A129 GY-18 N794-A129 GY-18 H476-A145 WH-18 1 (131) IMPLEMENT PRESSURE SWITCH K849-A150 YL-18 1 1 (128) HIGH PRESSURE SWITCH (STEM 1) ATCH
2434508 A-C6 235-A137 BK-18 2 1673466
36 41 H474-C34 GN-18 893-C47 GN-18 51 893-A32 GN-18 506-A35 PU-18 200-A8 BK-14 2359004 235-A151 BK-18 2 2 1673466
2304009
1 N960-GL2 OR-18 37 42 H475-C35 BU-18 892-C48 BR-18 52 892-A31 BR-18 578-A34 BU-16 200-A29 BK-14 103-A63 RD-16 103-A63 RD-16
CONN 2 2 N957-GL1 PK-18 38 43 H476-C30 WH-18 251-C49 YL-18 53
54
251-A47 YL-18 607-A81 PK-16 200-A51 BK-14 B/R 1 124-A86 GN-14 105-A10 RD-16 105-A10 RD-16 A-C13
1552269
A-C14
3E3364
I I
3 N979-GL3 GN-18 39 44 K843-C56 GN-18 261-C50 GN-18 261-A48 GN-18 616-A13 BU-16 200-A53 BK-16 B/W 2 200-A8 BK-14 113-A117 OR-18 113-A117 OR-18
CONNECTS TO GN-C5 4 40 45 K844-C53 GY-18 780-A83 PU-16 200-A93 BK-14 R 3 175-A87 RD-14 120-A1 YL-16 120-A1 YL-16 H473-A38 BR-18 1 1 (150) TRAVEL STRAIGHT PRESSURE SWITCH ATCH
LOC J-16 5
6
41
42
46
47
K847-C57
K848-C54
PU-18
WH-18
CONN 15 892-A31
893-A32
BR-18
GN-18
235-A33
251-A47
BK-18
YL-18
R/G
P
4
5
E554-A4
607-A91
PK-18
PK-16
127-A124
135-A25
OR-16
BU-16
120-A1
120-A109
YL-16
YL-16
235-A118 BK-18 2 2 1673466
43 48 K849-C36 YL-18 A588-A12 GN-18 261-A48 GN-18 B 6 200-A93 BK-14 154-A23 RD-18 120-A119 YL-16
44 49 K851-C37 BU-18 A755-A100 PK-18 308-A80 YL-16 R/W 7 210-A26 BK-16 135-A25 BU-16 A-C33 G-C1
45 J1939 HIGH 50 172-C2 RD-18 K852-C38 GN-18 C-C2 A-C29 A756-A99 BU-18 309-A153 GY-18 O/G 8 235-A37 BK-18 200-A94 BK-16 2305008
1343295 1343296 2434507
46 51 403-C14 GN-18 L972-C33 BU-18 A757-A98 GY-18 318-A20 BR-18 R/L 9 307-A24 OR-16 200-A102 BK-18
47 UNSWITCHED POWER 52 172-GN7 RD-18 L973-C80 GN-16 168-C51 RD-10 1 168-A70 RD-10 A758-A97 BR-18 321-A122 BR-18 10 308-A139 YL-16 200-A111 BK-16 E472-A84 GN-18 1 E472-G1 GN-18
48 53 430-C18 BU-18 N793-C1 GN-18 C468-A62 BU-18 322-A15 GY-16 11 320-A14 RD-18 210-A26 BK-16 E473-A50 GY-18 2 E473-G2 GY-18
J1939 HIGH
49
50
ALTERNATOR R-TERM 54
55
403-GN11 GN-18 892-C48 BR-18
893-C47 GN-18
N794-C58 GY-18 CONN 16 E472-A72
E472-A84
GN-18
GN-18
403-A52
405-A75
GN-18
GY-18
12 508-A68
509-A69
PU-18
WH-18
235-A88
235-A137
BK-18
BK-18
K843-A57
K847-A22
GN-18
PU-18
3
4
K843-G3
K847-G4
GN-18
PU-18
AL-C1 C-C22 G-C8 G-C9
UNSWITCHED POWER
51
52 172-EK1 RD-18
56
57 235-C160 BK-16 2434505 2304011
C-C3 A-C1
E472-A133
E472-A116
GN-18
GN-18
412-A60
430-A42
BU-18
BU-18
511-A66
512-A67
BR-18
GN-18
307-A24
308-A139
OR-16
YL-16 CONN 43 103-G28 RD-16 2397352 2472693
GL-C2 GL-C3 53 58 308-C140 YL-16 H24 780-AL1 PU-16 1 1 780-C8 PU-16 2434510 2304009 E472-A116 GN-18 487-A43 OR-18 535-A65 BU-16 508-A68 PU-18 A-C24 G-C2 105-G8 RD-16 E472-G1 GN-18 1 1 1 +B
8T8732 8T8731 ALTERNATOR R-TERM 54 403-EK4 GN-18 59 403-C151 GN-18 2 2 E473-A50 GY-18 491-A56 PK-18 575-A39 YL-18 509-A69 WH-18 2304009 2434510 113-G23 OR-18 235-G34 BK-18 2 2 2 GROUND
E474-C52 OR-18 1 E474-A79 OR-18
N979-GL3 GN-18 A 55 60 892-C121 BR-18 CAP2 1 K844-C53 GY-18 2 K844-A46 GY-18 E474-A79 OR-18 492-A156 GY-18 576-A40 PK-18 511-A66 BR-18 252-G13 YL-18 E473-G2 GY-18 3 3 SW-4 3 PWM OUT
N960-GL2 OR-18 B CONN 3 56 61 893-C116 GN-18 3422972 K848-C54 WH-18 3 K848-A36 WH-18 E554-A4 PK-18 495-A54 GN-18 607-A95 PK-16 512-A67 GN-18
1
2
K907-G5
L969-G6
BU-18
WH-18
262-G14 GN-18 235-G33 BK-18 4 4 SW-COM 4 SW-COM
CONN 14
N957-GL1 PK-18 C 57 RS232 PORT #3-TXD 62 N963-GN18 OR-18 E473-C55 GY-18 4 E473-A50 GY-18 E997-A154 RD-18 496-A61 WH-18 607-A103 PK-16 607-A95 PK-16 307-G12 OR-16 K843-G3 GN-18 5 5 SW-1 5 SW-1
C-C110 3 L968-G7 OR-18
58 RS232 PORT #3-RXD 63 N959-GN16 PK-18 K843-C56 GN-18 5 K843-A57 GN-18 F716-A115 WH-18 506-A35 PU-18 A537-A41 PK-18 607-A103 PK-16 308-G10 YL-16 K847-G4 PU-18 6 6 SW-2 6 SW-2
2818803 105-A10 RD-16 4 105-G8 RD-16
SERIAL SERVICE 59 RS232 PORT #3-GROUND 64 N981-GN22 GN-18 K847-C57 PU-18 6 K847-A22 PU-18 G976-A45 BU-18 578-A34 BU-16 A537-A41 PK-18 308-G10 YL-16
A537-A41 PK-18 5 A537-G9 PK-18 G-C10
CONNECTOR 60 GROUND 65 235-GN13 BK-18 +B 1 997-C300 OR-18 C-C113 N793-C1 GN-18 7 N793-A85 GN-18 H473-A38 BR-18 607-A81 PK-16 A755-A100 PK-18 308-G31 YL-16
AK-C1 6 K907-G5 BU-18 7Y3967
61 66 GROUND 2 A209-C302 BK-18 2434505 2304011 N794-C58 GY-18 8 N794-A129 GY-18 H474-A147 GN-18 616-A13 BU-16 A756-A99 BU-18 308-G32 YL-16 1 1
7
RS232 PORT #3-TXD 62 67 SIGNAL 3 P875-C306 BU-18 9 H475-A146 BU-18 780-A83 PU-16 A757-A98 GY-18 326-G11 RD-16 235-G35 BK-18 1 SW-3 SW-3
X738-AK1 PK-18 1 1 X738-C316 PK-18 8 L969-G6 WH-18 G-C11
RS232 PORT #3-RXD 63 68 10 H476-A145 WH-18 892-A31 BR-18 A758-A97 BR-18 508-G29 PU-18 1 1
(80) ATMOSPHERE SENSOR 2 2 9 L968-G7 OR-18 7Y3967
RS232 PORT #3-GROUND 64 69 11 K843-A57 GN-18 893-A32 GN-18 E472-A84 GN-18 509-G25 WH-18
10
CONN 42
3203063
GROUND 65 235-EK7 BK-18 KEY SWITCH ON 70 308-GN9 YL-16 CAP2 3 12 K844-A46 GY-18 C468-A62 BU-18 E473-A50 GY-18 511-G30 BR-18 L972-G19 BU-18 1
11
66 3422972 K847-A22 PU-18 E554-A4 PK-18 H476-A145 WH-18 512-G26 GN-18 (47) JOYSTICK RH(3 SWITCH) ATCH (48) JOYSTICK RH ATCH
12 (137) ONE TOUCH LOW IDLE SWITCH
67 235-GN23 BK-18 K848-A36 WH-18 F716-A115 WH-18 K843-A57 GN-18 607-G20 PK-16 2602127 2277616
68 CONN 13 CONN 17 K849-A150 YL-18 G976-A45 BU-18 K847-A22 PU-18 607-G27 PK-16 2220225
69 K851-A142 BU-18 L973-A114 GN-16 L972-A96 BU-18 A755-G15 PK-18
GK-C1 GN-C3 G-C3 G-C12 G-C14
KEY SWITCH ON 70 308-EK3 YL-16 K852-A105 GN-18 X738-A159 PK-18 BEACON LAMP ATCH A-C34 A756-G16 BU-18
2434508 2305010 2305010 1552264 3E3388
L972-A96 BU-18 2434508 A757-G17 GY-18 (49) MSS KEYREADER ATCH
CAP2 2
172-GK1 RD-18 1 172-GN8 RD-18 177-A71 RD-6 L973-A114 GN-16 A758-G18 BR-18 308-G32 YL-16 1 1 KEY ON (15) EXCITER COIL ATCH
3422972 308-A139 YL-16 1 308-G10 YL-16 2180404 M-C4
235-EK8 BK-18 308-GK3 YL-16 2 308-GN10 YL-16 N793-A85 GN-18 E472-G1 GN-18 200-G38 BK-18 2 2 GROUND M-C5 2065208
2 326-G11 RD-16 1552269
GK-C3 403-GK4 GN-18 3 403-GN12 GN-18 N794-A129 GY-18 E473-G2 GY-18 252-G13 YL-18 3 3 CAN + 3E3364
EM-C2 307-A24 OR-16 3 307-G12 OR-16
1552252 4 X738-A159 PK-18 EM-C1 K843-G3 GN-18 262-G14 GN-18 4 4 CAN - 2 2
2312295 4 252-G13 YL-18
5 2434509 K847-G4 PU-18 T901-G40 YL-18 5 5 COIL SIG 1 1
A-C17 5 262-G14 GN-18
235-GK2 BK-18 6 235-GN14 BK-18 1 113-EM1 OR-18 173-EM9 YL-18 1 L972-G19 BU-18 T902-G41 PK-18 6 6 COIL RET
2304011 6
2 200-EM2 BK-18 200-EM10 BK-18 2 200-G24 BK-18 7 7
CONN 4 CONN 37 3 509-EM3 WH-18 C563-EM11 BR-18 3 CONN 37 CONN 41 235-G22 BK-18 8 8 M-C2
7Y3952
4 512-EM4 GN-18 C565-EM12 GY-18 4 235-G22 BK-18
CONNECTS TO AR-26 5 607-EM5 PK-16 607-EM5 PK-16 5 CONNECTS TO G-C5 A-C42 G-C4 235-G33 BK-18 G-C13 M-C1 1 GROUND IND UNIT
H H
GK-C2 GN-C4 2434510 2304009 1027964 1211168
6 103-EM6 RD-16 153-EM13 RD-16 6 235-G34 BK-18 2 +B 1709324
2305010 2434508 LOC H-4 7 508-EM7 PU-18 C562-EM14 BU-18 7
LOC H-4 235-G35 BK-18 T902-G41 PK-18 12 T902-M12 PK-18
A755-A100 PK-18 1 A755-G15 PK-18
N960-GK6 OR-18 1 N960-GN17 OR-18 8 511-EM8 BR-18 C564-EM15 GN-18 8 A756-A99 BU-18 2 A756-G16 BU-18 235-G36 BK-18 T901-G40 YL-18 11 T901-M11 YL-18
N957-GK5 PK-18 2 N957-GN15 PK-18 200-G21 BK-16 607-G20 PK-16 1 607-M1 PK-16 M-C3
A757-A98 GY-18 3 A757-G17 GY-18
N979-GK9 GN-18 3 N979-GN21 GN-18 200-G21 BK-16 200-G37 BK-18 2 200-M2 BK-18 2305010
A758-A97 BR-18 4 A758-G18 BR-18
N970-GK7 YL-18 4 N970-GN19 YL-18 L972-A96 BU-18 5 L972-G19 BU-18 200-G37 BK-18 235-G36 BK-18 3 235-M3 BK-18 1 BK COM
(62) PRODUCT LINK 2ND GENERATION RADIO N973-GK8 BR-18 5 N973-GN20 BR-18 6 200-G38 BK-18 A755-G15 PK-18 4 A755-M4 PK-18 2 PK S1
2639088 6 7 A756-G16 BU-18 5 A756-M5 BU-18 3 BU S2 (147) THROTTLE POSITION SWITCH
(NOTE W)
A757-G17 GY-18 6 A757-M6 GY-18 4 GN S3 3194420
CONN 5 607-A95 PK-16 8
9
607-G20 PK-16
A758-G18 BR-18 7 A758-M7 BR-18 5 BR S4
10 308-G31 YL-16 8 308-M8 YL-16 6
200-A94 BK-16 11 200-G21 BK-16 326-G11 RD-16 21 326-M23 RD-16
AL-C2 177-A71 RD-6 307-G12 OR-16 9 307-M9 OR-16
235-A88 BK-18 12 235-G22 BK-18
2304011 (75) RH-SPEAKER (+) RELAY ATCH G-C6 G-C7 105-G8 RD-16 10 105-M10 RD-16
(100) QUICK COUPLER SOLENOID ATCH
2603877
1
2
780-AL1
200-AL2
PU-16
BK-18
1495050 (NOTE X)
EM-C5
CONN 40 200-G39 BK-18
2304011
2
2434505
113-G23
200-G24
OR-18
BK-18
13
14
113-M13
200-M14
OR-18
BK-18
R
A-C26 G-C5 C OFF

1495051 A537-G9 PK-18 1 509-G25 WH-18 15 509-M15 WH-18
2434509 2312295 S ON
1 183-EM26 GY-18 512-G26 GN-18 16 512-M16 GN-18
(42) SEAT HEATER ATCH B ST
2 200-EM30 BK-18 113-A117 OR-18 1 113-G23 OR-18 607-G27 PK-16 17 607-M17 PK-18
2299093
3 511-EM8 BR-18 508-EM7 PU-18 200-A102 BK-18 2 200-G24 BK-18 103-G28 RD-16 18 103-M18 RD-18 (132) KEY SWITCH
2359027(UN TILT)
200-AL2 BK-18 4 C564-EM15 GN-18 509-EM3 WH-18 509-A69 WH-18 3 509-G25 WH-18 508-G29 PU-18 19 508-M19 PU-18 2552751
5 C561-EM25 YL-18 511-EM8 BR-18 H43 512-A67 GN-18 4 512-G26 GN-18 511-G30 BR-18 20 511-M20 BR-18
AK-C2 512-EM4 GN-18 607-A103 PK-16 5 607-G27 PK-16
(127) HAMMER RETURN FILTER SWITCH ATCH
1
1552269
X738-AK1 PK-18
H48 200-EM37
200-EM37
BK-18
BK-18
103-A63
508-A68
RD-16
PU-18
6
7
103-G28
508-G29
RD-16
PU-18
CONN 50
2241687
2 235-AK2 BK-18 GC-C7 GA-C1 (74) RH-SPEAKER (-) RELAY ATCH 200-EM30 BK-18 511-A66 BR-18 8 511-G30 BR-18
2305010 2434508 780-GT1 PU-16 1495050 (NOTE X) 200-EM35 BK-18 ANTENNA ACC 1 113-M13 OR-18
235-AK2 BK-18
K866-GC3 WH-18 1 K866-GA1 WH-18 779-GT2
779-GT2
WH-16
WH-16
EM-C6
1495051
200-EM35
200-EM31
BK-18
BK-18
H40 CONN 37 GROUND
SPKR LH(-)
2
3
200-M14
509-M15
BK-18
WH-18
200-GC4 BK-18 2 200-GA2 BK-18
147-GC5 PU-16 3 147-GA3 PU-16 H48 779-GT5 WH-16 1 183-EM27 GY-18 200-EM32 BK-18 AUX-SPKR(-) 4 C566-M22 PK-18
H51 H51 H51 K872-GC6 OR-18 4 K872-GA5 OR-18 779-GT6 WH-16 2 200-EM31 BK-18 200-EM33 BK-18 H38 AJ-C1 SPKR RH(-) 5 512-M16 GN-18
K879-GC7 GN-18 5 K879-GA4 GN-18 A588-GT3 GN-18 3 512-EM4 GN-18 2312295 ILLUM 6 607-M17 PK-18
6 A588-GT3 GN-18 4 C565-EM12 GY-18 BACKUP 7 103-M18 RD-18
A588-GT7 GN-18 5 C567-EM24 PU-18 C562-EM14 BU-18 H40
1 113-AJ1 OR-18
CONN 37 SPKR LH(+) 8 508-M19 PU-18
CONN 12 A588-GT8 GN-18 C563-EM11 BR-18 2 200-AJ3 BK-18 AUX-SPKR(+) 9 C560-M21 OR-18
H47
3 509-AJ4 WH-18
200-GT4 BK-18 C564-EM15 GN-18
4 512-AJ5 GN-18
CONNECTS TO A-C26 SPKR RH(+) 10 511-M20 BR-18
200-GT4 BK-18 C565-EM12 GY-18 H39 H39 ATCH RADIO M-C6
H52 200-GU4 BK-18
GU-C1 GT-C6
200-GT12 BK-18 (65) LH-SPEAKER (+) RELAY ATCH 5 H41 LOC H-4
2434507 2305008 6 103-AJ6 RD-16 2510541 1532541
200-GU6 BK-18 H50 H50 H50 200-GT19 BK-18 1495050 (NOTE X) ATCH AM FM RADIO (OSJ)
200-GU5 BK-18 780-GU1 PU-16 1 780-GT1 PU-16 200-GT19 BK-18 EM-C7 183-EM29 GY-18 7 508-AJ7 PU-18
8 511-AJ8 BR-18 2510539
779-GU2 WH-16 2 779-GT2 WH-16 200-GT9 BK-18 1495051 183-EM28 GY-18
H53 A588-GU3 GN-18 3 A588-GT3 GN-18 200-GT10 BK-18 1 183-EM28 GY-18 183-EM34 GY-18 M-C7
G G
780-GU1 PU-16 200-GU4 BK-18 4 200-GT4 BK-18 200-GT11 BK-18 2 200-EM32 BK-18 183-EM34 GY-18 7Y3966
779-GU2 WH-16 H24 3 508-EM7 PU-18 183-EM26 GY-18 1
A588-GU3 GN-18
CONN 11 4
5
C562-EM14
C560-EM23
BU-18
OR-18
183-EM27
183-EM36
GY-18
GY-18
M-C8
7Y3967
H23 183-EM36 GY-18 1
DISCONNECT BOX C560-EM23 OR-18
C561-EM25 YL-18
109-CL1 RD-4 120A (64) LH-SPEAKER (-) RELAY ATCH C566-EM22 PK-18
1495050 (NOTE X) C567-EM24 PU-18
(12) ALT BREAKER EM-C8
A-C15 A-C3 A-C20 A-C27 A-C23
2164970 (6) BUS BAR 1495051 A-C22
2304011 1343295 1211168 1211168 1027964
2382279 1 183-EM29 GY-18 1254766 CONSOLE (RH)
2
3
200-EM33
509-EM3
BK-18
WH-18 CONN 19 CONN 20 CONN 32 CONN 38
177-WE1 RD-6 4 C563-EM11 BR-18 (145) SECONDARY SHUTDOWN SWITCH F-C7
80A AG-C1 F-C10 F-C6 F-C8 F-C9
5 C566-EM22 PK-18 4D1836 1288950
(14) MAIN BREAKER
1712210 2 1
2434505 1343296 1027964
CONN 33 1027964
CONN 34 1211168 CONN 49
(4) BLOCK ASSEMBLY 235-AG1 BK-18 F-C41 R-C1 R-C3
1211023 7Y3967 7Y3966 7Y3967
3
H41 615-F163 YL-16 1 615-R1 YL-16 615-R1 YL-16 1 RD-16 ATCH CAB LAMP(LH)
877-C136 YL-6 877-WF1 YL-8 1673441
108-WK1 RD-8 F716-AG2 WH-18 F-C42 R-C2 R-C4 1831035 (NOTE T)
60A
F-C35 7Y3966 7Y3967 7Y3966
(13) GLOW BREAKER
1712208 7Y3955 200-F161 BK-16 1 200-R2 BK-16 200-R2 BK-16 1 WH-16
109-C138 RD-2-SGX 109-CL1 RD-4
(10) BATTERY REAR (8) BATTERY FRONT 101-C139 RD-2-SGX 101-CJ1 RD-4 101-CJ1 RD-4
511-F118
512-F119
BR-18
GN-18
1
2
+
-
SPEAKER (R)
7Y5505
CONN 48
3T5760 3T5760 3
2639574 (NOTE A) 2639574(NOTE A) 177-A71 RD-6 177-WE1 RD-6
101-CA1 RD-00-SGX 101-CC1 RD-00-SGX 200-CE1 BK-00
C-C102 F-C34
CONN 47
2304011 7Y3955 F-C43 T-C1 T-C3
H15
POS NEG POS NEG 877-C287 YL-18 1 5A 508-F120 PU-18 1 + SPEAKER (L) 7Y3967 7Y3966 7Y3967
2 509-F121 WH-18 2 - 7Y5505 615-F164 YL-16 1 615-T1 YL-16 615-T1 YL-16 1 RD-16 ATCH CAB LAMP(RH)
3 1673441
C-C5 F-C44 T-C2 T-C4 1831035 (NOTE T)
3E3364 (5) HOLDER ASSEMBLY 7Y3966 7Y3967 7Y3966
3245808 200-F155 BK-16 1 200-T2 BK-16 200-T2 BK-16 1 WH-16
200-CE1 BK-00 200-CE1 BK-00 F793-C279 OR-18 1 200-F116 BK-14
101-CF1 RD-00-SGX 101-CG1 RD-00-SGX 200-CH1 BK-00 200-CH1 BK-00 200-CH1 BK-00 200-C310 BK-18 2 200-F116 BK-14
(63) GLOW RELAY
2418368 F-C12
200-F149
200-F149
BK-16
BK-16
CONN 46
POS NEG POS NEG (123) DISCONNECT SWITCH 877-WF1 YL-8 7Y3952 200-F155 BK-16
7N0719 (22) LAMP DIODE 1 A623-F131 BU-18 200-F161 BK-16
F (11) BATTERY REAR ATCH

2639574
(9) BATTERY FRONT ATCH
2639574
200-CE1 BK-00
200-CH1 BK-00
(38) DISCONNECT GROUND STRAP
108-WK1 RD-8 1211022 2 684-F130
684-F128
RD-18
RD-18
615-F163
615-F164
615-F129
YL-16
YL-16
YL-16
F
(NOTE A) (NOTE A) 1321805 615-F129 YL-16 F-C37
F-C59 H12
103-F96 RD-16 1673630
7Y3952 A584-F169 BU-18 103-F96 RD-16 1 DOME LAMP
119-F202 PK-18 1 200-F157 BK-18 200-F162 BK-16 3 1761986
HT-C1 C-C112 C-C24
(37) CHASSIS 5 GROUND 309-F99 GY-18 2 200-F162 BK-16 2
3E3364 1552269 7T5957
(21) ALTERNATOR DIODE 4
492-HT1 GY-18 1 492-C291 GY-18 H26 506-C45 PU-18 200-C165 BK-18 1 (56) WASHER MOTOR 1211022
MOTOR
235-HT2 BK-18 2 235-C292 BK-18 578-C46 BU-16 506-C45 PU-18 2 7T8890 309-F99 GY-18
T° (154) WINDOW LIMIT SWITCH
200-C163 BK-18 BOOM LAMP RELAY 120-F55 YL-16 200-F157 BK-18
C-C25 1176306
200-C163 BK-18 1613128 1 149-F125 RD-18 124-F65 GN-14
(81) COOLANT TEMPERATURE SENSOR 7T5957
200-C164 BK-18 2 645-F88 RD-18 127-F60 OR-16 A584-F169 BU-18
3422924 C-C64 200-C165 BK-18 200-C164 BK-18 1 (53) LOWER WASHER MOTOR ATCH 3 149-F125 RD-18 128-F208 PK-16
2304011 MOTOR
578-C46 BU-16 2 7T8890 4 149-F80 RD-16 130-F75 RD-14
(92) A/C CLUTCH SOLENOID 1 E554-C11 PK-18 5 616-F84 BU-16 154-F93 RD-18
2597244 2 200-C107 BK-18 113-F61 OR-18 168-F73 RD-10
(76) SINGLE RELAY ATCH (7) FUSE BASE 118-F90 GY-16 172-F10 RD-18
(26) MACHINE ECM 1495050 2382319 119-F202 PK-18 175-F72 RD-14
C-C26 F-C22 (52) MONITOR
2218874 (NOTE G,H) 120-F55 YL-16 184-F74 RD-14
1532630 GA-C2 2397356 2602193
403-C151 GN-18 101-C139 RD-2-SGX CHASSIS LAMP RELAY 15A 124-F65 GN-14 123-F64 WH-18 186-F207 WH-18
109-C138 RD-2-SGX 184-C5 RD-14 184-C5 RD-14 A982-C293 BR-18 1 SHUTOFF SOLENOID 1495051 1613128 1 160-F132 PU-18 5A 186-F207 WH-18 124-F65 GN-14 318-F92 GN-16 495-F1 GN-18 1 FUEL LEVEL
235-C283 BK-18 2 ATT STEM-4 RETRACT PRV 1 K866-GA1 WH-18 2 A623-F131 BU-18 10A 160-F53 PU-16 127-F60 OR-16 307-F94 OR-16 492-F209 GY-18 2 COOLANT TEMPERATURE
R 403-C151 GN-18 251-C49 YL-18 184-C105 RD-14 763-C75 BU-18 3 TRAVEL SPEED SOLENOID 2 200-GA2 BK-18 3 160-F132 PU-18 10A 129-F57 BU-16 128-F208 PK-16 320-F85 RD-18 491-F3 PK-18 3 HYDRAULIC OIL TEMPERATURE
(3) ALTERNATOR H36 H36
3445081 B+ 109-C138 RD-2-SGX 492-C291 GY-18 184-C109 RD-14 A768-C64 BU-18 4 PS PRESSURE PRV 3 147-GA3 PU-16 H48 4 160-F53 PU-16 10A 128-F208 PK-16 129-F57 BU-16 321-F44 BR-18 H41 (32) CAB 3 GROUND 403-F4 GN-18 4 ALT R-TERM.
(115A) B- C903-C281 BU-18 251-C103 YL-18 5 ATT STEM-4 EXTEND PRV 4 K879-GA4 GN-18 5 607-F87 PK-16 5A 113-F61 OR-18 147-F63 PU-16 322-F86 GY-16 5
E554-C11 PK-18 251-C133 YL-18 235-C166 BK-14 877-C287 YL-18 6 GLOW PLUG STATUS 5 K872-GA5 OR-18 607-F49 PK-18 10A 147-F63 PU-16 152-F59 BU-16 607-F87 PK-16 200-F160 BK-16 6
200-C107 BK-18 101-C139 RD-2-SGX 7 2WAY LEVER CHG SOLENOID 5A 123-F64 WH-18 186-F207 WH-18 616-F84 BU-16 7
C-C101 235-C292 BK-18 109-C138 RD-2-SGX 261-C50 GN-18 235-C106 BK-14 C903-C280 BU-18 8 STARTER RELAY 10A 152-F59 BU-16 160-F53 PU-16 638-F91 WH-16 403-F4 GN-18 405-F62 GY-18 8 ENGINE OIL PRESSURE
2304011 128-C296 PK-16 235-C110 BK-14 M737-C77 WH-18 9 FLOW LIMIT PRESSURE PRV 10A 118-F90 GY-16 199-F135 OR-16 308-F104 YL-16 412-F2 BU-18 C468-F9 BU-18 9 ENGINE OIL LEVEL
H9
1 C903-C281 BU-18 235-C294 BK-18 147-C72 PU-16 261-C104 GN-18 K871-C78 WH-18 10 2 PUMP FLOW COMBINE SOLENOID CAB LAMP RELAY 10A 127-F60 OR-16 105-F102 RD-16 405-F62 GY-18 412-F2 BU-18 10 COOLANT LEVEL
2 235-C283 BK-18 147-C313 PU-18 147-C313 PU-18 261-C132 GN-18 251-C103 YL-18 K866-C79 WH-18 11 1WAY/2WAY CHANGE SOLENOID 1613128 1 115-F127 RD-18 10A 120-F55 YL-16 103-F6 RD-16 491-F3 PK-18 496-F5 WH-18 11 HYDRAULIC OIL LEVEL
G S
(55) STARTING MOTOR 186-C288 WH-18 186-C288 WH-18 261-C104 GN-18 12 SPARE 2 684-F128 RD-18 10A 199-F135 OR-16 105-F77 RD-16 118-F90 GY-16 492-F209 GY-18 12 AIH CONT STATUS
788-C277 YL-18 200-C163 BK-18 318-C274 BR-18 308-C113 YL-16 M740-C74 PK-18 13 TRAVEL STRAIGHT SOLENOID 3 115-F127 RD-18 10A 180-F54 GN-16 130-F75 RD-14 152-F59 BU-16 495-F1 GN-18 F-C23
3545671 H11
MTR BAT 101-C139 RD-2-SGX 877-C136 YL-6 200-C171 BK-18 877-C287 YL-18 318-C274 BR-18 14 SPARE (OC 1) 4 115-F78 RD-16 5A 143-F41 BR-18 F-C39 168-F73 RD-10 200-F68 BK-14 496-F5 WH-18 2304009
101-CA1 RD-00-SGX 997-C311 OR-18 200-C310 BK-18 892-C121 BR-18 763-C75 BU-18 15 CAN 3 SHEILD 5 615-F129 YL-16 5A 119-F202 PK-18 7Y3967 H17 172-F10 RD-18 615-F129 YL-16 H8 C468-F9 BU-18 103-F24 RD-18 1 + BATTERY
101-CF1 RD-00-SGX A209-C307 BK-18 235-C42 BK-18 893-C116 GN-18 788-C277 YL-18 788-C277 YL-18 16 ENGINE SPEED - 5A 1 175-F72 RD-14 251-F189 YL-18 308-F144 YL-18 3 ACC
MOTOR
H54 A982-C293 BR-18 235-C43 BK-18 997-C300 OR-18 877-C287 YL-18 318-C274 BR-18 17 START DETECTION 10A 184-F74 RD-14 105-F102 RD-16 251-F23 YL-18 893-F11 GN-18 7 CDL +
A762-C278 PU-18 235-C160 BK-16 A209-C302 BK-18 892-C121 BR-18 K864-C82 PK-18 18 VARIABLE RELIEF-1 PRV 10A 188-GH5 WH-16 114-F79 RD-16 308-F104 YL-16 251-F147 YL-18 892-F12 BR-18 8 CDL -
C468-C28 BU-18 235-C166 BK-14 A588-C88 GN-18 893-C116 GN-18 K868-C215 BR-18 19 PRV RETURN 15A 115-F78 RD-16 251-F147 YL-18 200-F8 BK-18 2 GROUND
M736-C286 BU-18 235-C170 BK-18 A755-C24 PK-18 L968-C67 OR-18 20 PRV RETURN HORN RELAY 1 149-F80 RD-16 105-F77 RD-16 261-F152 GN-18 4
E (39) ENGINE GROUND STRAP

1321806
N769-C309
200-C289
235-C99
GY-18
BK-18
BK-18
235-C172
235-C175
235-C290
BK-18
BK-18
BK-18
A756-C25
A757-C26
A758-C27
BU-18
GY-18
BR-18
997-C298
997-C299
OR-18
OR-18
K869-C218
K906-C62
BU-18
GN-18
21
22
23
PRV RETURN
PRV RETURN
SWING BRAKE SOLENOID
1613128 1
2
3
114-F126
320-F85
114-F126
RD-18
RD-18
RD-18 H16
F-C55
7Y3967
149-F80
115-F78
RD-16
RD-16
113-F61
123-F64
129-F57
OR-18
WH-18
BU-16
261-F52
261-F51
261-F51
GN-18
GN-18
GN-18
251-F147 YL-18
261-F51 GN-18
5
6
9
CAN1 +
CAN1 -
J1939 SHIELD
E
E472-C29 GN-18 997-C300 OR-18 24 SPARE 4 114-F79 RD-16 114-F79 RD-16 147-F63 PU-16 308-F144 YL-18 10 J1939 +
101-CF1 RD-00-SGX 235-C99 BK-18 235-C283 BK-18 E473-C55 GY-18 A762-C278 PU-18 25 ENGINE SPEED + 5 322-F86 GY-16 188-GH5 WH-16 199-F135 OR-16 147-F83 PU-16 H13 892-F12 BR-18 11 J1939 -
101-CA1 RD-00-SGX 200-C289 BK-18 235-C284 BK-18 E474-C52 OR-18 A209-C301 BK-18 26 CAN 4 SHEILD 160-F53 PU-16 199-F69 OR-18 893-F11 GN-18 410-F89 WH-18 12 ALARM
235-C295 BK-18 E997-C84 RD-18 A588-C88 GN-18 27 HYDRAULIC LOCK SWITCH 15A 175-F72 RD-14 147-F83 PU-16 200-F138 BK-16 103-F7 RD-18
C-C111 200-C107 BK-18 235-C285 BK-18 F716-C208 WH-18 A209-C112 BK-18 K865-C89 PU-18 28 VARIABLE RELIEF-2 PRV 5A 172-F10 RD-18 154-F93 RD-18 200-F139 BK-16 103-F7 RD-18 410-F89 WH-18
3495085 200-C163 BK-18 F793-C279 OR-18 A209-C302 BK-18 29 SPARE 10A 149-F80 RD-16 199-F69 OR-18 200-F140 BK-16 103-F24 RD-18
(122) COLD START ADVANCE SWITCH F-C33
1 1 147-C313 PU-18 200-C171 BK-18 308-C126 YL-16 H473-C31 BR-18 30 SPARE NEUTRAL START RELAY 10A 115-F78 RD-16 307-F94 OR-16 331-F187 OR-18 200-F8 BK-18
2351790 1552269
200-C310 BK-18 403-C151 GN-18 H474-C34 GN-18 A588-C88 GN-18 G723-C92 YL-18 31 HEAVY LIFT SOLENOID 1613128 1 154-F93 RD-18 10A 103-F6 RD-16 H17 318-F92 GN-16 603-F133 PK-18
T°
H35 235-C42 BK-18 492-C291 GY-18 H475-C35 BU-18 A755-C24 PK-18 K860-C212 BU-18 32 ATT STEM-1 RETRACT PRV 2 200-F136 BK-18 10A 105-F77 RD-16 H16 320-F85 RD-18 607-F49 PK-18 200-F8 BK-18 199-F165 OR-18 1 (1) ACTION ALARM
235-C43 BK-18 788-C277 YL-18 H476-C30 WH-18 A756-C25 BU-18 F793-C279 OR-18 33 GLOW PLUG RELAY 3 307-F94 OR-16 10A 114-F79 RD-16 321-F44 BR-18 645-F88 RD-18 103-F27 RD-18 410-F89 WH-18 2 1321829
235-C160 BK-16 877-C136 YL-6 K843-C56 GN-18 A757-C26 GY-18 34 SPARE 4 25A 184-F74 RD-14 322-F86 GY-16 684-F130 RD-18 152-F59 BU-16
877-C136 YL-6 235-C166 BK-14 K844-C53 GY-18 A758-C27 BR-18 M739-C94 YL-18 35 PRV RETURN (68) QC HYDRAULIC LOCK PRIORITY RELAY ATCH 5 318-F92 GN-16 20A 130-F75 RD-14 331-F187 OR-18 103-F6 RD-16 403-F76 GN-18 410-F89 WH-18
235-C170 BK-18 997-C299 OR-18 K847-C57 PU-18 A762-C278 PU-18 36 CAN 4 + 1495050 10A 141-F16 RD-16 603-F133 PK-18 535-F117 BU-16
235-C172 BK-18 K848-C54 WH-18 A768-C64 BU-18 37 CAN 4 - GT-C2 10A 142-F15 RD-16 607-F49 PK-18 H7 535-F124 BU-16 F-C30
235-C175 BK-18 997-C311 OR-18 K849-C36 YL-18 A982-C293 BR-18 K856-C211 PU-18 38 ATT STEM-1 EXTEND PRV 1495051 15A 607-F87 PK-16 535-F151 BU-16 3495085
235-C284 BK-18 997-C312 OR-18 K851-C37 BU-18 C903-C280 BU-18 K861-C214 GN-18 39 ATT STEM-2 RETRACT PRV 1 E562-GT18 PU-16 30A 168-F73 RD-10 615-F129 YL-16 200-F166 BK-18 103-F27 RD-18 1 +B
235-C290 BK-18 K852-C38 GN-18 K857-C213 WH-18 40 ATT STEM-2 EXTEND PRV 2 200-GT9 BK-18 BEACON RELAY ATCH 15A 616-F84 BU-16 199-F165 OR-18 F-C31
235-C155 BK-18 A209-C112 BK-18 L968-C67 OR-18 E472-C114 GN-18 K862-C217 GY-18 41 ATT STEM-3 RETRACT PRV 3 E564-GT13 PK-18 1613128 1 603-F133 PK-18 20A NOTE J 638-F91 WH-16 H41 118-F90 GY-16 3495085 (51) SERVICE METER
(59) GLOW PLUG 200-C297 BK-16 L972-C33 BU-18 K858-C216 YL-18 42 ATT STEM-3 EXTEND PRV 4 E564-GT15 PK-18 2 200-F134 BK-18 20A 1 645-F88 RD-18 506-F103 PU-18 200-F166 BK-18 1 GROUND 3660367
A209-C307 BK-18 N793-C1 GN-18 E472-C41 GN-18 43 SPARE 5 A588-GT7 GN-18 3 199-F69 OR-18 10A 117-GH4 RD-18 684-F130 RD-18 A584-F169 BU-18 F-C32
F-C45
200-C297 BK-16 A209-C308 BK-18 N794-C58 GY-18 E472-C29 GN-18 M736-C286 BU-18 44 ENGINE SPEED COMMAND 4 199-F135 OR-16 25A 200-F134 BK-18 H4 H6 H7 3495085
C-C104 7Y3967
235-C155 BK-18 P875-C306 BU-18 45 CAN 3 + H47 5 638-F91 WH-16 25A 200-F136 BK-18 199-F165 OR-18 403-F76 GN-18 1 SIGNAL
2312295 128-C296 PK-16 A762-C278 PU-18 E474-C52 OR-18 46 CAN 3 - 30A FUSE 1 501-F28 GN-18
H5 H6
+B 1 186-C288 WH-18 147-C72 PU-16 A768-C64 BU-18 E473-C55 GY-18 47 CAN 2 + (J1939) (67) QC HYDRAULIC LOCK ON RELAY ATCH 5A 141-2759 200-F136 BK-18 530-F29 OR-18
F-C38
GROUND 2 200-C289 BK-18 308-C126 YL-16 A982-C293 BR-18 235-C166 BK-14 E997-C84 RD-18 48 CAN 2 - (J1939) 1495050 10A 113-8490 200-F134 BK-18 A586-F26 OR-18
7Y3967 (151) UNDER WINDOW LIMIT SWITCH ATCH
F/B 3 997-C312 OR-18 C468-C28 BU-18 235-C285 BK-18 F716-C208 WH-18 49 CAN 2 SHEILD GT-C3 15A 113-8491 200-F68 BK-14 590-F67 GY-18
ACCEL 4 A209-C308 BK-18 C903-C281 BU-18 308-C113 YL-16 F793-C279 OR-18 251-C103 YL-18 50 CAN 1 + 1495051 TRAVEL ALARM RELAY 20A 113-8492 200-F138 BK-16 200-F166 BK-18 1296466
(29) GOVERNOR
3863439 DECEL 5 H34 E554-C11 PK-18 763-C75 BU-18 G723-C92 YL-18 261-C104 GN-18 51 CAN 1 - 1 E564-GT14 PK-18 1613128 1 147-F58 PU-18 25A 113-8493 200-F139 BK-16
KEY 6 A209-C303 BK-18 G976-C32 BU-18 788-C277 YL-18 G973-C12 OR-18 52 CAN 1 SHEILD 2 200-GT10 BK-18 2 331-F187 OR-18 30A 124-3548 117-GH4 RD-18 200-F140 BK-16 200-F166 BK-18 152-F59 BU-16 535-F148 BU-16
ESS 7 M736-C286 BU-18 A209-C304 BK-18 K904-C117 GN-18 997-C299 OR-18 H473-C31 BR-18 E997-C84 RD-18 53 HYDRAULIC LOCK SOLENOID 3 A588-GT8 GN-18 3 147-F58 PU-18 TOOL 170-6888 H5 200-F8 BK-18
8 A768-C64 BU-18 L968-C67 OR-18 A209-C112 BK-18 H474-C34 GN-18 54 SPARE (FREQ IN 2) 4 4 147-F83 PU-16 H16 200-F160 BK-16
H54 G976-C32 BU-18 M736-C286 BU-18 A762-C278 PU-18 5 E564-GT14 PK-18 5 321-F44 BR-18 200-F168 BK-16 535-F151 BU-16
C-C107 K904-C117 GN-18 M737-C77 WH-18 A768-C64 BU-18 H475-C35 BU-18 184-C105 RD-14 1 +B E564-GT15 PK-18 200-F180 BK-18 535-F124 BU-16 535-F148 BU-16
1003320 H41
L968-C67 OR-18 M739-C135 YL-18 A982-C293 BR-18 H476-C30 WH-18 235-C106 BK-14 2 GROUND 535-F117 BU-16
(94) ENGINE SHUT OFF SOLENOID A A982-C293 BR-18 M737-C77 WH-18 N769-C309 GY-18 K843-C56 GN-18 3 RS422 RX+ H4 H4 F-C3
3412998 B 235-C294 BK-18 M739-C135 YL-18 R725-C305 WH-18 C903-C281 BU-18 K844-C53 GY-18 P875-C306 BU-18 4 ATMOSPHERE SENSOR (69) QC HYDRAULIC LOCK RELAY 1 ATCH 9G1906 (152) UNIVERSAL QC SWITCH ATCH
R725-C305 WH-18 T967-C118 YL-18 K847-C57 PU-18 R725-C305 WH-18 5 FUEL FILTER PLUGGED SENSOR 1495050
1055175
T967-C118 YL-18 C903-C280 BU-18 K848-C54 WH-18 N769-C309 GY-18 6 ENGINE OIL PRESSURE SENSOR GT-C4 1 103-AJ6 RD-16 129-F57 BU-16 1 (50) CIGAR LIGHTER
C-C105 C903-C282 BU-18 K849-C36 YL-18 K852-C38 GN-18 7 ATT STEM-4 STATUS 1495051 2 508-AJ7 PU-18 9W0335 (57) WIPER MOTOR
2818804 1
D D
K851-C37 BU-18 997-C298 OR-18 8 POWER SUPPLY FOR POTENTIO (+5V) 1 E564-GT13 PK-18 3 509-AJ4 WH-18 H41 2382318 1893424
2
+B 1 997-C311 OR-18 G723-C92 YL-18 K852-C38 GN-18 H476-C30 WH-18 9 IMPLEMENT PRESSURE SWITCH 2 200-GT11 BK-18 4 511-AJ8 BR-18 F-C4 147-GV1 PU-16
(82) ENGINE OIL PRESSURE SENSOR 3
GROUND 2 A209-C307 BK-18 K904-C117 GN-18 K856-C211 PU-18 A755-C24 PK-18 10 THROTTLE-1 3 E562-GT16 PU-16 5 512-AJ5 GN-18 200-F122 BK-16 1532602
3203060 (30) CAB 1 GROUND 4
SIGNAL 3 N769-C309 GY-18 K906-C62 GN-18 K857-C213 WH-18 A758-C27 BR-18 11 THROTTLE-4 4 200-AJ3 BK-18 (138) SWITCH PANEL
GG-C3 F-C1 F-C25 5
M736-C286 BU-18 K858-C216 YL-18 L972-C33 BU-18 12 ONE TOUCH LOW IDLE SWITCH 5 779-GT5 WH-16 113-AJ1 OR-18 113-F81 OR-18 2277575 MOTOR 147-GV2 PU-16
1552269 1636659 7Y3958 6
M737-C77 WH-18 K860-C212 BU-18 184-C109 RD-14 13 +B (88) 12V/10A SOCKET A ATCH 331-F187 OR-18
(112) STEM-3 RETRACT SOLENOID ATCH
1 K862-GG2 GY-18 M739-C135 YL-18 K861-C214 GN-18 235-C110 BK-14 14 GROUND H42 3245771 430-F33 BU-18 113-F81 OR-18 A1 ACC BU/BK 1 A579-F176 OR-16
C-C65 1119916
2 K869-GG4 BU-18 M740-C74 PK-18 K862-C217 GY-18 15 RS422 RX- 487-F34 OR-18 200-F25 BK-18 A2 GROUND BU/RD 3 A580-F177 BR-16 E565-GV4 BU-16
1552269 (NOTE R)
N769-C309 GY-18 K864-C82 PK-18 16 SQUEEZE PRESSURE SENSOR (70) QC HYDRAULIC LOCK RELAY 2 ATCH 1 501-F28 GN-18 251-F109 YL-18 A3 CAN1 + GN 6 A581-F178 GN-16 E562-GV3 PU-16
(124) ENGINE OIL LEVEL SWITCH
1 C468-C28 BU-18 R725-C305 WH-18 K865-C89 PU-18 17 SPARE (PWM IN 2) 1495050 2 530-F29 OR-18 261-F50 GN-18 A4 CAN1 - BU 4 A582-F179 PU-16
2130677 GG-C2 GT-C5
2 235-C99 BK-18 T967-C118 YL-18 K866-C79 WH-18 A209-C301 BK-18 18 ANALOG RETURN 3 590-F67 GY-18 A5 BK 5 200-F168 BK-16
1552269 147-C73 PU-16 K868-C215 BR-18 A756-C25 BU-18 19 THROTTLE-2 1495051 4 F-C46 645-F88 RD-18 430-F33 BU-18 A6 AIR CLEANER SWITCH 2
(111) STEM-3 EXTEND SOLENOID ATCH GG-C1 C-C28 H39
1 K858-GG1 YL-18 2305010 K869-C218 BU-18 A757-C26 GY-18 20 THROTTLE-3 1 779-GT6 WH-16 5 1532602 646-F32 RD-18 487-F34 OR-18 A7 CAPSULE FILTER SWITCH
1119916 2434508
2 K869-GG5 BU-18 147-C73 PU-16 K871-C78 WH-18 K848-C54 WH-18 21 LH HANDLE FORE SWITCH 2 200-GT12 BK-18 780-F30 PU-18 X738-F35 PK-18 A8 SP FILTER SWITCH 200-F168 BK-16
(NOTE R) K858-GG1 YL-18 1 K858-C216 YL-18 A9
E472-C41 GN-18 K904-C117 GN-18 K844-C53 GY-18 22 LH HANDLE UPPER SWITCH 3 E565-GT20 BU-16 210-F206 BK-14 A586-F26 OR-18 G976-F36 BU-18 WTR SPR LEVEL SWITCH
K862-GG2 GY-18 2 K862-C217 GY-18 F-C26
K869-GG3 BU-18 G973-C12 OR-18 K906-C62 GN-18 308-C113 YL-16 23 KEY SWITCH 4 135-F56 BU-14 H38 G976-F36 BU-18 T725-F37 WH-18 A10 FUEL FILTER SWITCH
1114816
C-C106
1552269
(MEDIUM CIRCUIT) K869-GG3 BU-18 K869-GG3 BU-18 3
4
K869-C218 BU-18 K856-C211 PU-18 L968-C67 OR-18 24 RS422 TX+ 5 780-GT1 PU-16 X738-F35 PK-18 A11 DIGITAL GROUND (139) QUICK COUPLER SWITCH ATCH
K857-C213 WH-18 L972-C33 BU-18 25 RS422 TX- E562-GT18 PU-16 (89) 12V/10A SOCKET B ATCH 251-F100 YL-18 A12 DIGITAL GROUND W. CCW 1 A579-F176 OR-16 7N2353
(83) ENGINE SPEED PICKUP SENSOR 1 788-C277 YL-18 5 K858-C216 YL-18 M736-C286 BU-18 26 SPARE (PWM IN 3) E562-GT16 PU-16 1 3245771 251-F109 YL-18 W. CW 2 A580-F177 BR-16
3181181 2 A762-C278 PU-18 6 K860-C212 BU-18 M737-C77 WH-18 E472-C114 GN-18 27 8V SUPPLY E565-GT20 BU-16 2 251-F189 YL-18 R725-F38 WH-18 1 2ND FILTER SWITCH REV 13 A581-F178 GN-16 2
H32 K861-C214 GN-18 28 SPARE WH-C1 3 251-F189 YL-18 2 OLWD CANCEL SWITCH STOP 12 A582-F179 PU-16 3
CONN 6 K862-C217
K864-C82
GY-18
PK-18
M739-C94 YL-18 K847-C57
K843-C56
PU-18
GN-18
29
30
RH HANDLE FORE SWITCH (FOR SMART BOOM)
RH HANDLE UPPER SWITCH (INSTEAD OF FOOT PEDAL) (155) LAMP DELAY TIMER ATCH 684-WH1 RD-18
3E3364
1
4
5
261-F52
261-F52
GN-18
GN-18
L886-F13 BU-18
L973-F110 GN-18
3
4
OPTION STG SWITCH
FINE SWING SWITCH
INT-6
INT-3
4
9
A586-F26
590-F67
OR-18
GY-18
K865-C89 PU-18 M739-C135 YL-18 H475-C35 BU-18 31 TRAVEL-L PRESSURE 1636704 2 F-C47 261-F50 GN-18 5 SM BM UP/DOWN LOW 8 501-F28 GN-18
GE-C3 K866-C79 WH-18 M739-C134 YL-18 K849-C36 YL-18 32 ATT STEM-1 STATUS F-C29 1532602 261-F48 GN-18 6 SM BM DOWN WASH 7 530-F29 OR-18
1552269 (NOTE E) 1552269
K868-C215 BR-18 893-C116 GN-18 33 CDL + 200-F25 BK-18 780-F30 PU-18 7 QUICK COUPLER SWITCH GROUND 10 200-F180 BK-18
(108) STEM 2 EXTEND SOLENOID (SYS 16) ATCH
1 K857-GE2 WH-18 K869-C218 BU-18 M740-C74 PK-18 K904-C117 GN-18 34 PUMP PRESSURE SENSOR-1 RELAY 1 1 684-F130 RD-18 AJ-C2 GH-C1 210-F97 BK-14 200-F181 BK-18 L885-F39 BU-18 8 OPTION ROCKER SWITCH RAISE-S 11
1119916 GH-C3
2 K868-GE5 BR-18 K871-C78 WH-18 N769-C309 GY-18 T967-C118 YL-18 35 PUMP PRESSURE SENSOR-2 LAMP SWITCH 2 2 646-F32 RD-18 2305010 2305010 (31) CAB 2 GROUND 135-F45 BU-14 199-F165 OR-18 530-F29 OR-18 9 WASHER WA+ 5 506-F103 PU-18
(NOTE M) F-C24 F-C28 2304013
M739-C134 YL-18 N793-C1 GN-18 36 SPARE 590-F67 GY-18 10 WIPER INT-3 ACC 6 118-F90 GY-16
GE-C2 GE-C1 CAP8 2 C-C32 N795-C59 WH-18 N794-C58 GY-18 37 SPARE 3E3370 1552267 F-C27 199-F165 OR-18 A586-F26 OR-18 11 WIPER INT-6 WIPER CUT 3 A584-F169 BU-18
1552269 2434509 3422975 2312295 AJ-C4 H1
200-AL2 BK-18 N795-C59 WH-18 E474-C52 OR-18 38 THUMB WHEEL-LH +B A A 105-F137 RD-16 2312295 9W1951 200-F181 BK-18 501-F28 GN-18 12 WIPER LOW (16) WIPER CONTROL
(105) STEM 1 EXTEND SOLENOID (SYS 16) ATCH
200-GC15 BK-18 1 K856-GE1 PU-18 K856-GE1 PU-18 1 1 K856-C211 PU-18 P875-C306 BU-18 H473-C31 BR-18 39 TRAVEL STRAIGHT PRESSURE SWITCH GROUND B B 200-F138 BK-16 L973-F110 GN-18 646-F32 RD-18 13 CHAS LAMP RELAY 1557042
1119916 GH-C4
200-GC4 BK-18 2 K868-GE4 BR-18 2 2 K860-C212 BU-18 R725-C305 WH-18 H474-C34 GN-18 40 TRAVEL-R PRESS KEY OFF C C 308-F141 YL-18 B 235-F114 BK-18 F-C36 645-F88 RD-18 14 BOOM LAMP RELAY
(NOTE M) 2434506
235-GC2 BK-18 K857-GE2 WH-18 3 3 K857-C213 WH-18 T967-C118 YL-18 41 ATT STEM-2 STATUS D 893-F142 GN-18 7Y3967 331-F187 OR-18 15 TRAVEL ALARM
235-GC18 BK-18 K868-GE3 BR-18 4 CONN 7 4 K861-C214 GN-18 K851-C37 BU-18 42 ATT STEM-3 STATUS 308-F141 YL-18 H4 CONN 31 E 892-F143 BR-18 1 L886-F13 BU-18 16 REVERSE FAN CHANGE 200-F168 BK-16
235-AK2 BK-18 (SYSTEM 3,16) K868-GE3 BR-18 K868-GE3 BR-18 5 5 K868-C215 BR-18 892-C121 BR-18 43 CDL - 308-F104 YL-16 AJ-C5
2434509 CONN 30 A 105-F40 RD-16 F-C19 17 DIGITAL GROUND
GT-C7 GV-C1
6
7
6
7
235-C285
251-C133
BK-18
YL-18
E473-C55
F716-C208
GY-18
WH-18
44
45
THUMB WHEEL-RH
USER DEFINED SHUTDOWN SWITCH
308-F144 YL-18
CONN 21 SERVICE CONNECTOR
C
F 1
7Y3967
L885-F39 BU-18 F-C2
18 DIGITAL GROUND
1636803 1673542 CONN 51
8 8 261-C132 GN-18 46 SPARE 308-F145 YL-18 G 1636699 147-GT17 PU-16 1 147-GV1 PU-16
C903-C282 BU-18 N793-C1 GN-18 47 FOOT SWITCH F-C5 GH-C2 H F-C14 E562-GT21 PU-16 2 E562-GV3 PU-16 GT-C1 AW-C1
G973-C12 OR-18 48 BOOM UP PRESSURE SWITCH 7Y3952 2434505 J 7Y3967 261-F48 GN-18 E565-GT20 BU-16 3 E565-GV4 BU-16 7Y3953 7Y3953
CAP12 1 C-C30
GC-C8
3422976 2304009 H32 49 2WAY LEVER CHANGE PRESSURE SWITCH 200-F146 BK-18 1 (23) MAIN RELAY DIODE 188-GH5 WH-16 1
CONN 29 1 R725-F38 WH-18 251-F100 YL-18 4
CONN 45
2434510 50 SPARE 308-F145 YL-18 2 1211022 139-GH6 OR-16 2 5
CONN 51 F-C50
C H18
147-GC5
K866-GC3
K871-GC8
PU-16
WH-18
WH-18
147-GC5
K871-GC8
K866-GC3
PU-16
WH-18
WH-18
1
2
3
1
2
3
147-C73
K871-C78
K866-C79
PU-16
WH-18
WH-18 N794-C58 GY-18
51
52
53
SPARE (PWM IN 17)
SPARE (PWM IN 18)
AUX PEDAL LH
308-F144 YL-18
308-F104 YL-16
308-F141 YL-18
308-F145 YL-18
200-F140 BK-16
(20) RADIO CONVERTER
3245770
(18) 12V POWER CONVERTER
3245770 AJ-C3 F-C51 F-C49 1
F-C11
7Y3967
T725-F37 WH-18
F-C48
3E3370 E562-GT22 PU-16
147-GT17 PU-16 CONNECTS TO F-C50
7Y3952
C
2434505 2434505 2304011 A 251-F100 YL-18
G973-GC1 OR-18 4 4 K864-C82 PK-18 N795-C59 WH-18 54 AUX PEDAL RH LOC C-1
B 261-F48 GN-18
G973-GC1
235-GC2
OR-18
BK-18
H46 5
6
CONN 8
5
6
M739-C134 YL-18 C-C27
1532620 177-A71 RD-6 112-FC1 PU-4
113-AJ1 OR-18
139-AJ9 OR-18
1
2 CONN 28 1
2
113-F185 OR-16
139-F186 OR-16 H3
(78) MACHINE CAN RESISTOR 2 C
E562-GT18
E562-GT18
PU-16
PU-16
7 7 K865-C89 PU-18 177-FA1 RD-4 1743016 E562-GT22 PU-16
K872-GC11 OR-18 H45 8 8 (66) MAIN RELAY H37 H37 E562-GT21 PU-16
K872-GC12 OR-18 G973-GC1 OR-18 9 9 G973-C12 OR-18 C-C103 2130772 E562-GT16 PU-16
1552269
CAB
10 10 177-FA1 RD-4 E562-GT16 PU-16
11 11 E472-C41 GN-18 C903-C282 BU-18 1 (25) START RELAY DIODE E565-GT20 BU-16
12 12 N795-C59 WH-18 235-C285 BK-18 2 1974385
(34) CHASSIS 2 GROUND (33) CHASSIS 1 GROUND
C-C34
GF-C10 3E3370
OPERATOR STATION
2434509 251-C133 YL-18 A
(77) MACHINE CAN RESISTOR 1
1 261-C132 GN-18 B
1743016
K860-GF2 BU-18 2 C
GC-C3
K857-GF3
K861-GF4
WH-18
GN-18
3
4
CONN 7 GF-C12
2304011
1552269 X-C3
(91) 1P 2P CHANGE SOLENOID 2 (SOL 3) ATCH K868-GF5 BR-18 5 CONNECTS TO C-C32 K864-GF10 PK-18 1 (101) RELIEF-1 SOLENOID ATCH
1 K871-GC14 WH-18 6 K864-GF10 PK-18 M739-GF22 YL-18 2 2448506 1160126
1211491
2 235-GC17 BK-18 7
LOC C-13 M739-GF6 YL-18 (NOTE P) 323-X12 WH-10 1 + - EM-C4
(NOTE G,H) AC-C1
H49
8 H49 M739-GF6
M739-GF22
YL-18
YL-18 CONN 22 2434505 616-AE1 BU-16
200-X5 BK-10 2
EM-C19
2312295
2305010 EM-C3
1552273 F-C17
GF-C6 M739-GF21 YL-18 GF-C8 1 616-AC1 BU-16 616-AC1 BU-16 1636803
2434510 GF-C4
K865-GF11 PU-18 2304011 CONNECTS TO AR-C1 2 200-AC2 BK-16 200-AC2 BK-16 (61) REFUELING PUMP ATCH
GC-C2 1552269
1552269
1 K865-GF11 PU-18 1 (102) RELIEF-2 SOLENOID ATCH LOC B-7 200-AE2 BK-16 2291859
H19 2 (110) STEM 2 RETRACT SOLENOID ATCH 1 K861-GF4 GN-18 K856-GF1 PU-18 M739-GF21 YL-18 2 2448506 F-C40 F-C20
(90) 1P 2P CHANGE SOLENOID 1 (SOL 2) ATCH X-C8 EM-C20 F-C13
1 K871-GC13 WH-18 3 1119916 2 K868-GF13 BR-18 K857-GF3 WH-18 (NOTE P) F-C18 1636803 1636803
1211491 2434509 1636803 F-C21
1552269
(NOTE G,H) 2 235-GC16 BK-18 K864-GF10 PK-18
M739-GF6 YL-18
4
5 CONN 8
GF-C3
1552269
K860-GF2
K861-GF4
BU-18
GN-18
616-AE1 BU-16
200-AE2 BK-16 168-X16 RD-18 1 CONN 39 1636803 1636803
6 K868-GF5 BR-18 329-X17 YL-18 2

K865-GF11 PU-18 7 CONNECTS TO C-C30 (109) STEM 2 EXTEND SOLENOID ATCH 1 K857-GF3 WH-18 K868-GF5 BR-18 (NOTE D)
GC-C1
8
9
LOC C-13
1119916 2
GF-C2
K868-GF14 BR-18 K868-GF15
K868-GF16
BR-18
BR-18
(24) POWER RELAY DIODE ATCH
1974385
CONN 44
1552269 10 K868-GF25 BR-18
(93) DOUBLE ACTION SOLENOID (SOL 3) ATCH 1552269
1 K879-GC7 GN-18 11 K868-GF25 BR-18 168-X15 RD-18 (125) FINE SWING CONTROL SWITCH ATCH
1211491
2 200-GC15 BK-18 12 (107) STEM 1 RETRACT SOLENOID ATCH 1 K860-GF2 BU-18 K868-GF13 BR-18 BOOM LAMP(LH) ATCH 168-X14 RD-18
(NOTE G,H) C-C38 AR-C1 2382212
1119916 2 K868-GF15 BR-18 K868-GF14 BR-18 1532521 168-X14 RD-18
2304011 2434505 616-AV1 BU-16 168-X13 RD-18
H49 GF-C1 (19) 12V RADIO CONVERTER ATCH
(CONFIG. 2,11) 1552269 616-C9 BU-16 1 616-AR1 BU-16 616-AR1 BU-16 168-X1 RD-10 3245770 (146) SPEAKER EXCHANGE SWITCH ATCH (144) SEAT HEATER SWITCH ATCH (133) LOWER WASHER SWITCH ATCH (140) RADIO MUTE SWITCH ATCH (134) LOWER WIPER SWITCH ATCH
B (106) STEM 1 EXTEND SOLENOID ATCH

1119916
1
2
K856-GF1 PU-18
K868-GF16 BR-18
200-C98 BK-16
CONN 22
2 200-AR2 BK-16 200-AR2
200-AV2
BK-16
BK-16
323-X12
329-X18
WH-10
YL-18
(71) REFUELING POWER RELAY ATCH
(NOTE X) 1702512
(NOTE X)
2382211 2382210 2382216 2382209
B
C-C109 GC-C6
2130772
2818803 (SYSTEM 18) (SYSTEM 18)
1552269 BOOM LAMP(RH) ATCH
(85) FUEL FILTER PLUGGED SENSOR +B 1 997-C312 OR-18 H46 H46 G973-GC1 OR-18 1 (121) BOOM RAISE PRESSURE SWITCH ATCH 1532521
IDENT PART NO. NOTE DESCRIPTION
3056873 GROUND 2 A209-C303 BK-18 235-GC2 BK-18 2 1673466 GC-C4
HARNESS ASSEMBLY
SIGNAL 3 R725-C305 WH-18 (NOTE G,H) 1552269 616-AV1 BU-16 F: CONFIG.1,3’
K872-GC12 OR-18 1 (103) SINGLE ACTION SOLENOID 1 ATCH 200-AV2 BK-16
A
C
421-2680
431-9251
PLATFORM
CHASSIS G: CONFIG.2
The following wire
H45 H45 H45 K872-GC11 OR-18 200-GC19 BK-18 2 2154890
C-C108
1552269
K872-GC12 OR-18 (NOTE G,H) (NOTE C) X-C4
1495051
E
F
291-7560
388-6805
FORWARD WARNING HORN
CAB H: CONFIG.11 pairs must be
200-GU5 BK-18 200-GC9 BK-18 GC-C5
(60) LIFTING PUMP
MOTOR
1 128-C296 PK-16 H53 H53 H53 200-GU6 BK-18 200-GC19 BK-18 1552269 L976-X9 GN-18 1
G
H
373-8980
251-0580
CONSOLE-RH
CONSOLE-LH
J: GH 5A twisted at least 1
3860195 2 200-C297 BK-16 128-C296 PK-16 779-GU2 WH-16 200-GC10 BK-18 K872-GC11 OR-18 1 (104) SINGLE ACTION SOLENOID 2 ATCH 322-E2 GY-16 (43) FORWARD WARNING HORN LH 365-X6 YL-18 2
147-C72 PU-16 780-GU1 PU-16 200-GC9 BK-18 2 2154890 200-E4 BK-16 7Y3919 200-X4 BK-18 3
M
R
328-0021
170-9295
KEY SW (CONSOLE)
CAB LAMP
M: SYSTEM 3,16
S: SYSTEM 18
turn per 25mm:
200-C297 BK-16 A588-GU3 GN-18 (NOTE G,H) 4
CALLOUTS
C-C8 T 170-9295 CAB LAMP
2818803
235-C155 BK-18 A588-GU3 GN-18 329-X18 YL-18 5 X 238-1579 REFUELING PUMP
W: 321SR
251 & 261
Y 238-1595 REFUELING PUMP X: 12V
(153) WATER SEPARATOR LEVEL SWITCH OUTPUT
GROUND
BU
BK
1
2
G976-C32
235-C155
BU-18
BK-18
308-C126
308-C126
YL-16
YL-16 C-C39 E-C1
Z 153-2492 JUMPER
Y: PL-GSM(CHINA) 252 & 262
3635084 C-C45 2434505 AA 238-1597 REFUELING PUMP
POWER RD 3 147-C72 PU-16 308-C182 YL-16 C-C44
3E3364
2304011 322-E2 GY-16 (73) REFUELING STOP RELAY ATCH AC 267-7628 D BOOM LAMP-LH Callout Number Component 892 & 893
308-C181 YL-16
G723-C92 YL-18
1552269
1 1 (97) HEAVY LIFT SOLENOID ATCH GU-C2
322-C6 GY-16
200-C97 BK-16
1
2
322-E1
200-E3
GY-16
BK-16
322-E1
200-E3
GY-16
BK-16
(44) FORWARD WARNING HORN RH
7Y3920
1495050 AE 267-7626 D BOOM LAMP-RH (Machine Location from (52) VALVE GP - CONTROL Name
1552269 AG 251-0299 SECONDARY SHUTDOWN SW Component Locations Table)
997-C312 OR-18 235-C175 BK-18 235-C85 BK-18 2 2 1216303 200-E4 BK-16 AJ 234-1124 RADIO CONVERTER 138-1234 Part Number SYMBOL DESCRIPTION ABBREV COLOR
C-C62
2304013
A209-C303 BK-18 H34 321-C40
487-C19
BR-18
OR-18 779-GU2 WH-16
780-GU1 PU-16
200-GU5 BK-18
1
2
(116) UNIVERSAL QC SOLENOID HIGH ATCH
1211491 CONN 23 X-C5 AK 421-3867 RETURN FILTER
NOTE A: USE WITH COLD WEATHER.
(86) PUMP 1 PRESSURE SENSOR +B 1 308-C182 YL-16 A209-C304 BK-18 491-C20 PK-18 C-C46 780-GU1 PU-16 1495051 AL
AM
369-0256
259-5129
QUICK COUPLER
FINE SWING
NOTE C: USE WITH LONG BOOM.
CIRCUIT CONNECTED RD RED
GROUND 2 A209-C154 BK-18 235-C176 BK-18 1552269 200-GU5 BK-18 GU-C3 L976-X19 GN-18 1
3669312 AR 259-5326 C BOOM LAMP-LH NOTE D: USE WITH SHORT BOOM.
1552269
WH WHITE
SIGNAL 3 K904-C117 GN-18 A209-C154 BK-18
A209-C123 BK-18
235-C177 BK-18 M740-C74
235-C185
PK-18
BK-18
1
2
(115) TRAVEL STRAIGHT SOLENOID
1211491
200-GU6 BK-18
779-GU2 WH-16 1 (117) UNIVERSAL QC SOLENOID LOW ATCH
607-C7 PK-16 CHASSIS LAMP
365-X7 YL-18
168-X15 RD-18
2
3
AV
AW
259-5327
238-2479
C BOOM LAMP-RH
QUICK COUPLER
WIRE GROUP COLOR DESCRIPTIONS NOTE E: USE WITH LAMP DELAY TIMER. CIRCUIT NOT CONNECTED
C-C53 C-C54
235-C173 BK-18 H31 200-GU6 BK-18 2 1211491
200-C96 BK-16 1532523
4 CA 388-6760 BAT.-STARTER NOTE F: USE WITH CONFIG.1,3'. ELECTRICAL CONNECTION TO OR ORANGE
A768-C64 BU-18
1552269 3E3364
L976-X19 GN-18 5 CC 170-6929 BAT. JUMPER GROUND CIRCUIT
MACHINE STRUCTURE
C-C63
2304013
G976-C32
K904-C117
BU-18
GN-18 321-C40 BR-18 1 1 (2) TRAVEL ALARM ATCH
H28 235-C172 BK-18
325-C174 PK-18 763-C75 BU-18
C-C47
1552269
L976-X10 GN-18 CE 231-1827 BAT.-DISC SW
WIRES THAT HAVE SYSTEM VOLTAGE WHEN THE KEY SWITCH IS OFF
NOTE G: USE WITH CONFIG.2.
YL YELLOW
C-C50 CF 388-6788 A BAT.-STARTER
NOTE H: USE WITH CONFIG.11. INTERNAL ELECTRICAL CONNECTION
+B 1 308-C181 YL-16 L968-C67 OR-18 235-C177 BK-18 2 2 2139100 495-C22 GN-18 A588-C167 GN-18 763-C75 BU-18 1 (114) TRAVEL SPEED SOLENOID
(87) PUMP 2 PRESSURE SENSOR
3669612 GROUND 2 A209-C123 BK-18 M737-C77 WH-18 1552269 G723-C92 YL-18 235-C86 BK-18 2 1211491 (72) REFUELING START RELAY ATCH
CG
CH
170-6929
259-5229
A
A
BAT. JUMPER
BAT.-DISC SW
WIRES THAT HAVE SYSTEM VOLTAGE WHEN THE KEY SWITCH IS ON
NOTE J: EXCHANGE TO 5A FUSE AT INSTALL GH HARNESS.
TO SURFACE OF COMPONENT PK PINK
SIGNAL 3 T967-C118 YL-18 M739-C135 YL-18 1 495-C22 GN-18 168-C51 RD-10 K906-C62 GN-18 1495050
VOLTAGE CONVERTER OUTPUT CIRCUIT
R725-C305 WH-18 2 235-C173 BK-18 H28 H29 322-C6 GY-16 H30 C-C48 168-X1 RD-10
CJ
CL
251-0303
251-0304
TERM. BLOCK-MAIN BREAKER
ALT BREAKER-TERM. BLOCK
NOTE M: USE WITH SYSTEM 3,16. CONNECTOR BK BLACK
T967-C118 YL-18 (84) FUEL LEVEL SENSOR 325-C174 PK-18 M740-C74 PK-18 1552269 365-X6 YL-18 STARTING CIRCUIT
EK 373-8965 Y PRODUCT LINK (PL-GSM)
C-C61
3411842 607-C7 PK-16 200-C171 BK-18 K906-C62 GN-18 1 (113) SWING BRAKE SOLENOID
C-C40 C-C41
X-C2 L976-X9 GN-18 X-C6
2434505
AA-C1
2304011 EM 283-2914 X 12V RADIO READY
START AID CIRCUIT
NOTE R: USE WITH MEDIUM CIRCUIT.
H# CIRCUIT GROUPING DESIGNATION GY GRAY
616-C9 BU-16 235-C170 BK-18 235-C93 BK-18 2 1211491 1211038 200-X4 BK-18 FA 238-2390 MAIN RELAY-FUSE BASE NOTE S: USE WITH SYSTEM 18.
1552269 1160126 1211038
C-C52 C-C51
L973-C80 GN-16 235-C170 BK-18 200-X5 BK-10 365-X8 YL-18 1 365-AA1 YL-18 FC 238-2391 MAIN RELAY-FUSE BASE TRANSMISSION / ENGINE PUMP CONTROL CIRCUIT PU PURPLE
CONN 24
(99) POWER SHIFT PRESSURE SOLENOID NOTE T: USE WITH CAB GUARD.
A A
1 A768-C64 BU-18 235-C93 BK-18 C-C49 168-C51 RD-10 1 1 168-X1 RD-10 168-X1 RD-10 168-X13 RD-18 325-X3 PK-18 2 325-AA2 PK-18 GA 251-0598 G,H CONFIG. 2,11 ATCH WIRE, CABLE, COMPONENT
1119916 2304011 2434505 MONITOR CIRCUIT
2 L968-C67 OR-18 235-C86 BK-18 1552269 200-C98 BK-16 200-C95 BK-10 2 2 200-X2 BK-10 325-X3 PK-18 168-X15 RD-18
BR BROWN
CONN 27
GC 369-0266 G,H CONFIG. 2,11 NOTE W: USE WITH PRODUCT LINK 321SR.
(79) HYDRAULIC TEMPERATURE SENDER 1 325-C174 PK-18 235-C85 BK-18 A588-C167 GN-18 1 (98) HYDRAULIC LOCK SOLENOID 200-C97 BK-16 365-X6 YL-18 168-X15 RD-18 (143) REFUELING STOP SWITCH (NC) ATCH GE 369-0269 M SYSTEM 3,16
3422924 2 235-C185 BK-18 200-C171 BK-18 2 1211491 200-C96 BK-16 365-X8 YL-18 365-X7 YL-18 9X4184 MACHINE SECURITY CONTROL CIRCUIT NOTE X: USE WITH 12V RADIO READY. SPLICE
WJ-C1 200-C95 BK-10 C-C42 C-C43 X-C1 365-X7 YL-18 L976-X10 GN-18
GF
GG
377-8092
369-0286
S
R
SYSTEM 18
MEDIUM CIRCUIT ENGINE CONTROL CIRCUIT
GN GREEN
491-C20 PK-18 2304011 GU-C4 GU-C5 200-C169 BK-18 2434505 2304011 2304011 L976-X9 GN-18 325-X3 PK-18 X-C7 Y-C1 NOTE Y: USE WITH PL-GSM(CHINA). BLADE, SPADE, RING OR SCREW
C-C60 C-C59 3E3364 1552269 2304011 2434505 GH 259-5254 EXTEND WIRE FOR 12V READY
BU BLUE
3E3364 1552269 T°
1
PILOT MANIFOLD
325-C174PK-18 1
CONN 25 1 325-X3 PK-18 L976-X10 GN-18 365-X8 YL-18 GK 275-6979 W PRODUCT LINK 121SR (RADIO) HEATER AND AIR CONDITIONER CIRCUIT TERMINAL
(96) FLOW LIMIT SOLENOID ATCH
1119916
1 1 M737-C77 WH-18 235-C175 BK-18
2
325-WJ1 PK-18 CONN 9 1
2
A588-GU7 GN-18
200-GU9 BK-18
A588-GU8 GN-18
200-GU9 BK-18
1
2 CONN 10 168-C51
322-C6
RD-10
GY-16
2 2 L976-X11
200-X2
GN-18
BK-10
168-X13
L976-X11
RD-18
GN-18
168-X13 RD-18
L976-X11 GN-18
1
2
168-Y1 RD-18
L976-Y2 GN-18
GL
GN
259-4940
259-4887
W
W
PRODUCT LINK (SERVICE CONN)
PRODUCT LINK 321SR (GATEWAY)
TURN SIGNAL / WIPER WASHER CIRCUIT
2 2 M739-C135 YL-18 WJ-C2 H29 325-C174 PK-18 200-X2 BK-10 GT 267-7644 UQC CAT DATA LINK
(NOTE F,G,H,K,L,M,N,P,S)
CONTROL VALVE
C-C56
1552269
1
2304011
325-WJ1 PK-18
(35) CHASSIS 3 GROUND
607-C7
616-C9
PK-16
BU-16 C-C36
2434505
C-C37
2304011
AM-C2
2304011
AM-C1
1552269
200-X4
200-X5
BK-18
BK-10 CONN 26 (142) REFUELING START SWITCH (NO) ATCH
6T9442
GU
GV
369-0257
267-7672
UQC
UQC RS-232 / RS-485 DATA LINK THIS SCHEMATIC IS FOR THE 320D2 EXCAVATOR ELECTRICAL SYSTEM
2 200-WJ2 BK-18 200-WJ2 BK-18 200-C169 BK-18 HT 418-6323 CHASSIS
CAN DATA LINK A
235-C176 BK-18
487-C19 OR-18
1
2
GROUND
SIGNAL (141) REFUELING LEVEL SWITCH ATCH
200-C169
L973-C80
BK-18
GN-16
L973-C80 GN-16
200-C169 BK-18
1
2 CONN 18 1
2
L973-AM1 GN-16
200-AM2 BK-18
1
2
(95) FINE SWING SOLENOID
2344460
PA
PC
7G-1060
132-1805
PLATFORM GND
DISCONNECT SW GROUND
CAN DATA LINK B
MEDIA NUMBER: UENR3604-02
3122645 PE 134-3355 STARTER GROUND
(130) HYDRAULIC OIL FILTER SWITCH
1733518 WE
WF
238-2280
377-8044
MAIN BREAKER-TERM. BLOCK
GLOW RELAY-TERM. BLOCK OTHER COLOR DESCRIPTIONS SCHEMATIC PART NUMBER: 388-6840, CHANGE: 04, VERSION: HE
WH
WJ
163-6758
319-1335
LAMP TIMER JUMPER
REFUELING PUMP
Components are shown installed on a fully operable machine with the key and engine off and with parking brake set.
HIGHWAYS
WK 377-8043 GLOW BREAKER GLOW RELAY
Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations.
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
PUMP ROOM COMPARTMENT RIGHT REAR
VIEW ALL CALLOUTS
60 117 100 116
87
99
86
96
153
130
79
85
111
112 110 90
108 109 91 105 106 93 107

PIVOT MOTOR FORWARD
VIEW ALL CALLOUTS
101 104 CONN 18 43 CONN 22 44
103
CONN 23
102
127
35
84
141
2
BELOW FUEL TANK
CONN 1 95
OPERATOR STATION TOP
VIEW ALL CALLOUTS
CONN 31
32
CONN 21
CONN 46
CONN 47
154
CONN 48 CONN 49
OPERATOR STATION RIGHT SIDE
VIEW ALL CALLOUTS
31 CONN 29 CONN 28 88 89 144 133 140 134 125 146
CONN 30 18 19 20 30 16 CONN 44 78 CONN 45 CONN 51 138 50 1 57 151

OPERATOR STATION REAR OF SEAT
VIEW ALL CALLOUTS
CONN 32
CONN 38
CONN 34
CONN 20 CONN 33
OPERATOR STATION MSS KEYREADER
VIEW ALL CALLOUTS
15
49
OPERATOR STATION M HARNESS CONN.
VIEW ALL CALLOUTS
CONN 50
OPERATOR STATION LEFT SIDE
VIEW ALL CALLOUTS
47 48 137 132 147 139 152 76 7 66

52
155
51 68
67
70
69
64
74
129 45 46 136 145 118 42 156 23 22 21 75 65

OPERATOR STATION BELOW
VIEW ALL CALLOUTS
126 150 120
CONN 36
40
58
41
148
36
149
17
54
CONN 35
131
CONN 40
135 128 CONN 19 CONN 39 CONN 37 CONN 42 CONN 43 CONN 41
MAIN VALVE
VIEW ALL CALLOUTS
115 121
CONN 9
97
CONN 10
98 113 114
FUELING PUMP ATCH
VIEW ALL CALLOUTS
72 73 CONN 24 CONN 25
71 24 CONN 26 CONN 27 143 142 61

ENGINE REAR
VIEW ALL CALLOUTS
59 94
122
83
82
CONN 8
CONN 7 33
CONN 6 124
ENGINE FRONT
VIEW ALL CALLOUTS
81
92
55
3
39
34
29
BATTERY COMPARTMENT
VIEW ALL CALLOUTS
CONN 2 26 27 28 62
CONN 4
CONN 5
119
53
56 80
CONN 14
CONN 13 11
CONN 3
77 10
25 8
CONN 12 CONN 11 CONN 16 CONN 15 CONN 17

DISCONNECT BOX
VIEW ALL CALLOUTS
4
63
13 6
14
5
12
123 37
38
Shutdown SIS
Previous Screen
Product: EXCAVATOR

320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i04810832
Charging System - Test

SMCS - 1406-038
Often when problems with the charging system are being investigated, the alternator is not the
problem. If a low battery condition is present, test the batteries first. See Special Instruction,
SEHS7633, "Battery Test Procedure" for more information. If the engine cranks slowly, then test the
starting system. See Service Magazine, SEPD0020, "Testing The Starter On The Engine" for more
information. If a warning indicator for the charging system is ON, see Service Magazine, SEBD1751,
"Difference Between Alternator Indicator In Electronic Monitoring System (EMS) And Low Voltage
Indicator In Operating Monitoring System (OMS)". When a problem with the charging system is
suspected, then complete the testing that is outlined in this Special Instruction.
See "Initial Troubleshooting Procedure" in order to begin troubleshooting. The procedures in this
Special Instruction are designed to guide you to the problem with as little testing as possible. In most
cases, you will only use a few of the tests to diagnose a problem. The tests are labeled as T1 - T8 for
easy reference. A descriptive title for each test is included as well.
Initial Troubleshooting Procedure

1. CHECK THE RESISTANCE IN THE EXCITATION CIRCUIT. This step is only for
alternators with external excitation when the terminal for excitation is labeled: "1", "REG" and
"D+". See "Alternator Specifications" if the method of excitation is unknown. Go to Step 3 if
your alternator is self-excited. Proceed to Step 2 if the excitation terminal of the alternator has
the label "IG".
a. Turn the key start switch to the ON position.
b. Verify voltage at the excitation terminal. Connect the red lead from a multimeter to the
excitation terminal. Connect the black lead to a ground source (alternator case ground).
c. Read the voltage that is shown on the multimeter.
Expected Result: The voltage reads at least .2 volts.
Results:
■ YES - The voltage reads .2 volts or more. The excitation circuit is correct. Proceed
to Step 3.
■ NO - The voltage is less than .2 volts. There is a failure in the wiring harness to the
alternator or there is a poor electrical connection. Correct the problem and operate
the machine. Watch for a recurrence of the problem.
2. CHECK THE RESISTANCE IN THE EXCITATION CIRCUIT (CONTINUED). This

step is only for alternators with external excitation when the terminal for excitation is labeled:
"IG". See "Alternator Specifications" if the method of excitation is unknown. Go to Step 3 if
your alternator is self-excited.
a. Turn the key start switch to the ON position.
b. Verify voltage at the excitation terminal. Connect the red lead from a multimeter to the
excitation terminal. Connect the black lead to a ground source. The case of the alternator
can be used as a good source of ground.
Note: For Denso G3B, K3A, and L3A alternators, Insert a 7X-1710 Multimeter Probe
Group into the rear of the middle wire in the connector. See figure 1 below. Insert the
probe (spoon lead) between the black seal that surrounds the wire and the outer shell of
the connector. Do not insert the probe between the wire insulation and the black seal.
This terminal (IG) is the terminal for excitation.
Special Technique Using A Wire Probe On The Denso Alternator
c. Read the voltage that is shown on the multimeter.
Expected Result: The voltage is within .5 volts of battery voltage.
Results:
■ YES - The voltage reads battery voltage. The excitation circuit is correct. Proceed
to Step 3.
■ NO - The voltage is more than .5 volts less than battery voltage. There is a failure
in the wiring harness to the alternator or there is a poor electrical connection.
Correct the problem and operate the machine. Watch for a recurrence of the
problem.
3. CHECK THE SYSTEM VOLTAGE.
a. Before starting the machine, connect a voltmeter between the "B+" terminal and the case
of the alternator. Turn OFF all electrical loads.
b. Turn the key to the ON position but do not start the engine.
Expected Result: This voltage should be system voltage.
Results:
■ YES - The voltage is system voltage. Go to Step 4
■ NO - The voltage is less than system voltage. Verify that the batteries are good and
verify that battery connections are good. Go to ""T4 Alternator Drive System -
Check"" if the batteries are good.
4. INITIAL CHECK OF THE OPERATION OF THE ALTERNATOR.
a. The voltmeter remains connected in the configuration from Step 3.
b. Start the machine. Set the throttle to at least 75 percent. Read the voltage on the
voltmeter.
Expected Result: The voltage is higher than the voltage that was recorded in the
previous Step 3.
Results:
■ YES - The voltage is higher than the voltage observed in the previous Step 3. The
voltage is also lower than the maximum voltage that is listed in the specifications
for the alternator. The alternator is partially charging. See the following diagnostic
flow chart for reference in continued testing. Proceed to ""T1 Alternator Output -
Test"".
■ YES - The voltage is higher than the voltage observed in the previous Step 3. The
voltage is also higher than the maximum voltage that is listed in the specifications
for the alternator. The alternator is over charging. Proceed to ""T8 Alternator
Overcharging - Test"".
■ NO - The voltage is not higher than the voltage observed in Step 3. Proceed to
""T4 Alternator Drive System - Check"".
Note: Severely discharged batteries can cause low system voltage. Severely discharged batteries can
occur even while the engine is running above idle, and the alternator is working properly. Proper low
engine idle is also important. Most of the alternators in Caterpillar applications are self-excited. These
alternators must exceed a turn-on speed before charging will begin. Alternator output can be low at
idle.
T1 Alternator Output - Test

1. Ensure that the batteries are NOT fully charged.
a. Fully charged batteries have open circuit voltage above 12.5 V on 12 V systems or 25 V
on 24 V systems.
b. If the batteries are fully charged, then crank the engine for 30 seconds. This action
reduces the battery voltage. Operate the lights for 10 minutes while the engine is off as an
alternative.
2. Connect the 9U-5795 Current Probe to a DMM (digital multimeter) or use a 225-8266
Ammeter Tool Gp . The multimeter must have a peak hold feature. Clamp the probe around
alternator output wire "B+". Before clamping the probe around the wire, ensure that the probe
is "zeroed" .
3. Set the digital multimeter to "peak hold" or "max mode" on the "mV" scale.
4. Turn on all electrical accessories: lights, air conditioning and radio.
5. Start the machine, and immediately set the throttle to at least 75 percent. The peak current will
appear on the voltmeter in "peak hold" or "max" mode.
Expected Result: This current reading should be at least 90 percent of the specified peak
output.
Results:
◦ OK - The current is at least 90 percent of the specified peak output. Go to ""T2a -

Undesired Electrical System Current - Test (For Machines Equipped With A Main
Disconnect Switch"" OR ""T2b - Undesired Electrical System Current - Test (For Any
Machine)"".
◦ NOT OK - The current is less than 90 percent of the specified peak output. Go to ""T4
Alternator Drive System - Check"".
T2a - Undesired Electrical System Current - Test (For

Machines Equipped With A Main Disconnect Switch)
1. Turn off all of the accessories. Turn the keyswitch to the OFF position.
2. Clamp a 9U-5795 Current Probe or 225-8266 Ammeter Tool Gp around the main ground cable.
Clamp the tool with the positive side away from the battery. Reset the probe (zero) before
clamping the probe around the wire. Read the current.
Expected Result: The current is below 2 A.
Results:
◦ YES - The current is below 2 A. Continue to Step 3.
◦ NO - The current is above 2 A. There is a current draw in the system. Go to ""T5

Alternator Current - Test"".
3. Turn the disconnect switch to the ON position. Connect a multimeter across the disconnect
switch terminals. Connect the red lead to the terminal on the frame side. Connect the black lead
to the terminal on the battery side. Use the 10A connections in order to avoid damage.
4. Turn off the disconnect switch and read the current.
Expected Result: The current is below .050 amperes (50 mA).
Note: The standard acceptable current draw is 50 mA. A current draw above 50 mA usually
indicates a problem. However, some large machines with multiple electronic control modules
have a higher acceptable limit. Contact a Caterpillar dealer for more information.
Results:
◦ YES - The current is below 0.050 A. The charging system is currently good. The fault is
possibly an intermittent draw in the system. The batteries may be faulty. Check that NO
accessories were ON during the test.
◦ NO - The current is above 0.050 A. There is a draw in the system. Go to ""T5 Alternator
Current - Test"".
T2b - Undesired Electrical System Current - Test (For Any

Machine)
1. Turn off all accessories. Turn the keyswitch to the OFF position.
clamping around the wire. Read the current.
Expected Result: The current is below 2 A.
Results:
◦ YES - The current is below 2 A. Continue to Step 3.
◦ NO - The current is above 2 A. There is a current draw in the system. Go to ""T5

Alternator Current - Test"".
3. Remove the ground cable from the battery terminal. For systems with 4 batteries, or 12 V
systems with 2 batteries, disconnect the ground cables from both negative batteries.
4. Connect a multimeter across the disconnect switch terminals. Connect the red lead to the
terminal on the frame side. Connect the black lead to the terminal on the battery side. Use the
10A connections in order to avoid damage.
Expected Result: The current is below .050 amperes (50 mA).
Note: The standard acceptable current draw is 50 mA. A current draw above 50 mA usually
indicates a problem. However, some large machines with multiple electronic control modules
have a higher acceptable limit. Contact a Caterpillar dealer for more information.
Results:
◦ YES - The current is below 0.050 A. The charging system is currently good. The fault is
possibly an intermittent draw in the system. The batteries may be faulty. Check that NO
accessories were ON during the test.
◦ NO - The current is above 0.050 A. There is a draw in the system. Go to ""T5 Alternator
Current - Test"".
Note: The following alternators have a connector for a regulator: 6T-1193 , 6T-1194 , 6T-1195 , 6T-
1196 , 9G-6079 and 9G-6081 . Disconnect the regulator connector from the alternator. Recheck the
current that was found in the previous Step. If the current is below 0.050 A (50 mA), the regulator is
faulty.
T3 Charging System - Test

1. Verify that the alternator B+ terminal nut is tight and verify that the wire has a good connection
to the B+ terminal.
2. Many Caterpillar machines are equipped with a connector for the 6V-2150 Starting/Charging
Analyzer . Use of this tester replaces the testing below. See Systems Operation, SENR2947,
"Starting and Charging Systems".
3. Start the engine and set the throttle to at least 75 percent. Turn ON all electrical accessories for
all test steps below. Allow the engine to run for at least 3 minutes before continuing to Step 4.
The following table will assist in making calculations during this test.
Table 1
Test Step Voltage Voltage should be below this Voltage should be below this
Reading for 12 V system for 24 V system
4
5
4 minus 5 1.0 V 2.0 V
=
6
7
6 minus 7 0.5 V 1.0 V
=
8 0.5 V 1.0 V
4. Measure the voltage between the alternator B+ terminal and the alternator case ground.
5. Measure the voltage across the battery. Put the red lead on the + battery terminal, and put the
black lead on the negative battery terminal. Step 5 should be completed as quickly as possible
after Step 4.
Expected Result: The voltage is less than the voltage or the voltage is equal to the voltage that
was recorded in Step 4 for a 12 V system. However, the voltage is within 1 V. On 24 V
systems, the voltage is within 2 V.
Results:
◦ YES - If the voltage in Step 4 is not more than 1 V for 12 V systems (2 V for 24 V
systems) higher than the voltage in Step 5, this test is complete and the related wiring is
correct at this time. Replace the alternator or disassemble the alternator and repair.
◦ NO - If the voltage in Step 4 is more than 1 V for 12 V systems (2 V for 24 V systems)

higher than the voltage in Step 5, there is high circuit resistance: corrosion, loose
connections and damaged wiring. Continue to Step 6.
6. Check the voltage between the machine frame and the alternator B+ terminal. Record the
voltage.
7. Check the voltage between the machine frame and the + battery post. Step 7 should be
completed as quickly as possible after Step 6.
Expected Result: The voltage difference between Step 6 and Step 7 does not exceed 1 V on 24
V systems or 0.5 V on 12 V systems.
Results:
◦ YES - The voltage difference does not exceed the tolerance. The charging circuit is good.
Go to Step 8.
◦ NO - The voltage difference exceeds the tolerance. There is high resistance in the
charging circuit: loose cables, corroded cables, damaged cables and faulty circuit breaker.
Correct the problem and retest the system.
8. Check the voltage between the negative battery post and the alternator case ground.
Expected Result: The voltage does not exceed 1 V on 24 V systems or 0.5 V on 12 V systems.
Results:
◦ YES - The voltage difference does not exceed the tolerance. The ground circuit is good.
There is an internal problem with the alternator. Go to ""T6 Residual Magnetism
Restoration"".
◦ NO - The voltage difference exceeds the tolerance. There is high resistance in the ground
circuit: loose cables, corroded cables, loose alternator mounting and poor engine ground.
Correct the problem and retest the system.
T4 Alternator Drive System - Check

1. Check the condition of the alternator drive belt. If the drive belt is oily, clean the pulleys.
Replace the drive belt, and retest the system. If the drive belt is wet, dry the belt and retest the
system. If the drive belt is worn, replace the belt and retest the system.
2. Check the tension of the alternator drive belt. If the tension is off, adjust the tension.
3. Check the nut on the alternator pulley. If the nut is loose, tighten the nut and retest the system.
4. If all of the previous steps find no problems, go to ""T3 Charging System - Test"".
T5 Alternator Current - Test

1. Turn the keyswitch to the OFF position.
2. Connect the 9U-5795 Current Probe to a DMM (digital multimeter) or use a 225-8266
Ammeter Tool Gp . Clamp the probe around the alternator output wire ("B+"). Before clamping
the probe around the wire, ensure that the probe is "zeroed" .
3. Read the current.
Expected Result: The current is under 2 A.
Results:
◦ YES - The current is under 2 A. Continue to Step 4.
◦ NO - The current is over 2 A. There is an internal problem with the alternator. Go to ""T6
Residual Magnetism Restoration"".
4. Disconnect the B+ terminal wire from the alternator. Connect the red lead of the multimeter to
the wire that was disconnected. Connect the black lead of the multimeter to the B+ terminal of
the alternator. Set the multimeter on the 10 amp scale. Read the current.
Expected Result: The current is under 0.015 A.
Results:
◦ YES - The current is under 0.015 A. The alternator is operating correctly. There is a
current draw on the machine. Go to ""T7 Identifying Source Of Current Draw - Test"".
◦ NO - The current is greater than 0.015 A. There is an internal problem with the
alternator. Go to ""T6 Residual Magnetism Restoration"".
T6 Residual Magnetism Restoration

This test is only for self-excited alternators. See Service Magazine, SEBD1672 July 1986, "Brushless
Alternators May Not Charge In Certain Conditions" for additional information.
1. Start the engine and set the throttle to at least 75 percent.
2. Connect a voltmeter between the "B+" terminal and the alternator case ground.
3. If a wire is connected, disconnect the wire from the "R" terminal.
Expected Result: The voltage remains unchanged.
Results:
◦ YES - The voltage stays the same. Continue to Step 4.
◦ NO - The voltage rises and the alternator begins charging. The wire to the "R" terminal is
shorted. Repair the wiring or replace the wiring. Go to "Initial Troubleshooting
Procedure" and retest the system.
4. Connect one end of a jumper wire to the "B+" terminal of the alternator.
5. Connect the other end of the jumper wire to the "R" terminal ("D+" terminal for Bosch) of the
alternator for 2 seconds.
Expected Result: The voltage output rises on the "B+" terminal.
Results:
◦ OK - The voltage output rises. The alternator is now charging. Go to "Initial

Troubleshooting Procedure" and retest the system.
◦ NOT OK - The voltage output does not rise. Proceed to Step 6, if the alternator has a wire
that is connected to the "I" terminal. Disassemble the alternator and repair the alternator.
Replace the alternator if the alternator cannot be repaired.
6. Remove the wire that is connected to the "I" terminal. Check for a rise in voltage on the "B+"
terminal.
Expected Result: The voltage rises.
Results:
◦ YES - The voltage rises. There is a short in the wiring to the terminal. Repair the wiring
or replace the wiring. Go to "Initial Troubleshooting Procedure" and retest the system.
◦ NOT OK - The voltage output does not rise. Disassemble the alternator and repair the
alternator. Replace the alternator if the alternator cannot be repaired.
T7 Identifying Source Of Current Draw - Test

1. Make sure that every electrical component is turned OFF. Make sure that the keyswitch is
turned OFF. Make sure that the dome lights are OFF.
clamping the probe around the wire. Use the current probe if the draw is above approximately 2
A. Use the Ammeter if the draw is below approximately 2 A.
3. Monitor the current and remove fuses and breakers one at a time. Check the current after each
fuse (breaker) is removed. After removing a fuse (breaker) and observing the current, reinstall
the fuse (breaker). Start with the main fuses (circuit breakers) first, and proceed to smaller
circuits.
4. If a removal of a fuse causes the current to drop, then the problem is in that circuit.
a. Check if any components on the circuit are ON.
b. If everything is OFF, disconnect electrical components on that circuit one at a time and
monitor current.
c. After all of the components in that circuit have been disconnected, check the current. If
the problem still exists, then check the wiring for corrosion or shorts to ground.
Note: The standard acceptable current draw is 50 mA. A current draw above 50 mA usually indicates
a problem. However, some large machines with multiple electronic control modules have a higher
acceptable limit. Contact a Caterpillar dealer for more information.
T8a - Alternator Overcharging - Test

This test should be used on alternators that have an "IG", a "S" or some other sensing terminal.
1. Clean the connection and tighten the connection to the wiring terminal on the alternator.
2. Verify that the alternator B+ terminal nut is tight and verify that the wire has a good connection
to the "B+" terminal.
Analyzer . See Systems Operation, SENR2947, "Starting and Charging Systems". Use of this
analyzer replaces the testing below through Step 8. Therefore, if the testing is good, go to Step
9. If the analyzer finds a problem, correct the problem and retest the system. Go to "Initial
Troubleshooting Procedure".
4. Start the engine and set the throttle to at least 75 percent. Turn ON all electrical accessories for
all test steps below. Allow the engine to run for at least 3 minutes before continuing to Step 5.
The following table will assist in making calculations during this test.
Table 2
5
6
5 minus 6 1.0 V 2.0 V
=
7
8
7 minus 8 0.5 V 1.0 V
=
5. Measure the voltage between the "B+" terminal of the alternator and the case of the alternator.
after Step 5.
Expected Result: The voltage is within 1 V of the voltage that is recorded in Step 5 for 12 V
systems. The voltage is within 2 V for 24 V systems.
Results:
systems) higher than the voltage in Step 6, this step is complete and the related wiring is
correct at this time. Go to Step 9.

connections and damaged wiring. Go to Step 7.
7. Check the voltage between the machine frame and the alternator B+ terminal. Record the
voltage.
Results:
Go to Step 9.
◦ NO - The voltage difference exceeds the tolerance. There is high resistance in the
charging circuit: loose cables, corroded cables, damaged cables, faulty circuit breaker and
faulty main relay. Correct the problem. Go to "Initial Troubleshooting Procedure" and
retest the system.
9. Start the engine and set the throttle to at least 75 percent. Turn OFF all of the accessories.
Special Technique Using A Wire Probe For The Denso Alternator
Note: The following information is used only for the Denso G3B, K3A, and L3A alternators:
Insert a 7X-1710 Multimeter Probe Group into the rear of the middle wire in the connector. See
figure 3. Insert the probe (spoon lead) between the black seal that surrounds the wire and the
outer shell of the connector. Do not insert the probe between the wire insulation and the black
seal. This terminal ("IG") is the terminal for excitation.
10. Measure the voltage between the sense terminal and the case of the alternator.
Expected Result: The voltage at the sense terminal is above the specification.
Results:
◦ YES - The voltage is over specification. There is an internal malfunction in the alternator.
See the appropriate service manual for the alternator in order to test the internal
components and connections.
◦ NO - The voltage is below that found in the initial tests (B+ to alternator case). The sense
circuit in the machine has high resistance. Correct the problem and retest the system . Go
to "Initial Troubleshooting Procedure".
T8b - Alternator Overcharging - Test (Continued)

This test is used for alternators that do not have an "IG", "S" or some other sense terminal.
1. Clean the connection and tighten the connection to the wiring terminal on the alternator.
2. Verify that the nut on the "B+" terminal of the alternator is tight. Verify that the wire has a
good connection to the "B+" terminal.
Analyzer . See Systems Operation, SENR2947, "Starting and Charging Systems". Use of this
analyzer replaces the testing below. If the analyzer finds a problem, correct the problem and
retest the system. Go to "Initial Troubleshooting Procedure".
4. Run the engine at 75 percent. Turn ON all electrical accessories for all test steps below. Allow
the engine to run for at least 3 minutes before continuing to Step 5. The following table
describes the measurements that are taken during this test.
Table 3
5
6
5 minus 6 1.0 V 2.0 V
=
7
8
7 minus 8 0.5 V 1.0 V
=
5. Measure the voltage between the "B+" terminal of the alternator and the case of the alternator.
after Step 5.
Expected Result: The voltage is within 1 V of the voltage that was recorded in Step 5 for 12 V
systems. The voltage is within 2 V for 24 V systems.
Results:
systems) higher than the voltage in Step 6, this step is complete and the related wiring is
correct at this time. There is an internal malfunction in the alternator. See the appropriate
service manual for the alternator in order to test the internal components and connections.

connections and damaged wiring. Go to Step 7.
7. Check the voltage between the machine frame and the "B+" terminal of the alternator. Record
the voltage.
Results:
There is an internal malfunction in the alternator. See the appropriate service manual for
the alternator in order to test the internal components and connections.
◦ NO - The difference in the voltage exceeds the tolerance. There is high resistance in the
charging circuit: loose cables, corroded cables, damaged cables, failed circuit breaker and
failed main relay. Correct the problem. Go to "Initial Troubleshooting Procedure" and
retest the system.
Specifications For Alternators

Table 4
Specifications For Alternators
Peak Current Minimum Peak
Rating (Amps) Current (Amps)
12 V Alternators
8C-5535 32 28
7N-4784 , OR-5201 40 36
6T-1396 , 7T-2096 , 8C-5908 , OR-3654 51 46
9W-2648 , 9W-2949 , 8T-9700 , 105-2811 (IG), OR-4327 55 49
(IG), 105-2812 (IG), OR-9273 (IG), 34-3268 , 68-4139 ,
3E-7295 (D+), 7T-2876 (D+), 100-8223
7G-7889 60 54
8C-5510 (I), OR5200 61 55
8N-2268 75 68
3E-7892 , OR-3616 85 77
105-2813 (IG), OR-9274 (IG), 105-2814 (IG), OR-4328 90 81
(IG), 149-2064 (REG), OR-9410 (REG), 9X-0341 (D+)
8C-6163 , OR-1699 , 107-2519 105 95
167-7816 110 99
9X-6796 , 9X-9096 , 121-4134 , 121-4136 , OR-3527 115 104

3E-8827 , 121-4135 , 117-1379 (I) 130 117
152-8746 135 122
125-9597 , OR-8332 145 131
24 V Alternators
2P-1204 , 3Y-8200 19 17
2Y-8310 21 19
6T-1395 , 7T-2095 , OR-3653 33 30
6N-9294 , OR-5217 , OR-3482 35 32
5N-5692 , OR-2698 45 41
5S-9088 , 100-5047 , 112-5041 , 3E-7578 , OR-5206 , OR 50 45
-3667 , OR-3668
109-2362 , 9W-3043 55 50
, OR-3652 (D+), 112-8032
3E-7772 (IG), OR-9437 (IG), 105-3132 (IG), 4N-3986 , 60 54
OR-5203
155-7434 , 132-2156 (I), 107-7977 (I), OR-8279 (I) 70 63
169-4319 , 167-7812 75 67.5
107-7976 , 114-2401 , OR-8997 , 3E-7577 , OR-3615 75 68
165-5140 100 90
9X-7803 , OR-3749 100 90
Parts-Service Only Discontinued 12 V Alternators
6T-1193 18 16
7N-6118 , 6N-5460 , 4N-4540 40 36
6T-1195 42 38
7X-1340 45 41
9G-6079 , 6T-1194 63 57
Parts-Service Only Discontinued 24 V Alternators
9G-6081 , 6T-1196 40 36
D+ - Diode trio output. Alternator requires external excitation.

REG - Regulator Terminal. Alternator requires external excitation.
I - Ignition Terminal. Alternator can be externally excited through this terminal.
IG - Ignition Terminal. System voltage must be supplied to this terminal to turn on the alternator.
Some of these alternators use the IG terminal as a sense terminal.
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Specifications
i05942752
Check Valve (Return Lines)

SMCS - 5067
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KHR1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PJP1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Table 1
Specification for 369-8420 Check Valve Gp
Apply Threebond 1305N.
1 - -
Torque to 35 ± 5 N·m (26 ± 4 lb ft).
Tighten plug to
2 1 -
150 ± 15 N·m (111 ± 11 lb ft).
Torque to
3 1 9S-6130 Plug
150 ± 15 N·m (111 ± 11 lb ft).
When check valve group is installed, use washer.
4 - - Tighten mounting bolt to
50 ± 10 N·m (37 ± 7 lb ft).
Apply Threebond 1305N.
5 - - Torque to
9 ± 1 N·m (80 ± 9 lb in).
Apply Threebond 1305N to threads.

6 - - Tighten nut to
16 ± 2 N·m (142 ± 18 lb in).
Torque to
7 1 190-7826 Plug
150 ± 15 N·m (111 ± 11 lb ft).
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i04046710
Compression - Test
SMCS - 1215
The cylinder compression test should only be used in order to compare the cylinders of an engine. If
one or more cylinders vary by more than 350 kPa (51 psi), the cylinder and related components may
need to be repaired.
A compression test should not be the only method which is used to determine the condition of an
engine. Other tests should also be conducted in order to determine if the adjustment or the
replacement of components is required.
Before the performance of the compression test, make sure that the following conditions exist:
• The battery is in good condition.
• The battery is fully charged.
• The starting motor operates correctly.
• The valve lash is set correctly.
• All glow plugs are removed.
• The fuel supply is disconnected.
Typical example
1. Remove the glow plug (1). Refer to Disassembly and Assembly, "Glow Plugs - Remove and
Install" for the correct procedure.
2. Install a suitable gauge for measuring the cylinder compression in the hole for the glow plug.
3. Remove the fuse for the glow plugs.
4. Operate the starting motor in order to turn the engine. Record the maximum pressure which is
indicated on the compression gauge.
5. Repeat Steps 6 and 4 for all cylinders.
6. Install the fuse for the glow plugs.
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i04046797
Connecting Rod - Inspect

SMCS - 1218-040
These procedures determine the following characteristics of the connecting rod:
• The length of the connecting rod
• The distortion of the connecting rod
• The parallel alignment of the bores of the connecting rod
Note: If the crankshaft or the cylinder block are replaced, the piston height for all cylinders must be
measured. The grade of length of the connecting rods may need to be changed in order to obtain the
correct piston height.
If the grade of length must be changed, one of the following actions must be taken:
• New connecting rod assemblies that are the correct grade of length must be installed. Refer to
"Length Of The Connecting Rod".
• New piston pin bearings must be bored after installation in the original connecting rods. Refer
to "Piston Pin Bearings".
Note: When the piston pin is installed, always install new retaining rings on each end of the piston
pin. If the piston pin cannot be removed by hand, heat the piston to a temperature of 45° ± 5 °C (113°
± 9 °F) in order to aid the removal of the piston pin. Heating the piston to this temperature may also
aid the installation of the piston pin.
Length of The Connecting Rod

The connecting rod length (CRL) is the length of the connecting rod. Refer to Table 1 for each grade
of length of connecting rod.
In order to ensure that the piston height above the cylinder block is correct, three grades of connecting
rods "R" to "B" are used during manufacture at the factory. Replacement connecting rods are
available in three grades. These grades of connecting rod are "R" to "B". The grade of length is
identified by a letter or a color which is marked on the side of the connecting rod. The longest grade
is marked with the letter "R". The shortest grade is marked with the letter "B". The difference in
length between each grade of connecting rods is the following value: 0.076 mm (0.0030 inch)
The grade of length of a connecting rod is determined in the factory by machining an eccentric hole in
a semi-finished piston pin bushing. Therefore, the grade of length is determined by the position of the
center of the hole in the piston pin bearing.
If the connecting rod must be replaced, a new connecting rod assembly must be purchased and
installed. Refer to Table 1 for more information.
A new piston pin bearing is installed in the new connecting rod at the factory. The bore of the piston
pin bearing is reamed to the correct eccentricity.
Piston Pin Bearings

Note: This procedure requires personnel with the correct training and the use of specialized
equipment for machining.
If the piston pin bearing requires replacement but the original connecting rod is not replaced, the
following procedures must be performed:
1. Determine the grade of length of the connecting rod. Use one of the following characteristics:
◦ The mark
◦ The color
◦ Measuring the length
2. Ensure that the connecting rod is aligned parallel and that the connecting rod is not distorted.
Refer to "Distortion Of A Connecting Rod" in this service module.
3. Remove the piston pin bearing from the connecting rod. Install a new bearing in the connecting
rod. The new bearing is partially finished. The new bearing must be bored off-center to the
correct diameter. This off-center position is determined by the grade of length of the connecting
rod. Refer to Table 1. The correct diameter of the bore in the piston pin bearing is given in
Specifications, "Connecting Rod".
Surface finish of the bored hole in the piston pin bearing ... Ra 0.8 micrometers
4. Machine the ends of the piston pin bearing to the correct length. Remove any sharp edges.
Refer to Specifications, "Connecting Rod".
5. If the grade of length of the connecting rod is changed, the letter that is stamped on the
connecting rod must be removed. Etch a letter that is for the new grade of length on the side of
the connecting rod.
Note: Do not stamp a new letter on the connecting rod. The force of stamping may damage the
connecting rod.
Table 1 references the following information: Grade of letter of the connecting rod, the color code of
the connecting rods and the lengths of the connecting rods.
Table 1
Length Grades for Connecting Rods
Grade Letter Color Code Length Of The Connecting Rod (CRL)
R Red
161.259 to 161.292 mm (6.3488 to 6.3501 inch)
G Green
161.183 to 161.216 mm (6.3458 to 6.3471 inch)
B Blue
161.107 to 161.140 mm (6.3428 to 6.3441 inch)
Measure The Length Of The Connecting Rod

If the mark or the color of the grade of length cannot be observed on the connecting rod, perform the
following procedure:
Measure the length of the connecting rod.
(1) Measuring pins
(2) Connecting rod
(CRL) Connecting Rod Length
1. Refer to Illustration 1. Use the following tools in order to measure the length of the connecting
rod:
◦ Appropriate gauges for measuring distance
◦ Measuring pins (1)
2. Ensure that the measuring pins (1) are parallel. "CRL" is measured when the bearing for the
crankshaft journal is removed and the original piston pin bearing is installed.
Measure "CRL". Compare the "CRL" that is given in Table 1. The grade of length of the
connecting rod is determined by the "CRL". Refer to Table 1 for the correct grade of length.
Distortion of The Connecting Rod

1. Use the following tools in order to measure the distances for the connecting rod (2) which are
specified in Illustration 1:
◦ Appropriate gauges for measuring distance
◦ Measuring pins (1)
Measure the connecting rod for distortion.
(1) Measuring pins
(2) Connecting rod
(L) The length between the centers of the piston pin bearing and the crankshaft journal bearing is shown in
Illustration 2.
2. Measure the connecting rod for distortion and parallel alignment between the bores.
The bores for the crankshaft bearing and the bearing for the piston pin must be square and
parallel with each other within the required limits. If the piston pin bearing is removed, the limit
"L" is the following value: ± 0.25 mm (± 0.010 inch)
The limits are measured at a distance of 127 mm (5.0 inch) from each side of the connecting
rod.
If the piston pin bearing is not removed, the limit "L" is the following value: ± 0.06 mm (±
0.0024 inch)
L is equal to 219.08 ± 0.03 mm (8.625 ± 0.001 inch).
3. Inspect the piston pin bearing and the piston pin for wear.
4. Measure the clearance of the piston pin in the piston pin bearing. Refer to the Specifications,
"Connecting Rod" for dimensions.
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Specifications
i04047908
Connecting Rod Bearing Journal

SMCS - 1202; 1219; 1225
S/N - -
The original size of the connecting rod bearing journal on the crankshaft ... 71.970 to 71.990 mm
(2.83346 to 2.83425 inch)
Maximum permissible wear of a bearing journal on the crankshaft when a new connecting rod is
installed ... 0.04 mm (0.0016 inch)
Width of the connecting rod bearing journals on the crankshaft ... 37.962 to 38.038 mm (1.4946 to
1.4976 inch)
Radius of the fillet of the connecting rod bearing journals ... 3.68 to 3.96 mm (0.145 to 0.156 inch)
Surface finish of connecting rod bearing journals ... Ra 0.2 microns
Surface finish of radii ... Ra 0.4 microns
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Specifications
i04048757
Connecting Rod
SMCS - 1218
S/N - -
Typical example
(1) The bearing shell for the connecting rod
Table 1
Thickness of Connecting Rod Bearing at the Center 1.994 to 2 mm (0.0785 to 0.0787

inch)
Thickness of Connecting Rod Bearing for the Cap at

1.994 to 2 mm (0.0785 to 0.0787
the Center
inch)
Bearing Clearance 0.025 to 0.070 mm (0.0010 to 0.0028

inch)
Table 2
Undersized Connecting Rod Bearing
0.25 mm (0.010 inch)
0.51 mm (0.020 inch)
0.76 mm (0.030 inch)
The mating surfaces of the connecting rod are produced by hydraulically fracturing the forged
connecting rod.
Tighten the setscrews for the connecting rod again to the following torque. ... 40 N·m (30 lb ft)
Tighten the setscrews for the connecting rod for an additional 120 degrees. The setscrews for the
connecting rod (2) must be replaced after this procedure.
Note: Always tighten the connecting rod cap to the connecting rod, when the assembly is out of the
engine. Tighten the assembly to the following torque 20 N·m (14 lb ft).
Typical example
(3) Diameter of the finished bore for the piston pin ... 39.738 to 39.723 mm (1.5645 to 1.5639 inch)
(4) Distance between the parent bores ... 219.05 to 219.1 mm (8.6240 to 8.6260 inch)
(5) Diameter for the finished bore for the connecting rod bearing ... 72.025 to 72.05 mm (2.8356 to
2.8366 inch)
Connecting rods are color coded. The color code is a reference for the length (Y) of the connecting
rod. Refer to table 3 for the different lengths of connecting rods.
Table 3
Length Grades for Connecting Rods
Grade Letter Color Code Length (Y)
R Red
161.259 to 161.292 mm (6.3488 to 6.3501 inch)
G Green
161.183 to 161.216 mm (6.3458 to 6.3471 inch)
B Blue
161.107 to 161.140 mm (6.3428 to 6.3441 inch)
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Specifications
i04574415
Control Manifold (Pilot Oil)

SMCS - 5059-M9; 5264
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - RAR1-UP
S/N - SDC1-UP
S/N - SDZ1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 239-8697 Control Manifold Gp
Item Qty
121-1491 Solenoid Valve Lubricate bore lightly with the lubricant that is
1 3
Gp being sealed.
Torque to
2 6 225-4818 Plug As
5.0 ± 1.5 N·m (44.3 ± 13.3 lb in).
Torque to
3 4 9S-8005 O-Ring Plug
50 ± 7 N·m (37 ± 5 lb ft).
Torque to
4 6 7I-2272 Bolt
4.0 ± 0.4 N·m (35.4 ± 3.5 lb in).
Length under test force is
18 mm (0.7 inch).
Test force is
5 1 197-0199 Spring
1.165 ± 0.060 N (0.262 ± 0.013 lb).
Free length after test is
19.600 mm (0.7717 inch).
22.5 mm (0.89 inch).
Test force is
6 1 197-0273 Spring
39.017 ± 1.950 N (8.771 ± 0.438 lb).
36.000 mm (1.4173 inch).
Torque to
25 ± 5 N·m (221 ± 44 lb in).
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Specifications
i04372690
Control Manifold (Pilot Oil)

SMCS - 5059-M9; 5264
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TMF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
239-8697 Control Manifold Gp
Table 1
Item Qty
1 6 225-4818 Plug As Torque to 5.0 ± 1.5 N·m (44.3 ± 13.3 lb in).

Torque to
2 6 7I-2272 Bolt
4.0 ± 0.4 N·m (35.4 ± 3.5 lb in).
Torque to
3 3 114-0623 Nut
7.4 ± 0.5 N·m (65.5 ± 4.4 lb in).
121-1491 Solenoid Valve Lubricate the bores lightly with the lubricant that is
4 3
Gp being sealed.
Torque to
50 ± 7 N·m (37 ± 5 lb ft).
Torque to
25 ± 5 N·m (221 ± 44 lb in).
18.0 mm (0.71 inch).
Test force is
7 1 197-0199 Spring
1.165 ± 0.060 N (0.2619 ± 0.0135 lb).
19.6 mm (0.77 inch).
22.5 mm (0.89 inch).
Test force is
8 1 197-0273 Spring
39.017 ± 1.950 N (8.7714 ± 0.4384 lb).
36.0 mm (1.42 inch).
239-8998 Control Manifold Gp
Table 2
Item Qty
Torque to
9 6 7I-2272 Bolt
4.0 ± 0.4 N·m (35.4 ± 3.5 lb in).
Torque to
10 3 114-0623 Nut
7.4 ± 0.5 N·m (65.5 ± 4.4 lb in).
121-1491 Solenoid Valve Lubricate the bores lightly with the lubricant that is
11 3
Gp being sealed.
18.0 mm (0.71 inch).
Test force is
12 1 197-0199 Spring
1.165 ± 0.060 N (0.2619 ± 0.0135 lb).
19.6 mm (0.77 inch).

22.5 mm (0.89 inch).
Test force is
13 1 197-0273 Spring
39.017 ± 1.950 N (8.7714 ± 0.4384 lb).
36.0 mm (1.42 inch).
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i02419296
Cooling System - Check

SMCS - 1350-535
Engine And Cooling System Heat Problems

1. The following conditions indicate that a heat problem exists.
a. Hot coolant is released through the pressure cap during the normal operation of the
engine. Hot coolant can also be released when the engine is stopped.
b. Hot coolant is released from the coolant system but not through the pressure cap during
normal operation of the engine. Hot coolant can also be released when the engine is
stopped.
c. Coolant must be added frequently to the cooling system. The coolant is not released
through the pressure cap or through an outside leak.
2. If any of the conditions in Step 1 exist, perform the following procedures:
a. Run the engine at medium idle, which is approximately 1200 rpm, for three minutes after
the high idle shuts off. Running the engine at medium idle will allow the engine to cool
before the engine is stopped.
b. Inspect the poly v-belt for wear or for damage. If necessary, replace the poly v-belt. Refer
to Disassembly and Assembly Manual, "Alternator Belt - Remove and Install" for the
correct procedure.
3. Refer to "Visual Inspection Of The Cooling System" in order to determine if a leak exists in the
cooling system.
a. Refer to "Testing The Radiator And Cooling System For Leaks" procedures.
4. If the coolant does not flow through the radiator and through other components of the cooling
system, perform the following procedures.
a. Perform the "Testing The Water Temperature Regulator " procedures.
b. Clean the radiator and other components with hot water or steam at low pressure.
Detergent in the water may also be used. Compressed air may be used to remove
materials from the cooling system. Identify the cause of the restriction before you choose
the method for cleaning.
c. Straighten any fins of the radiator if the fins are bent.
5. Check the high idle of the engine. The engine may overheat if the high idle rpm is set too high.
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i05182965
Cooling System - Inspect

SMCS - 1350-040
Introduction
This engine has a pressure type cooling system. A pressure type cooling system gives two advantages:
• The pressure type cooling system can operate safely at a higher temperature than the boiling
point of water at a range of atmospheric pressures.
• The pressure type cooling system prevents cavitation in the water pump.
Cavitation is the sudden generation of low-pressure bubbles in liquids by mechanical forces. The
generation of an air or steam pocket is much more difficult in a pressure type cooling system.
Regular inspections of the cooling system should be made in order to identify problems before
damage can occur. Visually inspect the cooling system before tests are made with the test equipment.
Inspection Procedure
Visual Inspection Of The Cooling System
1. Check the coolant level in the cooling system.
2. Look for leaks in the system.
Note: A small amount of coolant leakage across the surface of the water pump seals is normal.
This leakage is required in order to provide lubrication for this type of seal. A hole is provided
in the water pump housing in order to allow this coolant/seal lubricant to drain from the pump
housing. Intermittent leakage of small amounts of coolant from this hole is not an indication of
water pump seal failure.
3. Inspect the radiator for bent fins and other restriction to the flow of air through the radiator.
4. Inspect the drive belt for the fan.
5. Inspect the blades of the fan for damage.
6. Look for air or combustion gas in the cooling system.
7. Inspect the radiator cap for damage. The sealing surface must be clean.
8. Look for large amounts of dirt in the radiator core. Look for large amounts of dirt on the
engine.
9. Shrouds that are loose or missing cause poor air flow for cooling.
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i02414661
Cooling System - Test

SMCS - 1350-040; 1350-081
Remember that temperature and pressure work together. When a diagnosis is made of a cooling
system problem, temperature and pressure must be checked. The cooling system pressure will have an
effect on the cooling system temperature. For an example, refer to Illustration 1. This will show the
effect of pressure on the boiling point (steam) of water. This will also show the effect of height above
sea level.
Cooling system pressure at specific altitudes and boiling points of water
Personal injury can result from hot coolant, steam and alkali.
At operating temperature, engine coolant is hot and under pressure.

The radiator and all lines to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove filler cap slowly to relieve pressure only when engine is stopped
and radiator cap is cool enough to touch with your bare hand.
The coolant level must be to the correct level in order to check the coolant system. The engine must
be cold and the engine must not be running.
After the engine is cool, loosen the pressure cap in order to relieve the pressure out of the cooling
system. Then remove the pressure cap.
The level of the coolant should not be more than 13 mm (0.5 inch) from the bottom of the filler pipe.
If the cooling system is equipped with a sight glass, the coolant should be to the correct level in the
sight glass.
Making the Correct Antifreeze Mixtures

Do not add pure antifreeze to the cooling system in order to adjust the concentration of antifreeze.
Refer to Operation and Maintenance Manual, "Refill Capacities" for the correct procedure. The pure
antifreeze increases the concentration of antifreeze in the cooling system. The increased concentration
increases the concentration of dissolved solids and undissolved chemical inhibitors in the cooling
system.
The antifreeze mixture must consist of equal quantities of antifreeze and clean soft water. The
corrosion inhibitor in the antifreeze will be diluted if a concentration of less than 50% of antifreeze is
used. Concentrations of more than 50% of antifreeze may have the adverse effect on the performance
of the coolant.
Checking the Filler Cap

One cause for a pressure loss in the cooling system can be a faulty seal on the radiator pressure cap.
Typical schematic of filler cap
(1) Sealing surface between the pressure cap and the radiator

To check for the amount of pressure that opens the filler cap, use the following procedure:
1. After the engine cools, carefully loosen the filler cap. Slowly release the pressure from the
cooling system. Then, remove the filler cap.
2. Carefully inspect the filler cap. Look for any damage to the seals and to the sealing surface.
Inspect the following components for any foreign substances:
◦ Filler cap
◦ Seal
◦ Surface for seal
Remove any deposits that are found on these items, and remove any material that is found on
these items.
3. Install the pressure cap onto a suitable pressurizing Pump.
4. Observe the exact pressure that opens the filler cap.
5. Compare the pressure to the pressure rating that is found on the top of the filler cap.
6. If the filler cap is damaged, replace the filler cap.
Testing The Radiator And Cooling System For Leaks

Use the following procedure to test the radiator and the cooling system for leaks.

1. When the engine has cooled, loosen the filler cap to the first stop. Allow the pressure to release
from the cooling system. Then remove the filler cap.
2. Make sure that the coolant covers the top of the radiator core.
3. Put a suitable pressurizing Pump onto the radiator.
4. Use the pressurizing pump to increase the pressure to an amount of 20 kPa (3 psi) more than the
operating pressure of the filler cap.
5. Check the radiator for leakage on the outside.
6. Check all connections and hoses of the cooling system for leaks.
The radiator and the cooling system do not have leakage if all of the following conditions exist:
◦ You do NOT observe any leakage after five minutes.
◦ The dial indicator remains constant beyond five minutes.
The inside of the cooling system has leakage only if the following conditions exist:
◦ The reading on the gauge goes down.
◦ You do NOT observe any outside leakage.
Make any repairs, as required.
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Specifications
i04048911
Crankcase Breather
SMCS - 1317
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - KBS1-UP
S/N - KHR1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Unfiltered Breather
Typical example
Align the outlet of the breather to the flexible pipe.
(1) Clamp
Tighten the clamp to the following torque. ... 5 N·m (44 lb in)
Filtered Breather
Typical example
(1) Clamps
Tighten the clamps to the following torque. ... 5 N·m (44 lb in)
(2) Setscrews
Tighten the setscrews to the following torque. ... 22 N·m (16 lb ft)
(3) Canister
Tighten the canister to the following torque. ... 12 N·m (106 lb in)
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Specifications
i02934550
Crankshaft Seals
SMCS - 1160; 1161
S/N - -
Typical example
(1) Crankshaft
(2) Crankshaft seal
(3) Plastic sleeve
(4) Alignment tool
(5) Tighten bolts 1, 2, 3, 4, 5, 6, 7, and 10 in the sequence that is shown in Illustration 2 to the
following torque. ... 22 N·m (16 lb ft)
Remove the alignment tool.
Tighten bolts 8 and 9 in the sequence that is shown in Illustration 2 to the following torque. ... 22 N·m
(16 lb ft)
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Specifications
i04048918
Crankshaft
SMCS - 1202
S/N - -
Typical example
(1) Crankshaft gear
(2) Crankshaft
(3) Crankshaft thrust washers
Maximum permissible temperature of the gear for installation on the crankshaft ... 180 °C (356 °F)
The end play of a new crankshaft ... 0.1 to 0.41 mm (0.00394 to 0.01614 inch)
Standard thickness of thrust washer ... 2.69 to 2.75 mm (0.1059 to 0.1083 inch)
Oversize thickness of thrust washer ... 2.89 to 2.95 mm (0.1138 to 0.1161 inch)
(4) Journal #1
(5) Journal #2
(6) Journal #3
(7) Journal #4
(8) Journal #5
(9) Journal #6
(10) Journal # 7
Refer to table 1 for the run out of the crankshaft journals.
Table 1
Journal Run Out of the Journals
(1) Mounting
(2)
0.05 mm (0.0020 inch)
(3)
0.1 mm (0.0039 inch)
(4)
0.15 mm (0.0059 inch)
(5)
0.1 mm (0.0039 inch)
(6)
0.05 mm (0.0020 inch)
(7) Mounting
Inspect the crankshaft for wear or for damage. For more information regarding the servicing of the
crankshaft, contact the Dealer Solution Network (DSN).
Refer to Specifications, "Connecting Rod Bearing Journal" for more information on the connecting
rod bearing journals and connecting rod bearings.
Refer to Specifications, "Main Bearing Journal" for information on the main bearing journals and for
information on the main bearings.
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Specifications
i04047872
Cylinder Block
SMCS - 1201
S/N - -
Typical example
(1) Cylinder block
(2) Cylinder bore ... 105.000 to 105.025 mm (4.1338 to 4.1348 inch)
The maximum permissible wear for the cylinder bore ... 0.15 mm (0.0059 inch)
(3) Camshaft bearings
Diameter of the bushing in the cylinder block for the number 1 camshaft bearing ... 55.563 to
55.593 mm (2.1875 to 2.1887 inch)
Diameter of the bore in the cylinder block for the number 2 camshaft journal ... 50.546 to
50.597 mm (1.9900 to 1.9920 inch)
50.343 mm (1.9800 to 1.9820 inch)
50.089 mm (1.9700 to 1.9720 inch)
(4) Main bearings
Bore in the cylinder block for the main bearings ... 88.246 to 88.272 mm (3.4742 to 3.4753
inch)
(5) Main bearing cap bolts
Use the following procedure in order to install the main bearing cap bolts:
1. Apply clean engine oil to the threads of the main bearing cap bolts.
2. Put the main bearing caps in the correct position that is indicated by a number on the top of the
main bearing cap. Install the main bearing caps with the locating tabs in correct alignment with
the recess in the cylinder block.
3. Evenly tighten the main bearing cap bolts.
Torque for the main bearing cap bolts. ... 80 N·m (59 lb ft)
4. Tighten the bolts for the main bearing cap for an additional 90 degrees.
Note: Ensure that the crankshaft can rotate freely.
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320D2 Excavator Hydraulic System
i02838647
Cylinder Drift - Check - Empty Bucket

SMCS - 5051-535-FKK; 5117-535-FKK; 5453-535-FKK; 7562-535-D9; 7562
Note: The engine speed and/or the machine configuration that is used during this test can affect the
results of this test. Refer to Testing and Adjusting, "Engine Performance - Test (Engine Speed)" for
the engine speed that was used for this test. Refer to Testing and Adjusting, "Operational Checks" for
the machine configurations that were used for this test.
Note: The relief valve pressure settings must be set to the relief valve pressure specification before
performing this operational check. Refer to Testing and Adjusting, "Specifications".
Table 1
Required Tools
Description Qty
Measuring Tape 1
Stopwatch 1
Position the machine on level ground. Empty the bucket. Refer to Illustration 1.
Boom Cylinder Head End, Stick Cylinder Rod End, and Bucket
Cylinder Head End
1. Fully extend the bucket cylinder.
2. Fully retract the stick cylinder.
3. Extend the stick cylinder rod 70 mm (2.8 inch) from the fully retracted position.
4. Raise the boom until the stick to bucket pin is the same height as the boom foot pin. Refer to
Illustration 2.
5. Measure each cylinder's length from cylinder pin to cylinder pin.
6. Stop the engine.
7. Leave the machine in this position for five minutes. Measure each cylinder's length from
cylinder pin to cylinder pin for drift.
Table 2
Cylinder Drift (Empty Bucket)
Item New Rebuild Service Limit
Boom Cylinder
6.0 mm (0.24 inch) or 12.0 mm (0.47 inch) or 24.0 mm (0.94 inch) or
less less less
Stick Cylinder
10.0 mm (0.39 inch) 15.0 mm (0.59 inch) or 25.0 mm (0.98 inch) or
or less less less
Bucket
Cylinder
or less less less
Stick Cylinder Head End

1. Start the engine.
3. Fully extend the stick cylinder.
4. Retract the stick cylinder rod 60 mm (2.4 inch) from the fully extended position.
5. Raise the boom until the stick to bucket pin is 600.0 mm (23.6 inch) high from ground level.
Refer to Illustration 3.
6. Measure the stick cylinder's length from cylinder pin to cylinder pin.
7. Stop the engine.
8. Leave the machine in this position for five minutes. Measure the stick cylinder's length from
Table 3
Stick Cylinder
less less less
Bucket Cylinder Rod End
2. Fully retract the bucket cylinder.
4. Raise the boom until the stick to bucket pin is 600.0 mm ( 23.6 inch) high from ground level.
Refer to Illustration 4.
5. Measure the bucket cylinder's length from cylinder pin to cylinder pin.
6. Stop the engine.
7. Leave the machine in this position for five minutes. Measure the bucket cylinder's length from
Table 4
Bucket
Cylinder
or less less less
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i03197961
Cylinder Drift - Check - Loaded Bucket

SMCS - 5051-535-FKK; 5117-535-FKK; 5453-535-FKK; 7562-535-D9; 7562
Table 1
Required Tools
Description Qty
Measuring Tape 1
Stopwatch 1
1. Position the machine on level ground. Refer to Illustration 1.
2. Load the bucket.
Weight of bucket load
Standard Undercarriage ... 1050 kg (2310 lb)

Long Undercarriage ... 1200 kg (2640 lb)
3. Raise the boom until the stick to bucket pin is the same height as the boom foot pin.
6. Extend the stick cylinder rod 70 mm (2.8 inch) from the fully retracted position.
7. Measure each cylinder's length from cylinder pin to cylinder pin.
8. Stop the engine.
9. Leave the machine in this position for three minutes. Measure each cylinder's length from
Table 2
Cylinder Drift (Loaded Bucket)
Boom Cylinder
less less less
Stick Cylinder
less less less
Bucket Cylinder
less less less
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Specifications
i04048909
Cylinder Head Valves

SMCS - 1105
S/N - -
Typical example
(1) Valve spring
Length of the inlet valve spring under test force ... 41.75 mm (1.6437 inch)
Test force of the inlet valve spring ... 326.4 N (73.4 lb)
Length of the exhaust valve spring under test force ... 41.5 mm (1.6339 inch)
Test force of the exhaust valve spring ... 332.5 N (74.7 lb)
(2) Valve spring recess
(3) Valve guides
Inside diameter of valve guide ... 9.000 to 9.022 mm (0.3543 to 0.3552 inch)
Outside diameter of the exhaust valve guide ... 13.034 to 13.047 mm (0.5131 to 0.5137 inch)
Outside diameter of the inlet valve guide ... 13.034 to 13.047 mm (0.5131 to 0.5137 inch)
Interference fit of valve guide in cylinder head ... 0.007 to 0.047 mm (0.0003 to 0.0019 inch)
Length of valve guide ... 47.25 to 47.75 mm (1.86023 to 1.87992 inch)
Note: When new valve guides are installed, new valves and new valve seat inserts must be installed.
The valve guides and the valve seat inserts are supplied as partially finished parts. The unfinished
valve guides and unfinished valve seat inserts are installed in the cylinder head. Then, the guides and
inserts are cut and reamed in one operation with special tooling. This procedure ensures the
concentricity of the valve seat to the valve guide in order to create a seal that is tight. Refer to
Disassembly and Assembly for removal and installation procedures.
(4) Exhaust valve
Diameter of the exhaust valve stem ... 8.938 to 8.960 mm (0.3519 to 0.3528 inch)
Clearance of valve in valve guide ... 0.040 to 0.084 mm (0.00157 to 0.00331 inch)
Overall length of the exhaust valve ... 128.92 to 129.37 mm (5.075 to 5.093 inch)
(5) Inlet valve
Diameter of the inlet valve stem ... 8.957 to 8.971 mm (0.35264 to 0.35319 inch)
Clearance of valve in valve guide ... 0.029 to 0.065 mm (0.00114 to 0.00256 inch)
Overall length of the inlet valve ... 128.92 to 129.37 mm (5.075 to 5.093 inch)
(6) Exhaust valve face angle from the vertical axis
Valve face angle ... 30 degrees
Valve seat angle ... 30 degrees
(7) Diameter of the exhaust

valve head ... 41.51 to 41.75 mm (1.634 to 1.643 inch)
(8) Diameter of the head of the inlet valve ... 46.20 to 46.46 mm (1.819 to 1.829 inch)
(9) Angle of the inlet valve face from the vertical axis
Valve face angle ... 30 degrees

Valve seat angle ... 30 degrees
The valve lash is the following value when the engine is cold:
Inlet valves ... 0.35 mm (0.014 inch)

Exhaust valves ... 0.45 mm (0.018 inch)
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Specifications
i04051329
Cylinder Head
SMCS - 1100
S/N - -
Typical example
Lubricate the threads and the underside of the head bolts with clean engine oil.
Tighten the bolts in the sequence that is shown in Illustration 1 to the following torque. ... 50
N·m (37 lb ft)
Tighten the bolts again to the following torque. ... 160 N·m (118 lb ft)
Tighten the head bolts to the additional amount. ... 130 degrees
Minimum thickness of cylinder head ... 118 mm (4.64566 inch)
Typical example
Note: The maximum distortion of the cylinder head is given in table 1.
Table 1
Dimension Maximum Permissible Distortion
Width (A)
0.03 mm (0.0012 inch)
Length (B)
0.05 mm (0.0020 inch)
Diagonal Line (C)

0.05 mm (0.020 inch)
Typical example
(D) Valve guide height from the top of the valve guide to the valve spring seat ... 12.35 to 12.65 mm
(0.48622 to 0.49803 inch)
(E) Outside diameter of the valve guides ... 13.034 to 13.047 mm (0.51315 to 0.51366 inch)
(F) Length of the valve guides ... 47.25 to 47.75 mm (1.86023 to 1.87992 inch)
(G) Internal diameter of the valve guides ... 9.000 to 9.022 mm (0.35433 to 0.35520 inch)
(H) Valve depths
Inlet ... 0.995 to 1.495 mm (0.03917 to 0.05886 inch)

The service limit for the depth of the inlet valve ... 1.09 mm (0.04291 inch)
Exhaust ... 0.65 to 1.007 mm (0.02559 to 0.03965 inch)
The service limit for the exhaust valve depth ... 2.06 mm (0.08110 inch)
Typical example
(J) Diameter of the parent bore in the cylinder head ... 13.000 to 13.027 mm (0.51181 to 0.51287
inch)
(K) Seat angle
Inlet ... 120 degrees

Exhaust ... 120 degrees
Typical example
(L) Seat surface finish ... Ra 0.8 microns
(M) Concentricity of valve seat to valve guide parent bore Maximum Total Indicated Reading
(TIR) ... 0.05 mm (0.00197 inch)
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i05293522
Cylinder Speed - Check

SMCS - 5456-535-VF; 5458-535-VF
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - KBS1-UP
S/N - KHR1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - YBE1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
1. Perform the following steps in order to test the operating speed of the boom cylinders.
(A) Extension test
(B) Retraction test
a. Place the machine on level ground.
b. The bucket should be empty.
c. Fully retract the bucket cylinder and the stick cylinder.
d. Position the bucket on the ground. With a stopwatch, measure the time that is required to
extend the boom cylinders.
e. Position the boom cylinders at full extension. With a stopwatch, measure the time that is
required for the bucket to come in contact with the ground.
f. Refer to the specifications in Table 1 for the operating speed of the boom cylinders.
2. Perform the following steps in order to test the operating speed of the stick cylinder.
(A) Extension test
(B) Retraction test
c. Position the upper surface of the boom parallel to the ground.
d. Fully extend the bucket cylinder.
e. Retract the stick cylinder. With a stopwatch, measure the time that is required to extend
the stick cylinder.
f. Extend the stick cylinder. With a stopwatch, measure the time that is required to retract
the stick cylinder.
g. Refer to the specifications in Table 1 for the operating speed of the stick cylinder.
3. Perform the following steps in order to test the operating speed of the bucket cylinder.
(A) Extension test
(B) Retraction test
c. Position the upper surface of the boom parallel to the ground.
d. Position the stick so that the stick is perpendicular to the ground.
e. Fully retract the bucket cylinder.
f. With a stopwatch, measure the time that is required to extend the bucket cylinder.
g. Position the bucket cylinder at full extension. With a stopwatch, measure the time that is
required to retract the bucket cylinder.
h. Refer to the specifications in Table 1 for the operating speed of the bucket cylinder.
Table 1
Cylinder Operating Speed (seconds)

Extension 3.2 ± 0.5 3.6 (1) 4.0 (1)
Boom
Retraction 1.7 ± 0.5 2.0 (1) 2.2 (1)
Extension 3.4 ± 0.5 3.9 (1) 4.4 (1)
Stick
Retraction 2.6 ± 0.5 2.8 (1) 3.3 (1)
Extension 3.8 ± 0.5 4.4 (1) 4.9 (1)
(2)
Bucket
Retraction 2.1 ± 0.5 2.5 (1) 2.7 (1)
Extension 4.6 ± 0.5 5.3 (1) 6.0 (1)
(3)
Bucket
Retraction 2.6 ± 0.5 3.0 (1) 3.4 (1)
(1)
Maximum
(2)
B1-Family
(3)
CB2-Family
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03928549
Diagnostic Capabilities
SMCS - 1400
Monitoring System
(1) Up key
(2) Right key
(3) Home key
(4) Main menu key
(5) Left key
(6) Down key
(7) Back key
(8) OK key
The ECM uses the main display module on the Monitoring System for showing diagnostic
information to service personnel. Diagnostic information concerning the ECM is sent on the Cat Data
Link to the Monitoring System. Service personnel must be familiar with the Monitoring System in
order to troubleshoot the ECM.
"Service" screen
For troubleshooting the ECM, access the "Service" screen of the Monitoring System. Select the
"Diagnostic" option. See Illustration 2.
See Troubleshooting, "Using the Operator Monitor to Determine Diagnostic Codes".
The Caterpillar Electronic Technician (ET)
The Caterpillar Electronic Technician (ET) is a software program that is used to access data. The
service technician can use the Caterpillar Electronic Technician in order to perform maintenance
work on the machine. Some of the options that are available with the Caterpillar Electronic
Technician are listed:
• View Diagnostic codes. See Troubleshooting, "Using the Caterpillar Electronic Technician to
Determine Diagnostic Codes".
• View the status of parameters.
• Clear active diagnostic codes and clear logged diagnostic codes
• Perform calibration of machine systems.
• Program the ECM (Flash). This is done with the "WINflash" program. See Testing and
Adjusting, "Electronic Control Module (ECM) - Flash Program".
• Print reports.
The following list contains some of the diagnostic functions and programming functions that are
performed by the service tools.
• The failures of the ECM system are displayed.
• The status of most of the inputs and the outputs are displayed.
• The settings for the ECM are displayed.
• Display the status of the input and output parameters in real time.
• Display the clock hour of the internal diagnostic clock.
• The number of occurrences and the clock hour of the first occurrence and the last occurrence is
displayed for each logged diagnostic code.
• The definition for each logged diagnostic code and each event is displayed.
• Load new FLASH software.
See Troubleshooting, "Diagnostic Code List" for the list of diagnostic codes for the ECM.
See Troubleshooting, "Using the Caterpillar Electronic Technician to Determine Diagnostic Codes".
Diagnostic information is accessed with the following drop-down menus:
• Active diagnostic codes
• Logged diagnostic codes
Status Groups For The Electronic Technician

The Status groups are lists of machine parameters. The status of the parameters are shown in real
time.
Typical ET Status Screen
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i02796794
Diagnostic Code List

SMCS - 7569
The following table lists the diagnostic codes for the Machine Control (MID 039). When a diagnostic
code becomes active, refer to the Troubleshooting section of this manual for a specific
troubleshooting procedure.
Component Identifier (CID)

Table 1
Component Identifier (CID)
Machine ECM (MID 039)
For troubleshooting, see the procedure with the same diagnostic code.
CID / FMI Description
CID 0041 8 Volt DC Supply
FMI 06 Current Above Normal
CID 0096 Fuel Level Sensor
FMI 04 Voltage Below Normal
FMI 05 Current Below Normal
CID 0110 Engine Coolant Temperature Sensor
FMI 09 Abnormal Update Rate

CID 0167 Alternator Charging Voltage Sensor
FMI 12 Bad Device or Component
CID 0168 Electrical System Voltage
CID 0171 Ambient Air Temperature Sensor
FMI 03 Voltage Above Normal
CID 0190 Engine Speed Sensor
FMI 08 Abnormal Frequency, Pulse Width or Period
CID 0246 Proprietary CAN Data Link
CID 0247 SAE J1939 Data Link
CID 0254 Electronic Control Module
CID 0262 5 Volt DC Sensor Power Supply
CID 0271 Action Alarm
CID 0362 Engine Fan Speed Control Solenoid
CID 0374 Swing Brake Solenoid
CID 0581 Power Shift Solenoid

CID 0586 Engine Speed Dial Switch
CID 0588 Monitoring System Display
CID 0590Engine Control Module
FMI 09 Abnormal Update
CID 0598 Travel Speed Solenoid
CID 0600 Hydraulic Oil Temperature Sensor
CID 0735 Heavy Lift Solenoid
CID 1129Right Side Attachment Pedal Sensor
FMI 08 Abnormal Frequency
CID 1130 Left Attachment Pedal Position Sensor

CID 1160 Hydraulic Lock Solenoid
CID 1178 Machine Overload Warning Pressure Sensor
CID 1522 Relief Valve #2 Check Valve Solenoid
CID 1523 Relief Valve #1 Check Valve Solenoid
CID 1525 Straight Travel Solenoid
CID 1590 Main Pump Flow Limitation Pressure Solenoid
CID 1593 Attachment Valve #1 Extend Pressure Solenoid

CID 1596 Attachment Valve #1 Retract Pressure Solenoid
CID 1609 F2 Type Valve Load Sense Pressure Sensor
CID 1657 Left Joystick Thumbwheel

CID 1658 Right Joystick Thumbwheel
CID 1665 Variable Relief Valve #1 Pressure Solenoid
CID 1666 Variable Relief Valve #2 Pressure Solenoid
CID 1931 Auxiliary Circuit Flow Combining Solenoid
CID 2265 Hydraulic Pump #1 Outlet Pressure Sensor
CID 2266 Hydraulic Pump #2 Outlet Pressure Sensor
CID 2275 Hammer Return to Tank Solenoid
CID 2280 Travel Alarm Relay

CID 2300 Switch Panel
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Specifications
i05393680
Drain Line (Muffler)

SMCS - 1062-QN
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - KBS1-UP
S/N - KHR1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Table 1
Specification for 394-7470 Muffler and Mounting Gp
Item Qty
The clamp should be aligned to the edge of the pipe.

388-7014 Bent
1 1 Torque to
Bolt Clamp
47 ± 4 N·m (35 ± 3 lb ft).
Torque to
2 4 8T-4133 Nut
35 ± 7 N·m (26 ± 5 lb ft).
Torque to
3 4 8T-4133 Nut
15 ± 3 N·m (133 ± 27 lb in).
Do not reuse the clamp.
241-9264
Larger diameter side of clamp is for female pipe.
4 1 Muffler Clamp
Smaller diameter side of clamp is for male pipe.
Align the step shape of clamp with step shape of pipes.
Before assembly, apply 2P-2333 Sealant to the outer diameter
5 - - of male pipe end. Remove excess sealant from joint before
assembly.
Torque to
6 2 Bolt
68 ± 12 N·m (50 ± 9 lb ft).
Before assembly, apply 2P-2333 Sealant to taper of
7 - - turbocharger outlet pipe. Remove excess sealant from joint
before assembly.
Front view
Table 2
Set distance from U-bolt to outlet center position at
B - -
80.0 ± 5.0 mm (3.15 ± 0.20 inch).
Torque to
8 - Clamp
18 ± 2 N·m (159 ± 18 lb in).
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Specifications
i04048916
Electric Starting Motor

SMCS - 1453
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - KBS1-UP
S/N - KHR1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
24 V Starting Motor 8 kW
Typical example
(1) Tighten the positive terminal nut to the following torque. ... 25 N·m (18 lb ft)
(2) Tighten the nut for the solenoid terminal to the following torque. ... 2.5 N·m (22 lb in)
(3) Tighten the nut on the negative terminal to the following torque. ... 25 N·m (18 lb ft)
Rated voltage ... 24 V
24 V Starting Motor 4.5 kW
Typical example
(1) Tighten the negative terminal nut to the following torque. ... 15 N·m (11 lb ft)
(3) Tighten the solenoid terminal to the following torque. ... 3.5 N·m (31 lb in)
Typical example
(1) Tighten the positive terminal nut to the following torque. ... 6 N·m (53 lb in )
(2) Tighten the solenoid terminal to the following torque. ... 8 N·m ( 70 lb in)
(3) Tighten the negative terminal nut to the following torque. ... 8 N·m ( 70 lb in)
Typical example
(2) Tighten the nut for the solenoid terminal to the following torque. ... 2.5 N·m (22 lb in)
(3) Tighten the nut on the negative terminal to the following torque. ... 25 N·m (18 lb ft)
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i01945632
Electric Starting System - Test

SMCS - 1450-081
General Information
All electrical starting systems have four elements:
• Ignition switch
• Start relay
• Starting motor solenoid
• Starting motor
Start switches have a capacity of 5 to 20 amperes. The coil of a start relay draws about 1 ampere
between test points. The switch contacts of the start relay for the starting motor are rated between 100
and 300 amperes. The start relay can easily switch the load of 5 to 50 amperes for the starting motor
solenoid.
The starting motor solenoid is a switch with a capacity of about 1000 amperes. The starting motor
solenoid supplies power to the starter drive. The starting motor solenoid also engages the pinion to the
flywheel.
The starting motor solenoid has two coils. The pull-in coil draws about 40 amperes. The hold-in coil
requires about 5 amperes.
When the magnetic force increases in both coils, the pinion gear moves toward the ring gear of the
flywheel. Then, the solenoid contacts close in order to provide power to the starting motor. When the
solenoid contacts close, the ground is temporarily removed from the pull-in coil. Battery voltage is
supplied on both ends of the pull-in coil while the starting motor cranks. During this period, the pull-
in coil is out of the circuit.
Cranking of the engine continues until current to the solenoid is stopped by releasing the ignition
switch.
Power which is available during cranking varies according to the temperature and condition of the
batteries. The following chart shows the voltages which are expected from a battery at the various
temperature ranges.
Table 1
Typical Voltage Of Electrical System During Cranking At Various Ambient Temperatures
Temperature 12 Volt System 24 Volt System
6 to 8 volts 12 to 16 volts
−23 to −7°C (−10 to 20°F)
−7 to 10°C (20 to 50°F)
10 to 27°C (50 to 80°F)
The following table shows the maximum acceptable loss of voltage in the battery circuit. The battery
circuit supplies high current to the starting motor. The values in the table are for engines which have
service of 2000 hours or more.
Table 2
Maximum Acceptable Voltage Drop In The Starting Motor Circuit During Cranking
Circuit 12 Volt System 24 Volt System
Battery post "-" to the starting motor terminal "-" 0.7 volts 1.4 volts
Drop across the disconnect switch 0.5 volts 1.0 volts
Battery post "+" to the terminal of the starting motor 0.5 volts 1.0 volts
solenoid "+"
Solenoid terminal "Bat" to the solenoid terminal "Mtr" 0.4 volts 0.8 volts
Voltage drops that are greater than the amounts in Table 2 are caused most often by the following
conditions:
• Loose connections
• Corroded connections
• Faulty switch contacts
Diagnosis Procedure
The procedures for diagnosing the starting motor are intended to help the technician determine if a
starting motor needs to be replaced or repaired. The procedures are not intended to cover all possible
problems and conditions. The procedures serve only as a guide.
Note: Do not crank the engine for more than 30 seconds. Allow the starter to cool for two minutes
before cranking the engine again.
If the starting motor does not crank or cranks slow, perform the following procedure:
1. Measure the voltage of the battery.
Measure the voltage across the battery posts with the multimeter when you are cranking the
engine or attempting to crank the engine. Do not measure the voltage across the cable post
clamps.
a. If the voltage is equal or greater than the voltage in Table 1, then go to Step 2.
b. The battery voltage is less than the voltage in Table 1.
A low charge in a battery can be caused by several conditions.
■ Deterioration of the battery
■ A shorted starting motor
■ A faulty alternator
■ Loose drive belts
■ Current leakage in another part of the electrical system
2. Measure the current that is sent to the starting motor solenoid from the positive post of the
battery.
Note: If the following conditions exist, do not perform the test in Step 2 because the starting
motor has a problem.
◦ The voltage at the battery post is within 2 volts of the lowest value in the applicable
temperature range of Table 1.
◦ The large starting motor cables get hot.
Use a suitable ammeter in order to measure the current. Place the jaws of the ammeter around
the cable that is connected to the "bat" terminal. Refer to the Specifications Module, "Starting
Motor" for the maximum current that is allowed for no load conditions.
The current and the voltages that are specified in the Specifications Module are measured at a
temperature of 27°C (80°F). When the temperature is below 27°C (80°F), the voltage will be
lower through the starting motor. When the temperature is below 27°C (80°F), the current
through the starting motor will be higher. If the current is too great, a problem exists in the
starting motor. Repair the problem or replace the starting motor.
If the current is within the specification, proceed to Step 3.
3. Measure the voltage of the starting motor.
a. Use the multimeter in order to measure the voltage of the starting motor, when you are
cranking or attempting to crank the engine.
b. If the voltage is equal or greater than the voltage that is given in Table 1, then the battery
and the starting motor cable that goes to the starting motor are within specifications. Go
to Step 5.
c. The starting motor voltage is less than the voltage specified in Table 1. The voltage drop
between the battery and the starting motor is too great. Go to Step 4.
4. Measure the voltage.
a. Measure the voltage drops in the cranking circuits with the multimeter. Compare the
results with the voltage drops which are allowed in Table 2.
b. Voltage drops are equal to the voltage drops that are given in Table 2 or the voltage drops
are less than the voltage drops that are given in Table 2. Go to Step 5 in order to check
the engine.
c. The voltage drops are greater than the voltage drops that are given in Table 2. The faulty
component should be repaired or replaced.
5. Rotate the crankshaft by hand in order to ensure that the crankshaft is not stuck. Check the oil
viscosity and any external loads that could affect the engine rotation.
a. If the crankshaft is stuck or difficult to turn, repair the engine.
b. If the engine is not difficult to turn, go to Step 6.
6. Attempt to crank the starting motor.
a. The starting motor cranks slowly.
Remove the starting motor for repair or replacement.
b. The starting motor does not crank.
Check for the blocked engagement of the pinion gear and flywheel ring gear.
Note: Blocked engagement and open solenoid contacts will give the same electrical
symptoms.
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i02413102
Electrical Component and Connector Locations

SMCS - 1408-546-CY; 7553-546
Compartment for the Machine ECM (Typical)
Machine ECM
(Located in the Compartment to the Rear of the Cab on the left side of the machine)
(1) Controller
(2) J1 Connector
(3) J2 Connector
The electronic controls can communicate with each other through the Cat Data Link. Information
from these electronic controls can be accessed through the machine monitor or by using the
Caterpillar Electronic Technician (Cat ET) on a laptop computer.
Cat ET Service Connector
(located behind the operator's seat, under the Right Side Switch Console)
(4) Back of Operator seat (shifted forward for access)
(5) Backup Switches
(6) Right Side Switch Console
(7) Cat ET Service Connector
The service connector for the Cat ET is located in the operators compartment. The connector is
located behind the seat on the right side of the cab.
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320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05568173
Electrical Connector - Inspect

SMCS - 7553-040-WW
ReferenceSpecial Instruction, SEHS9615, "Servicing DT Connectors".
ReferenceSpecial Instruction, REHS0148, "Listing Of Deutsch Connector Components"
ReferenceSpecial Instruction, SEHS9065, "Use Of CE Connector Tools".
ReferenceService Magazine, SEPD034227 January 97, "Field Repair Of Single Wire Breaks In
Harnesses (Sealed Splice)".
ReferenceService Magazine, SEPD037128 July 97, "Protection Of Unsealed Electrical Terminations

For Machines In Corrosive Applications".
ReferenceService Magazine, SEPD047324 May 99, "New DT Connector Plugs With Improved Seal
Retention".
ReferenceService Magazine, SEPD054509 October 00, "Dielectric Grease Should Not Be Used In
Electrical Connectors".
ReferencePocket Guide, SEBD0402, "Guidelines For Routing And Installing Wire Harness
Assemblies".
This information will assist in detecting problems with connectors and wiring. If a problem is found,
correct the condition and verify that the problem is resolved.
Disconnecting and reconnecting connectors sometimes resolve intermittent electrical problems.

Check for diagnostic codes immediately before disconnecting a connector. Also check for diagnostic
codes after reconnecting the connector. If the status of a diagnostic code changed due to
disconnecting and reconnecting a connector, the likely reasons are:
• Loose terminals
• Improperly crimped terminals
• Moisture
• Corrosion
• Inadequate mating of a connection
Guidelines
• Use a 1U-5804 Crimp Tool (12-GA TO 18-GA) to service Deutsch HD and DT connectors.
Never solder the terminals onto the wires. See Tool Operating Manual, SEHS9615, "Servicing
Deutsch HD and DT Style Connectors".
• Use a 147-6456 Wedge Removal Tool to remove wedges from DT connectors. Never use a
screwdriver to pry a wedge from a connector.
• Use a breakout harness for a voltmeter probe or a test light. Never break the insulation of a wire
to access to a circuit for measurements.
• If a wire is cut, always install a new terminal for the repair.
Tests
Check Connectors for Moisture and Corrosion
(1) Former seal design
(2) Current seal design
(3) Seal for a three-pin connector (typical example)
The plug end of the DT connector has a seal at the mating end of the connector. This replaceable seal
has been improved on black connectors to help prevent slipping. This improvement will help keep
moisture and dirt from entering the connector.
The current seal design (2) is not interchangeable with the former design (1) . The receptacle has also
changed to the new colors.
1. Inspect all wiring harnesses. Ensure that the routing of the wiring harness allows the wires to
enter the face of each connector at a perpendicular angle. Otherwise, the wire will deform the
seal bore. This deformation will create a path for the entrance of moisture. Verify that the seals
for the wires are sealing correctly.
2. Disconnect the suspect connector and inspect the connector seal. Ensure that the seals are in
good condition. If necessary, replace the connector.
3. Thoroughly inspect the connectors for evidence of moisture entry.
Some minor seal abrasion on connector seals is normal. Minor seal abrasion will not allow the
entry of moisture. If moisture or corrosion is evident in the connector, the source of the
moisture entry must be corrected. If the source of the moisture entry is not repaired, the
problem will recur. Simply drying the connector will not fix the problem. Check the following
items for the possible moisture entry path:
◦ Missing seals
◦ Improperly installed seals
◦ Nicks in exposed insulation
◦ Improperly mated connectors
Moisture can also travel to a connector through the inside of a wire. If moisture is found in a
connector, thoroughly check the connector harness for damage. Also check other connectors
that share the harness for moisture.
4. Repair or replace any bad connector. Correct any moisture problems.
Check the Wire Insulation for Damage

1. Carefully inspect each wire for signs of abrasion, of nicks, and of cuts. Inspect the wires for the
following conditions:
◦ Exposed insulation
◦ Rubbing of a wire against the chassis
◦ Rubbing of a wire against a sharp point
2. Check all of the wiring harness fasteners to verify that the harness is properly secured. Check
all of the fasteners to verify that the harness is not compressed. Pull back the harness sleeves to
check for a flattened portion of wire. A fastener that has been overtightened will flatten the
harness. This damages the wires that are inside the harness.
3. Repair or replace any wire with insulation damage.
Inspect the Connector Terminals

Visually inspect each terminal in the connector.
1. Verify that the terminals are not corroded.
2. Verify that the terminals are not damaged.
3. Verify that the terminals are properly aligned in the connector.
4. Verify that the terminals are properly located in the connector.
5. Replace any bad terminal.
Perform a Pull Test on Each Wire Terminal Connection
1. Ensure that the locking wedge for the connector is installed properly. Terminals cannot be
retained inside the connector if the locking wedge is not installed properly.
2. Perform the 45 N (10 lb) pull test on each wire.
Each terminal and each connector should easily withstand 45 N (10 lb) of tension and each wire
should remain in the connector body. This test checks whether the wire was properly crimped
in the terminal and whether the terminal was properly inserted into the connector.
3. Replace any bad terminals.
Check Individual Pin Retention into the Socket

Inspect pin retention.
1. Verify that the sockets provide good retention for the pins.
2. Disconnect the harness. Insert a new pin into each socket one at a time to check for a good grip
on the pin by the socket.
3. Replace any bad pins or sockets.
Check the Locking Mechanism of the Connectors

1. Ensure that the connectors lock properly.
2. Lock the connectors, ensure that the two halves cannot be pulled apart.
3. Verify that the latch tab of the connector is properly latched.
4. Verify that the latch tab of the connector returns to the locked position.
5. Replace any bad connectors.
Perform the Wiggle Test with Cat® Electronic Technician (Cat ET)
1. Select the wiggle test from the diagnostic tests on Cat® ET.
2. Choose the appropriate group of parameters to monitor.
3. Press the "Start" button.
4. Wiggle the wiring harness to reproduce intermittent problems.
If an intermittent problem exists, the status will be highlighted and an audible beep will be
heard.
5. Repair or replace any loose connections.
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320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i04004000
Electronic Control Module (ECM) - Configure

SMCS - 7610-529-MCH
Follow these instructions to get to the configuration screen:
1. Connect the communications adapter and the computer to the diagnostic service tool connector.
2. Start the Cat Electronic Technician (ET).
Typical screen to select an ECM
3. Select "File". Go to "Select an ECM". Choose the "Machine Control".
4. Go to the "Service" Menu. Select "Configuration".
Typical ET Configuration screen
5. Select a configuration category in order to display the parameters. Certain operations or

characteristics can be changed. The "Machine Attachments" is shown selected in Illustration 2.
Typical User Configurable screen
6. Select the desired parameter for change. "Machine Overload Pressure Sensor Installation" is
shown selected in Illustration 3.
7. "Click" on the "New Value" drop-down in order to change the parameter.
8. Select the new parameter.
9. "Click" on "OK" in order to confirm the new parameter.
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320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i02325799
Electronic Control Module (ECM) - Flash Program

SMCS - 7610-591-MCH
Perform the following procedure in order to flash program the ECM. The ECM is flashed in order to
upgrade the software. Flash programming of the ECM must also be done if the ECM has been
replaced. The Caterpillar Electronic Technician (ET) contains the program WinFlash. WinFlash is
used in order to load software into the ECM. The following procedure is used in order to FLASH
software into the ECM.
1. Procedure
a. Connect the data link cable between the communication adapter and the electronic
technician.
b. Connect the data link cable between the communication adapter and the diagnostic
connector of the machine.
c. Turn the disconnect switch and the key start switch to the ON position.
d. Set the implement lockout to the LOCKED position.
e. Ensure that the transmission direction switch is in the neutral position.
f. Ensure that the engine is not running.
g. Use WinFlash in order to load the software.
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320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03116091
Electronic Control Module (ECM) - Replace

SMCS - 7610-510-MCH
Prior to the replacement of the ECM, ensure that replacement is necessary. The ECM is seldom the
cause of a failure. Always check that power is available to all of the contacts of the ECM that are
marked with "+ Battery".
Note: Corrupted configuration software or the wrong software may cause an ECM to incorrectly
report diagnostic codes. Prior to replacing the ECM, flash the ECM with the correct configuration
software in order to verify that the failure is not related to the corrupted software. See Testing and
Adjusting, "Electronic Control Module (ECM) - Flash Program".
Procedure
1. Turn the disconnect switch and the key start switch to the OFF position.
2. Disconnect the machine harness connectors from the ECM.
3. Verify that the part number of the replacement ECM is correct.
4. Install the replacement ECM.
5. Connect the machine harness to the ECM.
6. Turn the disconnect switch and the key start switches to the ON position.
7. If necessary, use the Electronic Technician (ET) to install the configuration software. Refer to
the Testing and Adjusting, "Electronic Control Module (ECM) - Flash Program" section of this
manual.
8. Verify that the ECM operates correctly.
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03929493
Emerging Symptom Information

SMCS - 7000-035
This space is for new information for this product.
Note: Use the Service Information System on the Web in order to find the most up-to-date
information.
To share your knowledge of symptoms, please use the form in "SIS" or "CBT" feedback. Write a
brief description about the symptom, testing, and repair of the machine. Your feedback information
will help Caterpillar improve the service information for this product.
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i04643912
Engine Crankcase Pressure (Blowby) - Test

SMCS - 1215; 1317
Table 1
Tools Needed
Part Number Part Name Quantity
348-5430 Multi-Tool Gp 1
285-0900 Blowby Tool Group 1
NETG5049 Software License 1
Damaged pistons or rings can cause too much pressure in the crankcase. This condition will cause the
engine to run rough. There will be more than a normal amount of blowby fumes rising from the
crankcase breather. The breather can then become restricted in a short time, causing oil leakage at
gaskets and seals that would not normally have leakage. Blowby can also be caused by worn valve
guides or by a failed turbocharger seal.
348-5430 Multi-Tool Gp
The 348-5430 Multi-Tool Gp , or the 285-0900 Blowby Tool Group is used to check the amount of
blowby. Refer to Tool Operating Manual, NEHS1087, " 348-5430 Multi-Tool Gp " for the test
procedure for checking the blowby.
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Specifications
i04047766
Engine Design
SMCS - 1201
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - KBS1-UP
S/N - KHR1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Cylinder and valve location
(A) Inlet valve
(B) Exhaust valve
Bore ... 105 mm (4.13385 inch)
Stroke ... 135 mm (5.31495 inch)
Displacement ... 7.01 L (427.78 cubic inch)
Cylinder arrangement ... In-line
Type of combustion ... Direct injection
Compression ratio for the C7.1 (Mech) 6301-Up engine ... 16:1
Compression ratio for the C7.1 (Mech) 6731-Up engine ... 18.5:1
Number of cylinders ... 6
Valves per cylinder ... 2
Valve lash
Inlet valve ... 0.35 mm (0.014 inch)

Exhaust valve ... 0.45 mm (0.018 inch)
Firing order ... 1, 5, 3, 6, 2, 4
When the crankshaft is viewed from the front of the engine, the crankshaft rotates in the following
direction. ... Clockwise
When the camshaft is viewed from the front of the engine, the camshaft rotates in the following
direction. ... Clockwise
The front of the engine is opposite the flywheel end of the engine. The left side of the engine and the
right side of the engine are determined from the flywheel end. No. 1 cylinder is the front cylinder of
the engine.
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i02652662
Engine Oil Cooler - Inspect

SMCS - 1378-040
Hot oil and hot components can cause personal injury. Do not allow hot
oil or hot components to contact the skin.
There are two types of engine oil cooler that can be installed on this engine.
Engine Oil Cooler with a Low Mounted Filter Base
Typical example
(1) Oil cooler
(2) Long setscrew
(3) Short setscrew
(4) Joint
(5) Setscrews
(6) Housing for the oil cooler
(7) Joint
Perform the following procedure in order to inspect the engine oil cooler with the low mounted filter:
1. Place a container under the oil cooler in order to collect any engine oil or coolant that drains
from the oil cooler.
2. Refer to Disassembly and Assembly, "Engine Oil Cooler - Remove" for removal of the engine
oil cooler.
3. Thoroughly clean the oil cooler (1) and the cylinder block.
Personal injury can result from air pressure.
Personal injury can result without following proper procedure. When

using pressure air, wear a protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less than 205 kPa (30 psi)
for cleaning purposes.
4. Inspect the oil cooler (1) for cracks and dents. Replace the oil cooler (1) if cracks or dents exist.
Ensure that no restrictions for the flow of lubricating oil exist in the oil cooler (1) .
Dry the oil cooler (1) with low pressure air. Flush the inside of the oil cooler (1) with clean
lubricating oil.
5. Refer to Disassembly and Assembly, "Engine Oil Cooler - Install" for installation of the engine
oil cooler.
6. Ensure that the cooling system of the engine is filled to the correct level. Operate the engine.
Note: Refer to Operation And Maintenance Manual, "Refill Capacities" for additional
information.
Check for oil or coolant leakage.
Engine Oil Cooler with a High Mounted Filter Base
Typical example
(1) Oil cooler
(2) Joint
(3) Housing for the oil cooler
(4) Nut
(5) Long setscrew
(6) Setscrew
(7) Joint
Perform the following procedure in order to inspect the engine oil cooler with the low mounted filter:
1. Place a container under the oil cooler in order to collect any engine oil or coolant that drains
from the oil cooler.
2. Refer to Disassembly and Assembly, "Engine Oil Cooler - Remove" for removal of the engine
oil cooler.
3. Thoroughly clean the oil cooler (1) and the cylinder block.
Personal injury can result from air pressure.
Personal injury can result without following proper procedure. When

using pressure air, wear a protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less than 205 kPa (30 psi)
for cleaning purposes.
4. Inspect the oil cooler (1) for cracks and dents. Replace the oil cooler (1) if cracks or dents exist.
Ensure that no restrictions for the flow of lubricating oil exist in the oil cooler (1) .
Dry the oil cooler (1) with low pressure air. Flush the inside of the oil cooler (1) with clean
lubricating oil.
5. Refer to Disassembly and Assembly, "Engine Oil Cooler - Install" for installation of the engine
oil cooler.
6. Ensure that the cooling system of the engine is filled to the correct level. Operate the engine.
Note: Refer to Operation And Maintenance Manual, "Refill Capacities" for additional
information.
Check for oil or coolant leakage.
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Specifications
i02636972
Engine Oil Cooler

SMCS - 1378
S/N - -
Engine Oil Cooler with a Low Mounted Filter Base
(1) Joint
(2) Housing
(3) Joint
(4) Oil cooler
(5) Setscrew
Setscrews
Tighten the setscrews (5) in the sequence that is in illustration 2 to the following torque. ... 22
N·m (16 lb ft)
Engine Oil Cooler with a High Mounted Filter Base
(6) Joint
(7) Nuts
(8) Housing
(9) Joint
(10) Oil cooler
Setscrews
Tighten the setscrews in the sequence that is in illustration 4 to the following torque. ... 22 N·m
(16 lb ft)
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Specifications
i03551117
Engine Oil Filter Base

SMCS - 1306
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - KBS1-UP
S/N - KHR1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Typical example
(1) Dust cap
(2) Engine oil filter
Torque for the engine oil filter ... 12 N·m (106 lb in)
(3) Engine oil sampling valve
Torque for the engine oil sampling valve (if equipped) ... 12 N·m (106 lb in)
Torque for the plug (if equipped) ... 12 N·m (106 lb in)
(4) Setscrew
Torque for the setscrews that retain the oil filter base ... 22 N·m (16 lb ft)
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Specifications
i04048914
Engine Oil Pan

SMCS - 1302
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - KBS1-UP
S/N - KHR1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Typical example
Tighten the fasteners in the sequence that is shown in illustration 1 to the following torque. ... 22 N·m
(16 lb ft)
Refer to Disassembly and Assembly for the correct procedure to install the engine oil pan.
Typical example
(1) Tighten the nut to the following torque. ... 18 N·m (13 lb ft)
(2) Tighten the plug to the following torque. ... 34 N·m (25 lb ft)
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i02648880
Engine Oil Pressure - Test

SMCS - 1304-081
Low Oil Pressure

The following conditions will cause low oil pressure.
• The oil level is low in the crankcase.
• A restriction exists on the oil suction screen.
• Connections in the oil lines are leaking.
• The connecting rod or the main bearings are worn.
• The rotors in the oil pump are worn.
• The oil pressure relief valve is operating incorrectly.
A worn oil pressure relief valve can allow oil to leak through the valve which lowers the oil pressure.
The minimum oil pressure at the maximum engine speed and at normal operating temperature is 315
kPa (45 psi). A lower pressure is normal at low idle.
A suitable pressure gauge can be used in order to test the pressure of the lubrication system.
High Oil Pressure

High oil pressure can be caused by the following conditions.
• The spring for the oil pressure relief valve is installed incorrectly.
• The plunger for the oil pressure relief valve becomes jammed in the closed position.
• Excessive sludge exists in the oil which makes the viscosity of the oil too high.
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Specifications
i02379117
Engine Oil Pressure

SMCS - 1924
S/N - -
The minimum oil pressure at the maximum engine speed and at normal operating temperature is the
following value. ... 315 kPa (45 psi)
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i02400036
Engine Oil Pump - Inspect

SMCS - 1304-040
If any part of the oil pump is worn enough in order to affect the performance of the oil pump, the oil
pump must be replaced.
Perform the following procedures in order to inspect the oil pump. Refer to the Specifications
Module, "Engine Oil Pump" for clearances and torques.
1. Remove the oil pump from the engine. Remove the cover of the oil pump.
2. Remove the outer rotor (1). Clean all of the parts. Look for cracks in the metal or other damage.
3. Install the outer rotor. Measure the clearance of the outer rotor to the body .
Clearance for the inner rotor body
4. Measure the clearance of the inner rotor to the outer rotor (2) .
End play measurement of the rotor
5. Measure the end play of the rotor with a straight edge and a feeler gauge (3).
6. Clean the top face of the oil pump and the bottom face of the cover. Install the cover on the oil
pump. Install the oil pump on the engine.
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Specifications
i02369776
Engine Oil Pump

SMCS - 1304
S/N - -
Type ... Gear-driven differential rotor
Number of lobes
Inner rotor ... 4

Outer rotor ... 5
(1) Clearance of the outer rotor to the body ... 0.050 to 0.330 mm (0.0020 to 0.0130 inch)
Checking the clearance
(2) Service limit of inner rotor to outer rotor ... 0.080 to 0.250 mm (0.0031 to 0.0098 inch)
Checking the end play
(3) End play of rotor assembly
Inner rotor ... 0.050 to 0.180 mm (0.0020 to 0.0071 inch)

Outer rotor ... 0.050 to 0.180 mm (0.0020 to 0.0071 inch)
Tighten the bolts that hold the front cover of the oil pump assembly to the following torque. ... 22
N·m (16 lb ft)
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i05293477
Engine Performance - Test - Engine Speed

SMCS - 1000-081
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - KBS1-UP
S/N - KHR1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - YBE1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Table 1
Required Tools
Part Number Description Qty
9U-7400 Multitach Tool Group 1
1. Position the machine on level ground.
2. Stop the engine.
3. Install 9U-7400 Multitach Tool Group on the engine.
5. Increase the hydraulic oil temperature to 55° ± 5°C (131° ± 9°F).
6. Read the engine speed display (rpm) on the multitach. Refer to Table 2 for the specifications
for engine speed at the desired engine operation.
Table 2
Specifications
Item
New Service Limit
1800 ± 50 rpm (2) 1600 to 1850 rpm (2)
(1)
No load high idle
1700 ± 50 rpm (3) 1500 to 1750 rpm (3)
No load speed (4) 1100 ± 50 rpm 1100 ± 100 rpm
No load low idle 1000 ± 50 rpm 1000 ± 100 rpm
Maximum speed with load (5) 1680 rpm ± 50 rpm 1580 rpm
(1)
AEC switch in the OFF position
(2)
Engine rpm within 3 seconds after the engine speed dial was placed at position "10"
(3)
Three seconds after the engine speed dial was placed at position "10"
(4)
AEC switch in the ON position
(5)
Pressure is relieved from both pumps (stall condition).
Note: A New specification is the performance that can be expected for a new machine. A Rebuild
specification is the performance that can be expected after rebuilding the components of a system.
Performance beyond the Service Limit is an indication of these problems: improper maintenance or
adjustment, component wear and failure.
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i04046711
Engine Valve Lash - Inspect/Adjust

SMCS - 1102-025
To prevent possible injury, do not use the starter to turn the flywheel.
Hot engine components can cause burns. Allow additional time for the
engine to cool before measuring valve clearance.
Cylinder and valve location
(A) Inlet valve
(B) Exhaust valve
If the valve lash requires adjustment several times in a short period of time, excessive wear exists in a
different part of the engine. Find the problem and make necessary repairs in order to prevent more
damage to the engine.
Not enough valve lash can be the cause of rapid wear of the camshaft and valve lifters. Not enough
valve lash can indicate that the seats for the valves are worn.
Valves become worn due to the following causes:
• Fuel injection nozzles that operate incorrectly
• Excessive dirt and oil are present on the filters for the inlet air.
• Incorrect fuel settings on the fuel injection pump.
• The load capacity of the engine is frequently exceeded.
Too much valve lash can cause broken valve stems, springs, and spring retainers. Too much valve
lash can be an indication of the following problems:
• Worn camshaft and valve lifters
• Worn rocker arms
• Bent pushrods
• Broken socket on the upper end of a pushrod
• Loose adjustment screw for the valve lash
If the camshaft and valve lifters show rapid wear, look for fuel in the lubrication oil or dirty
lubrication oil as a possible cause.
Valve Lash Check

An adjustment is NOT NECESSARY if the measurement of the valve lash is in the acceptable range.
Check the valve lash while the engine is stopped. The temperature of the engine does not change the
valve lash setting.
If the measurement is not within the acceptable clearance, adjustment is necessary. Refer to "Valve
Lash Adjustment".
Valve Lash Adjustment

Table 1
Inlet Valves Exhaust Valves
Valve Lash
0.35 mm (0.014 inch) 0.45 mm (0.018 inch)
TC Compression Stroke 1-2-4 1-3-5
TC Exhaust Stroke (1) 3-5-6 2-4-6
Firing Order 1-5-3-6-2-4 (2)
(1)
360° from TC compression stroke
(2)
The No. 1 Cylinder is at the front of the engine.
Setting the valve lash
(1) Adjustment screw
(2) Feeler gauge
1. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism
Cover - Remove" For the removal procedure.
2. Rotate the crankshaft in the direction of engine rotation until the inlet valve of the No. 6
cylinder has opened and the exhaust valve of the No. 6 cylinder has not completely closed. The
engine is now at TC compression stroke.
Table 2
TC Compression Stroke Inlet Valves Exhaust Valves
Valve Lash
0.35 mm (0.014 inch) 0.45 mm (0.018 inch)
Cylinders 1-2-4 1-3-5
3. Measure the valve lash for the valve when the engine is at TC compression stroke according to
Table 2. If necessary, make an adjustment to the valves according to Table 2.
a. Loosen the valve adjustment screw locknut that is on the adjustment screw (1) .
b. Place an appropriate feeler gauge (2) between the rocker arm and the valve. Turn the
adjustment screw (1) while the valve adjustment screw locknut is being held from
turning. Adjust the valve lash until the correct specification is achieved.
c. After each adjustment, tighten the valve adjustment screw locknut while you hold the
valve adjustment screw (1) from turning.
4. Rotate the crankshaft in the direction of engine rotation to TC exhaust stroke (360° from TC
compression stroke).
Table 3
TC Exhaust Stroke (1) Inlet Valves Exhaust Valves
Valve Lash
0.35 mm (0.014 inch) 0.45 mm (0.018 inch)
Cylinders 3-5-6 2-4-6
(1)
360° from TC compression stroke
5. Measure the valve lash for the valves when the engine is at TC exhaust stroke according to
Table 3. If necessary, make an adjustment to the valves according to Table 3.
a. Loosen the valve adjustment screw locknut that is on the adjustment screw (1) .
b. Place an appropriate feeler gauge (2) between the rocker arm and the valve. Turn the
adjustment screw (1) while the valve adjustment screw locknut is being held from
turning. Adjust the valve lash until the correct specification is achieved.
c. After each adjustment, tighten the valve adjustment screw locknut while you hold the
valve adjustment screw (1) from turning.
6. Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism
Cover - Install" for the installation procedure.
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i01126690
Excessive Bearing Wear - Inspect

SMCS - 1203-040; 1211-040; 1219-040
When some components of the engine show bearing wear in a short time, the cause can be a
restriction in an oil passage.
An engine oil pressure indicator may show that there is enough oil pressure, but a component is worn
due to a lack of lubrication. In such a case, look at the passage for the oil supply to the component. A
restriction in an oil supply passage will not allow enough lubrication to reach a component. This will
result in early wear.
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i02414692
Excessive Engine Oil Consumption - Inspect

SMCS - 1348-040
Engine Oil Leaks on the Outside of the Engine

Check for leakage at the seals at each end of the crankshaft. Look for leakage at the gasket for the
engine oil pan and all lubrication system connections. Look for any engine oil that may be leaking
from the crankcase breather. This can be caused by combustion gas leakage around the pistons. A
dirty crankcase breather will cause high pressure in the crankcase. A dirty crankcase breather will
cause the gaskets and the seals to leak.
Engine Oil Leaks into the Combustion Area of the Cylinders

Engine oil that is leaking into the combustion area of the cylinders can be the cause of blue smoke.
There are several possible ways for engine oil to leak into the combustion area of the cylinders:
• Failed valve stem seals
• Leaks between worn valve guides and valve stems
• Worn components or damaged components (pistons, piston rings, or dirty return holes for the
engine oil)
• Incorrect installation of the compression ring and/or the intermediate ring
• Leaks past the seal rings in the turbocharger shaft
• Overfilling of the crankcase
• Wrong dipstick or guide tube
• Sustained operation at light loads
Excessive consumption of engine oil can also result if engine oil with the wrong viscosity is used.
Engine oil with a thin viscosity can be caused by fuel leakage into the crankcase or by increased
engine temperature.
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Specifications
i02651906
Exhaust Manifold
SMCS - 1059
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - KBS1-UP
S/N - KHR1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Exhaust manifold for Top Mounted Turbocharger
Typical example
Tighten the exhaust manifold bolts in the sequence that is shown in illustration 1 to the following
torque. ... 44 N·m (32 lb ft)
Exhaust manifold for Side Mounted Turbocharger
Typical example
Tighten the exhaust manifold bolts in the sequence that is shown in illustration 2 to the following
torque. ... 44 N·m (32 lb ft)
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i02478555
Exhaust Temperature - Test

SMCS - 1088-081
Measure the Exhaust Temperature

Table 1
Required Tools
Tool Part Number Part Name Qty
A 164-3310 Laser Infrared Thermometer 1
When the engine runs at low idle, the temperature of an exhaust manifold port can indicate the
condition of a fuel injection nozzle.
A low temperature indicates that no fuel is flowing to the cylinder. An inoperative fuel injection
nozzle or a problem with the fuel injection pump could cause this low temperature.
A very high temperature can indicate that too much fuel is flowing to the cylinder. A malfunctioning
fuel injection nozzle could cause this very high temperature.
Use Tooling (A) in order to check the exhaust temperature at the exhaust outlet for each cylinder.
Compare the temperature readings for each exhaust outlet. Investigate any difference in the
temperature readings.
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Specifications
i05656240
Fasteners - Swing Drive and Final Drive

SMCS - 7553
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CXY1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PCM1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 227-6166 Swing and Final Drive Fastener Gp , and 227-6168 Swing and
Final Drive Fastener Gp
Item Qty
Before assembly, the surfaces must be clean and free from

1 - -
protective coating.
447-1719 Bolt
2 32 Torque to 520 ± 70 N·m (384 ± 52 lb ft).
Apply blue Loctite 242 to the threads of the bolts.

447-1726 Bolt
3 12 Torque to
900 ± 100 N·m (664 ± 74 lb ft).
4 1 096-4755 Pin Apply Loctite C5A Copper Anti-Seize to the pin.
5D-1026 Band Torque to
5 1
Clamp 4.5 ± 0.5 N·m (39.8 ± 4.4 lb in).
Before assembly into the upper frame group, coat the mating
6 - -
surfaces with 1U-8846 Gasket Sealant .
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Specifications
i05864134
Final Drive
SMCS - 4050
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - RAR1-UP
S/N - SDC1-UP
S/N - SDZ1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 333-2988 Final Drive Gp
Item Qty
095-0891 After installation of the spring pins, create two stake marks for each
1 6 Spring Pin pin slightly near the hole of spring pins. Refer to Illustration 1 for the
locations of the stake marks.
The distance from the edge of the spring pin hole to the stake mark is
D - -
2.25 ± 0.75 mm (0.089 ± 0.030 inch).
Before assembly, the contact surfaces of the bolts, the washers, and
the tightened parts must be clean and free from protective coating and
28 8T-0348
2 oil.
Bolt
Torque to
270 ± 40 N·m (199 ± 30 lb ft).
16 143-0811
3 oil.
Bolt
Torque to
105 ± 20 N·m (77 ± 15 lb ft).
Before assembly, apply blue Loctite 242 to the threads. Clean the
096-3216
threads before applying the sealant.
4 2 Socket
During assembly flush the setscrew with the surface of the cover
Setscrew
assembly.
114-1539
Apply Loctite C5A Copper Anti-Seize to the inside diameter and
5 6 Dowel Pin
outside diameter of the mating parts.
296-6220
Before assembly, apply Loctite C5A Copper Anti-Seize to the inside
6 2 Ball Bearing
diameter and outside diameter of the mating parts.
Rubber toric seals and all surfaces that in contact with the seals must
174-4874 be clean and dry at assembly. Prior to assembly apply, a thin layer of
7 1 Duo-Cone 6V-4876 Lubricant to the surfaces that are in contact with the metal
Seal Gp seals. The metal seal must be assembled square with the bore. Rubber
toric seals must not bulge. Rubber toric seals must not be twisted.
457-7976
8 1 Before assembly, apply 1U-8846 Gasket Sealant to the surface.
Cover
3E-2338 Torque to
9 2
Pipe Plug 80 ± 10 N·m (59 ± 7 lb ft).
457-7977
10 1 Before assembly, apply 1U-8846 Gasket Sealant to the surface.
Ring Gear
As required, use the following shims to achieve the correct clearance between the ball
bearing and the coupling gear. If two shims (11) are required, install the thinnest shim next
to the coupling gear:
11 096-1773 Thickness is
1
Shim 0.15 mm (0.006 inch).
096-1774 Thickness is
1
Shim 0.30 mm (0.012 inch).
1
Shim 0.40 mm (0.016 inch).
1
Shim 0.50 mm (0.020 inch).
1
Shim 0.60 mm (0.024 inch).
1
Shim 0.70 mm (0.028 inch).
1
Shim 0.80 mm (0.031 inch).
1
Shim 1.00 mm (0.039 inch).
1
Shim 1.60 mm (0.063 inch).
14 227-6034 oil.
12
Bolt Before assembly, apply blue Loctite 242 to the threads.
Torque to
270 ± 40 N·m (199 ± 30 lb ft).
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i03864807
Finding Top Center Position for No. 1 Piston

SMCS - 1105-531
Table 1
Required Tools
Tool Part Number Part Description Qty
A (1) 9U-6198 Crankshaft Turning Tool 1
9U-7336 Housing 1
A (2)
5P-7305 Engine Turning Tool 1
B 230-6284 Timing Pin (Camshaft) 1
136-4632 Timing Pin (Crankshaft) 1
C
268-1966 Adapter 1
(1)
The Crankshaft Turning Tool is used on the front pulley.
(2)
This Tool is used in the aperture for the electric starting motor.
1. Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and
Install".
2. Use Tooling (A) in order to rotate the crankshaft until the hole (X) in the camshaft gear (1)
aligns with the hole in the front housing. Refer to illustration 1.
Typical example
3. Install Tooling (B) through the hole (X) in the camshaft gear (1) into the front housing. Use
Tooling (B) in order to lock the camshaft in the correct position.
4. Remove the plug (4) from the cylinder block. Install Tooling (C) into the hole (Y) in the
cylinder block. Use Tooling (C) in order to lock the crankshaft in the correct position.
Note: Do not use excessive force to install Tooling (C) . Do not use Tooling (C) to hold the
crankshaft during repairs.
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i02656274
Flywheel - Inspect
SMCS - 1156-040
Table 1
Required Tools
A 8T-5096 Dial Indicator Group 1
Alignment of the Flywheel Face
Typical example
1. Install Tooling (A) in illustration 1, as shown.
2. Set the pointer of the dial indicator to 0 mm (0 inch).
3. Turn the flywheel. Read the dial indicator for every 45 degrees.
Note: During the check, keep the crankshaft pressed toward the front of the engine in order to
remove any end clearance.
4. Calculate the difference between the lowest measurement and the highest measurement of the
four locations. This difference must not be greater than 0.03 mm (0.001 inch) for every 25 mm
(1.0 inch) of the radius of the flywheel. The radius of the flywheel is measured from the axis of
the crankshaft to the contact point of the dial indicator.
Flywheel Runout
Typical example
1. Install Tooling (A) in illustration 2, as shown.
3. Turn the flywheel. Read the dial indicator for every 45 degrees.
4. Calculate the difference between the lowest measurement and the highest measurement of the
four locations. This difference must not be greater than 0.30 mm (0.012 inch).
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i05355821
Flywheel Housing - Inspect

SMCS - 1157-040
Table 1
Required Tools
8T-5096 Dial Indicator 1
A
- Magnetic Base and Stand 1
Concentricity of the Flywheel Housing

Note: This check must be made with the flywheel and the starter removed and the bolts for the
flywheel housing tightened lightly.
Typical example
1. Install Tooling (A) . See Illustration 1.
3. Check the concentricity at intervals of 45 degrees around the flywheel housing.
4. Calculate the difference between the lowest measurement and the highest measurement. This
difference must not be greater than the limit that is given in Table 2.
Note: Any necessary adjustment must be made on the flywheel housing. Then, recheck the
concentricity.
Alignment of the Flywheel Housing

Note: This check must be made with the flywheel and the starter removed and the bolts for the
flywheel housing tightened to the correct torque.
Typical example
1. Install Tooling (A) . See Illustration 2.
3. Check the alignment at intervals of 45 degrees around the flywheel housing.
4. Calculate the difference between the lowest measurement and the highest measurement. This
difference must not be greater than the limit that is given in Table 2.
Note: Any necessary adjustment must be made on the flywheel housing.
Table 2
Limits for Flywheel Housing Runout and Alignment (Total Indicator Reading)
Bore of the Housing Flange Maximum Limit (Total Indicator Reading)
410 mm (16.14 inch) 0.25 mm (0.010 inch)
448 mm (17.63 inch) 0.28 mm (0.011 inch)
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Specifications
i04047745
Flywheel
SMCS - 1156
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - KBS1-UP
S/N - KHR1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Typical example
(1) Flywheel ring gear
Heat the flywheel ring gear to the following temperature. ... 250 °C (480 °F)
Note: Do not use an oxyacetylene torch to heat the flywheel ring gear.
(2) Flywheel
(3) Bolt
Tighten the 12 flywheel bolts to the following torque. ... 140 N·m (103 lb ft)
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Specifications
i02935111
Front Housing and Covers

SMCS - 1162; 1166
S/N - -
The front housing must be aligned to the cylinder block face. ... + 0.05 to minus 0.05 mm (+ 0.0020 to
minus 0.0020 inch )
Alignment
Typical example
Tighten the setscrew to the sequence that is shown in illustration 2 to the following torque. ... 28 N·m
(20 lb ft)
(1) Tighten the bolts that fasten the front cover to the front housing to the following torque. ... 22 N·m
(16 lb ft)
Typical example
(2) Tighten the bolts that fasten the water pump to the front housing to the following torque. ... 22
N·m (16 lb ft)
Note: Refer to Specifications, "Water Pump" for the correct bolt tightening sequence for the water
pump.
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Specifications
i04051790
Fuel Filter Base - Primary Fuel Filter Base

SMCS - 1261; 1262
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - KBS1-UP
S/N - KHR1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Note: Refer to Systems Operation, Testing and Adjusting, "Cleanliness of Fuel System
Components" for detailed information on the standards of cleanliness that must be observed
during ALL work on the fuel system.
Typical example
(1) Tighten the setscrews to the following torque. ... 44 N·m (32 lb ft)
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Specifications
i04047836
Fuel Injection Lines

SMCS - 1252
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - KBS1-UP
S/N - KHR1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Typical example
(1) Tighten the union nuts for the fuel injector nozzles to the following torque. ... 30 N·m (22 lb ft)
(2) Tighten the union nuts for the fuel injection pump to the following torque. ... 30 N·m (22 lb ft)
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i05182682
Fuel Injection Nozzle - Test

SMCS - 1254-081
Specifications
Table 1
Specifications for Testing the Fuel Injection Nozzles
Bench Test Temperature

18° to 20 °C (64° to 70 °F)
Nozzle Cap Nut Torque

34 ± 3 N·m (25 ± 2 lb ft)
Introduction
Perform the following procedures in order to determine if a fuel injection nozzle does not work
correctly.
Required Tools
Table 2
Required Tools
5P-4150 Nozzle Testing Group 1
5P-4718 Adapter 1
6V-2170 Tube Assembly 1
8S-2270 Fuel Collector 1

1U-8857 Extension 1
6V-6068 SAE J-967 Calibration Fluid 1
Test Procedure
Bench test the fuel injection nozzles at a temperature of 18° to 20 °C (64° to 70 °F)
Test the Fuel Injection Nozzles

Bench test the fuel injection nozzles at a temperature of 18° to 20 °C (64° to 70 °F)
Fuel injection nozzles and lines
(1) Nut for the fuel supply line
1. Run the engine at low idle.
2. Loosen the nut for the fuel supply line (1) at the fuel injection nozzle on cylinder number 1. Do
not loosen the nut more than half of a turn. Listen for the low idle to decrease or become rough.
Tighten the nut for the fuel supply line on cylinder number 1. Perform this test on each
cylinder.
3. The fuel injection nozzle is faulty when the nut for the fuel supply line is loosened and the
following events occur:
◦ The engine rpm does not decrease.
◦ The engine does not idle roughly.
4. Remove the faulty fuel injection nozzle for additional testing.
Note: If leakage occurs at the nut for the fuel supply line, make sure that fuel supply line and
the nut are correctly aligned with the inlet connection of the fuel injection nozzle. Do not
tighten the nut for the fuel supply line on the high-pressure fuel line more than the
recommended torque. If the nut is tightened more, the fuel line may become restricted or the
threads of the fuel injection nozzle and the nut may be damaged.
Cleaning of the Fuel Injection Nozzles

Before a fuel injection nozzle is tested, remove any loose carbon from the tip of the fuel injection
nozzle. Do not use abrasive material or a wire brush in order to clean the nozzle.
The fuel injection nozzle is not a serviceable part. Disassembling or adjusting the nozzle will violate
the standards for emissions.
Note: Extra care should be used in handling the fuel injection nozzle in order to prevent damage to
the nozzle tip. A scratch or a burr could cause needle leakage or spray distortion. Dirt in the orifices
of the nozzle tip can damage engine components. Dirt can also distort the spray pattern of the nozzle.
Test the Spray Pattern
Ensure that you wear eye protection at all times during testing. When
fuel injection nozzles are tested, test fluids travel through the orifices of
the nozzle tip with high pressure. Under this amount of pressure, the
test fluid can pierce the skin and cause serious injury to the operator.
Always keep the tip of the fuel injection nozzle pointed away from the
operator and into the fuel collector and extension.
Correct spray pattern for a fuel injection nozzle
1. Connect fuel injection nozzle (3) to the tooling that is shown in Illustration 3.
Position the fuel injection nozzle so that the fuel spray is directed into the 1U-8857 Extension
(4) and the 8S-2270 Fuel Collector (6) .
2. Close the gauge protector valve and the shutoff valve. Open the pump isolator valve.
3. Pump the nozzle tester at approximately 60 strokes per minute and look at the spray pattern
when the fluid begins to flow through the orifices of the fuel injection nozzle.
The spray, which flows from all of the orifices, must have the same pattern. The fuel injection
nozzle is faulty if there is a difference in the vertical patterns or a difference in the horizontal
patterns. Refer to the correct spray pattern in Illustration 2.
Note: If the nozzle tester is pumped too slowly, the fuel injection nozzle can develop a
hydraulic lock. If this situation occurs, release the nozzle cap nut in order to release the pressure
and then tighten the nozzle cap nut to a torque of 34 ± 3 N·m (25 ± 2 lb ft). Test the spray
pattern again.
Note: Be sure that the gauge protector valve is closed before the fuel injection nozzle is
removed from the nozzle tester. Closing the valve will prevent damage to the pressure gauge.
Pressure Test
Ensure that you wear eye protection at all times during testing. When
fuel injection nozzles are tested, test fluids travel through the orifices of
the nozzle tip with high pressure. Under this amount of pressure, the
test fluid can pierce the skin and cause serious injury to the operator.
Always keep the tip of the fuel injection nozzle pointed away from the
operator and into the fuel collector and extension.
5P-4150 Nozzle Testing Group
(1) 5P-4718 Adapter
(2) 6V-2170 Tube assembly
(3) Fuel injection nozzle
(4) 1U-8857 Extension
(5) 8T-5313 Filter
(6) 8S-2270 Fuel collector
NOTICE
Do not use dirty test fluids when you test fuel injection nozzles. Also, do
not test fuel injection nozzles unless you have the correct service
tools.The use of dirty test fluids and the use of incorrect service tools
will result in damage to fuel injection nozzles.
Use clean 6V-6068 Calibration Fluid when the fuel injection nozzles are tested. The calibration
fluid is equivalent to SAE J-967 (ISO 4113) oil.
2. Close the gauge protector valve. Close the shutoff valve. Open the pump isolator valve. In order
to flush the fuel injection nozzle, operate the nozzle tester for 10 to 15 strokes at a rate of
approximately 60 strokes per minute.
3. Open the gauge protector valve. Move the pump lever quickly downward until the valve in the
fuel injection nozzle opens. Note the highest pressure indication on the dial indicator before the
pointer moves to 0 kPa (0 psi). This highest pressure indication is the opening pressure of the
fuel injection nozzle. The opening pressure is defined when the valve needle is lifted from the
valve seat.
4. Refer to the table in Specifications, "Fuel Injection Nozzles" for the correct pressure settings.
If the opening pressure is not within the range of the setting that is given in the table, the fuel
injection nozzle must be replaced.
Fuel Injection Nozzle and Seat Test

2. Pump the pressure of the nozzle tester at 60 strokes per minute to approximately 1030 kPa (150
psi) below the opening pressure of the fuel injection nozzle. A drop of fuel should not form on
the tip of the fuel injection nozzle for at least ten seconds. A light dampness is acceptable. If the
results of the tests are not acceptable, clean the fuel injection nozzle. After you clean the fuel
injection nozzle and the fuel leakage still occurs, the nozzle must be replaced.
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Specifications
i02709983
Fuel Injection Pump

SMCS - 1251; 1290
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - KBS1-UP
S/N - KHR1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Note: Before the fuel injection pump is removed from the engine the fuel injection pump shaft must
be locked. Position the engine to TC compression stroke of number one cylinder before tightening the
locking screw. The locking screw will prevent the shaft from rotating. If the fuel injection pump was
removed prior to correctly timing the engine and locking the shaft, the fuel injection pump will need
to be timed by trained personnel.
Typical example
Note: The solenoid on the fuel injection pump is a serviceable item. The fuel injection pump is a
nonserviceable item.
(1) O-ring
(2) Locking screw
(3) Washer
Locking the shaft
Loosen locking screw (2) and move the washer (3) to the locked position. Tighten the bolt to
the following torque. ... 17 N·m (12 lb ft)
Unlocking the shaft
Loosen locking screw (2) and install the washer (3) to the unlocked position. Tighten the bolt to
the following torque. ... 12 N·m (9 lb ft)
Typical example of a support bracket
(4) Tighten the mounting bolt to the following torque. ... 44 N·m (32 lb ft)
(5) Tighten the mounting bolt and the nut to the following torque. ... 22 N·m (16 lb ft)
Note: The support bracket must be installed after the coolant pump is installed. In order to stop the
distortion of the timing case, finger tighten the bolt (4) and then tighten the nut and bolt (5). Tighten
the bolt (4) .
Tighten the bolts that hold the fuel pump to the front housing to the following torque. ... 25 N·m (18
lb ft)
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i05182810
Fuel Quality - Test

SMCS - 1280-081
Introduction
This test checks for problems regarding fuel quality. Refer to Diesel Fuels and Your Engine,
SEBD0717 for additional details.
Use the following procedure to test for problems regarding fuel quality:
Required Tools
Table 1
Required Tools
5P-2712 Thermometer/Hydrometer 1
Test Procedure
1. Determine if water and/or contaminants are present in the fuel. Check the water separator (if
equipped). If a water separator is not present, proceed to Step 2. Drain the water separator, if
necessary. A full fuel tank minimizes the potential for overnight condensation.
Note: A water separator can appear to be full of fuel when the water separator is actually full of
water.
2. Determine if contaminants are present in the fuel. Remove a sample of fuel from the bottom of
the fuel tank. Visually inspect the fuel sample for contaminants. The color of the fuel is not
necessarily an indication of fuel quality. However, fuel that is black, brown, and/or similar to
sludge can be an indication of the growth of bacteria or oil contamination. In cold temperatures,
cloudy fuel indicates that the fuel may not be suitable for operating conditions. The following
methods can be used to prevent wax from clogging the fuel filter:
◦ Fuel heaters
◦ Blending fuel with additives
◦ Utilizing fuel with a low cloud point such as kerosene
Refer to Operation and Maintenance Manual, "Fuel Recommendations" for more information.
3. Check fuel API with a 5P-2712 Thermometer/Hydrometer for low-power complaints. The
acceptable range of the fuel API is 30 to 45 when the API is measured at 15 °C (60 °F), but
there is a significant difference in energy within this range.
Table 2
Fuel Density (API) (1) Correction Factors
API at
Correction Factor
16 °C (60 °F)
32.0 0.987
35.0 1.000
40.0 1.022
45.0 1.044
(1)
The measured fuel API rating and the corresponding temperature must be corrected to 16 °C (60 °F) before
selecting a fuel correction factor. Use the chart for the fuel density correction factor in order to determine the
fuel API rating at 16 °C (60 °F).
Note: A correction factor that is greater than 1.000 may be the cause of low power and/or poor
fuel consumption.
4. If fuel quality is still suspected as a possible cause to problems regarding engine performance,
disconnect the fuel inlet line, and temporarily operate the engine from a separate source of fuel
that is known to be good. This will determine if the problem is caused by fuel quality. If fuel
quality is determined to be the problem, drain the fuel system and replace the fuel filters.
Engine performance can be affected by the following characteristics:
◦ Cetane number of the fuel
◦ Air in the fuel
◦ Other fuel characteristics
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i05182667
Fuel System - Inspect

SMCS - 1250-040
Introduction
A problem with the components that send fuel to the engine can cause low fuel pressure. This can
decrease engine performance. Use the following procedure to inspect the fuel system.
Check Procedure
1. Check the fuel level in the fuel tank. Ensure that the vent in the fuel cap is not filled with dirt.
2. Check all fuel lines for fuel leakage. The fuel lines must be free from restrictions and faulty
bends. Verify that the fuel return line is not collapsed.
3. Inspect the fuel filter for excess contamination. If necessary, install a new fuel filter. Determine
the source of the contamination. Make the necessary repairs.
4. Service the primary fuel filter (if equipped).
5. Remove any air that may be in the fuel system. Refer to Testing and Adjusting, "Fuel System -
Prime".
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i05779897
Fuel System - Prime

SMCS - 1258-548
If air enters the fuel system, the air must be purged from the fuel system before the engine can be
started. Air can enter the fuel system when the following events occur:
• The fuel tank is empty or the fuel tank has been partially drained.
• The low-pressure fuel lines are disconnected.
• A leak exists in the low-pressure fuel system.
• The fuel filter is replaced.
Use the following procedures in order to remove air from the fuel system:
Type 1 Fuel Filters
Typical example
1. Loosen the vent screw (1) on the secondary fuel filter base.
2. Operate the priming lever of the fuel priming pump to eliminate any air between the fuel
priming pump and the fuel filters.
Note: The fuel priming pump is mechanically operated by the camshaft. If the lobe of the
camshaft is acting upon the arm of the fuel priming pump, the ability to hand prime the fuel
system will be reduced. If the resistance on the priming lever is low, rotate the crankshaft in
order to move the camshaft lobe off the fuel priming pump arm.
3. Operate priming lever of the fuel priming pump by hand. Check that there is correct resistance
on the fuel priming pump. Operate the fuel priming pump until fuel, free of air, comes from the
vent screw.
4. Tighten the vent screw (1) to a torque of 20 N·m (15 lb ft)
5. Energize the stop solenoid on the fuel injection pump. Operate the priming lever of the fuel
priming pump several times.
6. Crank the engine with the throttle lever in the CLOSED position until the engine starts.
7. Start the engine and run the engine at idle for 1 minute.
NOTICE
Do not crank the engine continuously for more than 30 seconds. Allow
the starting motor to cool for two minutes before cranking the engine
again.
8. Cycle the throttle lever from the low idle position to the high idle position three times. The
cycle time for the throttle lever is one second to 6 seconds for one complete cycle.
Note: To purge air from the fuel injection pump on engines with a fixed throttle, the engine
should be run at full load for 30 seconds. The load should then be decreased until the engine is
at high idle. This should be repeated three times. This will assist in removing trapped air from
the fuel injection pump.
9. Check for leaks in the fuel system.
Type 2 Fuel Filters
Typical example
1. Loosen the vent plug (1) on the primary fuel filter base.
2. Operate the priming lever of the fuel priming pump to eliminate any air between the fuel
priming pump and the fuel filters.
Note: The fuel priming pump is mechanically operated by the camshaft. If the lobe of the
camshaft is acting upon the arm of the fuel priming pump, the ability to hand prime the fuel
system will be reduced. If the resistance on the priming lever is low, rotate the crankshaft in
order to move the camshaft lobe off the fuel priming pump arm.
3. Operate priming lever of the fuel priming pump by hand. Check that there is correct resistance
on the fuel priming pump. Operate the fuel priming pump until fuel, free of air, comes from the
vent screw.
4. Tighten the vent plug (1) .
5. Energize the stop solenoid on the fuel injection pump. Operate the priming lever of the fuel
priming pump several times.
6. Crank the engine with the throttle lever in the CLOSED position until the engine starts.
7. Start the engine and run the engine at idle for 1 minute.
NOTICE
Do not crank the engine continuously for more than 30 seconds. Allow
the starting motor to cool for two minutes before cranking the engine
again.
8. Cycle the throttle lever from the low idle position to the high idle position three times. The
cycle time for the throttle lever is one second to 6 seconds for one complete cycle.
Note: To purge air from the fuel injection pump on engines with a fixed throttle, the engine
should be run at full load for 30 seconds. The load should then be decreased until the engine is
at high idle. This should be repeated three times. This will assist in removing trapped air from
the fuel injection pump.
9. Check for leaks in the fuel system.
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i04051469
Fuel System Pressure - Test

SMCS - 1250-081; 1256-081
1. Disconnect the fuel outlet pipe from the fuel transfer pump.
2. Install a pressure gauge that can measure a pressure of up to 70 kPa (10 psi) to the outlet of the
fuel transfer pump.
3. Release the connection at the gauge and operate the priming lever of the fuel transfer pump to
eliminate air from the pipe.
4. When fuel, free of air, flows from the pipe tighten the connection. Ensure that there are no leaks
at the connections between the pump and the gauge.
5. Operate the starting motor for 10 seconds with the engine stop control in the stop position or
with the stop solenoid disconnected.
6. If the pressure on the gauge indicated is less than 26 kPa (3.77 psi) repair or renew the fuel
transfer pump.
7. Check the rate at which the pressure reduces to half the maximum pressure obtained. If the rate
is less than 30 seconds, repair or renew the fuel transfer pump.
8. Remove the gauge and connect the outlet pipe to the transfer pump.
9. Release the vent screw on the fuel filter head. Operate the priming lever until fuel, free of air,
flows from the vent screw. Tighten the vent screw.
10. Connect the engine stop solenoid.
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Specifications
i04047860
Fuel Transfer Pump

SMCS - 1256
S/N - DFM1-UP
S/N - DNP1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - KBS1-UP
S/N - KHR1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - RAR1-UP
S/N - TMF1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Typical example
(1) (2) Tighten the union nuts to the following torque. ... 30 N·m (22 lb ft)
(3) Tighten the setscrews to the following torque. ... 22 N·m (16 lb ft)
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i02652636
Gear Group - Inspect

SMCS - 1206-040
(1) Camshaft gear
(2) Idler gear
(3) Fuel injection pump gear
Note: If one or more of the gears need to be removed for repair, refer to Disassembly and
Assembly, "Gear Group (Front) - Remove" in order to properly remove the gears. Refer to the
Disassembly and Assembly, "Gear Group (Front) - Install" in order to properly install the gears.
1. Inspect the gears for wear or for damage. If the gears are worn or damaged, use new parts for
replacement.
2. Measure the backlash between the camshaft gear (1) and the idler gear (2). Refer to
Specifications, "Gear Group (Front)" for the backlash measurement.
3. Measure the backlash between the idler gear (2) and the crankshaft gear (4). Refer to
4. Measure the backlash between the fuel injection pump gear (3) and the idler gear (2). Refer to
5. Measure the end play on idler gear (2). Refer to Disassembly and Assembly, "Idler Gear -
Install" for the correct procedure. Refer to Specifications, "Gear Group (Front)" for the end play
measurement.
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Specifications
i02796838
Gear Group (Front)

SMCS - 1206
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - KBS1-UP
S/N - KHR1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Gear train
(1) Fuel injection pump drive gear
Tighten the nut to the following torque. ... 24 N·m (18 lb ft)
Release the lock on the fuel injection pump shaft. Torque the nut to the following torque. ... 90
N·m (66 lb ft)
Number of teeth ... 68
Note: Refer to the Specifications Module, "Fuel injection pump" for the locking torque for the fuel
injection pump shaft.
(2) Camshaft gear
Tighten the bolt for the camshaft gear to the following torque. ... 95 N·m (70 lb ft)
(3) Idler gear and hub
Tighten the bolts for the idler gear to the following torque. ... 44 N·m (33 lb ft)
Width of idler gear and split bearing assembly ... 30.164 to 30.135 mm (1.1876 to 1.1864 inch)
Inside diameter of idler gear bearings with flanges ... 50.797 to 50.818 mm (1.9999 to 2.0007
inch)
Outside diameter of idler gear hub ... 50.716 to 50.737 mm (1.9967 to 1.9975 inch)
Clearance of idler gear bearing on hub ... 0.06 to 0.102 mm (0.0024 to 0.0040 inch)
Idler gear end play ... 0.10 to 0.205 mm (0.0039 to 0.0081 inch)
Maximum permissible end play ... 0.38 mm (0.015 inch)
Idler gear end play with roller bearings ... 0.10 to 0.75 mm (0.0039 to 0.0295 inch)
The gear train for the oil pump
(4) Crankshaft gear
Bore diameter of crankshaft gear ... 51.00 to 51.03 mm (2.0079 to 2.0091 inch)
Outside diameter of crankshaft hub ... 51.021 to 51.002 mm (2.0087 to 2.0079 inch)
Clearance of gear on crankshaft ... −0.020 to +0.020 mm (−0.0008 to +0.0008 inch)
(5) Oil pump idler gear
Inside diameter of oil pump idler gear bearing ... 16.012 to 16.038 mm (0.6304 to 0.6314 inch)
Outside diameter of oil pump idler gear shaft ... 15.966 to 15.984 mm (0.6286 to 0.6293 inch)
Clearance of oil pump idler gear bearing on shaft ... 0.028 to 0.072 mm (0.0011 to 0.0028 inch)
End play of the oil pump idler gear ... 0.050 to 0.275 mm (0.0019 to 0.0108 inch)
(6) Oil pump gear
The number of teeth on the oil pump gear ... 17
Backlash values
Backlash between the idler gear (5) and the oil pump drive gear (6) ... 0.05 to 0.15 mm (0.0020
to 0.0059 inch)
Backlash between the oil pump idler gear (5) and the crankshaft gear (4) ... 0.08 to 0.23 mm
(0.0031 to 0.0091 inch)
Backlash between the idler gear (3) and the crankshaft gear (4) ... 0.05 to 0.15 mm (0.0020 to
0.0059 inch)
Backlash between the camshaft gear (2) and the idler gear (3) ... 0.05 to 0.15 mm (0.0020 to
0.0059 inch)
Backlash between the fuel injection pump gear (1) and the idler gear (3) ... 0.05 to 0.15 mm
(0.0020 to 0.0059 inch)
Backlash between the water pump gear (not shown) and the fuel injection pump gear (1) ... 0.05
to 0.15 mm (0.0020 to 0.0059 inch)
Backlash between the power take-off drive ( if equipped) and the idler gear (3) ... 0.05 to 0.250
mm (0.0020 to 0.0098 inch)
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i05293439
Gear Pump (Pilot) - Test

SMCS - 5085-081-GT
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - KBS1-UP
S/N - KHR1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - YBE1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Flow meter tool layout
(1) Swing motor
(2) Connector at swing motor
(3) 6V-9840 Swivel Tee
(4) Makeup line (swing motor)
(6) 6V-9509 Face Seal Plug
(7) 4C-9910 Portable Hydraulic Tester (Flow meter)
(8) Pilot line (delivery line from the pilot pump)
(9) Connector at pilot pump
(10) Pilot filter
(14) Pilot pump
(30) 5K-9090 O-Ring Seal
(31) 5P-0201 Hose
(32) 5P-1010 Sleeve
(33) 4C-8767 Coupling
(34) 7M-8485 O-Ring Seal
(35) 4C-6481 Coupler Assembly
(36) 4C-6482 Nipple Assembly
(37) 4I-6141 Coupling
(38) 8C-9026 Adapter
(40) 6V-9854 Swivel Elbow
(48) 8C-8762 Elbow
(49) 6V-8398 O-Ring Seal
To prevent personal injury or equipment damage from failure of the

hydraulic test equipment or associated circuit components because of
blocked pump flow, make sure that the test equipment valves are fully
open before starting the engine.
NOTICE
Care must be taken to ensure that fluids are contained during

performance of inspection, maintenance, testing, adjusting, and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
Dispose of all fluids according to local regulations and mandates.
2. Stop the engine.
3. Release the pressure in the hydraulic system. Refer to Testing and Adjusting, "Hydraulic
System Pressure - Release".
4. Attach 311-1362 Vacuum Cap onto the hydraulic tank. Attach an air supply hose onto the
assembly. Apply 276 to 414 kPa (40 to 60 psi). This procedure will pull a vacuum on the
hydraulic system.
Circuit diagram
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(5) Main control valve
(6) Plug
(7) Portable hydraulic tester
(8) Pilot line
(9) Connector at pilot pump
(10) Pilot filter
(12) Engine
(13) Multitach group
(14) Pilot pump
(40) Elbow
5. Install the following tools in accordance with the flow meter tool layout and the circuit
diagram. Refer to Illustration 1 and Illustration 2.
a. Install multitach group (13) on engine (12) .
b. Remove pilot line (8) from the connector at pilot pump (14) .
c. Install seal (49) and plug (6) to the end of pilot line (8) .
d. Install seal (49) and elbow (48) to connector (9) at pilot pump (14) .
e. Install seal (34), coupling (47), seal (34) and nipple assembly (36) to elbow (48) .
Swing motor
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(40) Elbow
f. Disconnect makeup line (4) from connector (2) at swing motor (1) .
g. Assemble and install seals (30), tee (3), swivel elbow (40) and coupling (37) to connector
(2) at swing motor (1) .
h. Remove 311-1362 Vacuum Cap and install the filler plug for the hydraulic tank.
i. Connect portable hydraulic tester (7) and test hoses between nipple assembly (36) at the
pilot pump and coupling (37) at the swing motor.
7. Place the machine controls at the following settings: engine speed dial "10" and AEC switch
OFF. Refer to Testing and Adjusting, "Engine Performance - Test (Engine Speed)" for engine
rpm settings.
Portable hydraulic tester (flow meter)
(7) Portable hydraulic tester (flow meter)
(16) Valve (flow meter)
9. Turn valve (16) on portable hydraulic tester (7) clockwise until pressure gauge (11) on the
portable hydraulic tester shows a reading of 4100 ± 200 kPa (595 ± 29 psi).
10. Record the pilot pump flow at 4100 ± 200 kPa (595 ± 29 psi) in Table 1.
Table 1
Pump Flow Test
Oil temperature C° (F°)

Engine speed (rpm)
Flow measured liter/min (US gpm)
Flow corrected liter/min (US gpm)
New
23 ± 2 (6.0 ± 0.5)
Specification for pump flow liter/min (US gpm)
Service limit
19 (5) (1)
(1)
Minimum Flow
Note: Specifications for pump flow are based on an engine speed of 1700 rpm. To get more accurate
test results, measured flow should be corrected by the following calculation.
Table 2
Measured flow x 1700 rpm
Corrected flow =
measured rpm
Flow measurements must be done in pressure rise.
Service Information System Page 1 of 1
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05357038
General Information
SMCS - 5050; 7000
The diagnostics for the ECM can be accessed through one of the following tools: the Machine
Monitoring System and Cat Electronic Technician (ET). In order to troubleshoot the electronic control
system of the machine, additional information is required from the Service Manual of the machine. The
following list contains some of the required support materials: Service Manual, RENR8068, "Machine
Monitoring System", Service Manual, the Electrical System Schematic, the Parts Manual and the
Operation and Maintenance Manual.
As a guide, a typical system schematic is included at the end of this manual. For an accurate
representation of the machine that is being diagnosed, refer to Electrical System Schematic in the
Service Manual.
When the troubleshooting procedure instructs you to "REPAIR THE HARNESS OR REPLACE THE
HARNESS", use the Electrical System Schematic for the machine that is being serviced to trace the
circuit. Perform continuity checks at the harness connectors in order to locate harness failures. At the
connectors of the components, always check the ground circuit. Less than 5 ohms of resistance is
required between the ground contacts of the connector and the frame ground. The power circuits of the
ECM should have less than 2 ohms of resistance between the contacts of the ground connector and the
frame ground. Less than 5 ohms of resistance is required for signal circuits for normal operation.
Excessive ground resistance that is greater than 5 ohms can cause incorrect diagnosing of problems.
During troubleshooting, inspect all connections before any component is replaced. If these connections
are not clean and tight, permanent electrical problems or intermittent electrical problems can result.
Check that the wires are pushed into the connectors completely. Make sure that the connections are tight
before other tests are made.
Failure of an electrical component can cause the failure of other components. Also, failure of an
electrical component can be caused by the failure of other components. Always attempt to correct the
cause of an electrical system failure before you replace a component.
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i02662145
General Testing and Adjusting Information

SMCS - 5050
Hydraulic oil pressure can remain in the hydraulic systems after the
engine and pump have been stopped. Serious injury can be caused if
this pressure is not released before any service is done on the hydraulic
systems. To prevent possible injury, refer to the section, Testing and
Adjusting, "Hydraulic System Pressure - Release" before any fitting,
hose or component is loosened, tightened, removed or adjusted.
When possible, the work tool must always be lowered to the ground
before service is started. When it is necessary for the boom to be in the
raised position while tests or adjustments are done, be sure that the
boom, stick and work tool have correct support.
The swing lock (if equipped) must be engaged before service is started.
Always move the machine to a location away from the travel of other
machines. Be sure that other personnel are not near the machine when
the engine is running and tests or adjustments are being made.
The correct oil temperature, flow, and pressure are necessary for correct operation. Pump output (oil
flow) is a function of engine speed (rpm) and valve adjustment. Oil pressure is caused by resistance to
the flow of oil.
Visual checks and measurements are the first steps during troubleshooting. Refer to Testing and
Adjusting, "Visual Inspection". Next, perform the operational checks. Refer to Testing and Adjusting,
"Operational Checks". Finally, perform the required tests and adjustments on the machine.
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320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i04405324
Glossary of Electrical Terms

SMCS - 5050; 7000
Abnormal - Means a condition that is not normal. The presence of an abnormal condition or an
abnormal signal indicates the existence of a problem. A warning is activated in order to alert the
operator.
Active - Pertains to the status of a fault or to the status of a service code. When the fault is active, the
fault is currently present.
Alert Indicator - An alert indicator is a red indicator lamp. The alert indicator is located on the top
portion of the monitoring system display. The alert indicator notifies the operator of an abnormal
condition. When only the alert indicator is illuminated, a Warning Category 1 is indicated.
Alternating Current (AC) - An alternating current is electrical current which flows in both
directions alternately.
Ampere - Amperes are the unit of measure for the flow of electrical current in a circuit.
+Battery - Pertains to any of the harness wiring which is part of the circuit that connects to the +
battery post.
+V - +V is a constant voltage that is supplied to a component. This voltage provides electrical power
for the component operation. +V is provided by an electronic control module or the battery.
Cat® Data- Link - Cat data-link is an electrical connection for communication. This connection has
onboard devices that use the data-link (ECM, CMS, VIMS, electronic drivetrain, electronic
dashboards, and service tools such as the Cat Electronic Technician). The Cat data-link is also the
medium that is used for programming and troubleshooting with Cat service tools.
Cat Electronic Technician (Cat ET) - This service tool is a diagnostic service tool for a personal
computer (PC). This software program is designed to replace the ECAP service tool.
Circuit - A circuit is a continuous path along a conductor for the flow of electrical current. A circuit
goes from an electrical source, through various components, and back to the electrical source.
Code - See Diagnostic Codes.
Component Identifier (CID) - A CID is a code that is used to identify a particular component.
Communication Adapter - The communication adapter provides a communication link between the
ECM and the Cat ET. The adapter converts Cat data-link communication to RS-232 communication.
Conductor - A conductor is a substance that can transfer an electrical current.
Connector Contact - A connector contact is the component that actually makes the electrical
connection between the harness connector and another connector plug.
Current - A current is the movement of electricity along a conductor. Current is measured in

amperes.
Data Event - The ECM recognizes the occurrence of an abnormal machine operation. When the
ECM receives a combination of signals, the ECM decides when the machine is operating abnormally.
Data events are logged by the ECM and data events are viewed by using a service tool.
Data-Link - See "Cat data-link".
Deadband - During this portion of the range of movement of a sensor such as the throttle position
sensor, the output signal remains constant.
Demand Fan Control - A system which controls the fan speed according to the coolant temperature.
This system is controlled by the engine ECM. The hydraulic fan motor operates at a minimum speed
when the coolant temperature is below a specific value. Fan speed increases as the coolant
temperature increases.
Detected Fault - A fault that has been found by the ECM. The fault is recorded and diagnostic
information is available in the service mode.
Diagnostic - Pertains to the monitoring of information that is abnormal and/or the recording of
information that is abnormal. Diagnostic information can be accessed from the service, the status, the
tattletale, or the numeric readout mode.
Diagnostic Code - A code which describes a problem in a system.
Digital Sensors - Digital sensors produce PWM signal (duty cycle signal). These sensors are powered
from a power supply of 8 to 28 DCV.
Digital Signal - This signal is a PWM signal (duty cycle) that has a variable width and a constant
amplitude. Also see Pulse Width Modulation (PWM).
Diode - A diode is an electrical device that will allow current to pass in one direction only.
Direct Current (DC) - Direct current flows in only one direction along a conductor from a point of
high potential to a point of lower potential.
Display - Display refers to the gauges, the indicators, or the readouts within the Caterpillar
Monitoring System display area.
Duty Cycle - See Pulse Width Modulation (PWM).
ECM - Electronic control module
Failure Mode Identifier (FMI) - An FMI is a diagnostic code that identifies the type of failure that
has occurred. The FMI consists of two-digit code which is preceded by a decimal point ".". This code
is shown on the display area when the main display module is in service mode.
Flash Programming - A means of programming the personality module in the ECM without needing
to replace the module.
Floating - An input that is not connected to the positive source or connected to ground
Fuse - A fuse is a replaceable safety device for an electrical circuit.
Ground - A ground is any part of a wiring circuit that accidentally touches a part of the machine
frame.
Grounded Circuit - A grounded circuit is a connection of any electrical unit to any part of the
machine. In a grounded circuit, the electrical circuit is completed to the power source.
Harness - A harness is the bundle of wiring that connects components in the system.
Harness Code - The harness code provides the characteristics of the machine such as the size of the
engine, idle speed, tire size, and attachments. The message display uses the data-link to provide the
harness code to the implement ECM.
Hertz (Hz) - Hz is a measurement of frequency in cycles per second.
Hold or On Hold - Pertains to the holding of diagnostic information that is shown on the fault lamp
when the ECM is in the service mode.
Indicator - Indicator is any of the items within the Cat Monitoring System display. Indicators operate
in an ON, FLASHING, or OFF manner to bring attention to a machine condition.
Jumper - A jumper is a piece of wire that is used to make an electrical connection during
troubleshooting.
Machine Code - The machine code is a two-digit number. The machine code is assigned to a
particular harness code for a particular machine by the ECM. Each sales model has a specific harness
code.
Machine Service Connector - A socket that is used to connect a service tool to the onboard
electronic systems such as the implement ECM or the drivetrain ECM. The machine service
connector is mounted on the machine and the Cat data-link is used for the connection.
Module Identifier (MID) - An MID is a diagnostic code that identifies the ECM which diagnosed
the fault. The two-digit code is displayed in the message area of the message display when the
machine is in the service mode.
Ohm - An ohm is the standard unit for measuring resistance to the flow of electrical current.
Open Circuit - If an electrical wire or a connection is broken, the flow of electrical current through
the circuit is interrupted.
Parameter - A parameter is a programmable value which determines the characteristics of the engine
and/or of the electrical system.
Personality Module - A personality module is a small module that is inserted into the ECM. The
personality module contains all of the instructions for the ECM and the performance maps for the
ECM in a specific engine application.
Plug (connector) - A plug is a fitting for making an electrical connection to a circuit. Insert the plug
into a receptacle or into the body of electrical equipment.
Pull Up Voltage - A voltage that is supplied from within an ECM through an internal resistor. The
reference voltage is used to monitor the state (Open/Short) of a signal circuit.
Present - Pertains to the status of a fault or to the status of a service code. When a fault is present, the
fault is currently active.
Pulse Width Modulation (PWM) - The PWM is a signal that consists of variable pulse widths at
fixed intervals. The duty cycle can be varied.
Receptacle (connector) - A receptacle is an electrical fitting that receives the plug assembly in an
electrical circuit.
Resistor - A resistor is a device that provides a resistance to current flow. A resistor is made of wire
or of carbon.
Sales Model Harness Code - The harness code informs the ECM of the information that is flashed
into the ECM. The ECM uses the data-link to communicate the harness code information to the ET.
This information is necessary because the ECM can operate on different sales models.
Scroll - When you scroll through information in the display area, all available sets of diagnostic
information are shown by one set at a time. A set of diagnostic information is shown briefly. Then,
the display automatically advances to the next set. After all sets have been shown, the sets are
repeated.
Sensor - A sensor is a device that measures conditions such as pressure, temperature, or movement.
This information is sent as an electrical signal that can be interpreted by the ECM.
Service Code - A service code describes a condition in an electrical control system. This code is
stored in the control for the service technician.
Service Tool Connector - See the Machine Service Connector.
Short Circuit - If one part of a circuit contacts another part of the same circuit, the flow is diverted
from the desired path.
Signal - Pertains to the condition of the control inputs that are sent to the ECM. A ground signal has
continuity with the frame ground. An open signal is not connected to the frame ground and the
voltage is approximately 5 DCV. A +battery signal is at the same voltage as the battery (25 to 30
DCV).
Signal Wire - The signal wire is a harness wire that connects a sensor or switch to the ECM.
Solenoid - A solenoid is a coil that is used to produce a magnetic field. The solenoid usually performs
some type of mechanical work.
Supply Voltage - Supply voltage is a constant voltage that is supplied to a component in order to
provide electrical power for the operation of the component. Supply voltage may be generated by the
ECM. Also, supply voltage may be battery voltage that is supplied by machine wiring.
Switch Input - Switch input is any ECM input which is expecting a ground signal, an open signal or
a +battery signal.
System Voltage - System voltage is the actual voltage that exists between the + battery post and the
frame ground. System voltage is also known as +battery voltage.
Undetected Fault - A fault that is not detected by the main display module, but is found by the
operator or service technician. The many diagnostic functions of the main display module assist with
the troubleshooting of undetected faults.
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i02404376
Glow Plugs - Test

SMCS - 1412-081
Continuity Check of the Glow Plugs

The following test will check the continuity of the glow plugs.
1. Disconnect the power supply and the bus bar.
2. Use a suitable digital multimeter to check continuity (resistance). Turn the audible signal on the
digital multimeter ON.
3. Place one probe on the connection for the glow plug and the other probe to a suitable ground.
The digital multimeter should make an audible sound. Replace the glow plug if there is no
continuity.
4. Check the continuity on all the glow plugs.
Checking The Operation of The Glow Plug

The following test will check the operation of the glow plugs.
1. Disconnect the power supply and the bus bar.
2. Connect the power supply to only one glow plug.
3. Place a suitable ammeter on the power supply wire.
4. Connect a suitable digital multimeter to the terminal on the glow plug and to a suitable ground.
5. Turn the switch to the ON position in order to activate the glow plugs.
Table 1
12 Volt System
Amp Time (sec)
16.6 Initial
12 5.7
9 11.1
7 20
6 60
Table 2
24 Volt System
Amp Time (sec)
9 Initial
7 3.3
6 5.3
3 60
6. Check the reading on each of the glow plugs.
7. If there is no reading on the ammeter check the electrical connections. If the readings on the
ammeter are low replace the faulty glow plug. If there is still no reading replace the faulty glow
plug.
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Specifications
i05987950
Handle Control (Travel)

SMCS - 5051-LK
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TMF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 170-9497 Pilot Operated Hydraulic Control Gp , 216-2680 Handle Control
Gp , 196-3295 Pilot Operated Hydraulic Control Gp , 214-1316 Pilot Operated Hydraulic
Control Gp , 237-5352 Pilot Operated Hydraulic Control Gp , 237-9078 Pilot Operated
Hydraulic Control Gp , and 155-7162 Handle Control Gp
Before assembly, apply blue Loctite 243 to the
1 2 095-0728 Screw
threads.
A - - Amount of free play is 12.4 degrees.
2 4 8T-4191 Bolt Torque to 33.3 ± 3.4 N·m (295.0 ± 30.0 lb in).
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Specifications
i04374387
Handrail
SMCS - 7256
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CXY1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 170-2602 Handrail Gp , 256-1644 Handrail Gp , and 142-3835 Handrail Gp

1 3 135-8578 Bolt As Apply red Loctite 271 to the threads.
Shutdown SIS
Previous Screen
Product: EXCAVATOR

i05293509
Travel on Level Ground - Test

SMCS - 4351-081
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - KBS1-UP
S/N - KHR1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - YBE1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Table 1
Required Tools
Description Qty
Measuring Tape 1
Stopwatch 1
(A) Preliminary run 5 m (16.4 ft)
(B) Travel distance 20 m (65.6 ft)
(C) Bucket height 0.5 to 1 m (1.6 to 3.3 ft)
1. Travel distance must be at least 25 m (82 ft) long. Travel test ground must be hard and as level
as possible.
2. Draw a 25 m (82 ft) straight line on travel test ground as a reference line.
4. Place the machine controls at the following settings: Engine speed dial "10" and AEC switch
OFF.
6. The bucket should be empty.
7. Position the machine so that one track is parallel with the reference line. Position the machine
for the travel test. Refer to Illustration 1.
8. Place the travel speed control switch in HIGH position.
9. Move the machine by operating both travel levers at the same time.
10. The first 5 m (16.4 ft) are for a preliminary run. Measure the travel time that is required to
travel the remaining 20 m (65.6 ft). Measure the time that is required in each direction.
11. Measure the travel deviation from the reference line.
12. Place the travel speed control switch on the LOW position and repeat Steps 9 through 11.
Table 2
Travel Time (time in seconds)
Travel Speed New Rebuild Service Limit
Forward
HIGH 14.0 or less 15.0 or less 16.0 or less
Reverse
Forward
LOW 22.8 or less 24.3 or less 25.8 or less
Reverse
Note: The following table represents the travel deviation (distance) from the reference line.
Table 3
Travel Deviation
mm (inch)
Forward
HIGH 800 (31.5) or less 1200 (47.2) or less 1500 (59.1) or less
Reverse
Forward
LOW 800 (31.5) or less 1200 (47.2) or less 1500 (59.1) or less
Reverse
INTERACTIVE SCHEMATIC
Bookmarks X
*This document is best viewed at a
Options
screen resolution of 1024 X 768.
Features
Cover Page
To set your screen resolution do the following:
Tables RIGHT CLICK on the DESKTOP.
Component Select PROPERTIES.
Connector
CLICK the SETTINGS TAB.
Schematic
Machine Views
MOVE THE SLIDER under SCREEN RESOLUTION
Chassis View until it shows 1024 X 768.
Cab View CLICK OK to apply the resolution.
Engine View
*Due to different monitor sizes and PDF reader preferences
The Bookmarks panel will allow you to there may be some variance in linked schematic locations
quickly navigate to points of interest.
Click here to save a copy of

EC-C2 E-C60 this interactive schematic
EC-C3
to your desktop
E-C61
VIEW ALL CALLOUTS
EC-C1
When only one callout is showing on a
machine view, clicking on this button will
Click on any text that is BLUE and make all of the callouts visible. This
underlined. These are hyperlinks button is located in the top right corner
that can be used to navigate the of every machine view page.
schematic and machine views.
ELECTRICAL SYMBOLS BASIC HYDRAULIC

HOTKEYS (Keyboard Shortcuts) COMPONENT SYMBOLS
T

Switch Circuit Breaker Pump
FUNCTION KEYS
Switch Switch Switch
or Motor Variability
Click here to view the

Zoom In “CTRL” / “+” Schematic Symbols
Fluid
Conditioner
Spring
(Adjustable)
Zoom Out “CTRL” / “-” and Definitions page
Fit to Page “CTRL” / “0” (zero)

Hand Tool “SPACEBAR” (hold down)
Find “CTRL” / “F”
SCHEMATIC SYMBOLS AND DEFINITIONS
VALVES INTERNAL PASSAGEWAYS PUMPS BASIC HYDRAULIC

ENVELOPES FLOW IN ONE
DIRECTION
FLOW ALLOWED IN
EITHER DIRECTION
PARALLEL
FLOW
CROSS
FLOW
FIXED DISPLACEMENT
COMPONENT SYMBOLS
One Position Two Position Three Position Unidirectional Bidirectional Pump

Infinite Two Three Variability
Positioning Position Position or Motor
PORTS VARIABLE DISPLACEMENT
NON- COMPENSATED
Spring
CYLINDERS Fluid
(Adjustable)
Two-way Three-Way Four-Way Conditioner
CONTROL
AB AB
Single Acting Double Acting
MOTORS Pressure
FIXED DISPLACEMENT Spring
P T P T Compensation
Normal Position Shifted Position Infinite Position
CHECK
Control Line Restriction
ACCUMULATORS Unidirectional Bidirectional
Valves (Variable)
VARIABLE DISPLACEMENT
Basic Spring Shuttle Pilot NON- COMPENSATED
Symbol Loaded Controlled Spring Loaded Gas Charged Line Restriction
Restriction
(Fixed)
MAIN AUX.
Line Restriction
PILOT CONTROL Variable and Pressure
2-Section
RELEASED PRESSURE ROTATING SHAFTS Compensated
Pump
External Return Internal Return
Attachment Pump: Variable and
REMOTE SUPPLY PRESSURE Pressure Compensated
Internal Hydraulic Pneumatic

Simplified Complete Supply Pressure Energy Triangles
COMBINATION CONTROLS
LINES MEASUREMENT
Solenoid Solenoid Solenoid Solenoid and Servo Thermal Detent Crossing Joining
or Manual and Pilot Pilot or Manual Pressure Temperature Flow
MANUAL CONTROL FLUID STORAGE RESERVOIRS
Push-pull Lever Manual Shutoff General Manual Push Button Pedal Spring Vented Pressurized Return Above Fluid Level Return Below Fluid Level
HYDRAULIC SYMBOLS - ELECTRICAL ELECTRICAL SYMBOLS

G
M T

Transducer Transducer Generator Electric Pressure Pressure Switch Temperature Electrical
Switch Switch Switch Switch Circuit Breaker
(Fluid) (Gas / Air) Motor Switch (Adjustable) Switch Wire
BASIC ELECTRICAL COMPONENT SYMBOLS HARNESS AND WIRE SYMBOLS

Wire, Cable, or Harness Assembly Identification:
Fuse: A component in an electrical circuit that will open the circuit if too much current flows through it. Includes Harness Identification Letters and Harness
Connector Serialization Codes (see sample).
Switch (Normally Open): A switch that will close at a specified point (temp, press, etc.). The circle indicates
that the component has screw terminals and a wire can be disconnected from it.
AG-C4 L-C12
Switch (Normally Closed): A switch that will open at a specified point (temp, press, etc.). 111-7898 3E-5179
No circle indicates that the wire cannot be disconnected from the component. Part Number: for 1
Connector Plug
Ground (Wired): This indicates that the component is connected to a grounded wire. 2
The grounded wire is fastened to the machine.
Plug Receptacle
Pin or Socket Number
Ground (Case): This indicates that the component does not have a wire connected to ground.
It is grounded by being fastened to the machine. Harness Identification Letter(s): (A, B, C, AA, AB, AC, ...)
Reed Switch: A switch whose contacts are controlled by a magnet. A magnet closes the contacts of Harness Connector Serialization Code: The "C" stands for
"Connector" and the number indicates which connector in the
a normally open reed switch; it opens the contacts of a normally closed reed switch.
harness (C1, C2, C3, ...)
L-C12
Sender: A component that is used with a temperature or pressure gauge. 3E-5179
The sender measures the temperature or pressure.
T Its resistance changes to give an indication to the gauge of the temperature or pressure. 5A
Component
Relay (Magnetic Switch): A relay is an electrical component that is activated by electricity. Fuse (5 Amps) 9X-1123 Part Number
The electromagnet can open or close the switch part of the relay. 325-AG135 PK-14
Harness identification code:
This example indicates wire group 325, Wire Gauge
Solenoid: A solenoid is an electrical component that is activated by electricity. wire 135 in harness "AG". Wire Color
The electromagnet can open or close a valve or move a piece of metal that can do work. 1 Deutsch connector: Typical representation
of a Deutsch connector. The plug contains all
2 sockets and the receptacle contains all pins.
Magnetic Latch Solenoid: An electrical component that is activated by electricity and held latched by a
permanent magnet. It has two coils (latch and unlatch) that make electromagnet 1 Sure-Seal connector: Typical representation
when current flows through them. It also has an internal switch that places of a Sure-Seal connector. The plug and receptacle
2 contain both pins and sockets.
the latch coil circuit open at the time the coil latches.
UENR3603-03
July 2013
320D2 Excavator
Hydraulic System
GBA1-UP
LMA1-UP
YEA1-UP
XBB1-UP
TMF1-UP
FKK1-UP
DFM1-UP
JFM1-UP
HDM1-UP
LMA1-UP
DNP1-UP
KHR1-UP
ZCS1-UP
NBT1-UP
© 2013 Caterpillar, All Rights Reserved Printed in U.S.A.

COMPONENT TABLE
Component Locations
Part Machine Schematic
Description
Number Location Location
Accumulator Gp - Hydraulic (Charged) 169-6981 1 B-8
Filter & Valve Gp - Pilot (Hydraulic Oil) 158-8987 2 A-6
Filter Gp - Oil (Hydraulic Return) 188-4140 3 A-8
Filter Gp - Oil (Hydraulic, Case Drain) 289-8194 4 A-6
Manifold Gp - Control (Pilot Oil Supply) 215-5037 5 C-9
Motor Gp - Swing 334-9968 6 F-13
Motor Gp - Travel (LH) 209-5992 7 C-14
Motor Gp - Travel (RH) 209-5992 8 C-12
Pump Gp - Main Hydraulic 376-8862 9 C-3
Sensor As - Pressure (Drive Pump) 366-9312 10 A-5
Sensor As - Pressure (Idler Pump) 366-9312 11 C-5
Swivel Gp 234-4440 12 A-12
Valve Gp - Check 369-8420 13 A-9
Valve Gp - Load Control (Boom Drift Red, Line Relief) 255-5683 14 G-2
Valve Gp - Load Control (Stick Drift Red, Line Relief) 255-5680 15 G-8
Valve Gp - Main Control ( Standard) 259-7464 16 F-10
Valve Gp - Main Control (Heavy - Lift) 285-1323 17 F-10
Valve Gp - Pilot (Joystick) (LH) 297-0533 18 I-14
Valve Gp - Pilot (Joystick) (RH) 297-0532 19 I-12
Valve Gp - Pilot (Travel) 310-0414 20 J-9
Valve Gp - Pressure Reducing (Boom, Swing Priority) 310-0210 21 C-7
Valve Gp - Shuttle 169-6974 22 D-7
Valve Gp - Shuttle 185-0462 23 H-13
Valve Gp - Solenoid (Heavy Lift) 352-7176 24 D-5
Valve Gp - Swing Cushion (Fine Swing) 322-8716 25 E-13
Valve Gp - Travel Counterbalance (LH) 322-8714 26 B-14
Valve Gp - Travel Counterbalance (RH) 322-8714 27 B-11
TAP TABLE
Tap Locations
Pressure, Sampling, and Sensor
Tap Schematic
Description
Number Location
AA Idler Pump Delivery Pressure C-5
BB Drive Pump Delivery Pressure A-5
CC Power Shift Pressure 1 A-3
DD Pump Drain Pressure B-5
EE Power Shift Pressure 2 C-3
PG Pilot Pump Delivery Pressure A-6
SOS Oil Sampling Port A-6
(20)VALVE GP
TP PILOT (TRAVEL)
310-0414
TT
5 6 3 2 PD-Dr TRAVEL(L) TRAVEL(R)

1
4
4 1
(18)VALVE GP 5 6 3 2 PD-Pi
PILOT (JOYSTICK) (LH)
297-0533
JLP JRP (FWD) (BKWD) (BKWD) (FWD)
JLT JRT T2 T5 T1 T3 T6 T4
BUCKET CYLINDER STICK CYLINDER BOOM CYLINDER
STICK SWING BUCKET BOOM
bL1 aL1 aR1 bR1
(19)VALVE GP
(OUT) (IN) (R) (L) (OPEN) (CLOSE) (DOWN) (UP)
PILOT (JOYSTICK) (RH)
JL1 JL3 JL2 JL4 JR2 JR4 JR1 JR3 297-0532
AR3 BR3 AL3 BL3 AR4 BR4
A1 A2 A3 A4 A5 A6 A7 A8 (23)VALVE GP
SHUTTLE
185-0462
(14)VALVE GP
LOAD CONTROL (15)VALVE GP
B1 B2 B3 B4 B5 B6 B7 B8 SDr SPi LOAD CONTROL
(BOOM DRIFT RED, LINE RELIEF)
255-5680 (STICK DRIFT RED, LINE RELIEF)
aR3 bR3 bL2 aL2 SPi BR5 BL3 AL3 BDr BPi 255-5683
aL4 AL4 BR4 BR5 AR5

aL4 Pi1 bR5 Pi2
SP3 SP2 BP3 BP2
aL4-2 AR5 aL2
BPi bL3 bL4 aL3 PRV-P1
bR4 aR4 AL4 aL3 aL2-2 BL1 Di4 Pi4 BR1 AR1 AR4
aR5
(6)MOTOR GP
AL2 AL1 aR3 Pi1
SWING
334-9968 (16)VALVE GP C/V-T R3
SWG SWING MOTOR MAIN CONTROL BL2 aL1 aR1 BR3 AR3 aR4
PRKG BK (STANDARD) T SP1 ST aR2 BR2 AR2 BP1 BT
CONTROL PG 259-7464
(UP) BL3 R2 (IN) (L) (BACK) (BACK) (CLOSE) (DOWN) BR4 R1 (IN)
(17)VALVE GP
SWG DR MAIN CONTROL
MOTOR
DRAIN (HEAVY LIFT)
MU 285-1323
MU
AG BG
A1 DR B1
(25)VALVE GP
SWING CUSHION
(FINE SWING)
322-8716
(OUT) (R) (FWD) (FWD) (OPEN) (UP) (OUT)

bR2
DST
Di3 bL2-2 bR1
bR3 bR4 Di1 bR5 HR
PR
(R) A B (L) HL bL4 Di2 Pi2 bL3 Pi3 bL2 bL1
PL
BL2 AL2 RR FR
aL2-2 bL2-2
(7)MOTOR GP (8)MOTOR GP Pi5
(22)VALVE GP U Pi5 (24)VALVE GP
TRAVEL (LH) TRAVEL (RH) SOLENOID (HEAVY LIFT)
209-5992 209-5992 SHUTTLE HEAVY LIFT
164-6979 352-7176
TRAVEL MOTOR (LEFT) TRAVEL MOTOR (RIGHT)
aL4-2
T P
(5)MANIFOLD GP aR5 Pi3 HL - Dr HL - Pi
CONTROL (9)PUMP GP
2 SPEED MAIN HYDRAULIC
TRAVEL (PILOT OIL SUPPLY)
HL - Pi 230-2720 HEAVY LIFT 376-8862
CONTROL (21)VALVE GP
B1 A1 B2 A2
PRESSURE REDUCING G2
(BOOM, SWING PRIORITY) (11)SENSOR AS Pn2
Pi4 MF-P Di4 PD-Pi PD-Dr Di3 PRESSURE M2 HL
310-0210
Pp3 Pp3 (IDLER PUMP) Ps2
P2 Pi1 P-IN PSA2 DR1 PSA1 T-OUT2 DR2
AA EE
366-9312
Dr A2
PRV-Dr PsM2
T1 T1 PL
P1 P2
T2 T2 DST G4
PRV-P1 PRV-P2
(4)FILTER GP LINE PATTERNS
PRV-P2 OIL (HYDRAULIC, CASE DRAIN) S1 Pm Pressure Line
(1)ACCUMULATOR GP 289-8194 Pilot / Load Sensing Pressure
HYDRAULIC (CHARGED) S3
M
Drain / Return Lines
AG BG BG AG
P1 169-6981 Component Group
Attachment
PAC SDr G3
Dr Air Line
DR3 DR4 Pi2 DR5 T-OUT1 DR6 BDr DD DrM PsM1

CALLOUTS
HL - Dr DRAIN YY Taps (Pressure, Sampling, Sensor - by letter)
SWG MF-TANK FILTER A3 52 Components (By number)
A B B A PRV-Dr PRKG BK Di1 MF-P PR Ps1 CC

CONTROL A1 HYDRAULIC CIRCUIT COLOR DESCRIPTIONS
HR
BB
PILOT PUMP OUTPUT
Di2 OUT IN Pn1 DRIVE PUMP OUTPUT
Ps M1 PS PRESS EPRV
LEFT TRAVEL CONTROL AND LEFT TRAVEL MOTOR CIRCUIT
(26)VALVE GP (27)VALVE GP SUPPLY LINE
(13)VALVE GP G1
STICK CONTROL AND STICK CYLINDER CIRCUIT
TRAVEL COUNTERBALANCE TRAVEL COUNTERBALANCE R3 MF-TANK T

ATTACHMENT CIRCUIT
SWING CONTROL AND SWING MOTOR CIRCUIT
(BKWD) (FWD) (BKWD) (FWD) CHECK Pi
(LH) (RH) DRAIN / RETURN LINE
AL1 BL1 AR1 BR1 369-8420 (10)SENSOR AS

SWING BREAK CONTROL CIRCUIT
322-8714 322-8714 B D
IDLER PUMP OUTPUT
TRAVEL SPEED CONTROL CIRCUIT
2 SPEED PRESSURE Ps BUCKET CONTROL AND BUCKET CYLINDER CIRCUIT
RIGHT TRAVEL CONTROL AND LEFT TRAVEL MOTOR CIRCUIT
TRAVEL A G PG PC (DRIVE PUMP) BOOM CONTROL AND BOOM CYLINDER CIRCUIT
CONTROL C/V-T 366-9312

POWER SHIFT CONTROL CIRCUIT
HEAVY LIFT CONTROL CIRCUIT
SWG PG SOS
DRAIN (12)SWIVEL GP E F (3)FILTER GP (2)FILTER & VALVE GP THIS SCHEMATIC IS FOR THE 320D2 AND 323D2 EXCAVATOR HYDRAULIC SYSTEM
MOTOR C
FILTER 234-4440 OIL (HYDRAULIC RETURN) PILOT (HYDRAULIC OIL)
MEDIA NUMBER: UENR3603-01
DRAIN 188-4140 SCHEMATIC PART NUMBER: 369-8400, CHANGE: 00, VERSION: HE
158-8987 Components are shown installed on a fully operable machine with the key and engine off, transmission shifter
in neutral and with parking brake set.
MU Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations.
MACHINE RIGHT SIDE VIEW
VIEW ALL CALLOUTS
7 26
27 8
MACHINE TOP VIEW
VIEW ALL CALLOUTS
13 6 25 12
3
MAIN CONTROL VALVE VIEW
VIEW ALL CALLOUTS
16
17
14
21
24
15
1
5
22
NOT
SHOWN
MAIN PUMP VIEW
VIEW ALL CALLOUTS
PG
SOS
DD
CC
BB
AA
10
AA
11
EE
OPERATOR STATION TOP VIEW
VIEW ALL CALLOUTS
20
18 23 19
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Specifications
i05984010
Hydraulic Oil Cooler Lines Group

SMCS - 1374; 5057
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KHR1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PJP1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Rear view
Table 1
Specification for 376-6308 Hydraulic Oil Cooler Lines Gp
1 6 8T-4956 Bolt Torque to 50 ± 10 N·m (37 ± 7 lb ft).
Torque to
2 4 7X-2544 Bolt
55 ± 10 N·m (41 ± 7 lb ft).
Torque to
3 4 101-7402 Bolt
50 ± 10 N·m (37 ± 7 lb ft).
Torque to
4 2 096-4883 Locknut
22 ± 3 N·m (195 ± 27 lb in).
Shutdown SIS
Previous Screen
Product: EXCAVATOR

i01246594
Hydraulic System Pressure - Release

SMCS - 4250-553-PX; 5050-553-PX
The release of hydraulic pressure in a hydraulic circuit is required before service is performed to that
hydraulic circuit. Release the pressure in the following hydraulic circuits before any hydraulic lines
are disconnected or removed from that hydraulic circuit.
• Boom hydraulic circuit
• Stick hydraulic circuit
• Bucket hydraulic circuit
• Swing hydraulic circuit
• Travel hydraulic circuit
• Attachment hydraulic circuits (if equipped)
• Pilot hydraulic circuit
• Return hydraulic circuit
Note: Refer to the Disassembly and Assembly Manual for additional information concerning service
of the components of specific hydraulic circuits.
Release Of Hydraulic Pressure From A Single Hydraulic

Circuit
Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic system after the
engine has been stopped. Serious injury can be caused if this pressure is
not released before any service is done on the hydraulic system.
Make sure all of the attachments have been lowered to the ground, and
the oil is cool before removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the filler cap is cool
enough to touch with your bare hand.
NOTICE

performance of inspection, maintenance, testing, adjusting and repair
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Perform the following Steps in order to release the hydraulic pressure from a single hydraulic circuit
of the main hydraulic system.
2. Fully retract the stick cylinder rod. Adjust the position of the bucket so that the bucket is
parallel to the ground. Lower the boom until the bucket is flat on the ground. Refer to
Illustration 1.
3. Shut off the engine.
4. Turn the engine start switch to the ON position without starting the engine.
5. Place the hydraulic activation control lever in the UNLOCKED position.
6. Move only the joysticks or the pedals of the hydraulic circuit that requires service to the FULL
STROKE positions. This will release the high pressure only in that single hydraulic circuit.
This will also release any pressure that might be present in the pilot hydraulic circuit.
Note: If the desired hydraulic circuit that requires service requires the activation of a switch for
operation, activate the necessary switches for the operation of the hydraulic circuit.
7. Place the hydraulic activation control lever in the LOCKED position.
8. Turn the engine start switch to the OFF position.
9. Slowly loosen the filler plug on the hydraulic tank and release the pressure from the hydraulic
tank. Leave the filler plug loose for a minimum of 45 seconds. This will release the pressure
that may be present in the return hydraulic circuit.
10. Tighten the filler plug on the hydraulic tank to the specified torque.
11. The pressure in the single hydraulic circuit that requires service is now released and lines and
components can be disconnected or removed from that hydraulic circuit.
Release Of Hydraulic Pressure From Multiple Hydraulic

Circuits
Make sure all of the attachments have been lowered to the ground, and
NOTICE

containing fluids.

Perform the following Steps in order to release the hydraulic pressure from multiple hydraulic circuits
of the main hydraulic system.
2. Fully retract the stick cylinder rod. Adjust the position of the bucket so that the bucket is
parallel to the ground. Lower the boom until the bucket is flat on the ground. Refer to
Illustration 2.
4. Turn the engine start switch to the ON position without starting the engine.
6. Move only the joysticks or the pedals of the hydraulic circuit that requires service to the FULL
STROKE positions. This will release the high pressure only in that hydraulic circuit. This will
also release any pressure that might be present in the pilot hydraulic circuit.
Note: If the hydraulic circuit that requires service requires the activation of a switch for
operation, activate the necessary switches for the operation of the hydraulic circuit.
7. Place the hydraulic activation control lever in the LOCKED position.
9. Place the hydraulic activation control lever in the UNLOCKED position. Do not move any
joysticks or pedals from the NEUTRAL position during this step. Do not activate any
switches during this Step.
10. Return the hydraulic activation control lever to the LOCKED position.
12. Repeat Steps 4 through 11 for each additional hydraulic circuit that requires service.
13. After releasing the hydraulic pressure in each of the desired hydraulic circuits, place the
hydraulic activation control lever in the LOCKED position.
14. Turn the engine start switch to the OFF position.
15. Slowly loosen the filler plug on the hydraulic tank and release the pressure. Leave the filler
plug loose for a minimum of 45 seconds. This will release the pressure that may be present in
the return hydraulic circuit.
16. Tighten the filler plug on the hydraulic tank to the specified torque.
17. The pressure in the multiple hydraulic circuits that require service is now released and lines and
components can be disconnected or removed from those hydraulic circuits.
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Specifications
i05496789
Hydraulic Tank and Filter

SMCS - 5056; 5068
S/N - A6F1-UP
S/N - A8F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CXY1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - FAL1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NZF1-UP
S/N - PBE1-UP
S/N - PCM1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TMF1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 395-3364 Hydraulic Tank and Filter Gp
Item Qty
1 4 8T-4195 Bolt Torque to 30 ± 7 N·m (266 ± 62 lb in).

Torque to
2 1 207-6403 Plug
68 ± 7 N·m (50 ± 5 lb ft).
Torque to
3 3 8T-4136 Bolt
30 ± 7 N·m (266 ± 62 lb in).
Before you mount the sight gauge group, boss
threads must be clean.
4 1 347-6081 Sight Gauge Gp
Tighten the 236-3259 Special Bolt to
6 ± 1 N·m (53 ± 9 lb in).
Torque to
5 4 8T-4908 Bolt
26 ± 3 N·m (230 ± 27 lb in).
164-5590 Fluid Sampling Torque to
6 1
Valve Gp 14.5 ± 1.5 N·m (128.3 ± 13.3 lb in).
164-5567 Quick Disconnect Torque to
7 1
Coupler As 31 ± 3 N·m (274 ± 27 lb in).
342-2924 Temperature Sender Torque to
8 1
As 34 ± 5 N·m (301 ± 44 lb in).
Torque to
9 1 9J-7031 Drain Plug
68 ± 7 N·m (50 ± 5 lb ft).
227-0590 Breather
Table 2
Tighten to
10 - -
3.5 ± 1.0 N·m (31.0 ± 8.9 lb in).
Apply red Loctite 271 to the mating surface.
11 - - Tighten to
9 ± 1 N·m (80 ± 9 lb in).
387-3783 Hydraulic Screen Gp
Table 3
Torque to
12 1 8T-4133 Nut
29 ± 5 N·m (257 ± 44 lb in).
Torque to
13 1 8T-4133 Nut
18 ± 2 N·m (159 ± 18 lb in).
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Specifications
i05861188
Hydraulic Tank Mounting

SMCS - 5056-MT
S/N - DFM1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - KCE1-UP
S/N - KHR1-UP
S/N - LMA1-UP
S/N - NBT1-UP
S/N - PJP1-UP
S/N - TMF1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Table 1
Specification for 415-7828 Hydraulic Tank and Mounting Gp and 433-8178 Hydraulic Tank
and Mounting Gp
Before assembly, apply red Loctite 271 to the threads.
1 6 -
Tighten bolts to 270 ± 40 N·m (199 ± 30 lb ft).
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Specifications
i02676273
Lifter Group
SMCS - 1209
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - KBS1-UP
S/N - KHR1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
(A) Diameter of the lifter body ... 18.987 to 19.012 mm (0.7475 to 0.7485 inch)
Bore diameter in the cylinder block ... 19.05 to 19.082 mm (0.7500 to 0.7513 inch)
Clearance
Clearance of the lifter ... 0.038 to 0.095 mm (0.0015 to 0.0037 inch)
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i05383589
Machine Drift on a Slope - Check

SMCS - 4095-535
Specification
Table 1
"Machine Drift on a Slope - Check"
Drift mm (inch)
New Rebuild Service Limit Actual
0 0 0
Introduction
Measuring the amount of drift of the machine on a slope will determine if there is a need to check the
travel brake.
Note: The machine configuration that is used during this test can affect the results of this test. Refer
to Testing and Adjusting, "Operational Checks" for the machine configurations that were used for this
test.
Required Tools
Table 2
Required Tools
Description Qty
Stopwatch 1
Scale 150 mm (6 inch) 1
Test Procedure
1. Place the machine on a slope of 12 degrees. The surface of the slope must be hard and smooth.
2. Position the implements, as shown. Refer to Illustration 1.
4. To indicate the relative position of the machine to the slope, put a mark on both the track and
the track roller frame. Refer to Illustration 2.
5. Stop the engine.
6. Measure the machine movement on the slope after 3 minutes.
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Specifications
i04047857
Main Bearing Journal

SMCS - 1202; 1203
S/N - -
The original size of the main bearing journal ... 83.99 to 84.01 mm (3.307 to 3.308 inch)
Maximum permissible wear of the main bearing journals ... 0.040 mm (0.0016 inch)
Surface finish of bearing journals and crank pins ... 0.2 microns
Width of new main bearing journal ... 35.235 to 35.165 mm (1.3872 to 1.3844 inch)
The shell for the main bearings

The shells for the main bearings are available for remachined journals which have the following
undersize dimensions.
Undersize bearing shell ... 0.25 mm (0.010 inch)

Thickness at center of the shells ... 2.083 to 2.089 mm (0.0820 to 0.0823 inch)
Width of the main bearing shells ... 31.62 to 31.88 mm (1.244 to 1.255 inch)
Clearance between the bearing shell and the main bearing journals ... 0.026 to 0.084 mm (0.0010 to
0.0033 inch)
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Specifications
i05661964
Main Control Valve

SMCS - 5051-MV
S/N - A6F1-UP
S/N - A8F1-UP
S/N - BZP1-UP
S/N - CXY1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - XBB1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
(Section A-A) Boom regeneration valve
(Section B-B) Stick unloading valve and stick regeneration valve
(Section C-C) Line relief valve for the negative flow control in the right valve bank
(Section D-D) Stick (2)
(Section E-E) Boom (1)
(Section F-F) Bucket
(Section G-G) Attachment
(Section H-H) Travel (Right side)
(Section J-J) Straight Travel
(Section K-K) Travel (Left side)
(Section L-L) Swing
(Section M-M) Stick (1)
(Section N-N) Boom (2)
(Section P-P) Line relief valve for the negative flow control in the left valve bank
Table 1
Specification for 259-7464 Main Control Valve Gp , and 270-5920 Main Control Valve Gp
Item Qty
111-9959 Pipe Plug

1 2 Torque to 35 ± 3 N·m (26 ± 2 lb ft).
Torque to
2 40 8T-4195 Bolt
49 ± 5 N·m (36 ± 4 lb ft).
8T-6759 Pipe Plug Torque to
3 2
15 ± 2 N·m (133 ± 18 lb in).
Torque to
4 1 114-0623 Nut
7.4 ± 0.5 N·m (65.5 ± 4.4 lb in).
121-1491 Solenoid Lubricate the O-ring seals of the solenoid valve group
5 1
Valve Gp lightly with the lubricant that is being sealed.
Torque to
6 2 225-4818 Plug As
10 ± 1 N·m (89 ± 9 lb in).
Boom Regeneration Valve
Section A-A
Table 2
Item
Lubricate the O-ring seals and the backup ring lightly with lubricant that is being sealed.
-
Torque to
7 1 236-6421 Plug
220 ± 20 N·m (162 ± 15 lb ft).
33.45 mm (1.317 inch).
Test force is
8 1 153-5293 Spring
21.2 ± 1.1 N (4.8 ± 0.2 lb).
38.55 mm (1.518 inch).
Torque to
9 1 153-5290 Plug
285 ± 30 N·m (210 ± 22 lb ft).
Torque to
10 1 153-5291 Connector
105 ± 10 N·m (77 ± 7 lb ft).
52.5 mm (2.07 inch).
Test force is
11 1 153-5288 Spring
145.4 ± 7.3 N (32.7 ± 1.6 lb).
55.7 mm (2.19 inch).
Stick Unloading Valve and Stick Regeneration Valve
Section B-B
Table 3
Item
-
Torque to
12 1 236-6421 Plug
220 ± 20 N·m (162 ± 15 lb ft).
33.45 mm (1.317 inch).
Test force is
13 1 153-5293 Spring
21.2 ± 1.1 N (4.8 ± 0.2 lb).
38.55 mm (1.518 inch).
52.5 mm (2.07 inch).
Test force is
14 1 153-5288 Spring
145.4 ± 7.3 N (32.7 ± 1.6 lb).
55.7 mm (2.19 inch).
Torque to
15 2 153-5290 Plug
285 ± 30 N·m (210 ± 22 lb ft).
Torque to
16 1 153-5291 Connector
105 ± 10 N·m (77 ± 7 lb ft).
Torque to
17 1 123-2485 Plug
35 ± 3 N·m (26 ± 2 lb ft).

65.5 mm (2.58 inch).
Test force is
18 1 153-5311 Spring
179.8 ± 9.0 N (40.4 ± 2.0 lb).
80.4 mm (3.17 inch).
Negative Flow Control (Right side)
Section C-C
Table 4
Item
-

44.0 mm (1.73 inch).
Test force is
19 1 107-6370 Spring
565.3 ± 45.2 N (127.1 ± 10.2 lb).
49.3 mm (1.94 inch).
Torque to
20 1 109-5152 Relief Valve Gp
145 ± 15 N·m (107 ± 11 lb ft).
As required, Use the following shims:
Thickness is
1 4J-7386 Shim
21 0.25 mm (0.010 inch).
Thickness is
1 4J-7385 Shim
1.22 mm (0.048 inch).
Torque to
22 1 236-6419 Plug
240 to 260 N·m (177 to 192 lb ft).
23.9 mm (0.94 inch).
Test force is
23 1 7I-1248 Spring
6.174 N (1.388 lb).
28.0 mm (1.10 inch).
Stick (2)
Section D-D
Table 5
Item Qty
-
Torque to
24 1 236-6419 Plug
240 to 260 N·m (177 to 192 lb ft).
23.9 mm (0.94 inch).
Test force is
25 1 7I-1248 Spring
6.174 N (1.388 lb).
28.0 mm (1.10 inch).
55.5 mm (2.19 inch).
Test force is
26 1 104-7294 Spring
594 ± 30 N (134 ± 7 lb).
62.27 mm (2.452 inch).
Before assembly, apply red Loctite 271 to threads of
153-5276 Special Bolt bolt.
27 1
Torque to
50.0 to 59.8 N·m (36.9 to 44.1 lb ft).
Boom (1)
Section E-E
Table 6
Item Qty
-
Torque to
28 1 236-6419 Plug
240 to 260 N·m (177 to 192 lb ft).
23.9 mm (0.94 inch).
Test force is
29 1 7I-1248 Spring
6.174 N (1.388 lb).
28.0 mm (1.10 inch).
352-7122 Relief Valve Gp Torque to
30 1
95 ± 14 N·m (70 ± 10 lb ft).
Torque to
31 - Nut
58.8 ± 5.9 N·m (43.4 ± 4.4 lb ft).
Torque to
32 - Nut
19.6 ± 2.0 N·m (173.5 ± 17.7 lb in).
55.5 mm (2.19 inch).
Test force is
33 1 104-7293 Spring
390 ± 20 N (88 ± 4 lb).
59.68 mm (2.350 inch).
Before assembly, apply red Loctite 271 to threads of
bolt.
34 1 153-5276 Special Bolt
Torque to
50.0 to 59.8 N·m (36.9 to 44.1 lb ft).
Bucket
Section F-F
Table 7
Item Qty
-
Torque to
35 1 236-6419 Plug
240 to 260 N·m (177 to 192 lb ft).
23.9 mm (0.94 inch).
Test force is
36 1 7I-1248 Spring
6.174 N (1.388 lb).
28.0 mm (1.10 inch).
Torque to
37 - Nut
19.6 ± 2.0 N·m (173.5 ± 17.7 lb in).
Torque to
38 - Nut
58.8 ± 5.9 N·m (43.4 ± 4.4 lb ft).
39 1
95 ± 14 N·m (70 ± 10 lb ft).
40 1 153-5276 Special Bolt Before assembly, apply red Loctite 271 to threads of
bolt.
Torque to
50.0 to 59.8 N·m (36.9 to 44.1 lb ft).
55.5 mm (2.19 inch).
Test force is
41 1 104-7293 Spring
390 ± 20 N (88 ± 4 lb).
59.68 mm (2.350 inch).
Attachment
Section G-G
Table 8
Item Qty
Torque to
42 1 236-6419 Plug
240 to 260 N·m (177 to 192 lb ft).
23.9 mm (0.94 inch).
Test force is
43 1 7I-1248 Spring
6.174 N (1.388 lb).
28.0 mm (1.10 inch).
310-0404 Control Valve Plug Torque to
44 2
Gp 95 ± 14 N·m (70 ± 10 lb ft).
45 1 104-7293 Spring Length under test force is

55.5 mm (2.19 inch).
Test force is
390 ± 20 N (88 ± 4 lb).
59.68 mm (2.350 inch).
Before assembly, apply red Loctite 271 to
threads of bolt.
Torque to
50.0 to 59.8 N·m (36.9 to 44.1 lb ft).
Travel (Right side)
Section H-H
Table 9
55.5 mm (2.19 inch).
Test force is
47 1 104-7296 Spring
393 ± 20 N (88 ± 4 lb).
60.03 mm (2.363 inch).
Before assembly, apply red Loctite 271 to threads.
48 1 153-5276 Special Bolt Torque to
50.0 to 59.8 N·m (36.9 to 44.1 lb ft).
Straight Travel
Section J-J
Table 10
Item
-
Torque to
49 2 201-9263 Plug
225 to 240 N·m (166 to 177 lb ft).
24.6 mm (0.97 inch).
Test force is
50 1 6I-6795 Spring
2.19 ± 0.17 N (0.49 ± 0.04 lb).
30.0 mm (1.18 inch).
32.200 mm (1.2677 inch).
Test force is
51 1 4I-3510 Spring
218.676 ± 10.934 N (49.161 ± 2.458 lb).
35.600 mm (1.4016 inch).
Torque to
135 ± 10 N·m (100 ± 7 lb ft).
Torque to
53 1 171-0035 Holder
75 ± 10 N·m (55 ± 7 lb ft).
Torque to
54 1 4I-7714 Nut
50 ± 10 N·m (37 ± 7 lb ft).
24.0 mm (0.94 inch).
Test force is
55 2 4T-3148 Spring
4.00 ± 0.20 N (0.90 ± 0.04 lb).
34.8 mm (1.37 inch).
Torque to
56 1 158-8135 Guide
50 ± 7 N·m (37 ± 5 lb ft).
53.0 mm (2.09 inch).
Test force is
57 1 6E-5169 Spring
196.1 ± 15.7 N (44.1 ± 3.5 lb).
72.2 mm (2.84 inch).
7.9 mm (0.31 inch).
Test force is
58 1 2S-2596 Spring
4.226 ± 0.338 N (0.950 ± 0.076 lb).
33.3 mm (1.31 inch).
Travel (Left side)
Section K-K
Table 11
Item
-
Torque to
59 1 250-2447 Plug
240 to 260 N·m (177 to 192 lb ft).
50.0 to 59.8 N·m (36.9 to 44.1 lb ft).
55.5 mm (2.19 inch).
Test force is
61 1 104-7296 Spring
393 ± 20 N (88 ± 4 lb).
60.03 mm (2.363 inch).
Swing
Section L-L
Table 12
Item
-
Torque to
62 1 250-2447 Plug
240 to 260 N·m (177 to 192 lb ft).
23.9 mm (0.94 inch).
Test force is
63 1 7I-1248 Spring
6.174 N (1.388 lb).
28.0 mm (1.10 inch).
55.5 mm (2.19 inch).
Test force is
64 1 104-7293 Spring
390 ± 20 N (88 ± 4 lb).
59.68 mm (2.350 inch).
50.0 to 59.8 N·m (36.9 to 44.1 lb ft).
Stick (1)
Section M-M
Table 13
Item
-
Torque to
66 1 264-9961 Plug
305 to 325 N·m (225 to 240 lb ft).
31.5 mm (1.24 inch).
Test force is
67 1 153-5306 Spring
4.10 ± 0.20 N (0.92 ± 0.04 lb).
39.2 mm (1.54 inch).
68 1
95 ± 14 N·m (70 ± 10 lb ft).
Torque to
69 - Nut
58.8 ± 5.9 N·m (43.4 ± 4.4 lb ft).
Torque to
70 - Nut
19.6 ± 2.0 N·m (173.5 ± 17.7 lb in).
55.5 mm (2.19 inch).
Test force is
71 1 104-7293 Spring
390 ± 20 N (88 ± 4 lb).
59.68 mm (2.350 inch).
Before assembly, apply red Loctite 271 to
threads.
Torque to
50.0 to 59.8 N·m (36.9 to 44.1 lb ft).
Boom (2)
Section N-N
Table 14
Item
-
Torque to
73 3 225-4818 Plug As
10 ± 1 N·m (89 ± 9 lb in).
61.3 mm (2.41 inch).
Test force is
74 1 158-8177 Spring
163.8 ± 8.2 N (36.8 ± 1.8 lb).
67.60 mm (2.661 inch).
34.0 mm (1.34 inch).
Test force is
75 1 158-8186 Spring
2.63 ± 0.34 N (0.59 ± 0.08 lb).
41.4 mm (1.63 inch).
76 1 4T-3148 Spring 24.0 mm (0.94 inch).
Test force is
4.00 ± 0.20 N (0.90 ± 0.04 lb).

34.8 mm (1.37 inch).
Torque to
77 1 250-2446 Plug
240 to 260 N·m (177 to 192 lb ft).
55.5 mm (2.19 inch).
Test force is
78 1 104-7294 Spring
594 ± 30 N (134 ± 7 lb).
62.27 mm (2.452 inch).
50.0 to 59.8 N·m (36.9 to 44.1 lb ft).
Negative Flow Control (Left side)
Section P-P
Table 15
Torque to
145 ± 15 N·m (107 ± 11 lb ft).
81 1 107-6370 Spring 44.0 mm (1.73 inch).
Test force is
565.3 ± 45.2 N (127.1 ± 10.2 lb).

49.3 mm (1.94 inch).
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i02437323
Main Hydraulic Pump Air - Purge

SMCS - 5070-542-AI
Table 1
Required Tools
6V-4143 Coupler (1) 1
177-7860 Hose As 1
(1)
Install the coupler on one end of the hose assembly and leave the other end of the hose assembly open to the air.
When the main pumps have been serviced or the hydraulic oil has been replaced, remove the air from
the hydraulic system. Remove the air from the hydraulic system in the following manner:
NOTICE

containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Tool Catalog" for tools and supplies suitable to collect and contain
Make sure all of the work tools have been lowered to the ground, and
Pump compartment
(1) Connector
(2) O-Ring seal
(3) Case drain hose
(4) Negative flow control hose
1. While the engine is stopped, disconnect hose (3) from connector (1) .
2. Remove connector (1) and O-Ring seal (2) from the pump housing.
3. Fill the main pumps with oil.
4. Inspect O-Ring seal (2). If the seal is damaged, replace the seal.
5. Install O-Ring seal (2) and connector (1) at the pump housing.
6. Connect hose (3) to connector (1). Tighten hose (3) to the specified torque.
NOTICE
To avoid system damage, make sure that the hydraulic pump is

properly filled with hydraulic oil before start-up.
8. Place the engine at low idle position. Raise the boom and hold the boom in this position.
9. Slowly loosen hose (4) until oil begins to flow around the hose connection.
10. Tighten hose (4) to the specified torque.
11. Stop the engine and slowly lower the boom until the bucket is on the ground. This pressurizes
the hydraulic tank.
(5) Pressure tap
12. Connect 6V-4143 Coupler and 177-7860 Hose As to pressure tap (5) until oil begins to flow
from the open end of the hose.
13. Remove the quick coupler from pressure tap (5) .
Shutdown SIS
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Specifications
i05241839
Main Hydraulic Pump

SMCS - 5070-MV
S/N - A6F1-UP
S/N - A8F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - RAC1-UP
S/N - RAR1-UP
S/N - SDC1-UP
S/N - SDZ1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 272-6955 Main Hydraulic Pump Gp , 376-8862 Main Hydraulic Pump Gp
and 397-3680 Main Hydraulic Pump Gp
Apply blue Loctite High Flex GM to the threads of
1 16 094-1882 Plug plugs.
Torque to 13 ± 2 N·m (115 ± 18 lb in).
189-9763 O-Ring Seal Lubricate the bore lightly with the lubricant being
2 8
sealed.
Extension of the dowel from the body (3) is
C 2 129-7979 Dowel
6.8 to 9.0 mm (0.27 to 0.35 inch).
Extension of the dowel from the body (3) is
D 2 129-7979 Dowel
3.8 to 6.0 mm (0.15 to 0.24 inch).
Section A-A
Table 2
Item Qty
192-0573 Extension of the dowel pin from the surface of the bearing (4) is
E 4
Dowel Pin 2.67 to 2.92 mm (0.105 to 0.115 inch).
5 6 - Lubricate the bore lightly with the lubricant being sealed.
173-3498 The location of both ports for the barrel must be matched during
6 1
Barrel assembly of the right pump and the left pump.
Apply blue Loctite High Flex GM to the threads of plugs.

190-4896 Plug
7 2 Torque to
25 ± 3 N·m (221 ± 27 lb in).
31.0 mm (1.22 inch).
118-4057 Test force is
8 18
Spring 360 ± 36 N (81 ± 8 lb).
35.900 mm (1.4134 inch).
Section F-F
Table 3
Item Qty
9 6 - Lubricate the bore lightly with the lubricant being sealed.

Lubricate the sealing lip of the lip type seal lightly with the
341-2862 Lip lubricant that is being sealed. Assemble the lip type seal to a
10 1
Type Seal maximum of
0.5 mm (0.02 inch) in parallel to the surface of the body (3) .
11 2
44 ± 4 N·m (32 ± 3 lb ft).
173-3496 The location of both ports for the barrel must be matched during
12 1
Barrel assembly of the right pump and the left pump.
094-1875 Extension of the dowel from the body (3) is
H 4
Dowel 5.55 to 5.80 mm (0.219 to 0.229 inch).
Shutdown SIS
Previous Screen
Product: EXCAVATOR

i05113795
Main Pump (Flow) - Test - Hydraulic Power

SMCS - 5070-081-FW
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - KHR1-UP
S/N - LMA1-UP
S/N - NBT1-UP
S/N - TMF1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Table 1
Required Tools
Pressure Gauge (
8T-0861 2
60000 kPa (8700 psi))
4C-9910 Portable hydraulic tester (flow meter) 1
This test measures two pump flow to the boom cylinders at the boom foot. Both pumps are tested for
output flow at specified pressures. If the results from this test are not within the specification, refer to
Testing and Adjusting, "Main Pump (Flow) - Test (Constant Horsepower Flow Control)" in order to
isolate any problem with the pumps.
(A) Message display
(B) Monitor
The electronic control module is located in the compartment behind the cab.
(C) Alarm lamp
(D) Electronic control module
Note: Before starting main pump flow tests, check message display (A) on monitor (B) and alarm
lamp (C) on electronic control module (D) for normal operation. If no faults are present, perform the
operational checks. Refer to Testing and Adjusting, "Operational Checks".
Note: If the operational checks (cycle time) indicate that slow speed of an implement is common to
the circuits of one pump, the problem is most likely in the hydraulic system. Then perform the pump
flow tests. Refer to Testing and Adjusting, "Main Pump (Flow) - Test (Hydraulic Power)".
Note: The engine, the fuel, or the working altitude may be the problem if the operational checks
indicate that slow speed of an implement is common to both pump circuits.
Note: Perform the following procedures before testing the main pump flow.
• Set the pilot pressure to the specifications in Testing and Adjusting, "Relief Valve (Pilot) - Test
and Adjust" for the machine.
• Set the main relief valve to specifications. Refer to Testing and Adjusting, "Relief Valve
(Main) - Test and Adjust" for the machine.
• Calibrate the power shift pressure. Refer to Testing and Adjusting, "Calibration" for the
Machine Electronic Control System.
Flow meter tool layout at boom foot
(1) Connector (boom cylinder lines)
(2) 6V-9831 Cap
(3) Boom cylinder
(4) Line (boom cylinder head end)
(5) Line (boom cylinder rod end)
(8) 7J-9108 O-Ring Seal
(9) 6V-8943 Reducer
(11) 6V-9510 Plug
(12) 7I-0048 Connector
(17) 5P-1010 Sleeve
(18) 5P-0201 Hose
Circuit diagram
(2) 6V-9831 Cap
(3) Boom cylinder
(11) 6V-9510 Plug
(23) Control valve (supply oil from drive pump for BOOM RAISE)
(24) Control valve (supply oil from idler pump for BOOM RAISE)
(25) Joystick control for BOOM RAISE
(26) 8T-0861 Pressure gauge
(27) Idler pump
(28) Drive pump
Preparation
NOTICE

containing fluids.

Cat products.
1. Position the machine on level ground in the service position. Refer to Illustration 5.
2. Stop the engine.
hydraulic system.
Pump compartment
(29) Pressure tap (delivery pressure for drive pump)
(30) Pressure tap (delivery pressure for idler pump)
5. Connect 60000 kPa (8700 psi) pressure gauges (26) to pressure tap (29) and pressure tap (30)
for delivery pressure from both pumps.
a. Disconnect line (6) and line (7) from boom cylinder (3) .
b. Install O-ring seal (8) and plug (11) to the end of line (6) and line (7) .
c. Install cap (2) on connector (1) for the boom cylinder lines.
d. Disconnect line (4) and line (5) from boom cylinder (3) .
e. Install cap (2) on connector (1) for the boom cylinder lines.
f. Install O-ring seal (8), reducer (9), O-ring seal (10), connector (12), O-ring seal (13), and
nipple assembly (14) to the end of line (4) and line (5) .
g. Remove 311-1362 Vacuum Cap and install the filler plug for the hydraulic tank.
h. Connect portable hydraulic tester (21) and the test hoses between nipple assembly (14)
on line (4) and nipple assembly (14) on line (5) .
Note: In order to avoid damage to the flow meter, make sure that the direction of oil flow
is correct. The proper direction of flow is from line (4) for the boom cylinder head end,
through flow meter (21), and return through line (5) for the boom cylinder rod end.
Test

To prevent personal injury and/or equipment damage from failed lines

or components while the hydraulic test equipment is returned to the
open flow position, slowly open the hydraulic test equipment valve while
monitoring the pump flow.
If pump flow does not increase as the valve is opened, shut the engine
off and determine what is preventing the pump from upstroking.
rpm settings.
4. Move the joystick for the boom to the full BOOM RAISE position. Hold the joystick for the
boom in this position.
(31) Valve
5. Turn valve (31) on portable hydraulic tester (21) clockwise. Record pump flow at each of the
following pressures in Table 2. Use pressure gauge (26) at pressure tap (29) and pressure tap
(30) to monitor delivery pressure from both pumps.
6. Return the joystick for the boom to the NEUTRAL position.
Table 2
320D2, 320D2 L
Hydraulic Power Pump Flow at Boom Foot
Measuring Points
BOOM RAISE
15700 kPa (2465 29400 kPa (3625
psi) psi)
Oil temperature °C (°F)
Specification for flow rate liter/min (US New
gpm) 320.0 (84.00) (1) 153.5 (40.50) (1)
(1)
Minimum
Note: Flow measurements must be done only during pressure rise.
Shutdown SIS
Previous Screen
Product: EXCAVATOR

i05293006
Main Pump (Flow) - Test - Maximum Output Flow, Constant

Horsepower Flow Control
SMCS - 5070-081-FW
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - KHR1-UP
S/N - LMA1-UP
S/N - NBT1-UP
S/N - TMF1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
This test measures individual pump flow at the pump. Each pump is tested individually for output
flow at specified pressures. The pump that is not being tested is not under load and the pump remains
at low-pressure standby.
The electronic control module is located in the compartment behind the cab.
(1) Alarm lamp
(2) Electronic control module
(3) Monitor
(4) Message display
Note: Before starting main pump flow tests, check message display (4) on monitor (3) and alarm
lamp (1) on electronic control module (2) for normal operation. If no faults are present, perform the
operational checks. Refer to Testing and Adjusting, "Operational Checks".
Note: If the operational checks (cycle time) indicate that slow speed of an implement is common to
the circuits of one pump, the problem is most likely in the hydraulic system. Then perform the pump
flow tests. Refer to Testing and Adjusting, "Main Pump (Flow) - Test (Constant Horsepower Flow
Control)".
Note: The engine, the fuel, or the working altitude may be the problem if the operational checks
indicate that slow speed of an implement is common to both pump circuits.
Note: Perform the following procedures before testing the main pump flow.
• Set the pilot pressure to the specifications in Testing and Adjusting, "Relief Valve (Pilot) - Test
and Adjust" for the machine.
• Set the main relief valve to specifications. Refer to Testing and Adjusting, "Relief Valve
(Main) - Test and Adjust" for the machine.
• Calibrate the power shift pressure. Refer to Testing and Adjusting, "Calibration" for the
Machine Electronic Control System.
(1) Swing motor
(4) Makeup Line (swing motor)
(6) Negative flow control line (drive pump)
(11) Delivery line (idler pump)
(12) Delivery line (drive pump)
(13) Negative flow control line (idler pump)
(17) 9U-7335 Blocking Cover
(23) Drive pump
(24) Idler pump
(29) 1U-8303 Fitting
(31) 5P-0201 Hose
(32) 5P-1010 Sleeve
(42) 1P-3703 Rectangular Seal
(46) 8T-4184 Bolt
(47) 8T-4223 Hard Washer
(48) 6V-0400 Half Flange
(49) 1U-8292 Adapter
Circuit diagram
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(11) Delivery line for idler pump
(12) Delivery line for drive pump
(21) Engine
(22) Multitach
(23) Drive pump
(24) Idler pump
(40) Elbow
(50) Pressure tap (power shift pressure)
Drive Pump
NOTICE

containing fluids.

Cat products.
Note: Perform the test for the drive pump and the test for the idler pump one at a time.
Pump compartment
(23) Drive pump
(24) Idler pump
2. Stop the engine.
hydraulic system.
a. Disconnect delivery line (12) from drive pump (23) .
b. Install seal (42) , half flanges (48) and blocking cover (17) to the end of delivery line (12)
by using bolts (46) and washers (47) .
c. Assemble and install seal (42) , adapter (49) , seals (34) , fitting (29) and nipple assembly
(36) on drive pump (23) by using half flanges (48) , bolts (46) and washers (47) .
Swing motor (top view)
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(40) Elbow
d. Disconnect makeup line (4) from connector (2) at swing motor (1) .
e. Assemble and install seals (30) , tee (3) , swivel elbow (40) and coupling (37) to
connector (2) at swing motor (1) .
f. Install seal (30) and makeup line (4) to tee (3) .
h. Connect portable hydraulic tester (10) and the test hoses between nipple assembly (36) at
drive pump (23) and coupling (37) at the swing motor.
i. Connect 60000 kPa (8700 psi) pressure gauge (9) to pressure tap (16) for delivery
pressure for the drive pump.
j. Install multitach group (22) on engine (21) . This is used to monitor engine speed.
Idler Pump
NOTICE

containing fluids.

Cat products.
Pump compartment
(23) Drive pump
(24) Idler pump
2. Stop the engine.
hydraulic system.
a. Disconnect delivery line (11) from idler pump (24) .
b. Install seal (42) , half flanges (48) and blocking cover (17) to the end of delivery line (11)
c. Assemble and install seal (42) , adapter (49) , seals (34) , fitting (29) and nipple assembly
(36) on idler pump (24) by using half flanges (48) , bolts (46) and washers (47) .
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(40) Elbow
e. Assemble and install seals (30) , tee (3) , swivel elbow (40) and coupling (37) to
connector (2) at swing motor (1) .
h. Connect portable hydraulic tester (10) and the test hoses between nipple assembly (36) at
i. Connect 60000 kPa (8700 psi) pressure gauge (9) to pressure tap (8) for delivery pressure
for the idler pump.
j. Install multitach group (22) on engine (21) . This is used to monitor engine speed.
Maximum Output Flow Test



Monitor
(A) Display
(B) Keypad
(C) Up key
(D) Left key
(E) Down key
(F) Right key
(G) Cancel key
(H) Home key
(I) OK key
(J) Menu key
3. Start Service Mode and input a fixed power shift pressure of 1300 kPa (188 psi).
a. Press menu key (J) .
Note: If more than thirty seconds pass between pushing the keys on the keypad, the menu
mode will be Canceled and the previous display will be restored to message display (A) .
b. Press right key (F) in order to highlight "SERVICE" menu option.
c. After the "SERVICE" option is highlighted, press OK key (I) .
d. After OK key (l) is pressed, the screen in Illustration 14 will be displayed. The password
for the service menu is "FFF2". The keys for direction are used to input the password.
Press left key (D) or right key (F) in order to change the position of the flashing
character. Press OK key (I) in order to enter the highlighted character.
e. After entering the last letter of the password, the monitor will continue with the
"SERVICE" screen.
f. Repeatedly press down key (E) in order to highlight the "DEVICE TEST" line on the
display.
g. After the "DEVICE TEST" line is highlighted, press OK key (I) .
h. Once the "DEVICE TEST" screen is displayed, press down key (E) until "POWER
SHIFT PRES" appears on the display.
i. When "POWER SHIFT PRES" is highlighted, press OK key (I) .
j. Place the machine controls at the following settings: engine speed dial "10" and AEC
switch OFF. Refer to Testing and Adjusting, "Engine Performance - Test (Engine
Speed)" for engine rpm settings.
Note: Press OK key (I) within 5 seconds after completion of Step 3.j in order to ensure
high idle.
k. The "POWER SHIFT PRES" will now be displayed. Line 4 of the display will now
change to a numeric value. These characters represent the power shift pressure (kPa).
l. Press left key (D) or right key (F) in order to increase or decrease the numeric value that
is displayed on line 4 of the display. Pressing left key (D) decreases the power shift
pressure. Pressing right key (F) increases the power shift pressure.
Note: The value for power shift pressure on the monitor may not always match the
pressure reading on the pressure gauge. Adjust the value on the monitor until the desired
power shift pressure is attained on the pressure gauge that is connected to the pressure tap
for power shift pressure. The actual power shift pressure must be 1300 kPa (188 psi) on
the pressure gauge.
Note: To prevent a change in power shift pressure during the relief valve adjustment, do
not exit the "DEVICE TEST" screen and do not turn the engine start switch to the OFF
position.
Note: Refer to System Operation, "Monitoring System" for additional information on

Service Mode.
4. In order to perform flow measurements for either one of the pumps, the other pump must not be
under load.
(22) Multitach
(26) Valve
following pressures in Table 3. Use pressure gauge (9) at pressure tap (16) to monitor delivery
pressure for the drive pump or use pressure tap (8) to monitor delivery pressure for the idler
pump.
Table 1
Pump Flow Test
8000 kPa (1160 psi)

Drive Pump
Idler Pump
Engine speed (rpm)
Drive Pump
Idler Pump
New
194 ± 5 (28 ± 2.6)
Specification for flow rate liter/min (US gpm)
Service Limit
181 (48) (1)
(1)
Minimum Flow
Note: Specifications for output flow rates are based on an engine speed of 1700 rpm. To attain more
accurate test results, measured flow should be corrected with the following calculation.
Table 2
Corrected flow =
measured rpm
Note: Specifications for output flow rates are based on a power shift pressure at the pump of 1300
kPa (188 psi). The output flow rate changes approximately 6 L/min (1.6 US gpm) for each 100 kPa
(14 psi) of power shift pressure in the lower range of the constant horsepower control. The output
flow rate changes approximately 3 L/min (0.8 US gpm) for each 100 kPa (14 psi) of power shift
pressure in the higher range of the constant horsepower control.
Note: If the output flow rate of the pump is not within the specification, disconnect the negative flow
control line from the pump that is being tested and perform the test again.
Constant Horsepower Control Test



Monitor
(A) Display
(B) Keypad
(C) Up key
(D) Left key
(E) Down key
(F) Right key
(G) Cancel key
(H) Home key
(I) OK key
(J) Menu key
3. Start Service Mode and input a fixed power shift pressure of 2350 kPa (340 psi).
Note: If more than thirty seconds pass between pushing the keys on the keypad, the menu
"SERVICE" screen.
display.
high idle.
for power shift pressure. The actual power shift pressure must be 2350 kPa (340 psi) on
the pressure gauge.
position.

Service Mode.
4. In order to perform flow measurements for either one of the pumps, the other pump must not be
under load.
(22) Multitach
(26) Valve
following pressures in Table 3. Use pressure gauge (9) at pressure tap (16) to monitor delivery
pressure for the drive pump or use pressure tap (8) to monitor delivery pressure for the idler
pump.
Table 3
Pump Flow Test
12000 kPa 17000 kPa 25000 kPa 30000 kPa

(1740 psi) (2465 psi) (3626 psi) (4351 psi)
Flow measured liter/min Drive
(US gpm) Pump
Idler
Pump
Engine speed (rpm)
Drive
Flow corrected liter/min Pump
(US gpm) Idler
Pump
New 153 ± 10 129 ± 8 (34 92 ± 7 (24 ± 81 ± 8 (23 ±

Specification for flow rate (40 ± 2.6) ± 2.1) 1.8) 1.8)
liter/min (US gpm)
Service
120 (32) (1) 103 (27) (1)
Limit 63 (17) (1) 54 (14) (1)
(1)
Minimum Flow
Note: Specifications for output flow rates are based on an engine speed of 1700 rpm. To attain more
accurate test results, measured flow should be corrected with the following calculation.
Table 4
Corrected flow =
measured rpm
Note: Specifications for output flow rates are based on a power shift pressure at the pump of 2350
kPa (340 psi). The output flow rate changes approximately 6 L/min (1.6 US gpm) for each 100 kPa
(14 psi) of power shift pressure in the lower range of the constant horsepower control. The output
flow rate changes approximately 3 L/min (0.8 US gpm) for each 100 kPa (14 psi) of power shift
pressure in the higher range of the constant horsepower control.
Note: If the output flow rate of the pump is not within the specification, disconnect the negative flow
control line from the pump that is being tested and perform the test again.
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i04161812
MID 039 - CID 0041 - FMI 06

SMCS - 1439-038
Conditions Which Generate This Code:
ECM 8VDC Sensor Supply circuit schematic
This diagnostic code is associated with the 8VDC Sensor Supply circuit. An FMI 06 diagnostic code
means the ECM has determined the current of the sensor supply circuit is above normal.
• The sensor supply output is shorted to ground.
• A sensor in the 8VDC circuit has failed.
• The machine ECM may have failed, but is unlikely.
Poor connections are often the cause of a problem in electrical circuits. Before performing this
procedure, inspect all of the harness connectors involved in the circuit. Verify that all of the
connections in the circuit are clean, secure, and in good condition. If a problem is found with
any of the connections: correct the problem and verify that diagnostic code CID 0041 FMI 06 is
still active, before performing this procedure.
Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic
codes now, but clear those codes after the original diagnostic code has been corrected.
Test Step 1. CHECK THE SENSORS VOLTAGE.
A. Turn the disconnect switch and the key start switch to the ON position.
B. Do not disconnect any of the machine harnesses at this time. Check for +8 VDC at the harness
connector of every sensor supplied by the ECM +8 VDC power supply.
Note: An 8VDC Sensor Supply ground return is also found at contact J1-14 (235-BK).
Always check these parallel ground wires. Make sure to repair or replace any that are
found open.
Expected Result:
The voltage readings are 8.0 ± 0.5 DCV.
Results:
• YES - The voltages are 8.0 ± 0.5 DCV. Check if the diagnostic code is still active. If the code is
still active, go to Test Step 2.
• NO - The voltage at one or more of the sensors is not 8.0 ± 0.5 DCV. There is a problem with
the ECM +8 VDC voltage supply.
Repair: Refer to the complete electrical schematics for the machine. Investigate and repair the
+8 VDC power supply problem.
After +8 DCV power supply problem is repaired, check if the 0041 FMI 06 diagnostic code is
still active. If the diagnostic code is still active, go to Test Step 2.
Test Step 2. CHECK THE SENSORS.
A. The disconnect switch and the key start switch remain in the ON position.
B. One at a time, disconnect and reconnect each and every sensor supplied by this ECM 8 VDC
Sensor Supply.
C. While each sensor is disconnected, check the status of the CID 0041 FMI 06 diagnostic code.
Expected Result:
The CID 0041 FMI 06 diagnostic code remains active while each sensor is disconnected and
reconnected.
Results:
• YES - None of the disconnected sensors causes the diagnostic code to change. None of the
sensors are causing the problem. Go to Test Step 4.
• NO - While one sensor is disconnected, the CID 0041 FMI 06 diagnostic code becomes
inactive. That sensor is causing the problem.
Repair: Replace that sensor.
Go to Test Step 4.
Test Step 3. CHECK FOR A SHORT TO GROUND.
A. Turn the disconnect switch and the key start switch to the OFF position.
B. Disconnect both the J1 and J2 harness connectors from the machine ECM.
C. At the J1 machine harness connector for the ECM, measure the resistance from connector
contact J1-27 (E472-GN), the ECM 8 VDC Sensor Supply, to all possible sources of ground in
both the J1 and J2 ECM harness connectors.
Expected Result:
Each resistance is more than 5000 ohms.
Results:
• YES - Each resistance is more than 5000 ohms. Go to Test Step 4.
• NO - A resistance is not more than 5000 ohms. The 8 VDC Sensor Supply output is shorted to
ground.
Repair: Repair or replace the harness.
Go to Test Step 4.
Test Step 4. CHECK THE DIAGNOSTIC CODE STATUS.
A. Reconnect all harness connectors. Make sure that the connectors are fully seated. Observe that
the clips for each connector are securely fastened.
B. Turn the disconnect switch and the key start switch to the ON position.
C. Clear all inactive diagnostic codes.
D. Operate the machine.
E. Check the status of the CID 0041 FMI 06 diagnostic code.
Expected Result:
The CID 0041 FMI 06 diagnostic code is not active.
Results:
• YES - The CID 0041 FMI 06 diagnostic code is no longer active. The code does not exist at
this time.
Repair: The cause for the diagnostic code appears to have been corrected. Return the machine
back to normal operations.
STOP
• NO - The CID 0041 FMI 06 diagnostic code is still active. The problem has not been corrected.
Repair: If you have not inspected the harness connectors in a previous Test Step, do that now.
Clean the contacts of the harness connectors. Check the wires for damage to the insulation
caused by excessive heat, battery acid, or chafing.Perform a 45 N (10 lb.) pull test on each of
the wires that are associated with the sensor circuit.Perform a "wiggle test" on the sensor circuit
of the machine wiring harness, using the Caterpillar Electronic Technician service tool. The
"wiggle test" can be used to detect open or shorted connections in the machine wiring
harness.Reconnect all harness connectors. Make sure that the connectors are fully seated.
Observe that the clips for each connector are fastened. Perform Test Step 4 again. If the
problem has NOT been found, and the original code is still active, the ECM may have
failed.Prior to replacing an ECM, always contact your Dealership Technical Communicator for
possible consultation with Caterpillar, or with the Dealer Solutions Network. This consultation
may greatly reduce repair time. If the ECM needs to be replaced, see Testing and Adjusting,
"Electronic Control Module (ECM) - Replace".
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i04140751
MID 039 - CID 0096 - FMI 04

SMCS - 1273-038-UN
Schematic for the Fuel Level sensor
This diagnostic code is associated with the Fuel Level sensor. An FMI 04 diagnostic code means the
machine ECM has determined the sensor circuit voltage is below normal.
Possible causes for this diagnostic code are:
• The sensor has failed.
• The sensor output signal wire is shorted to ground.
• The machine ECM has failed, but is unlikely.
Note: Poor connections are often the cause of a problem in electrical circuits. Before performing
this procedure, inspect all the machine harnesses and connectors involved in the circuit. Make
sure to verify that all of the connections in the circuit are clean, secure, and in good condition.
Correct any problems found with any of the connections. Verify the diagnostic code CID 0096
FMI 04 is still active, before continuing with this procedure.
codes now, but clear those diagnostic codes when the original diagnostic code has been corrected.
Test Step 1. CHECK THE SENSOR
B. Disconnect the machine harness connector from the Fuel Level sensor.
C. Turn the disconnect switch and the key start switch to the ON position.
D. Observe the status of the diagnostic code.
Expected Result:
The CID 0096 FMI 04 diagnostic code remains active.
Results:
• YES - The diagnostic code remains active. The sensor is correct. Go to Test Step 2.
• NO - The diagnostic code is no longer active. The sensor has failed.
Repair: Replace the sensor.
Go to Test Step 3.
Test Step 2. CHECK THE SENSOR CIRCUIT FOR A SHORT .
A. Turn the key start switch and the disconnect switch to the OFF position.
B. The Fuel Level sensor remains disconnect from the harness connector.
C. Disconnect the machine harness connector from the monitor.
D. At the machine harness connector for the Monitor, measure the resistance from the contact for
wire 495-GNof the Monitor harness connector to all possible sources of ground. Measure the
resistance to all other contacts used in the Monitor harness connector.
Expected Result:
Each resistance measured is more than 5000 ohms.
Results:
• YES - The measurements all are more than 5000 ohms. The harness is correct. Go to Test Step
3.
• NO - A resistance measurement is not more than 5000 ohms. There is a short in the machine
harness.
Repair: The short is between wire 495-GN and the wire with the low resistance. Repair or
replace the machine harness.
Go to Test Step 3.
the clips on each connector are securely fastened.
Expected Result:
The CID CID 0096 FMI 04 diagnostic code is not active.
Results:
• YES - The CID 0096 FMI 04 diagnostic code is not active and does not exist at this time.
Repair: The cause for that problem has been repaired. Return the machine to normal operation.
STOP
• NO - The CID 0096 FMI 04 code is still active. The cause for the code has not been repaired.
Observe that the clips for each connector are securely fastened. From Test Step 1, perform this
procedure again. If the cause for this problem was not found this time, and the original
diagnostic code is still active, the ECM may have failed.Prior to replacing an ECM, always
contact your Dealership Technical Communicator for possible consultation with Caterpillar, or
with the Dealer Solutions Network. This consultation may greatly reduce repair time. If the
ECM needs to be replaced, see Testing and Adjusting, "Electronic Control Module (ECM) -
Replace".
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i04140752
MID 039 - CID 0096 - FMI 05

SMCS - 1273-038-UN
Schematic for the Fuel Level sensor
This diagnostic code is associated with the Fuel Level sensor. An FMI 05 diagnostic code means the
machine ECM has determined the sensor circuit current is below normal.
• There is an open wire in the circuit.
• The attachment code is incorrect.
• The machine ECM has failed, but is unlikely.
Test Step 1. CHECK THE SENSOR.
B. Disconnect the machine harness connector from the Fuel Level sensor.
C. At the Fuel Level sensor machine harness connector, place a jumper wire between the contact
for wire 495-GN to the contact for wire 235-BK in the sensor harness connector.
D. Turn the disconnect switch and the key start switch to the ON position.
E. Observe the status of the CID 0096 FMI 05 diagnostic code.
Expected Result:
Results:
• YES - The diagnostic code remains active. The sensor is not the problem. Go to Test Step 2.
• NO - The diagnostic is no longer active. The sensor has failed.
Go to Test Step 3.
Test Step 2. CHECK THE HARNESS FOR AN OPEN.
B. Disconnect the machine harness connecting the Fuel Level sensor to the Monitor module.
C. The jumper wire in the harness connector remains in place.
D. At the harness connector for the Monitor, measure the resistance from signal contact 1 (wire
495-GN) to 1 (wire 235-BK) in the Monitor harness connector.
Expected Result:
The resistance is less than 5.0 ohms.
Results:
• YES - The resistance is less than 5.0 ohms. The harness is correct. Go to Test Step 3.
• NO - A resistance is more than 5.0 ohms. There is an open circuit in the machine harness.
Repair: The open is in wire 495-GN or in wire 235-BK of the machine harness. Repair or
Go to Test Step 3.
the clips on each connector are securely fastened.
Expected Result:
The CID CID 0096 FMI 05 diagnostic code is not active.
Results:
STOP
Observe that the clips for each connector are securely fastened. From Test Step 1, perform this
procedure again. If the cause for this problem was not found this time, and the original
diagnostic code is still active, the ECM may have failed.Prior to replacing an ECM, always
contact your Dealership Technical Communicator for possible consultation with Caterpillar, or
with the Dealer Solutions Network. This consultation may greatly reduce repair time. If the
ECM needs to be replaced, see Testing and Adjusting, "Electronic Control Module (ECM) -
Replace".
STOP
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i02488123
MID 039 - CID 0110 - FMI 04

SMCS - 1906-038
Schematic of the Cat Data Link circuit
This diagnostic code is associated with the Engine Coolant Temperature Sensor.
Note: This diagnostic code comes to the Machine ECM from the Engine ECM through the Cat Data
Link. First check for an Engine ECM diagnostic code MID 036 CID 0110 FMI 04. Diagnose this or
any other diagnostic code before attempting to diagnose the MID 039 CID 0110 FMI 04 diagnostic
code from the Machine ECM. For additional Engine ECM information refer to Troubleshooting,
RENR 5089, "MID 036 CID 0110 FMI 04".
This diagnostic code is recorded when the monitoring system reads a low sensor signal. When this
diagnostic code occurs, the gauge indicates an abnormally high value. The following symptoms could
cause the diagnostic code:
• The signal circuit in the machine harness is shorted to ground.
• The monitoring system has failed.
Note: The monitoring system is unable to determine when a sensor is open. Also, the monitoring
system is unable to determine when a harness for the sensor signal is open. This condition is
recognized when the gauge constantly indicates a value at the far left side of the scale.
Service Notes: Ensure that the desired diagnostic code is on hold. Ensure that the code is active. The
schematic that is shown above represents a typical installation of the component. Verify the connector
contact and wire numbers by using the Electrical System Schematic for the machine that is being
serviced.
Test Step 1. CHECK THE MONITORING SYSTEM AND THE HARNESS.
B. The diagnostic code is active.
C. Disconnect the machine harness from the sensor that is causing the diagnostic code.
D. Observe the diagnostic code indicator.
Expected Result:
The diagnostic code indicator is ON.
Results:
• YES - The diagnostic code indicator stays ON. The harness wiring or the monitoring system
has failed. Proceed to test step 2.
• NO - The diagnostic code indicator turns OFF. The sensor has failed.
STOP
Test Step 2. CHECK THE SIGNAL WIRE FOR A SHORT TO GROUND.
A. The disconnect switch and the key start switch remain in the ON position.
B. At the machine harness for the sensor, measure the voltage between the frame ground and the
sensor signal wire.
Expected Result:
The voltage that is measured is within one of the following specifications.
Results:
• 6.0 ± 0.5 DCV - The voltage is 6.0 ± 0.5 DCV. The voltage is correct. Verify that the
diagnostic code remains.
Repair: It is unlikely that the monitoring system has failed. Exit this procedure and perform
this procedure again. Also, recheck if the diagnostic code indicator is illuminated for this
diagnostic code. If the cause of the diagnostic code is not found, replace the monitoring system.
See Testing and Adjusting, "Electronic Control Module (ECM) - Replace".
STOP
• LESS THAN 0.5 DCV - The voltage is less than 0.5 DCV. The harness wiring has failed.
There is an open circuit or a short to ground in the signal wire for the sensor.
Repair: Repair the harness or replace the harness. Exit this procedure and perform this
procedure again. Also, recheck if the diagnostic code indicator is illuminated for this diagnostic
code. It is unlikely that the monitoring system has failed. If the cause of the diagnostic code is
not found, replace the monitoring system. See Testing and Adjusting, "Electronic Control
Module (ECM) - Replace".
STOP
• NOT 6.0 BUT ABOVE 0.5 DCV - The voltage is less than 0.5 DCV. The harness wiring has
failed. There is an open circuit or a short to ground in the signal wire for the sensor.
Repair: Repair the harness or replace the harness. Exit this procedure and perform this
procedure again. Also, recheck if the diagnostic code indicator is illuminated for this diagnostic
code. It is unlikely that the monitoring system has failed. If the cause of the diagnostic code is
not found, replace the monitoring system. See Testing and Adjusting, "Electronic Control
STOP
Shutdown SIS
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03101426
MID 039 - CID 0110 - FMI 09

SMCS - 1906-038
Schematic of the Cat Data Link Circuit
This diagnostic code is associated with the "Engine Coolant Temperature" sensor.
This diagnostic code is recorded when the Machine ECM does not receive expected information
through the Cat Data Link from the Engine ECM. The possible causes of this diagnostic code are
listed below:
• The wires for the Cat Data Link to the Engine ECM are open or the wires are shorted.
• The wrong software is installed on an ECM.
Test Step 1. VERIFY THE HARDWARE AND THE SOFTWARE PART NUMBERS.
A. Verify that the following information is correct:
◦ The part number of the flash software for the Engine ECM
◦ The part number of the flash software for the Machine ECM
◦ The part number of the Engine ECM
◦ The part number of the Machine ECM
Note: Consult your Caterpillar Dealer for the correct part numbers of the flash software.
Expected Result:
All of the part numbers are correct.
Results:
• OK - All of the part numbers are correct. Proceed to Test Step 2.
• NOT OK - All of the part numbers are not correct.
Repair: The installed Engine ECM or the Machine ECM have the wrong part number or the
incorrect flash software is installed. Replace the Engine ECM or replace the Machine ECM that
is incorrect. Replace the ECM with a module that has the correct part number. Flash the correct
software. See Testing and Adjusting, "Electronic Control Module (ECM) - Flash Program" for
additional information.
STOP
Test Step 2. INSPECT THE HARNESS CONNECTIONS.
A. Turn the disconnect switch to the OFF position.
B. Inspect all harness connections that are related to the Cat Data Link. Make sure that the
connectors are clean and tight.
C. Check the connectors for proper mating. Ensure that all the seals are present and in place.
D. Check the harness for signs of damage or abrasion.
E. Check the wires at the connector. Ensure that the wires are secured tightly into the connector.
Take care not to pull the wire out of the connector.
F. Check the exposed wires at the connectors for nicks or signs of abrasion.
G. Check for moisture inside the connector.
H. Check the connectors for dirty contacts or corroded contacts.
I. Check each pin and each socket of the machine harness connectors. Ensure that the contacts are
properly installed. The contacts should mate correctly when the two pieces of the connector are
placed together.
Expected Result:
The connectors of the machine harness are tight and free of corrosion.
Results:
• OK - The connectors of the machine harness are tight and free of corrosion. Proceed to Test
Step 3.
• NOT OK - The connectors of the machine harness are in need of repair.
Repair: Repair the machine harness or replace the machine harness.
STOP
Test Step 3. CHECK FOR SHORTS
A. The disconnect switch remains in the OFF position.
B. Disconnect the connectors of the machine harness from all electronic control modules that use
the Cat Data Link.
C. At the machine harness connector for the Machine ECM, measure the resistance between
connector contact J1-33 (wire 893-GN) and all of the contacts that are used in the machine
harness connector for the ECM. Perform the same measurements for J1-43 (wire 892-BR).
Expected Result:
Each resistance measurement is greater than 5000 ohms.
Results:
• OK - Each of the resistance measurements is greater than 5000 ohms. The harness circuit
resistance is correct. Proceed to Test Step 4.
• NOT OK - One of the resistance measurements is less than 5000 ohms. The machine harness
has failed.
Repair: There is a short between the Cat contacts of the Data Link (wires 893-GN and 892-
BR) of the Cat Data Link and the circuit with the low resistance measurement. Repair the
machine harness or replace the machine harness.
STOP
Test Step 4. CHECK FOR OPEN HARNESS
B. All related electronic control modules remain disconnected from the machine harness.
C. Check the resistance of the Cat Data Link circuit in the machine harness:
◦ Measure the resistance between connector contact J1-8 (wire 893-GN) of the Engine
ECM and connector contact J1-33 (wire 893-GN) of the Machine ECM.
◦ Measure the resistance between connector contact J1-9 (wire 892-BR) of the Engine
ECM and connector contact J1-43 (wire 892-BR) of the Machine ECM.
Expected Result:
The resistance measures less than 5 ohms.
Results:
• OK - The resistance is less than 5 ohms. The Cat Data Link circuit in the machine harness is
correct. Proceed to Test Step 5.
• NOT OK - The resistance is greater than 5 ohms. The machine harness has failed.
Repair: The Cat Data Link circuit is open in the machine harness. Repair the machine harness
or replace the machine harness.
STOP
Test Step 5. CHECK IF THE DIAGNOSTIC CODE REMAINS
A. Inspect the contacts of the harness connectors. Clean the contacts of the harness connectors.
B. Reconnect all harness connectors.
Expected Result:
The CID 0110 FMI 09 diagnostic code is active.
Results:
• YES - The CID 0110 FMI 09 diagnostic code is active. The diagnostic code has not been
corrected. The ECM may have failed.
Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure
again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and
Adjusting, "Electronic Control Module (ECM) - Replace".
STOP
• NO - The CID 0110 FMI 09 diagnostic code is not active. The diagnostic code does not exist at
this time.
Repair: The initial diagnostic code was probably caused by a poor electrical connection or a
short at one of the harness connectors that was disconnected and reconnected. Resume normal
machine operation.
STOP
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05455410
MID 039 - CID 0167 - FMI 12

SMCS - 1406-038
This diagnostic code is associated with the "Alternator Charging Voltage" sensor. The FMI 12
diagnostic code means that the ECM has determined that the signal (frequency) of the sensor is below
the normal range.
This diagnostic code is recorded when the Machine ECM does not receive expected information from
the "Monitor Display". The possible causes of this diagnostic code are listed below:
• Harness wires for the "CAN Data Link" to the Machine ECM are open or the wires are shorted.
Note: Check the "R" term voltage at the alternator and all of the ECM contacts with the wire 403-GN.
All "R" term voltage checks should match. If one voltage is missing check for an open harness to that
ECM, see Test Step 4.
Test Step 1. VERIFY THE HARDWARE AND THE SOFTWARE PART NUMBERS
Note: Consult your Caterpillar dealer for the correct part numbers of the flash software.
Expected Result:
Results:
Repair: The installed Machine ECM has the wrong part number or the incorrect flash software
is installed. Replace the Machine ECM that is incorrect. Replace the ECM with a module that
has the correct part number. Flash the correct software. See Testing and Adjusting, "Electronic
Control Module (ECM) - Flash Program" for additional information.
STOP
Test Step 2. INSPECT THE HARNESS CONNECTIONS
B. Inspect all harness connections that are related to the "CAN Data Link". Make sure that the
connectors are clean and that the connectors are tight.
placed together.
Expected Result:
The machine harness connectors are tight and free of corrosion.
Results:
• OK - The machine harness connectors are tight and free of corrosion. Proceed to Test Step 3.
• NOT OK - The machine harness connectors are in need of repair.
STOP
B. Disconnect the machine harness connectors from all electronic control modules that use the
"CAN Data Link".
connector contact J2-50 (wire 251-YL) and all of the contacts that are used in the machine
harness connector for the ECM. Perform the same measurements for J2-51 (wire 261-GN).
Expected Result:
Results:
has failed.
Repair: There is a short between contacts J2-50 (wire 251-YL) or J2-51 (wire 261-GN) of the
CAN Data Link and the circuit with the low resistance measurement. Repair the machine
harness or replace the machine harness.
STOP
C. Check the resistance of the "CAN Data Link" circuit in the machine harness following the
process below:
◦ Measure the resistance between connector contact 5 in CN-1 connector (wire 251-YL) of
the Monitor Display and connector contact J2-50 (wire 251-YL) of the Machine ECM.
◦ Measure the resistance between connector contact 6 in CN-1 connector (wire 261-GN) of
the Monitor Display and connector contact J2-51 (wire 261-GN) of the Machine ECM.
Expected Result:
Results:
• OK - The resistance is less than 5 ohms. The "CAN Data Link " circuit in the machine harness
is correct. Proceed to Test Step 5.
Repair: The "CAN Data Link" circuit is open in the machine harness. Repair the machine
STOP
A. Inspect the contacts of the harness connectors and clean the contacts.
C. Turn the disconnect switch and the starter keyswitch to the ON position.
Expected Result:
Results:
Repair: ECM failure is unlikely. Perform this procedure again. If the cause of the diagnostic
code is not found, contact your dealer Technical Communicator (TC) for possible consultation
with Caterpillar. This consultation may greatly reduce repair time and expense. if the ECM
must be replaced, refer to Testing and Adjusting, "Electronic Control Module (ECM) -
Replace".
STOP
this time.
Repair: The diagnostic code was probably caused by a poor electrical connection or a short at
one of the harness connectors that was disconnected and reconnected. Resume normal machine
operation.
STOP
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320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03754249
MID 039 - CID 0168 - FMI 05

SMCS - 1406-038
This diagnostic code is recorded when the ECM detects that the current output of the alternator is
below the expected level.
The possible causes of this diagnostic code are listed below:
• A charging system component has failed.
• The machine harness is open.
• The ECM has failed. This is unlikely.
Test Step 1. CHECK THE CHARGING SYSTEM AT HIGH IDLE
A. Start the engine. Run the engine at high idle.
B. Enter the diagnostic menu on the monitor. Observe the status of the diagnostic code.
Expected Result:
The diagnostic code is NO longer active.
Results:
• YES - The diagnostic code is NO longer active. Proceed to Test Step 2.
• NO - The diagnostic code remains active. Proceed to Test Step 3.
Test Step 2. CHECK THE CHARGING SYSTEM AT LOW IDLE
A. Start the engine. Run the engine at low idle.
B. Observe the status of the diagnostic code.
Expected Result:
Results:
• YES - The diagnostic code is NO longer active. Watch for a recurrence.STOP
• NO - The diagnostic code is active. The charging system is not charging at the proper level.
Repair: If the engine low idle speed is too low, the alternator may not be producing the
required output. Ensure that the engine low idle speed is correct and perform this test again. If
the diagnostic code is still active, a charging system component may be defective. Check the
charging system. See Special Instruction, REHS0354, "Charging System Troubleshooting" for
more information.
STOP
Test Step 3. CHECK FOR AN OPEN CIRCUIT
A. Turn the disconnect switch and the key switch to the OFF position.
B. Disconnect the connector from the Gateway Worldview Module ECM. Disconnect wire 403-
GN from the alternator "R" terminal.
C. Measure the resistance of wire 403-GN between the Gateway Worldview Module ECM harness
connector contact 54 and the disconnected wire 403-GN at the alternator.
Expected Result:
The resistance should measure 5 ohms or less.
Results:
• YES - The resistance measures 5 ohms or less. The machine harness appears to be correct.
Either the alternator is not working correctly or the ECM may be recording this diagnostic code
incorrectly.
Repair: Check the charging system. See Special Instruction, REHS0354, "Charging System
Troubleshooting" for more information. If the charging system checks are correct, the ECM
may have failed. It is unlikely that the ECM has failed. Exit this procedure and perform this
procedure again. If the cause of the diagnostic code is NOT found, replace the ECM. See
Testing and Adjusting, "Electronic Control Module (ECM) - Replace".
STOP
• NO - The resistance measurement is greater than 5 ohms. Wire 403-GN between the ECM and
the alternator is open in the machine harness.
Repair: Refer to the machine electrical schematic and ensure that all harness connectors in the
circuit are tight and in good condition. Repair the machine harness or replace the machine
harness.
STOP
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320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i04161813
MID 039 - CID 0171 - FMI 03

SMCS - 1928-038
Ambient Air Temperature sensor circuit schematic
This diagnostic code is for the Ambient Air Temperature sensor. An FMI 03 diagnostic code means
the machine ECM has determined the sensor output signal voltage is above the normal limit.
Possible causes of this diagnostic code are:
• Failed sensor power supply.
• Failed sensor.
• Open sensor circuit wire.
• Sensor signal output wire shorted to +battery.
• Failed machine ECM, but most unlikely.
this procedure, inspect all of the harness connectors involved in the circuit. Verify that all of the
still active, before performing the following procedures.
System Response:
This failure may cause ambient air temperature to indicate the maximum temperature. The failure
may also cause hydraulic oil temperature to indicate the maximum temperature, intermittently.
Test Step 1. VERIFY THE +8 DCVSUPPLY.
A. Turn the disconnect switch and the key start switch to the "ON" position.
B. Do not disconnect any of the machine harness connectors at this time.
C. In the machine harness connector for the Ambient Air Temperature sensor, measure the voltage
between the contact for terminal A (wire A760-GY) and the contact for terminal B (wire 235-
BK) in the sensor connector.
Expected Result:
The voltage is 8.0 ± 0.5 DCV.
Results:
• YES - The voltage is 8.0 ± 0.5 DCV. The power supply is not the problem. Go to Test Step 2.
• NO - The voltage is not 8.0 ± 0.5 DCV. There is a problem with the +8 DCV power supply.
ECM +8 DCV power supply problem.
still active. If the diagnostic code is still active, proceed to Test Step 2.
Test Step 2. CHECK THE SENSOR, THE ECM, AND THE MACHINE HARNESS.
B. Disconnect the machine harness connector from the Ambient Air Temperature sensor.
C. In the harness connector for the sensor, place a jumper wire between the contact for terminal C
(wire N789-BU) and the contact for terminal B (wire 235-BK) in the sensor connector.
D. Turn the key start switch and the disconnect switch to the ON position.
E. Observe the status of the diagnostic code.
Expected Result:
The 0171 FMI 03 diagnostic code remains active.
Results:
• YES - The CID 0171 FMI 03 diagnostic code remains active. The sensor is not the problem.
Go to Test Step 3.
• NO - The CID 0171 FMI 03 diagnostic code is no longer active. The diagnostic code has been
replaced by an active CID 0171 FMI 04 diagnostic code. The sensor has failed.
Go to Test Step 5.
Test Step 3. CHECK THE SENSOR OUTPUT FOR AN OPEN CIRCUIT.
B. The sensor remain disconnected from the harness.
C. The wire jumper remains in the sensor connector.
D. Disconnect both the J1 and J2 harness connector from the machine ECM.
E. At the ECM J1 harness connector, measure the resistance between contact J1-4 (N789-BU) and
contact J1-2 (235-BK) in the J1 harness connector.
Note: An Ambient Air Temperature sensor Ground Return is also found at contact J1-14
(235-BK). Always check these parallel ground wires. Make sure to repair or replace any
that are found open.
Expected Result:
The resistance is less than 5 ohms.
Results:
• YES - The resistance is less than 5 ohms. Go to Test Step 4.
• NO - The resistance is not less than 5 ohms.
Repair: The machine harness has failed. There is an open circuit in the machine harness.
Repair or replace the harness.
Go to Test Step 5.
Test Step 4. CHECK THE SENSOR OUTPUT FOR A SHORT CIRCUIT.
A. The disconnect switch and the key start switch remain in the OFF position.
B. The sensor, and the ECM harness connectors, remain disconnected.
C. Remove the jumper wire from the sensor connector.
D. At the J1 ECM harness connector measure resistance from contact J1-4 (wire N789-BU) to all
the other contacts used in both the J1 and J2 ECM harness connectors.
Expected Result:
All measurements are more than 5000 ohms.
Results:
• YES - All measurements are more than 5000 ohms. Go to Test Step 5.
• NO - All measurements are not more than 5000 ohms. There is a short circuit in the machine
harness.
Go to Test Step 5.
Test Step 5. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE.
A. Reconnect all disconnected machine harness connectors. Make sure that all the connectors are
fully seated. Observe that the clips for each connector are securely fastened.
B. Turn the key start switch and the disconnect switch to the ON position.
Expected Result:
Results:
• YES - The CID 0171 FMI 03 diagnostic code is no longer active and does not exist at this time.
Repair: The cause for the diagnostic code has been corrected. Return the machine back to
normal operations.
STOP
The ECM may have failed.
problem was again not found, and the original code is still active, the machine ECM may have
STOP
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320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i04161814
MID 039 - CID 0171 - FMI 04

SMCS - 1928-038
Ambient Air Temperature sensor schematic
This diagnostic code is for the Ambient Air Temperature sensor. An FMI 04 indicates the machine
ECM has determined the sensor output signal voltage is below the normal limit.
• The sensor may have failed.
• The sensor output signal circuit may be shorted to ground.
System Response:
This failure may cause the Ambient Air Temperature sensor to indicate a maximum temperature,
either constantly, or intermittently.
Test Step 1. CHECK THE SENSOR THE ECM, AND THE MACHINE HARNESS.
B. Disconnect the machine harness connector from the Ambient Air Temperature sensor.
C. Turn the key start switch and the disconnect switch to the ON position.
Expected Result:
The CID 0171 FMI 04 code remains active.
Results:
• YES - The CID 0171 FMI 04 code remains active. The sensor is not the problem. Go to Test
Step 2.
• NO - The CID 0171 FMI 04 code is no longer active and has been replaced by an active CID
0171 FMI 04 diagnostic code. The sensor has failed.
Go to Test Step 3.
Test Step 2. CHECK THE SENSOR OUTPUT WIRE FOR A GROUND SHORT.
B. The sensor remains disconnected from the harness connector.
C. Disconnect both the J1 and J2 ECM harness connectors from the ECM.
D. At the J1 harness connector for the ECM, measure the resistance from contact J1-4 (N789-BU)
to all of the other contacts used in both the J1 and J2 ECM harness connectors.
Expected Result:
STOP.
Results:
• YES - Each resistance is more than 5000 ohms. Go to Test Step 3.
• NO - A resistance is less than 5000 ohms. There is a short circuit in the machine harness.
Repair: Repair or replace the machine harness.
Go to Test Step 3.
A. Reconnect all harness connectors. Make sure that all connectors are fully seated. Observe that
Expected Result:
The CID 0171 FMI 04 code is not active.
Results:
• YES - The CID 0171 FMI 04 code is no longer active and does not exist at this time.
normal operations.
STOP
the wires that are associated with the solenoid circuit.Perform a "wiggle test" on the solenoid
circuit of the machine wiring harness, using the Caterpillar Electronic Technician service tool.
The "wiggle test" can be used to detect open or shorted connections in the machine wiring
Observe that the clips for each connector are securely fastened. Perform Test Step 3 again. If
the problem has NOT been found, and this diagnostic code is still active, the ECM may have
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i05259917
MID 039 - CID 0190 - FMI 08

SMCS - 1907-038
(Engine Speed Sensor - Abnormal Frequency, Pulse Width, or Period)
Engine Speed sensor circuit schematic
This diagnostic code is for the Engine Speed sensor. This sensor is located near the top of the
flywheel housing.
The Machine ECM monitors the input signals from the speed sensor in order to determine the rotation
speed of the flywheel. The frequency of the sensor output signal varies as the teeth on the flywheel
pass the sensor. The frequency of the sensor output signal is proportional to the speed of the flywheel.
An FMI 8 diagnostic code indicates the machine ECM has determined the sensor output signal has an
abnormal frequency, pulse width, or period.
• Speed sensor air gap is out of adjustment
• Failed or damaged speed sensor
• Open wire connections or intermittent open connections in the speed sensor circuit
• Shorted wire connections or intermittent shorted connections in the speed sensor circuit
• Failed machine ECM. ECM failure is most unlikely
any of the connections: correct the problem and verify that the 190-8 diagnostic code is still
active, before performing the following procedures.
Note: The engine must be running in order for this diagnostic code to be active.
Test Step 1. CHECK THE SENSOR CIRCUIT FOR AN OPEN WIRE
A. Turn the key start switch to the OFF position.
B. Disconnected the machine harness connector from the Engine Speed sensor.
C. In the harness connector for the sensor, place a jumper wire between the contact for terminal 1
(wire 788-YL) and the contact for terminal 2 (wire A762-PU) in the sensor connector.
D. Disconnect both the J1 and J2 harness connectors from the machine ECM.
E. At the J2 ECM harness connector, measure the resistance between contact J2-16 (wire 788-YL)
and contact J2-25 (wire A762-PU) of the J2 ECM harness connector.
Expected Result:
The resistance is 5 ohms or less.
Results:
• YES - The resistance is 5 ohms or less. Go to Test Step 2.
• NO - The resistance is not less than 5 ohms. There is an open wire in the sensor circuit.
Go to Test Step 4.
Test Step 2. CHECK THE SENSOR OUTPUT FOR A SHORT CIRCUIT
B. The sensor, and both ECM harness connectors, remain disconnected.
C. Remove the jumper wire from the connector.
D. At the J2 ECM harness connector, measure resistance from contact J2-16 (wire 788-YL) to all
E. Again at the J2 ECM harness connector, measure resistance from contact J2-25 (wire A762-
PU) to all the other contacts used in both the J1 and J2 ECM harness connectors.
Expected Result:
Results:
• NO - All measurements are not more than 5000 ohms. There is a short circuit in the harness.
Go to Test Step 3.
A. The keyswitch and the disconnect switch remain in the OFF position.
B. Remove and inspect the sensor. Perform the adjustment procedure . See Testing and Adjusting,
"Speed Sensor - Adjust" and follow the inspection and adjustment steps.
Note: Replace the sensor if the magnetic pickup tip looks damaged or has metal embedded into
the tip. If damage can be seen to the gear teeth, remove the pump for further inspection of the
flywheel and rear gear train. Refer to Disassembly and Assembly, "Pump Drive Group -
Remove".
C. If suspect, replace the sensor and perform the adjustment for the replacement sensor.
D. Turn the keyswitch and the disconnect switch to the ON position.
E. Start the engine.
F. Monitor the status of the diagnostic code.
Expected Result:
The diagnostic code moves from active to logged.
Results:
• OK - The diagnostic code moves from active to logged. Sensor failure / incorrect adjustment
was the cause of the fault.
Repair: Leave the replacement sensor installed.
STOP
• NOT OK - The diagnostic code remains active.
Repair: Reinstall the original sensor. Refer to Testing and Adjusting, "Speed Sensor - Adjust"
to repeat the procedure.
Proceed to test step 4
E. Check the status of the 190-8 diagnostic code.
Expected Result:
The 190-8 diagnostic code is not active.
Results:
• YES - The 190-8 diagnostic code is no longer active and does not exist at this time.
normal operations.
STOP
• NO - The 190-8 diagnostic code is still active. The problem has not been corrected. The ECM
may have failed.
caused by excessive heat, battery acid, or chafing. Refer to Testing and Adjusting , "Electrical
Connector - Inspect ".Perform a 45 N (10 lb.) pull test on each of the wires that are associated
with the sensor circuit. Perform a "wiggle test" on the sensor circuit of the machine wiring
harness, using the Caterpillar Electronic Technician service tool. The "wiggle test" can be used
to detect open or shorted connections in the machine wiring harness. Reconnect all harness
connectors. Make sure that the connectors are fully seated. Observe that the clips for each
connector are fastened. Perform Test Step 5 again. If the problem was again not found, and the
original code is still active, the machine ECM may have failed.Prior to replacing an ECM,
always contact your Dealership Technical Communicator for possible consultation with
Caterpillar®. This consultation may greatly reduce repair time. If the ECM needs to be replaced,
see Testing and Adjusting, "Electronic Control Module (ECM) - Replace".
STOP
Shutdown SIS
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Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03996494
MID 039 - CID 0246 - FMI 12

SMCS - 7610-038-MCH
Schematic of the CAN Data Link Circuit
This diagnostic code is recorded when the Monitor does not receive expected information from the
machine ECM for more than 5 seconds.
For machines equipped with the E-Fence feature, reference Troubleshooting, "E-Ceiling and
Cab Avoidance - Troubleshoot"
System Response:
This failure results in events that are logged against an ECM that cannot be explained directly. The
Monitor cannot communicate with the Machine ECM, or the ECM appears to communicate
intermittently with the Monitor.
Test Step 1. CHECK THE HARNESS FOR A SHORT TO GROUND.
A. The key start switch and the disconnect switch remain in the OFF position.
B. Disconnect the machine harness from all electronic control modules that use the CAN Data
Link.
C. At the machine harness connector for the ECM, measure the resistance between the frame
ground and the CAN Data Link circuits (contacts J2-50 and J2-51).
Expected Result:
The resistance measurement should be greater than 5000 ohms.
Results:
• YES - The resistance is greater than 5000 ohms. The harness circuit resistance is correct.
Proceed to Test Step 2.
• NO - The resistance is less than 5000 ohms.
Repair: The machine harness has failed. There is a short between the CAN Data Link circuit
and frame ground in the machine harness. Repair, or replace, the machine harness.
STOP
Test Step 2. CHECK THE HARNESS FOR A SHORT TO A VOLTAGE SOURCE.
B. All related control modules remain disconnected from the machine harness.
C. At the harness for the ECM, measure the resistance between the +battery circuit (contact J1-1)
and the CAN Data Link (contacts J2-50 and J2-51).
Expected Result:
The resistance is greater than 5000 ohms.
Results:
• OK - The resistance is greater than 5000 ohms. The harness circuit resistance is correct.
• NOT OK - The resistance is less than 5000 ohms.
Repair: The harness has failed. There is a short between the +battery contact and the CAN
Data Link circuit in the machine harness. Repair, or replace, the machine harness.
STOP
Test Step 3. CHECK FOR AN OPEN IN THE HARNESS.
C. Check the continuity of the CAN Data Link circuit in the machine harness.
D. Measure the resistance between the contact J2-50 of the Machine ECM (wire 251-YL) and the
corresponding connection (wire 251-YL) of the switch panel. Measure the resistance between
the Machine ECM and the connection of the Monitor.
E. Measure the resistance from contact J2-51 (wire 261-GN) and the corresponding connection
(wire 261-GN) of the switch panel and the "Monitor".
Expected Result:
Each resistance measurement is less than 5 ohms.
Results:
• YES - Each resistance measurement is less than 5 ohms.
Repair: The CAN Data Link circuit in the machine harness is correct. The ECM has failed. Is
unlikely that the ECM has failed. If you have not inspected the harness connectors in a previous
Test Step, do that now. Clean the contacts of the harness connectors. Check the wires for
damage to the insulation caused by excessive heat, battery acid, or chafing.Perform a 45 N (10
lb.) pull test on each of the wires that are associated with the solenoid circuit.Perform a "wiggle
test" on the solenoid circuit of the machine wiring harness, using the Caterpillar Electronic
Technician service tool. The "wiggle test" can be used to detect open or shorted connections in
the machine wiring harness.Reconnect all harness connectors. Make sure that the connectors
are fully seated. Observe that the clips for each connector are securely fastened. Perform Test
Step 4 again. If the problem has NOT been found, and this diagnostic code is still active, the
ECM may have failed.Prior to replacing an ECM, always contact your Dealership Technical
Communicator for possible consultation with Caterpillar, or with the Dealer Solutions Network.
This consultation may greatly reduce repair time. If the ECM needs to be replaced, see Testing
and Adjusting, "Electronic Control Module (ECM) - Replace".
STOP
• NO - Any resistance measurement is greater than 5 ohms.
Repair: The machine harness has failed. The CAN Data Link circuit is open in the machine
harness. Repair, or replace, the machine harness.
STOP
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Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i02414869
MID 039 - CID 0247 - FMI 12

SMCS - 7610-038-MCH
• The Electronic Control Module (ECM) detects an unexpected loss of a continuous J1939 speed
signal on the J1939 data link.
• The expected continuous speed signal has never been received on the J1939 data link.
Check the configuration of the ECM. If the ECM for the engine has been incorrectly configured to
expect a continuous J1939 speed signal, remove "Continuous" for the J1939 speed signal on the main
"J1939" screen on the electronic service tool.
Test Step 1. Perform the following diagnostic procedure: "

Use the OEM information to determine the machine ECM that provides the continuous speed signal.
Refer to the troubleshooting procedures from the OEM to diagnose the faulty speed signal."
Results:
• OK - STOP
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03917813
MID 039 - CID 0248 - FMI 12

SMCS - 7610-038-MCH
This diagnostic code is recorded when the ECM does not receive expected information. The
information from the Cat Data Link indicates the abnormal values in the readout. The possible causes
of this diagnostic code are listed below. The causes are listed in order of probability:
• Poor electrical connection at a machine harness connector
• The circuit for the Cat Data Link in the machine harness is shorted to ground.
• The circuit for the Cat Data Link in the machine harness is shorted to a power supply source.
• The circuit for the Cat Data Link in the machine harness is open.
System Response:
The machine response is listed:
• The service tool cannot detect the ECM.
• The communication that is related to the codes is indicated by another ECM.
Note: The Machine ECM is equipped with LED indicators that serve as a self-diagnostic check. With
the key start switch in the ON position, the technician can observe the status of the indicator lights. If
the technician observes that all of the LED lights are OFF, power is not being supplied to the Machine
ECM. The technician should proceed to check the power supply to the Machine ECM. If the
technician observes that the yellow LED is ON, a communication error exists at the "CAN1" circuit.
The Machine ECM may not be loaded with software if the yellow LED is flashing. The Machine
ECM must be replaced if the red LED is flashing.
Note: Ensure that the diagnostic code is active.
Test Step 1. CHECK FOR OTHER CODES.
A. Check for other diagnostic codes that are related to the Cat Data Link.
Expected Result:
There are other diagnostic codes that are showing.
Results:
• YES - Exit this procedure and perform the other procedures for the diagnostic codes that are
shownSTOP
• NO - There are not any other diagnostic codes that are shown. Proceed to Test Step 2.
Test Step 2. INSPECT THE HARNESS CONNECTORS.
B. Inspect the connections for the machine harness that are related to the Cat Data Link.
C. Make sure that connectors are clean and tight.
Expected Result:
The machine harness is correct.
Results:
• OK - The machine harness is correct. Proceed to Test Step 3.
• NOT OK - The machine harness is not correct.
STOP
B. Disconnect the machine harness from all the electronic control modules that use the Cat Data
Link.
C. At the machine harness connector for the ECM, measure the resistance between frame ground
and the circuits of the Cat Data Link, contacts J1-33 (wire 893-GN) and J1-43 (wire 892-BR).
Expected Result:
Results:
• YES - The resistance is greater than 5000 ohms. The harness circuit resistance is correct.
• NO - The resistance is less than 5000 ohms. The machine harness has failed. There is a short
between the frame ground and the Cat Data Link circuit in the machine harness.
STOP
Test Step 4. CHECK FOR A SHORT TO A POWER SUPPLY SOURCE.
C. At the machine harness connector for the ECM, measure the resistance between the +battery
circuit J1-1 and J1-13 (wire 184-RD) and the circuits of the Cat Data Link, contacts J1-33 (wire
893-GN) and J1-43 (wire 892-BR).
Expected Result:
Results:
• NOT OK - The resistance is less than 5000 ohms. The machine harness has failed. There is a
short circuit. The short circuit is between the +battery and the circuit for the "Cat Data Link" in
the machine harness.
STOP
Test Step 5. CHECK FOR AN OPEN HARNESS.
C. Check the continuity of the Cat Data Link circuit in the machine harness.
D. Measure the resistance from the connector contacts J1-33 (wire 893-GN) and J1-43 (wire 892-
BR) of the ECM to the connector for each of the related circuits for the other electronic control
modules.
Expected Result:
Results:
• YES - The resistance is less than 5 ohms. The Cat Data Link circuit in the machine harness is
correct.
Repair: Is unlikely that the ECM has failed. Exit this procedure and perform this procedure
again. Also, recheck if the diagnostic code is active. If the cause of the diagnostic code is not
found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) -
Replace".
STOP
• NO - The resistance is greater than 5 ohms. The machine harness has failed. The Cat Data Link
circuit is open in the machine harness.
STOP
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Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03917949
MID 039 - CID 0254 - FMI 12

SMCS - 7610-038-MCH
This diagnostic code is for the Machine ECM.
This diagnostic code is recorded when the ECM reads a problem that is internal to the ECM.
Test Step 1.
Results:
• OK - This diagnostic code can only be caused if the ECM is faulty.
Repair: Replace the Machine ECM. See Testing and Adjusting, "Electronic Control Module
(ECM) - Replace".
STOP
Shutdown SIS
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Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i04161815
MID 039 - CID 0262 - FMI 06

SMCS - 1439-038
ECM +5 VDC sensor supply circuit schematic
This diagnostic code is for the ECM +5 VDC sensor supply. An FMI 06 indicates the ECM has
determined the current of the ECM +5 VDC Sensor supply circuit is above normal.
• The +5 VDC supply output shorted to ground.
• A failed sensor in the +5 VDC supply circuit.
• A failed machine ECM, but is most unlikely.
System Response:
Components that receive power from the +5 VDC sensor supply will not be available.
Test Step 1. CHECK THE SENSOR VOLTAGE.
B. Do not disconnect any of the machine harnesses at this time. Check for +5 VDC at the harness
connector of every sensor suplied by the ECM +5 VDC power supply.
Expected Result:
The voltage at each sensor is 5.0 ± 0.5 DCV.
Results:
• YES - The voltage at each sensor is 5.0 ± 0.5 DCV. Check if the diagnostic code is still active.
If the code is still active, go to Test Step 2.
• NO - The voltage at one or more of the sensors is not 5.0 ± 0.5 DCV. There is a problem with
the ECM +5 VDC voltage supply.
+5 VDC power supply problem.
still active. If the diagnostic code is still active, goo to Test Step 2.
Test Step 2. CHECK THE SENSORS.
B. One at a time disconnect and reconnect each and every sensor supplied by the ECM +5 VDC
sensor power supply.
C. While each sensor is disconnected, check the status of the CID 0262 FMI 06 diagnostic code.
Expected Result:
The CID 0262 FMI 06 diagnostic code remains active while each sensor is disconnected and
reconnected.
Results:
• YES - The CID 0262 FMI 06 diagnostic code remains active while each sensor is disconnected
and reconnected. None of the sensors are causing the problem. Go to Test Step 3.
• NO - While one of the sensors is disconnected, the CID 0262 FMI 06 diagnostic code becomes
inactive. That sensor is causing the problem.
Repair: Replace that sensor.
Go to Test Step 4.
B. Disconnect both the J1 and J2 ECM harness connectors from the machine ECM.
C. At the J1 machine harness connector for the ECM, measure resistance from contact J1-5
(sensor supply) A760-GY to all possible sources of ground in both the J1 and J2 ECM harness
connectors.
Expected Result:
Each measurement is more than 5000 ohms.
Results:
• YES - Each resistance measurement is greater than 5000 ohms. Go to Test Step 4.
• NO - A resistance measurement is less than 5000 ohms. There is a short circuit in the machine
harness.
Go to Test Step 4.
Expected Result:
Results:
this time.
normal operations.
STOP
problem has again not been found, and the original code is still active, the ECM may have
STOP
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03755057
MID 039 - CID 0271 - FMI 06

SMCS - 7407-038
Schematic of Action alarm and "Monitor" module
This diagnostic code is recorded when the "Monitor" module determines that the current of the action
alarm is above normal. The "Monitor" module indicates the fault to the Machine ECM over the CAN
Data Link.
• The energize circuit of the action alarm is shorted to ground.
• The action alarm has failed.
codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure
that the diagnostic code of CID 0271 FMI 06 is active before performing this procedure.
Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure.
Test Step 1. CHECK THE ACTION ALARM.
A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine.
C. Disconnect the action alarm with the active diagnostic code from the machine harness.
Expected Result:
The status of CID 0271 FMI 06 diagnostic code changes when the action alarm is disconnected.
Results:
• YES - The status of CID 0271 FMI 06 diagnostic code changes when the action alarm is
disconnected. The circuit is correct.
Repair: The action alarm has failed. Repeat this test "CHECK THE ACTION ALARM" in
order to verify the failure of the action alarm. Replace the action alarm.
STOP
• NO - The CID 0271 FMI 06 diagnostic code remains active. Proceed to Test Step 2.
Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE ACTION ALARM FOR A SHORT
TO GROUND.
B. The action alarm remains disconnected from the machine harness.
C. Disconnect the machine harness connector(s) from the ECM.
D. At the machine harness connector, measure the resistance from the signal contact 12 (wire 410-
WH) to all contacts that are used in the connectors of the machine harness for the ECM.
Expected Result:
Results:
• OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct.
• NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the
machine harness. The short is between contact 12 (wire 410-WH) and the circuit with the low
resistance measurement.
STOP
Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS.
A. Inspect the harness connectors. Clean the contacts of the harness connectors.
Expected Result:
Results:
Repair: It is unlikely that the "Monitor" module has failed. Exit this procedure and perform
this procedure again. Refer to the Electrical System Schematic for this machine and check all
involved wiring harness connectors and wiring. Ensure that the connector contacts are clean
and that the connector contacts are in good condition. Ensure that all wiring of the machine
harness is intact and that all wiring of the machine harness is in good condition. If the cause of
this diagnostic code is not found, replace the "Monitor" module.
STOP
this time.
machine operation.
STOP
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i04450529
MID 039 - CID 0291 - FMI 03

SMCS - 1359-038-OD
Schematic of the "Variable Fan Speed Control" Solenoid
This diagnostic code is associated with the "Variable Fan Speed Control" Solenoid. The FMI 03
means that the ECM has determined that the voltage of the solenoid circuit is above normal. The
solenoid is within the "ATCH Viscus Clutch".
• The energize circuit of the solenoid is shorted to the +battery circuit.
Before performing this procedure, inspect the harness connectors that are involved in the
circuit. Poor connections can often be the cause of a problem in an electrical circuit. Verify that
all connections in the circuit are clean, that all connections are secure and that all connections
are in good condition. If a problem with a connection is found, correct the problem and verify
that this diagnostic code is active before performing this procedure.
Note: Use a Digital Multimeter for the measurements in the procedure.
System Response:
A level 1 warning will be generated.
Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO
THE +BATTERY CIRCUIT.
A. Turn the key start switch and the disconnect switch to the ON position.
Note: Use a wire removal tool to remove the appropriate wires from the machine harness
connector for the ECM.
B. Remove the wire for the solenoid signal (H746-YL) of the connector contact J1-7 for the
Machine ECM.
C. Measure the voltage from the wire for the solenoid signal (H746-YL) to frame ground.
D. Remove the wire for the solenoid return (A209-BK) of the connector contact J2-18 for the
Machine ECM.
E. Measure the voltage from the wire for the solenoid return (A209-BK) to frame ground.
Expected Result:
The voltage is 0 VDC.
Results:
• OK - The voltage is 0 VDC. There are no shorts in the wires. Proceed to Test Step 2.
• NOT OK - There is the presence of a voltage in a wire. The short is in the wire with a
measured voltage. The machine harness has failed.
STOP
E. Determine if the CID 0291 FMI 03 is active.
Expected Result:
The CID 0291 FMI 03 is active.
Results:
• YES - The CID 0291 FMI 03 is active. The problem has not been corrected. The ECM may
have failed.
Repair: If the cause of the problem is not found, contact the Technical Communicator for your
dealership for possible consultation with Caterpillar. This consultation may greatly reduce
repair time. If the ECM requires replacement, see Troubleshooting, "Electronic Control Module
(ECM) - Replace".
STOP
• NO - The CID 0291 FMI 03 is not active. The problem does not exist at this time.
machine operation.
STOP
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i04450549
MID 039 - CID 0291 - FMI 05

SMCS - 1359-038-OD
Schematic of the "Variable Fan Speed Control" Solenoid
This diagnostic code is associated with the "Variable Fan Speed Control" Solenoid. The FMI 05
indicates that the ECM has determined that an open connection exists in the circuit for the solenoid.
This solenoid is located within the "ATCH Viscus Clutch".
• The energize circuit of the solenoid is open.
• The return circuit of the solenoid is open.
• The solenoid has failed.
Note: The following procedure may create other diagnostic codes. Ignore these created diagnostic
codes and clear these diagnostic codes when the original diagnostic code has been corrected.Ensure
Note: Use a Digital Multimeter for the measurements in this procedure.
System Response:
Test Step 1. CHECK THE SOLENOID.
A. Turn the disconnect switch and the key start switch to the ON position. DO NOT start the
engine.
B. Disconnect the solenoid with the active diagnostic code from the machine harness.
C. At the machine harness connector for the "ATCH Viscus Clutch", place a jumper wire from
contact 3 (wire H746-YL) to contact 2 (wire A209-BK).
D. Observe the status of the CID 0291 FMI 05.
Expected Result:
The CID 0291 FMI 05 remains active when the jumper wire is installed.
Results:
• YES - The diagnostic code of FMI 05 is active. The jumper wire does not affect the diagnostic
code. Proceed to Test Step 2.
• NO - The diagnostic code changes from FMI 05 to FMI 06.
Repair: The solenoid has failed. Replace the solenoid. Verify that the new solenoid corrects the
problem.
STOP
B. Disconnect the machine harness connector(s) from the ECM.
C. The jumper wire that was installed in the previous Test Step remains.
D. At the machine harness connector for the ECM, measure the resistance from signal contact J1-7
(wire H746-YL) to contact J2-18 (wire A209-BK).
Expected Result:
The resistance should be less than 5.0 ohms.
Results:
• OK - The resistance is less than 5.0 ohms. The machine harness is correct. Proceed to Test Step
3.
• NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not
correct. There is an open circuit in the machine harness.
Repair: The open connection is in the wire with the resistance that is measured at more than
5000 ohms. The open is in either signal wire (H746-YL) or return wire (A209-BK) of the
machine harness. Repair the machine harness or replace the machine harness.
STOP
A. Inspect the contacts of the harness connectors and clean the harness connectors.
E. Check the status of the CID 0291 FMI 05.
Expected Result:
Results:
• YES - The CID 0291 FMI 05 is active. The diagnostic code has not been corrected. The ECM
may have failed.
(ECM) - Replace".
STOP
• NO - The CID 0291 FMI 05 is not active. The diagnostic code does not exist at this time.
Repair: The initial diagnostic code was probably caused by a poor electrical connection at one
of the harness connectors that was disconnected and reconnected. Resume normal machine
operation.
STOP
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Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i04450551
MID 039 - CID 0291 - FMI 06

SMCS - 1359-038-OD
Schematic of the "Variable Fan Speed Control" solenoid
This diagnostic code is associated with the "Variable Fan Speed Control" solenoid. The FMI 06
means that the ECM has determined that there is a short to ground in the solenoid circuit. This
solenoid is located within the "ATCH Viscus Clutch".
• The energize circuit of the solenoid is shorted to ground.
Note: Use a Digital Multimeter for the measurements in this procedure.
System Response:
A. Turn the disconnect switch and the key start switch to the ON position. DO NOT start the
engine.
C. Observe the status of the diagnostic code.
Expected Result:
CID 0291 FMI 06 changes to CID 0291 FMI 05 when the solenoid is disconnected.
Results:
• YES - CID 0291 FMI 06 changes to CID 0291 FMI 05 when the solenoid is disconnected. The
circuit is correct.
Repair: The solenoid has failed. Replace the solenoid. Verify that the new solenoid corrects the
problem.
STOP
• NO - The CID 0291 FMI 06 remains active. Proceed to Test Step 2.
GROUND.
B. The solenoid remains disconnected from the machine harness.
C. Disconnect the machine harness connectors from the ECM.
D. At the machine harness connector, measure the resistance from the signal contact J1-7 (wire
H746-YL) to all contacts that are used in the machine harness connectors for the ECM.
Expected Result:
Results:
• OK - Each resistance is greater than 5000 ohms. The machine harness is correct. Proceed to
Test Step 3.
machine harness. The short is between contact J1-7 (wire H746-YL) and the circuit with the
low resistance measurement.
STOP
A. Inspect the harness connectors. Clean the contacts of the harness connectors. Check the wires
for damage to the insulation that is caused by excessive heat, corrosion, or chafing.
B. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit.
C. Reconnect all harness connectors. Make sure that the connectors are fully seated. Observe that
the clips for each connector are completely fastened.
E. Operate the machine.
F. Check the status of CID 0291 FMI 06.
Expected Result:
Results:
• YES - The CID 0291 FMI 06 is active. The diagnostic code has not been corrected. The ECM
may have failed.
(ECM) - Replace".
STOP
• NO - The diagnostic code has not been corrected.
machine operation.
STOP
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Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03755083
MID 039 - CID 0362 - FMI 03

SMCS - 1359-038; 5479-038
Schematic of the "Radiator Fan Speed Viscus" clutch
This diagnostic code is associated with the "Radiator Fan Speed Viscus" clutch. The FMI 03
diagnostic code means that the ECM has determined that the voltage of the clutch circuit is above
normal.
The possible causes of the diagnostic code are listed below:
• The clutch has failed.
• The energize circuit of the clutch is shorted to the +battery circuit.
System Response:
The diagnostic code of CID 0362 FMI 03 will be logged in the internal memory of the Machine
ECM.
Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE CLUTCH FOR A SHORT TO
B. Disconnect the machine harness connectors from the solenoid and the ECM.
C. At the machine harness connector for the ECM, measure the resistance from contact J2-24
(wire G834-PU) to all contacts that are used in the machine harness connectors for the Machine
ECM.
Expected Result:
Results:
machine harness. The short is between J2-24 (G834-PU) and the circuit that has a low
STOP
E. Determine if the CID 0362 FMI 03 diagnostic code is active.
Expected Result:
Results:
• YES - The CID 0362 FMI 03 diagnostic code is active. The problem has not been corrected.
STOP
• NO - The CID 0362 FMI 03 diagnostic code is not active. The problem does not exist at this
time.
machine operation.
STOP
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03755194
MID 039 - CID 0362 - FMI 05

SMCS - 1359-038; 5479-038
diagnostic code means that the ECM has determined that an open in the circuit exists.
• The energize circuit of the clutch is open.
• The return circuit of the clutch is open.
Test Step 1. CHECK THE CLUTCH.
B. Disconnect the clutch with the active diagnostic code from the machine harness.
C. At the machine harness connector for the clutch, place a jumper wire from contact 1 (wire
G834-PU) to contact 2 (wire H747-BR).
D. Observe the status of the CID 0362 FMI 05 diagnostic code.
Expected Result:
Results:
• YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code.
• NO - The diagnostic is no longer active. The clutch has failed.
Repair: The clutch has failed. Repeat this Test Step "CHECK THE CLUTCH" in order to
verify the clutch failure. Replace the clutch. Verify that the new clutch corrects the problem.
STOP
B. Disconnect the machine harness connector(s) from the Machine ECM.
C. The jumper wire that was installed in the previous Test Step remains in place.
D. At the machine harness connector, measure the resistance from signal contact J2-24 (wire G834
-PU) to contact J2-22 (wire H747-BR).
Expected Result:
Results:
• OK - The resistance is less than 5 ohms. The machine harness is correct. Proceed to Test Step
3.
• NOT OK - The resistance is greater than 5 ohms. The resistance measurement is not correct.
There is an open circuit in the machine harness.
Repair: The open is in wire G834-PU or in wire H747-BR of the machine harness. Repair the
STOP
Expected Result:
Results:
STOP
this time.
operation.
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03755202
MID 039 - CID 0362 - FMI 06

SMCS - 1359-038; 5479-038
diagnostic code means that the ECM has determined that there is a short to ground in the circuit.
• The energize circuit of the clutch is shorted to ground.
Test Step 1. CHECK THE CLUTCH.
C. Disconnect the "Fan Speed Viscus" clutch from the machine harness.
Expected Result:
The CID 0362 FMI 06 diagnostic code changes to a CID 0362 FMI 05 diagnostic code when the
clutch is disconnected.
Results:
• YES - The CID 0362 FMI 06 diagnostic code changes to a CID 0362 FMI 05 diagnostic code
when the clutch is disconnected. The circuit is correct.
Repair: The clutch has failed. Repeat this test "CHECK THE CLUTCH" in order to verify the
clutch failure. Replace the clutch.
STOP
Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE CLUTCH FOR A SHORT TO
GROUND.
B. The clutch remains disconnected from the machine harness.
G834-PU) to all contacts that are used in the machine harness connectors for the ECM.
Expected Result:
Results:
machine harness. The short is between J2-24 (wire G834-PU) and the circuit with the low
STOP
A. Inspect the harness connectors and clean the contacts of the harness connectors.
Expected Result:
Results:
again. If the cause of the diagnostic code is not found, replace the Machine ECM. See Testing
STOP
this time.
machine operation.
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05422816
MID 039 - CID 0374 - FMI 03

SMCS - 5059-038-ZWB; 5479-038-ZWB
Schematic of the Swing Brake solenoid for machine models 311D, 312D, 314D, 315D, and 319D.
Schematic of the Swing Brake Cancel solenoid for machine models 312D2, 313D2, and 318D2. (Note change in signal
wire for this schematic.)
This diagnostic code is associated with the Swing Brake solenoid. An FMI 03 diagnostic code means
the ECM has determined the voltage of the solenoid circuit is above normal.
• The Swing Brake solenoid energize circuit has shorted to a voltage source.
• The Machine ECM may have failed, but this situation is unlikely.
any of the connections: correct the problem, and verify that diagnostic code CID 0374 FMI 03 is
System Response:
Diagnostic code CID 0374 FMI 03 will be logged in the internal memory of the Machine ECM.
Test Step 1. CHECK THE SOLENOID, THE ECM, AND THE CIRCUIT CONNECTIONS IN
THE MACHINE HARNESS.
B. The Backup EPR Valve switch is in the OFF position, if applicable.
C. Disconnect the machine harness connector from the Swing Brake solenoid.
D. At the harness connector for the solenoid, place a jumper wire from contact 1 (K906-GN) to
contact 2 (235-BK) in the connector.
E. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine.
F. Observe the status of the CID 0374 FMI 03 diagnostic code.
Expected Result:
Results:
• YES - The CID 0374 FMI 03 diagnostic code remains active. The jumper wire did not change
the code. The solenoid is NOT the cause of the problem
Repair: The machine harness has failed, or the ECM may have failed.
Go to Test Step 2.
• NO - The CID 0374 FMI 03 diagnostic code is no longer active, and has been replaced by an
active CID 0374 FMI 05 diagnostic code. The ECM has detected a valid diagnostic code.
Repair: The ECM, and the harness connections, are correct. The solenoid has failed. Perform
Test Step 1 again, to verify the solenoid failure. Replace the solenoid.
Go to Test Step 3
Test Step 2. CHECK THE SOLENOID ENERGIZE CIRCUIT FOR A SHORT TO A

VOLTAGE SOURCE.
B. The harness connector remains disconnected from the Swing Brake solenoid.
C. The Backup EPR Valve switch is in the OFF position, if applicable.
D. Disconnect the J1 and J2 machine harness connectors from the Machine ECM.
E. At the ECM J2 harness connector, measure the resistance from contact J2-23 (K907-BU or
K906-GN) to all of the other contacts used in the ECM machine harness connectors.
Expected Result:
Results:
• YES - Each resistance is more than 5000 ohms. The machine harness is correct. Go to Test
Step 3.
• NO - Each resistance is NOT more than 5000 ohms. There is a short in the harness. The short is
between J2-23 (K907-BU or K906-GN) and the circuit with the low resistance measurement.
Repair: Repair, or replace, the harness.
Go to Test Step 3.
A. Remove any jumper wires still inserted.
B. Reconnect all harness connectors. Make sure that the connectors are fully seated. Observe that
E. Clear all inactive diagnostic codes.
F. Operate the machine.
G. Check the status of the CID 0374 FMI 03 diagnostic code.
Expected Result:
Results:
• YES - The CID 0374 FMI 03 code is not active. The code does not exist at this time.
STOP
• NO - The CID 0374 FMI 03 diagnostic code is still active. The problem has NOT been
corrected.
problem has NOT been found, and this diagnostic code is still active, the ECM may have
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05422904
MID 039 - CID 0374 - FMI 05

SMCS - 5059-038-ZWB; 5479-038-ZWB
Schematic of the Swing Brake solenoid for sales models 311D, 312D, 314D, 315D, and 319D.
Schematic of the Swing Brake solenoid for machine models 312D2, 313D2, and 318D2.
the ECM has determined the current of the solenoid circuit is below normal.
• The Swing Brake solenoid has failed.
• An open wire in the Swing Brake solenoid circuits.
• The Backup EPR Valve switch has failed, if applicable.
System Response:
D. At the harness connector for the solenoid, place a jumper wire from contact 1 (K906-GN) to
contact 2 (235-BK) on the connector.
E. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine.
F. Observe the status of the CID 0374 FMI 05 diagnostic code.
Expected Result:
Results:
the code. The solenoid is NOT the cause of the problem.
Repair: The machine harness has failed, the Backup EPR Valve switch has failed (if
applicable), or the ECM may have failed.
Go to Test Step 2.
Go to Test Step 5.
Test Step 2. CHECK THE SOLENOID CIRCUITS FOR AN OPEN CONNECTION.
C. The jumper wire that was placed into the Swing Brake solenoid harness connector during Test
Step 1 remains in place.
D. The Backup EPR Valve switch is in the OFF position, if applicable.
E. Disconnect the J1 and the J2 machine harness connectors from the Machine ECM.
F. At the ECM harness connectors, measure the resistance from contact J2-23 (K907-BU or K906-
GN) to contact J1-2 (235-BK).
Note: A Swing Brake solenoid Ground Return is also found at contact J1-14 (235-BK).
Always check these parallel ground wires. Make sure to repair or replace any that are
found open.
Expected Result:
Results:
• YES - The resistance is less than 5 ohms. The machine harness, and the Backup EPR Valve
switch, are correct. Go to Test Step 5.
• NO - The resistance is NOT less than 5 ohms. There is an open in the harness, or the Backup
EPR Valve switch has failed, if applicable. Go to Test Step 3
Test Step 3. CHECK THE MACHINE HARNESS FOR AN OPEN CONNECTION (NOT
APPLICABLE FOR MODELS 312D2, 313D2, OR 318D2).
B. Disconnect the machine harness connector from the Backup EPR Valve switch. The harness
connector remains disconnected from the Swing Brake solenoid. Remove the jumper wire
inserted during Test Step 1.
C. At the ECM J2 harness connector, measure the resistance from contact J2-23 (K907-BU) to
contact 3 (K907-BU) on the Backup EPR Valve switch harness connector.
D. At the Backup EPR Valve switch harness connector, measure the resistance from contact 2
(K906-GN) to contact 1 (K906-GN) on the Swing Brake solenoid harness connector.
E. At the Swing Brake solenoid harness connector, measure the resistance from contact 2 (235-
BK) to contact 10 (235-BK) on the Backup EPR Valve switch harness connector.
F. At the Backup EPR Valve switch harness connector, measure the resistance from contact 10
(235-BK) to contact J1-2 (235 -BK) on the ECM J2 harness connector.
Note: A Swing Brake solenoid Ground Return is also found at contact J1-14 (235-BK). Always
check these parallel ground wires. Make sure to repair or replace any that are found open.
Expected Result:
Each measurement is less than 5 ohms.
Results:
• YES - Each measurement is less than 5 ohms. The machine harness connections are correct.
The Backup EPR Valve switch may have failed. Go to Test Step 4.
• NO - Each measurement is NOT less than 5 ohms. There is an open circuit in the harness
connections for the solenoid circuit. The open is on the connection with the high resistance
measurement.
Go to Test Step 5.
Test Step 4. CHECK FOR A FAILURE IN THE SWITCH .
Table 1
Switch Position Contacts Results

OFF 2 to 3 Less than 5 ohms
ON 2 to 3 More than 5000 ohms
A. The starter key switch and the disconnect switch remain in the OFF position.
B. Disconnect the Backup EPR Valve switch from the panel.
C. The Backup EPR Valve switch is in the OFF position.
D. Measure the resistance between contact 2 and contact 3 of the switch.
E. Place the Backup EPR Valve switch in the ON position.
F. Again measure the resistance between contact 2 and contact 3 of the switch.
Expected Result:
Each measurement agrees with Table 1.
Results:
• YES - Each measurement agrees with Table 1. The switch is correct. Go to Test Step 5.
• NO - Each measurement does NOT agree with Table 1. The switch has failed.
Repair: Replace the switch.
Go to Test Step 5.
the clips for each connector are fastened securely.
C. The Backup EPR Valve switch is in the OFF position.
Expected Result:
The CID 0374 FMI 05 diagnostic code is NOT active.
Results:
• YES - The CID 0374 FMI 05 diagnostic code is not active. The code does not exist at this time.
STOP
corrected.
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05422914
MID 039 - CID 0374 - FMI 06

SMCS - 5059-038-ZWB; 5479-038-ZWB
Schematic of the Swing Brake solenoid for sales models 311D, 312D, 314D, 315D, and 319D.
Schematic of the Swing Brake solenoid for models 312D2, 313D2, and 318D2.
the ECM has determined the current of the solenoid circuit is above normal.
• The Swing Brake solenoid has failed.
• The Swing Brake solenoid energize circuit is shorted to ground.
• The Machine ECM may have failed. A failure of the Machine ECM is unlikely.
any of the connections: correct the problem, and verify that diagnostic code CID 0374 FMI 06 is
System Response:
D. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine.
Expected Result:
Results:
• YES - The CID 0374 FMI 06 diagnostic code remains active. Disconnecting the solenoid did
not change the code. The solenoid is NOT the cause of the problem.
Go to Test Step 2.
Repair: The ECM, and the harness connections, are correct. The solenoid has failed.Perform
Go to Test Step 3
GROUND.
D. Disconnect the J1 and the J2 machine harness connectors from the Machine ECM.
E. At the ECM J2 harness connector, measure the resistance from contact J2-23 (K907-BU of
K906-GN) to all of the other contacts of the ECM harness connectors.
Expected Result:
Results:
• YES - Each resistance is more than 5000 ohms. The harness is correct. Go to Test Step 3.
between J2-23 (K907-BU or K906-GN) and the circuit with the low resistance measurement.
Go to Test Step 3.
Expected Result:
Results:
• YES - The CID 0374 FMI 06 diagnostic code is not active. The code does not exist at this time.
STOP
corrected.
circuit of the machine wiring harness, using the Cat® Electronic Technician service tool. The
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05264022
MID 039 - CID 0544 - FMI 08

SMCS - 1359-038; 1439-038-FM
(Engine Cooling Fan Speed Sensor - Abnormal Frequency, Pulse Width, or Period)
Radiator Fan Speed sensor circuit schematic
This diagnostic code is recorded when the ECM receives intermittent signals from the engine cooling
fan speed sensor (CID 0544) while the engine is running. An FMI 08 diagnostic code indicates the
machine ECM has determined the sensor output signal voltage has an abnormal frequency, pulse
width, or period.
This Hall-effect type fan speed sensor is mounted near the center of the viscous fan drive clutch. The
fan speed sensor is not separately serviceable from the fan drive clutch assembly.
The ECM fan speed map uses actual fan speed, coolant temperature, and engine rpm inputs to
determine the targeted fan speed. For more information, refer to Special Instruction, REHS4721,
"Operation, Troubleshooting and Testing of the Viscous Coupling".
Possible causes for this active diagnostic code are:
• Sensor output wire is open
• Sensor output wire is short to +battery
• Sensor output wire is short to ground
• Failed sensor
• Failed viscous clutch
• Failed machine ECM (most unlikely)
any of the connections: correct the problem and verify that the 544-8 diagnostic code is still
active, before performing the following procedures.
Note: Check for other related diagnostic codes before performing the following diagnostic code
procedure. If a 248-12 diagnostic code for the data link exists, correct the data link problem. Then
view the status of the other diagnostic codes and correct the other active codes.
System Response:
If a fan speed signal is not supplied to the machine ECM, the fan will default to maximum fan speed.
Test Step 1. CHECK THE SENSOR OUTPUT FOR AN OPEN CIRCUIT
Note: The engine cooling fan speed sensor circuit wires are routed through the viscous fan
drive clutch harness connector.
B. Disconnected the machine harness connector from the Viscus Clutch.
C. In the harness connector for the Viscus Clutch, place a jumper wire between the contact for
terminal 1 (wire G834-PU) and the contact for terminal 2 (wire A209-BK) in the Viscus Clutch
harness connector.
E. At the ECM harness connectors, measure resistance between contact J1-18 (wire A209-BK)
and contact J2-24 (wire G834-PU) in the ECM harness connectors.
Expected Result:
Results:
• NO - The resistance is not less than 5 ohms. There is an open circuit in the harness.
Go to Test Step 3.
Test Step 2. CHECK THE SENSOR OUTPUT FOR A SHORT CIRCUIT
B. The Viscus Clutch, and both ECM harness connectors, remain disconnected.
C. Remove the jumper wire from the Viscus Clutch harness connector.
D. At the J2 ECM harness connector, measure resistance from contact J2-24 (wire G834-PU) to all
Expected Result:
Results:
Go to Test Step 3.
E. Check the status of the 544-8 diagnostic code.
Expected Result:
The 544-8 diagnostic code is not active.
Results:
• YES - The 544-8 diagnostic code is no longer active and does not exist at this time.
normal operations.
STOP
• NO - The 544-8 diagnostic code is still active. The problem has not been corrected. The fan
speed sensor, viscous clutch, or machine ECM, may have failed.
caused by excessive heat, battery acid, or chafing. Perform a 45 N (10 lb.) pull test on each of
the wires that are associated with the sensor circuit. Perform a "wiggle test" on the sensor
harness. Refer to Testing and Adjusting, "Electrical Connector - Inspect " in this
manual.Reconnect all harness connectors. Make sure that the connectors are fully seated.
problem was not found, and the original code is still active, the fan speed sensor, viscous
clutch, or machine ECM, may have failed. Is highly recommended that you replace the Fan
Drive Assembly first, and then perform Test Step 3 again. Refer to Special Instruction,
REHS4721, "Operation, Troubleshooting and Testing of the Viscous Coupling". Prior to
replacing an ECM, always contact your Dealership Technical Communicator for possible
consultation with Caterpillar. This consultation may greatly reduce repair time. If the ECM
needs to be replaced, see Testing and Adjusting, "Electronic Control Module (ECM) -
Replace".
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i04165709
MID 039 - CID 0581 - FMI 03

SMCS - 5479-038-QY
Power Shift Pressuresolenoid circuit schematic
This diagnostic code is for the Power Shift Pressure solenoid. An FMI 03 diagnostic code indicates
the machine ECM has determined the solenoid circuit voltage is above the normal limit.
• The solenoid energize circuit is shorted to +battery.
• The machine ECM has failed, but is most unlikely.
Note: The following test procedure may create other diagnostic codes. Ignore all the created
diagnostic codes now, but clear all those codes after the cause for the original diagnostic code has
been corrected.
Test Step 1. CHECK THE SIGNAL CIRCUIT FOR A SHORT.
B. Disconnect the machine harness from the Power Shift Pressure solenoid.
C. Disconnect both the J1 and J2 harness connectors from the machine ECM.
D. At J2 ECM harness connector, measure resistance from contact J2-4 (wire L969-WH) to all the
other contacts used in both the J1 and J2 ECM Harness connectors.
Expected Result:
Each resistance is greater than 5000 ohms.
Results:
• YES - Each resistance is greater than 5000 ohms. Go to Test Step 2.
• NO - Each resistance is not greater than 5000 ohms. There is a short circuit in the machine
harness.
Go to Test Step 2.
Expected Result:
Results:
normal operations.
STOP
problem is not found, and the original code is still active, the machine ECM may have
failed.Prior to replacing an ECM, contact your Dealership Technical Communicator for
consultation with Caterpillar, or the Dealer Solutions Network. This consultation may greatly
reduce repair time. If the ECM needs to be replaced, see Testing and Adjusting, "Electronic
Control Module (ECM) - Replace".
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i04161820
MID 039 - CID 0581 - FMI 05

SMCS - 5479-038-QY
Power Shift Pressure solenoid circuit schematic
This diagnostic code is for the Power Shift Pressure solenoid. An FMI 05 diagnostic code indicates
the machine ECM has determined the solenoid circuit current is below normal.
• The Backup Switch has failed.
• There is an open in the solenoid circuit.
• The machine ECM has failed, but is most unlikely.
been corrected.
Test Step 1. CHECK THE SWITCH.
Table 1
Switch State Switch Contacts Status
Active Contacts 5 & 6 and 11 & 12 Closed
Active Contacts 5 & 4 and 11 & 10 Open
Inactive Contacts 5 & 6 and 11 & 12 Open
Inactive Contacts 5 & 4 and 11 & 10 Closed
A. Turn the starter keyswitch and the disconnect switch to the OFF position.
B. Disconnect the Backup Switch from the panel.
C. Toggle the switch from one state to the other. On each of the switch two states, check for
continuity on the switch pins listed on Table 1.
Expected Result:
Both states of the switch continuity agree with table 1.
Results:
• YES - The switch continuity is correct. Go to Test Step 2.
• NO - The switch continuity is not correct. The Backup Switch has failed.
Go to Test Step 4.
A. The disconnect switch and the starter keyswitch remain in the the OFF position.
B. Reconnect the backup switch.
C. Disconnect the machine harness from the Power Shift Pressure solenoid.
D. In the machine harness connector for the solenoid, place a jumper wire from the contact for
terminal 1 (wire A768-BU) to the contact for terminal 2 (wire A769-GY) in the solenoid
harness connector.
E. Turn the starter keyswitch and the disconnect switch to the ON position.
F. Observe the status of the CID 0581 FMI 05diagnostic code.
Expected Result:
Results:
• YES - The diagnostic code is active. The solenoid is not the problem. Go to Test Step 3.
• NO - The CID 0581 FMI 05 diagnostic code is not active and has been replaced by an active
CID 0581 FMI 05 diagnostic code. The solenoid has failed.
Repair: Replace the solenoid.
Go to Test Step 4.
Test Step 3. CHECK THE SOLENOID CIRCUIT FOR AN OPEN.
A. Turn the starter keyswitch and the disconnect switch to the OFF position.
B. The harness connector remains disconnected from the solenoid.
C. The jumper wire remains in the solenoid harness connector.
D. Disconnect the J2 harness connectors from the machine ECM.
E. At the J2 harness connector, measure resistance from contact J2-4 (wire L969-WH) to J2-20
(wire L968-OR) in the J2 ECM harness connector.
Expected Result:
Results:
• NO - The resistance is more than 5 ohms. There is an open circuit in the machine harness.
Go to Test Step 4.
Expected Result:
Results:
normal operations.
STOP
problem is not found, and the original code is still active, the machine ECM may have
failed.Prior to replacing an ECM, contact your Dealership Technical Communicator for
consultation with Caterpillar, or the Dealer Solutions Network. This consultation may greatly
reduce repair time. If the ECM needs to be replaced, see Testing and Adjusting, "Electronic
Control Module (ECM) - Replace".
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i04161821
MID 039 - CID 0581 - FMI 06

SMCS - 5479-038-QY
Power Shift Pressure solenoid circuit schematic
This diagnostic code is for the Power Shift Pressure solenoid. An FMI 06 indicates the machine ECM
has determined that the solenoid circuit current is above normal.
• The solenoid energize circuit is shorted to ground.
• The ECM may have failed, but is unlikely.
been corrected.
Table 1
Switch State Switch Contacts Status
Active Contacts 5 & 6 and 11 & 12 Closed
Active Contacts 5 & 4 and 11 & 10 Open
Inactive Contacts 5 & 6 and 11 & 12 Open
Inactive Contacts 5 & 4 and 11 & 10 Closed
B. Disconnect the Backup Switch from the panel.
C. Toggle the switch from one state to the other. On each of the switch two states, check for
continuity on the switch pins listed on Table 1.
Expected Result:
The switch continuity agrees with table 1.
Results:
• YES - The switch continuity is correct. Go to Test Step 2.
• NO - The switch continuity is not correct. The Backup Switch has failed.
Go to Test Step 4.
A. The disconnect switch and the starter keyswitch remain in the OFF position.
B. Reconnect the backup switch.
C. Disconnect the machine harness from the Power Shift Pressure solenoid.
Expected Result:
Results:
• YES - The diagnostic code is still active. The solenoid is not causing the problem. Go to Test
Step 3.
• NO - The CID 0581 FMI 06 diagnostic code is not active and has been replaced by an active
CID 0581 FMI 05 diagnostic code. The solenoid has failed.
Repair: Replace the solenoid.
Go to Test Step 4.
Test Step 3. CHECK THE SOLENOID CIRCUIT FOR A SHORT TO GROUND.
B. The harness connector remains disconnected from the solenoid.
C. Disconnect both the J1 and J2 harness connector from the machine ECM.
D. At the J2 machine harness connector, measure for resistance from contact J2-4 (wire L969-
WH) to all possible sources of ground in both the J1 and J2 ECM harness connectors.
Expected Result:
Each resistance measurement is more than 5000 ohms.
Results:
• YES - Each resistance measurement is more than 5000 ohms. Go to Test Step 4.
• NO - Each resistance measurement is not more than 5000 ohms. There is a short circuit in the
machine harness.
Go to Test Step 4.
Expected Result:
Results:
normal operations.
STOP
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05428865
MID 039 - CID 0586 - FMI 05

SMCS - 7332-038
Schematic of the "Engine Speed Dial" switch
This diagnostic code is associated with the "engine speed dial" switch. The FMI 05 diagnostic code
means that the ECM has determined that the current of the switch is below normal.
• The circuit of the switch is open.
• The switch has failed.
• The ECM has failed, but is unlikely.
A. Turn the disconnect switch and the key start switch to the OFF position. Do not start the engine.
B. Disconnect the "engine speed dial" switch from the machine harness.
C. Use the following table for the position of the rotary dial and check the corresponding
resistance for the switch.
Table 1
Rotary Dial Position Check the Resistance Between the Following Contacts on the
Switch.
Contact (1)
1 to
Contact (2)
Contact (1)
3 to
Contact (3)
Contact (1)
7 to
Contact (4)
Contact (1)
10 to
Contact (5)
Expected Result:
Results:
• OK - The resistance is less than 5 ohms. The switch is correct. Proceed to Test Step 2.
There is an open circuit in the switch.
STOP
B. Disconnect the machine harness connectors from the ECM.
C. Use the following table for the placement of a jumper wire to the connector for the switch.
Check the corresponding resistance for the contacts of the machine harness connectors.
Table 2
Jumper Location on the
Connections on the Machine Harness
Connector for the Switch
Contact (1)
Contact J1-10 (wire A755-PK) and contact J1-2 or J1-14
to
(wire 235-BK) of the machine harness.
Contact (2)
Contact (1)
Contact J1-19 (wire A756-BU) and contact J1-2 or J1-14
to
Contact (3)
Contact (1)
Contact J1-20 (wire A757-GY) and contact J1-2 or J1-
to
14 (wire 235-BK) of the machine harness.
Contact (4)
Contact (1)
Contact J1-11 (wire A758-BR) and contact J1-2 or J1-14
to
Contact (5)
Expected Result:
Results:
• OK - The resistance is less than 5 ohms. The machine harness is correct. Proceed to Test Step
3.
There is an open circuit in the machine harness.
STOP
Expected Result:
Results:
Repair: A failure of the Machine ECM is unlikely. Exit this procedure and perform this
procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing
STOP
this time.
operation.
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05428871
MID 039 - CID 0586 - FMI 12

SMCS - 7332-038
Schematic of the Engine Speed Dial switch
This diagnostic code is recorded when the ECM cannot communicate with the Engine Speed Dial
switch.
• The switch has failed.
• The machine harness has failed.
B. Disconnect the Engine Speed Dial switch from the machine harness.
C. Use Table 1 to check resistance on the rotary switch for each position listed on the table.
Table 1
Rotary Dial Position Check the Resistance Between the Following Contacts on the
Switch.
1 Contact (1) to Contact (2)
Expected Result:
Each resistance measurement is less than 5 ohms.
Results:
• OK - Each resistance measurement is less than 5 ohms. The switch is correct. Proceed to Test
Step 3.
• NOT OK - A resistance measurement is greater than 5 ohms. The resistance measurement is

not correct. There is an open circuit in the switch.
STOP
B. Inspect the harness connections. Make sure that the connectors are clean and that the
connectors are tight.
C. Check the mating of the harness connectors.
D. Check wires at the connector.
E. Check each wire for nicks or signs of abrasion in the insulation.
F. Check for moisture at the connector.
G. Check for dirty contacts or corroded contacts.
H. Check each pin and each socket.
Expected Result:
Results:
• NOT OK - The machine harness connectors are NOT tight or NOT free of corrosion.
STOP
Test Step 3. CHECK THE HARNESS FOR AN OPEN CIRCUIT.
B. Disconnect the J1 and J2 machine harness connectors from the Machine ECM.
C. Use the following table for the placement of a jumper wire to the connector for the switch.
Check the corresponding resistance for the contacts of the machine harness connectors.
Table 2
Jumper Location on the
Connectors on the Machine Harness
Connector for the Switch
Contact (1)
Contact J1-10 (wire A755-PK) and contact J1-2 or J1-14
to
Contact (2)
Contact (1)
Contact J1-19 (wire A756-BU) and contact J1-2 or J1-
to
Contact (3)
Contact (1)
Contact J1-20 (wire A757-GY) and contact J1-2 or J1-
to
Contact (4)
Contact (1)
Contact J1-11 (wire A758-BR) and contact J1-2 or J1-14
to
Contact (5)
Expected Result:
The resistance measurements are all less than 5 ohms.
Results:
• OK - The resistance measurements are all less than 5 ohms. The machine harness is correct.
• NOT OK - A resistance measurement is greater than 5 ohms. The resistance measurement is

not correct. There is an open circuit in the machine harness.
Repair: Repair, or replace, the machine harness.
STOP
Test Step 4. CHECK FOR A SHORT TO GROUND
B. The ECM and the Engine Speed Dial switch remain disconnected from the machine harness.
C. At the machine harness connector for the ECM, measure the resistance between frame ground
and the following connector contacts: J1-10 (wire A755-PK), J1-19 (wire A756-BU), J1-20
(wire A757-GY) and J1-11 (wire A758-BR).
Expected Result:
The resistance measurements are all greater than 5000 ohms.
Results:
• OK - The resistance measurements are all greater than 5000 ohms. The resistance of the
circuits is correct. Proceed to Test Step 5.
• NOT OK - A resistance measurement is less than 5000 ohms. The resistance of the circuit is
not correct.
Repair: There is a short between the frame ground and the circuits that measured less than
5000 ohms in the machine harness. Replace, or repair, the machine harness.
STOP
A. Inspect the contacts of the harness connectors. Clean the contacts.
D. Clear all of the inactive diagnostic codes.
F. Check for an active diagnostic code of CID 0586 FMI 12.
Expected Result:
The diagnostic code of CID 0586 FMI 12 is not active.
Results:
• OK - The diagnostic code of CID 0586 FMI 12 is not active. The code does not exist at this
time.
back to normal machine operations.
STOP
corrected.
STOP
Shutdown SIS
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Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05428894
MID 039 - CID 0588 - FMI 09

SMCS - 7490-038
Schematic of the Cat Data Link
This diagnostic code is caused by abnormal communications between the Machine ECM and the
Monitor Display module through the Data Link. The update rate is not correct. Check for diagnostic
codes that are related to the data link circuits. Check in the "Machine ECM" and in the Monitor
Display module. If diagnostic codes are present, correct the related diagnostic codes first.
A possible cause of this diagnostic code is that the Machine ECM is operating intermittently.
The Data Link is an input and output of all electronic control modules. The Data Link is designed to
carry communications between the electronic control modules. The Data Link is not a visible
component. The Data Link consists of internal control circuits and the connecting harness wiring
between the components.
System Response:
This failure results in events that are logged against a Machine ECM that cannot be explained
directly. The Machine ECM cannot communicate with the Monitor Display module or the Machine
ECM appears to communicate intermittently with the Monitor Display module.
◦ The part number of the flash software for the Machine ECM.
◦ The part number of the flash software for the Monitor Display ECM.
◦ The part number of the Machine ECM.
◦ The part number of the Monitor Display ECM.
Expected Result:
Results:
Repair: The installed Machine ECM or the Monitor Display ECM have the wrong part number
or the incorrect flash software is installed. Replace the incorrect Machine ECM or the Monitor
Display ECM with a module that has the correct part number. Flash the correct software. See
the Testing and Adjusting, "Electronic Control Module (ECM) - Flash Program" section for
STOP
placed together.
Expected Result:
Results:
STOP
Test Step 3. CHECK FOR SHORTS TO GROUND
B. Disconnect the machine harness connectors from all electronic control modules that use the Cat
Data Link.
C. At the machine harness for the Machine ECM, measure the resistance between frame ground
and connector contacts J1-33 (wire 893-GN) and J1-43 (wire 892-BR) of the Cat Data Link
circuit.
Expected Result:
Results:
• NOT OK - The resistance is less than 5000 ohms. The machine harness has failed.
Repair: There is a short between frame ground and contacts J1-33 (wire 893-GN) and J1-43
(wire 892-BR) of the Cat Data Link circuit in the machine harness. Repair the machine harness
STOP
Test Step 4. CHECK FOR SHORT TO THE +BATTERY CIRCUIT
C. At the machine harness connector for the Machine ECM, perform the checks that are listed
here:
◦ Measure the resistance between the connector contact J1-1 (wire 184-RD) and connector
contact J1-33 (wire 893-GN).
◦ Measure the resistance between connector contact J1-1 (wire 184-RD) and connector
contact J1-43 (wire 892-BR).
Expected Result:
Results:
• OK - The harness circuit resistance is correct. Proceed to Test Step 5.
• NOT OK - The resistance is less than 5000 ohms. The machine harness has failed.
Repair: There is a short between the +battery circuit and contacts J1-33 (wire 893-GN) and J1-
43 (wire 892-BR) of the Cat Data Link circuit in the machine harness. Repair the machine
STOP
Test Step 5. CHECK FOR AN OPEN HARNESS
C. Check the resistance of the Cat® Data Link circuit in the machine harness:
◦ Measure the resistance between connector contact J1-33 (wire 893-GN) of the Machine
ECM and connector contact 7 (wire 893-GN) of the Monitor Display ECM.
◦ Measure the resistance between connector contact 43 (wire 892-BR) of the Machine
ECM and connector contact 8 (wire 892-BR) of the Monitor Display ECM.
Expected Result:
Results:
STOP
Test Step 6. CHECK FOR ADDITIONAL DIAGNOSTIC CODES FOR THE OTHER
ELECTRONIC CONTROL MODULES.
B. One at a time, reconnect the electronic control modules that use the Cat Data Link.
C. Turn the disconnect switch and the key start switch to the ON position after reconnecting each
module.
D. After each of the electronic control modules has been reconnected, check for diagnostic codes
that are logged against that electronic control module.
Make sure to turn the key start switch and the disconnect switch to the OFF position
before each control module is reconnected.
Expected Result:
Diagnostic codes are not present for the other electronic control modules.
Results:
• OK - Diagnostic codes are not present for the other electronic control modules. The Monitor
Display module has failed.
Repair: Is unlikely that the Monitor Display module has failed. Exit this procedure and
perform this procedure again. If the failure is not found, replace the Monitor Display module.
STOP
• NOT OK - Diagnostic codes are present for the other electronic control modules. The
"Machine ECM" has failed.
Repair: A failure of the "Machine ECM" is unlikely. Exit this procedure. Perform this
procedure again. If the failure is not found, contact your Dealership Technical Communicator
for possible consultation with Caterpillar. If the "Machine ECM" needs to be replaced,
reference Testing and Adjusting, "Electronic Control Module (ECM) - Replace" section.
STOP
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Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03755740
MID 039 - CID 0590 - FMI 09

SMCS - 1901-038
This diagnostic code is recorded when the Machine ECM does not receive expected information from
the Engine ECM. The possible causes of this diagnostic code are listed below:
• The wires for the Cat Data Link to the Engine ECM are open or the wires are shorted.
◦ The part number of the flash software for the Engine ECM
◦ The part number of the Engine ECM
Expected Result:
Results:
Repair: The installed Engine ECM or the Machine ECM have the wrong part number or the
incorrect flash software is installed. Replace the Engine ECM or replace the Machine ECM that
is incorrect. Replace the ECM with a module that has the correct part number. Flash the correct
software. See Testing and Adjusting, "Electronic Control Module (ECM) - Flash Program" for
STOP
placed together.
Expected Result:
Results:
STOP
B. Disconnect the machine harness connectors from all electronic control modules that use the Cat
Data Link.
connector contact J1-33 (wire 893-GN) and all of the contacts that are used in the machine
harness connector for the ECM. Perform the same measurements for J1-43 (wire 892-BR).
Expected Result:
Results:
has failed.
Repair: There is a short between contacts J1-33 (wire 893-GN) or J1-43 (wire 892-BR) of the
Cat Data Link and the circuit with the low resistance measurement. Repair the machine harness
STOP
C. Check the resistance of the Cat Data Link circuit in the machine harness:
◦ Measure the resistance between connector contact J1-23 (wire 893-GN) of the Engine
ECM and connector contact J1-33 (wire 893-GN) of the Machine ECM.
◦ Measure the resistance between connector contact J1-24 (wire 892-BR) of the Engine
ECM and connector contact J1-43 (wire 892-BR) of the Machine ECM.
Expected Result:
Results:
STOP
Expected Result:
Results:
corrected. The Machine ECM may have failed.
Repair: It is unlikely that the Machine ECM has failed. Exit this procedure and perform this
STOP
this time.
machine operation.
STOP
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Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03755872
MID 039 - CID 0598 - FMI 03

SMCS - 5051-038-MV; 5479-038-V6
Schematic of the "Travel Speed Solenoid" valve
This diagnostic code is associated with the "Travel Speed Solenoid" valve. The FMI 03 diagnostic
code means that the Machine ECM has determined that the voltage of the solenoid circuit is above
normal.
B. Disconnect the machine harness connectors from the solenoid and the Machine ECM.
C. At the machine harness connector for the ECM, measure the resistance from contact J2-3 (wire
763-BU) to all contacts that are used in the machine harness connectors for the Machine ECM.
Expected Result:
Results:
machine harness. The short is between J2-3 (763-BU) and the circuit that has a low resistance
measurement.
STOP
Expected Result:
Results:
The Machine ECM may have failed.
STOP
time.
machine operation.
STOP
Shutdown SIS
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Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03755892
MID 039 - CID 0598 - FMI 05

SMCS - 5051-038-MV; 5479-038-V6
code means that the Machine ECM has determined that the current of the solenoid is below normal.
• The ground circuit of the solenoid is open.
C. At the machine harness connector for the solenoid, place a jumper wire from contact 1 (wire
763-BU) to contact 2 (wire 235-BK).
Expected Result:
Results:
• NO - The diagnostic is no longer active. The solenoid has failed.
Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" in order to
verify the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the
problem.
STOP
D. At the machine harness connector, measure the resistance from signal contact J2-3 (wire 763-
BU) to ground (wire 235-BK).
Expected Result:
Results:
3.
Repair: The open is in wire 763-BU or in wire 235-BK of the machine harness. Repair the
STOP
A. Inspect the contacts of the harness connectors. Clean the harness connectors.
Expected Result:
Results:
STOP
this time.
machine operation.
STOP
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Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03755896
MID 039 - CID 0598 - FMI 06

SMCS - 5051-038-MV; 5479-038-V6
code means that the ECM has determined that the current of the solenoid is above normal.
C. Disconnect the solenoid with the active diagnostic code from the machine harness.
Expected Result:
solenoid is disconnected.
Results:
when the solenoid is disconnected. The circuit is correct.
Repair: The solenoid has failed. Repeat this test "CHECK THE SOLENOID" in order to verify
the solenoid failure. Replace the solenoid.
STOP
GROUND.
763-BU) to all contacts that are used in the machine harness connectors for the ECM.
Expected Result:
Results:
machine harness. The short is between J2-3 (wire 763-BU) and the circuit with the low
STOP
Expected Result:
Results:
STOP
this time.
machine operation.
STOP
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Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05434373
MID 039 - CID 0600 - FMI 04

SMCS - 509T-038
Schematic of the Hydraulic Oil Temperature sensor
This diagnostic code is associated with the Hydraulic Oil Temperature sensor. An FMI 04 diagnostic
code means that the Monitor ECM has determined the voltage of the sensor is below normal. The
ECM records this diagnostic code from information received from the Monitoring System through the
Cat® Data Link.
Possible causes of this diagnostic code are listed below:
• The sensor output signal circuit is shorted to ground.
• The Monitor ECM may have failed (unlikely).
System Response:
Test Step 1. CHECK THE SENSOR, AND THE MONITOR ECM.
A. Turn the engine OFF. Turn the disconnect switch and the key start switch to the OFF position.
B. Disconnect the machine harness from the sender.
C. Turn the disconnect switch and the key start switch to the ON position. Turn the engine back
ON.
Expected Result:
The CID 0600 FMI 04 diagnostic code is no longer present.
Results:
• YES - The CID 0600 FMI 04 diagnostic code is no longer active. The sensor has failed.
Repair: Replace the sender.
STOP
• NO - The CID 0600 FMI 04 diagnostic code remains active. The sensor is not the cause of the
code. Proceed to Test Step 2.
Test Step 2. CHECK THE HARNESS FOR A SHORT TO GROUND.
A. The sensor remains disconnected from the machine harness.
B. Turn the engine OFF. Turn the disconnect switch and the key start switch to the OFF position.
C. At the machine harness connector for the sensor, measure the resistance between the sensor
output signal, contact (wire 491-PK), and frame ground.
Expected Result:
Results:
Repair: A failure of the Monitor ECM is unlikely.Perform Test Step 2 again. If the problem
has NOT been found, and the diagnostic code is still active, the Monitor ECM may have
possible consultation with Caterpillar, or with the Dealer Solutions Network. If the Monitor
ECM needs to be replaced, see Testing and Adjusting , "Electronic Control Module (ECM) -
Replace".
STOP
short between frame ground and the sensor output signal circuit in the machine harness.
Repair: Repair, or replace, the machine harness.
STOP
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Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03755921
MID 039 - CID 0735 - FMI 03

SMCS - 5479-038-LQ
Schematic of the "Heavy Lift Solenoid" valve
This diagnostic code is associated with the "Heavy Lift Solenoid" valve. The FMI 03 diagnostic code
means that the Machine ECM has determined that the voltage of the solenoid circuit is above normal.
(wire G723-YL) to all contacts that are used in the machine harness connectors for the ECM.
Expected Result:
Results:
machine harness. The short is between J2-31 (G723-YL) and the circuit that has a low
STOP
A. Inspect the contacts of the harness connector. Clean the contacts of the harness connectors.
Expected Result:
Results:
procedure again. If the cause of the diagnostic code is not found, replace the Machine ECM.
STOP
time.
machine operation.
STOP
Shutdown SIS
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Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03756021
MID 039 - CID 0735 - FMI 05

SMCS - 5479-038-LQ
means that the ECM has determined that the current of the solenoid is below normal.
• The ground circuit of the solenoid is open.
G723-YL) to contact 2 (wire 235-BK).
Expected Result:
Results:
problem.
STOP
D. At the machine harness connector, measure the resistance from signal contact J2-31 (wire G723
-YL) to ground (wire 235-BK).
Expected Result:
Results:
3.
Repair: The open is in wire G723-YL or in wire 235-BK of the machine harness. Repair the
STOP
Expected Result:
Results:
STOP
this time.
machine operation.
STOP
Shutdown SIS
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Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03756028
MID 039 - CID 0735 - FMI 06

SMCS - 5479-038-LQ
means that the ECM has determined that the current of the solenoid is above normal.
Expected Result:
Results:
STOP
GROUND.
C. Disconnect the machine harness connector(s) from the Machine ECM.
G723-YL) to all contacts that are used in the machine harness connectors for the Machine
ECM.
Expected Result:
Results:
machine harness. The short is between J2-31 (wire G723-YL) and the circuit with the low
STOP
Expected Result:
Results:
STOP
this time.
machine operation.
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03756088
MID 039 - CID 1129 - FMI 04

SMCS - 1439-038-P9
Schematic of the circuit for the "Right Side Auxiliary" pedal
This diagnostic code is associated with the sensor for the "Right Side Auxiliary" pedal. The FMI 04
diagnostic code means that the Machine ECM has determined that the voltage of the circuit for the
position sensor is below normal.
• The signal circuit for the sensor is shorted to ground.
codes and clear the diagnostic codes when the original diagnostic code has been corrected. Ensure
B. Ensure that the diagnostic code is active.
C. Observe the status of the diagnostic code. Disconnect the sensor from the machine harness.
Expected Result:
Results:
• OK - The diagnostic code remains active. The sensor is correct. Proceed to Test Step 2.
• NOT OK - The diagnostic code is no longer active. The sensor has failed.
STOP
Test Step 2. CHECK THE WIRING HARNESS OF THE SENSOR FOR A SHORT TO
GROUND.
B. Disconnect the machine harness from the sensor.
D. At the machine harness connector for the Machine ECM, measure the resistance from the signal
contact J1-54 (wire N795-WH) of the machine harness to all possible sources of ground.
Measure the resistance to all contacts of the machine harness connectors for the ECM.
Expected Result:
Results:
• NOT OK - One or more resistance measurements is not correct. There is a short in the machine
harness.
Repair: The short is between signal contact J1-54 (wire N795-WH) and the circuit with the
low resistance measurement. Repair the machine harness or replace the machine harness.
STOP
Expected Result:
Results:
STOP
this time.
machine operation.
STOP
Shutdown SIS
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i04170111
MID 039 - CID 1129 - FMI 08

SMCS - 1439-038-P9
Right side"Auxiliary Pedal" pedal position sensor circuit schematic
This diagnostic code is for the right side Auxiliary Pedal position sensor. An FMI 08 diagnostic code
means the machine ECM has determined the sensor output signal has an abnormal frequency, pulse
width, or period.
• Failed sensor.
• Short circuit to the sensor output signal wire.
System Response:
This failure may result in erratic movement of the machine.
B. Disconnect the machine harness connector from the right side Auxiliary Pedal position sensor.
(wire N795-WH) and the contact for terminal 2 (wire 235-BK) in the sensor connector.
Expected Result:
Results:
• YES - The CID 1129 FMI 08 diagnostic code remains active. The sensor is not causing the
problem. Go to Test Step 2.
replaced by an active CID 1129 with a different FMI code. The sensor has failed.
Go to Test Step 3.
Test Step 2. CHECK THE MACHINE HARNESS FOR A SHORT CIRCUIT.
E. At the ECM J1 harness connector, measure the resistance between contact J1-54 (wire N795-
WH) and frame ground.
F. Again at the ECM J1 harness connector, measure the resistance between contact J1-54 (wire
N795-WH) and all of the other contacts that are used in both the J1 and J2 ECM harness
connectors.
Expected Result:
All resistance readings are greater than 5000 ohms.
Results:
• YES - All resistance readings are greater than 5000 ohms. Go to Test Step 3.
• NO - All resistance readings are not greater than 5000 ohms. There is a short circuit in the
machine harness.
Go to Test Step 3.
Expected Result:
Results:
normal operations.
STOP
STOP
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05434448
MID 039 - CID 1130 - FMI 03

SMCS - 1439-038-P9
Schematic for the Left Side Auxiliary pedal sensor
This diagnostic code is associated with the Left Side Auxiliary pedal sensor. An FMI 03 diagnostic
code means the Machine ECM has determined the signal output voltage of the sensor is above
normal.
• The sensor power supply may have failed.
• The sensor output signal may be shorted to a voltage source.
• The sensor output signal may be open.
Test Step 1. VERIFY THE +8 VDC SUPPLY.
A. Turn the key start switch and the disconnect switch to the ON position. Do not start the engine.
C. At the back of the harness connector for the Left Side Auxiliary pedal sensor: insert the 7X-
1710 Multimeter Probes along contact 1 (E472-GN), the sensor contact for the +8 VDC supply,
and contact 2 (235-BK), the sensor ground return.
D. Measure a DC voltage from contact 1 to contact 2.
Expected Result:
The voltage measurement is 8 ± 0.5 VDC.
Results:
• YES - The voltage measurement is 8 ± 0.5 VDC. The power supply is correct. Go to Test Step
2.
• NO - The voltage is NOT 8 VDC. The 8 VDC power supply in the machine ECM has failed, or
the machine harness has failed. Go to Test Step 3
Test Step 2. CHECK THE SENSOR, THE ECM, AND THE CIRCUIT CONNECTIONS IN
B. Disconnect the machine harness connector from the Left Side Auxiliary pedal sensor.
C. At the harness connector for the Left Side Auxiliary pedal sensor, place a jumper wire between
contact 3 (N794-GY) and contact 2 (235-BK) on the connector.
D. Turn the key start switch and the disconnect switch to the ON position. Do not start the engine.
Expected Result:
Results:
the code. The sensor is NOT the cause of the problem.
Go to Test Step 3.
Repair: The ECM, and the harness, are correct. The sensor has failed. Replace the sensor.
Go to Test Step 5
Test Step 3. CHECK THE SENSOR OUTPUT SIGNAL FOR AN OPEN.
C. At the harness connector for the Left Side Auxiliary pedal sensor, place a jumper wire between
contact 3 (N794-GY) and contact 2 (235-BK) on the connector.
D. At the Machine ECM, disconnect the J1 and J2 machine harness connector from the ECM.
E. At the ECM J1 harness connector, measure the resistance between the pin for contact J1-53
(N794-GY) and the pin for contact J1-2 (235-BK) on the harness connector.
Note: A Left Side Auxiliary sensor Ground Return is also found at contact J1-14 (235-
BK). Always check these parallel ground wires. Make sure to repair or replace any that
are found open.
Expected Result:
Results:
• YES - The resistance is less than 5 ohms. The sensor output circuit is not open. Go to Test Step
4
• NO - The resistance is NOT less than 5 ohms. The sensor output signal is open.
Repair: The open is in wire N794-GY in the harness connector. Repair, or replace, the harness.
Go to Test Step 5.
Test Step 4. CHECK THE SENSOR OUTPUT SIGNAL FOR A SHORT TO A VOLTAGE
SOURCE.
B. Both the ECM harness connectors remain disconnected.
C. The Left Side Auxiliary pedal sensor harness connector remains disconnected.
D. Remove the jumper wire from the connector.
E. At the J1 harness connector for the ECM, measure the resistance between contact J1-53 (N794-
GY) and all of the other contacts used in the harness connectors for the ECM.
Expected Result:
Results:
• YES - Each resistance is more than 5000 ohms. The sensor output signal is NOT shorted to a
power supply. Proceed to Test Step 4.
• NO - One of the resistance measurements is NOT greater than 5000 ohms. There is a short in
the harness. The sort is between the sensor output signal wire and the wire with the low
A. Remove the jumper wire from the connector.
B. Reconnect all disconnected machine harness connectors. Make sure that all the connectors are
C. Turn the key start switch and the disconnect switch to the ON position.
D. Clear all inactive diagnostic codes.
F. Check the status of the CID 1130 FMI 03 diagnostic code.
Expected Result:
Results:
this time.
STOP
of the machine wiring harness, using the Cat® Electronic Technician service tool. The "wiggle
test" can be used to detect open or shorted connections in the machine wiring
may greatly reduce repair time. If the ECM needs to be replaced, see Testing and Adjusting , "
Electronic Control Module (ECM) - Replace".
STOP
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03942796
MID 039 - CID 1130 - FMI 04

SMCS - 1439-038-P9
Schematic for the Left Side Auxiliary pedal sensor
This diagnostic code is associated with the Left Side Auxiliary pedal sensor. An FMI 04 diagnostic
code means the machine ECM has determined the signal output voltage of the sensor is below
normal.
• The sensor output signal circuit may be shorted to ground.
Test Step 1. CHECK THE SENSOR, THE ECM, AND THE CIRCUIT CONNECTIONS IN
C. Turn the key start switch and the disconnect switch to the ON position. Do not start the engine.
Expected Result:
Results:
• YES - The CID 1130 FMI 03 diagnostic code remains active. Disconnecting the sensor did not
change the code. The sensor is NOT the cause of the problem.
Go to Test Step 2.
Repair: The ECM, and the harness, are correct. The sensor has failed. Replace the sensor.
Go to Test Step 3.
Test Step 2. CHECK THE SENSOR OUTPUT SIGNAL FOR A SHORT TO GROUND.
B. At the machine ECM, disconnect the J1 and J2 machine harness connectors from the ECM.
C. The harness connector remains disconnected from the Left Side Auxiliary pedal sensor.
D. At the J1 harness connector for the ECM, measure the resistance between contact J1-53 (N794-
GY) and all of the other contacts used in the ECM harness connectors.
Expected Result:
Results:
• YES - Each resistance is more than 5000 ohms. The sensor output signal circuit is not shorted
to ground. Go to Test Step 3.
• NO - One of the resistance measurements is NOT more than 5000 ohms. There is a short in the
harness. The short is between the sensor output signal wire and the wire with the low resistance.
Repair, or replace, the harness. Go to Test Step 3.
Test Step 3. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE
B. Reconnect all disconnected machine harness connectors. Make sure that all the connectors are
Expected Result:
Results:
• YES - The CID 1130 FMI 04 code is no longer active. The code does not exist at this time.
STOP
corrected.
Observe that the clips for each connector are securely fastened. Perform Test Step 3 again. If
the problem has NOT been found, and this diagnostic code is still active, the ECM may have
STOP
Shutdown SIS
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Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i04170112
MID 039 - CID 1130 - FMI 08

SMCS - 1439-038-P9
Left side"Auxiliary Pedal" position sensor circuit schematic
This diagnostic code is for the left side Auxiliary Pedal position sensor. An FMI 08 diagnostic code
means the machine ECM has determined the sensor output signal has an abnormal frequency, pulse
width, or period.
• Failed sensor.
System Response:
B. Disconnect the machine harness connector from the left side Auxiliary Pedal position sensor.
(wire N794-GY) and the contact for terminal 2 (wire 235-BK) in the sensor connector.
Expected Result:
Results:
Go to Test Step 3.
E. At the ECM J1 harness connector, measure the resistance between contact J1-53 (wire N794-
GY) and frame ground.
N794-GY) and all of the other pins that are used in both the J1 and J2 ECM harness connectors.
Expected Result:
Results:
machine harness.
Go to Test Step 3.
Expected Result:
Results:
normal operations.
STOP
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03756647
MID 039 - CID 1160 - FMI 03

SMCS - 5059-038-M9; 5479-038-HLK
Schematic of the "Hydraulic Lock" solenoid
This diagnostic code is associated with the "Hydraulic Lock" solenoid. The FMI 03 diagnostic code
means that the ECM has determined that the voltage of the solenoid circuit is above normal.
• The hydraulic lock relay has failed.
• The Machine ECM has failed. This is unlikely.
When this diagnostic code occurs, a warning is displayed on the Monitoring System and the Machine
ECM disables the hydraulic system.
System Response:
ECM.
B. Disconnect the machine harness connector J2 from the solenoid at the ECM.
C. Place a jumper between contacts 3 (wire A588-GN) and 5 (wire E564-PK) of the hydraulic lock
on relay.
D. At the machine harness connector for the ECM, measure the resistance from contact J2-27
(wire A588-GN) to all contacts that are used in the machine harness connectors for the Machine
ECM.
Expected Result:
Results:
machine harness. The short is between J2-27 (A588-GN) and the circuit that has a low
STOP
A. Inspect the contacts. Clean the contacts of the harness connectors.
C. Remove the jumper that was placed in the previous test.
F. Determine if the CID 1160 FMI 03 diagnostic code is active.
Expected Result:
Results:
STOP
time.
machine operation.
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05434522
MID 039 - CID 1160 - FMI 05

SMCS - 5059-038-M9; 5479-038-HLK
Schematic of the "Hydraulic Lock" solenoid
This diagnostic code is associated with the "Hydraulic Lock" solenoid.
• The solenoid energizer circuit is open.
• A hydraulic lock relay has failed.
• The neutral start switch has failed.
• The Machine ECM has failed. This situation is unlikely.
When this diagnostic code occurs, a warning is displayed on the Monitoring System and the Machine
ECM disables the circuit.
codes and clear the diagnostic codes when the original diagnostic code is corrected.
B. Disconnect the suspect solenoid from the machine harness.
C. At the machine harness connector of the solenoid, measure the resistance between contact 1
(wire A588-GN) and contact 2 (wire 200-BK).
Expected Result:
The resistance is between 25 and 39 ohms.
Results:
• OK - The resistance is between 25 and 39 ohms. The resistance is correct. The machine harness
or the hydraulic lock relay has failed. Proceed to Test Step 2.
• NOT OK - The resistance is NOT between 25 and 39 ohms. The resistance is not correct.
Repair: The solenoid has failed. Replace the solenoid.
STOP
Test Step 2. CHECK THE HARNESS.
C. At the machine harness connector for the solenoid, measure the voltage between contact 1 (wire
A588-GN) and contact 2 (wire 200-BK) while the hydraulic lock lever is moved from the
LOCKED position to the RELEASED position.
Expected Result:
The voltage measures 18 VDC to 28 VDC when the lever is in the RELEASED position. The voltage
measures approximately 0.0 ± 0.5 VDC in the LOCKED position.
Results:
• OK - The voltage measures 18 VDC to 28 VDC when the lever is in the RELEASED position.
The voltage measures approximately 0.0 ± 0.5 VDC in the LOCKED position. The voltage is
• NOT OK - The voltage does not measure 18 VDC to 28 VDC when the lever is in the
RELEASED position. The voltage does not measure approximately 0.0 ± 0.5 VDC in the
LOCKED position. The voltage is not correct. The machine harness or the hydraulic lock relay
may have failed. Proceed to Test Step 4.
A. Inspect the connectors. Clean the contacts of the harness connectors.
D. Clear all active diagnostic codes from the Monitoring System by pressing the "OK" key on the
keypad.
F. Check the Monitoring System for an active diagnostic code. The diagnostic information may
also be viewed with the Cat® Electronic Technician.
Expected Result:
The diagnostic code for the solenoid is not present.
Results:
• OK - The diagnostic code for the solenoid is not present. The diagnostic code was probably
caused by a poor electrical connection or an open at one of the harness connectors that was
disconnected and reconnected. Resume normal machine operation.STOP
• NOT OK - The diagnostic code is still present. The Machine ECM has failed. A failure of the
Machine ECM is unlikely. Exit this test procedure and perform this procedure again.
Repair: If the cause of the diagnostic code is not found, replace the ECM. See Testing And
STOP
Test Step 4. CHECK THE HYDRAULIC LOCK CIRCUIT
B. Place a jumper between contacts 3 (wire A588-GN) and 5 (wire E564-PK) of the hydraulic lock
on relay.
C. Place a jumper between contacts 1 (wire A588-PK) and 2 (wire 200-BK) of the machine
harness connector for the solenoid.
D. Disconnect the machine harness connectors J1 and J2 from the Machine ECM.
E. At the machine harness connector J2, measure the resistance between contact J2-27 (wire A588
-GN) and frame ground.
Expected Result:
Results:
• OK - The resistance measures less than 5 ohms. The resistance is correct. Proceed to Test Step
5.
• NOT OK - The resistance is greater than 5 ohms. The resistance is not correct. The machine
harness has failed.
STOP
Test Step 5. CHECK THE HYDRAULIC LOCK RELAY.
A. Reconnect the machine harness connectors J1 and J2 to the Machine ECM.
C. At the machine harness connector of the hydraulic lock on relay, measure the voltage between
contact 1 (wire E564-PK) and frame ground while the hydraulic lock lever is moved from the
LOCKED position to the RELEASED position.
Expected Result:
The voltage measures 18 VDC to 28 VDC when the lever is in the RELEASED position and the
voltage measures approximately 0.0 ± 0.5VDC in the LOCKED position.
Results:
• OK - The voltage measures 18 VDC to 28 VDC when the lever is in the RELEASED position
and the voltage measures approximately 0.0 ± 0.5 VDC in the LOCKED position. The voltage
is correct.
Repair: The relay has failed. Replace the hydraulic lock relay.
STOP
• NOT OK - The voltage does not measure 18 VDC to 28 VDC when the lever is in the
RELEASED position and the voltage does not measure approximately 0.0 ± 0.5 VDC in the
LOCKED position. The voltage is not correct. The machine harness or the neutral start switch
has failed. Proceed to Test Step 6.
Test Step 6. CHECK THE "NEUTRAL START" SWITCH CIRCUIT.
B. Disconnect the machine harness connector from the "neutral start" switch.
C. At the machine harness connector of the "neutral start" switch, measure the resistance between
contacts B and C while the hydraulic lock lever is moved from the LOCKED position to the
RELEASED position.
Expected Result:
The resistance is less than 5 ohms when the lever is in the RELEASED position. The resistance is
greater than 5000 ohms when the lever is in the LOCKED position.
Results:
• OK - The resistance is less than 5 ohms when the lever is in the RELEASED position. The
resistance is greater than 5000 ohms in the LOCKED position. The resistance is correct.
Repair: The machine harness is open. Repair the machine harness or replace the machine
harness.
STOP
• NOT OK - The resistance does not measure less than 5 ohms when the lever is in the
RELEASED position. The resistance is not greater than 5000 ohms in the LOCKED position.
The resistance is not correct.
Repair: The neutral start switch has failed. Replace the neutral start switch.
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i02365054
MID 039 - CID 1160 - FMI 06

SMCS - 5059-038-M9; 5479-038-HLK
Schematic of the Hydraulic Lock Solenoid
This diagnostic code is associated with the Hydraulic Lock Solenoid. The FMI 06 means that the
machine ECM determined that the current is above normal.
The possible causes of this diagnostic code are listed:
• The solenoid energizer circuit is shorted to ground.
• The hydraulic lock relay has failed.
• The machine ECM has failed. This is unlikely.
When this diagnostic code occurs, a warning is displayed on the Monitoring System and the machine
ECM disables the hydraulic system.
codes and clear the diagnostic codes when the original diagnostic code has been corrected.
A. Ensure that the hydraulic lock lever is in the UP position.
B. Turn the disconnect switch and the key start switch to the ON position. Do NOT start the
engine.
C. Ensure that the diagnostic code is active on the Monitoring System.
D. Disconnect the suspect solenoid from the machine harness.
E. Observe the Monitoring System.
Expected Result:
The diagnostic code changed on the Monitoring System.
Results:
• OK - The diagnostic code changed on the Monitoring System. The circuit is correct.
Repair: The solenoid has failed. Replace the solenoid.
STOP
• NOT OK - The diagnostic code did not change on the Monitoring System. The diagnostic code
remains active. Proceed to Test Step 2.
Test Step 2. CHECK THE HYDRAULIC ACTIVATION CIRCUIT OF THE HARNESS.
A. Turn the key start switch to the OFF position.
B. Disconnect the machine harness connectors J1 and J2 from the machine ECM.
C. The solenoid remains disconnected from the machine harness.
D. Place a jumper between contacts 3 (wire A588-GN) and 5 (wire E564-PK) of the hydraulic lock
on solenoid.
E. Place the hydraulic lock lever in the locked position (the down position).
F. At the machine harness connector J2 for the machine ECM, measure the resistance between
contact J2-27 (wire E997-BR) and all sources of ground.
Expected Result:
The resistance measurements are greater than 5000 ohms.
Results:
• OK - The resistance measurements are greater than 5000 ohms. The resistance is correct.
• NOT OK - The resistance is less than 5000 ohms. The solenoid energizer circuit is shorted to
+battery.
STOP
A. Reconnect all machine harness connectors.
B. Remove the jumper that was placed in the previous test.
D. Clear all active diagnostic codes from the Monitoring System by pressing the OK key that is
located on the keypad.
F. Check the Monitoring System for an active diagnostic code.
Expected Result:
The diagnostic code for the solenoid is not present. The diagnostic information may also be viewed
with the ET.
Results:
• OK - The diagnostic code for the solenoid is not present. The diagnostic code was probably
caused by a poor electrical connection or an open at one of the harness connectors that was
disconnected and re connected. Resume normal machine operation.STOP
• NOT OK - The diagnostic code for the solenoid is still present. The diagnostic code has not
been corrected. The machine ECM has failed. It is unlikely that the ECM has failed. Exit this
procedure and perform this diagnostic code procedure again.
Repair: If the cause of this diagnostic code is not found, replace the machine ECM. See
Testing And Adjusting, "Electronic Control Module (ECM) - Replace".
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03756680
MID 039 - CID 1178 - FMI 03

SMCS - 1439-038-BM
Schematic of the "Boom Overload Pressure" Sensor
This diagnostic code is recorded when the Machine ECM reads the signal voltage of the pressure
sensor as being too high.
• The sensor supply or the ground circuit in the machine harness is open.
• The signal circuit in the machine harness is open or the sensor is disconnected.
B. Ensure that the diagnostic code is present.
C. Observe the status of the diagnostic code. Then, disconnect the machine harness from the
sensor.
Expected Result:
If the sensor is not the cause of the diagnostic code, the diagnostic code remains present. If the sensor
has failed, the diagnostic code is NO longer present.
Results:
• OK - The diagnostic code remains present. The sensor has not failed. The machine harness or
the Machine ECM may have failed. Proceed to Test Step 2.
• NOT OK - The diagnostic code is NO longer present. The machine harness is correct and the
Machine ECM is operating properly. The sensor has failed.
Repair: Replace the sensor. Verify that the new sensor corrects the problem.
STOP
Test Step 2. CHECK THE SIGNAL CIRCUIT.
B. The machine harness remains disconnected from the sensor.
C. Disconnect the J1 and J2 connector from the Machine ECM.
D. At the J1 connector for the ECM, measure the resistance from contact J1-37 (wire H446-PK) to
all other J1 and J2 contacts.
Expected Result:
The resistance should be greater than 5 ohms.
Results:
• YES - The resistance is greater than 5 ohms. The harness is correct. Proceed to Test Step 3.
• NO - The resistance is not greater than 5 ohms for each measurement. There is a short in the
harness.
Repair: The short is in the wire with the low resistance measurement. Repair the harness or
replace the harness.
STOP
Test Step 3. CHECK THE RETURN CIRCUIT FOR AN OPEN.
A. The sensor remains disconnected.
B. The disconnect switch and the key start switch remain in the OFF position.
C. The machine harness connectors remain disconnected from the Machine ECM.
D. At the J1 connector for the ECM, measure the resistance between the return contact J1-18 (wire
A209-BK) and contact 2 (wire A209-BK) at the sensor.
Expected Result:
Results:
• YES - The resistance is less than 5 ohms. The harness resistance is correct. Proceed to Test
Step 4.
• NO - The resistance is greater than 5 ohms. The return circuit of the harness has failed.
Repair: There is an open in the return wire (A209-BK). Repair the machine harness or replace
STOP
A. Inspect the contacts and clean the contacts of the harness connectors.
E. Check if the diagnostic code is active.
Expected Result:
The diagnostic code is NOT active.
Results:
• YES - The diagnostic code is NO longer active. The initial diagnostic code was probably
caused by a poor electrical connection or a short at one of the harness connectors that was
disconnected and reconnected. Resume normal machine operation.STOP
• NO - The diagnostic code remains active. The Machine ECM has failed.
procedure again. Also, recheck if the indicator is illuminated for this diagnostic code. If the
cause of the diagnostic code is not found, replace the Machine ECM. See Testing and
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03756743
MID 039 - CID 1178 - FMI 04

SMCS - 1439-038-BM
Schematic of the "Boom Overload Pressure" Sensor
sensor as being too low.
• Wire H446-PK is shorted to ground.
C. Observe the status of the diagnostic code. Disconnect the machine harness from the sensor.
Expected Result:
The diagnostic code will remain active if the sensor is not the cause of the problem. The sensor is the
cause of the problem if the diagnostic code is NO longer active.
Results:
• OK - The diagnostic code remains active. The sensor has not failed. The machine harness may
have failed or the Machine ECM may have failed. Proceed to Test Step 2.
• NOT OK - The diagnostic code is NO longer active.
Repair: The machine harness and the Machine ECM are operating properly. The sensor has
failed. Replace the sensor.
STOP
Test Step 2. CHECK THE SIGNAL CIRCUIT FOR A SHORT TO GROUND
B. Turn the key start switch and the disconnect switch to the OFF position.
C. Disconnect the machine harness connector J1 and J2 from the Machine ECM.
D. At the J1 machine harness connector, measure the resistance from contact J1-37 (H446-PK) to
all source of ground.
Expected Result:
Results:
• OK - The resistance is greater than 5 ohms. The machine harness is correct. Proceed to Test
Step 3.
Repair: There is a short in the machine harness. The short is between the signal circuit (wire
H446-PK) and the circuit with the low resistance measurement. Repair the machine harness or
STOP
A. Clean the contacts of the harness connectors.
Expected Result:
Results:
• YES - The diagnostic code is NO longer active. The diagnostic code does not exist at this time.
The initial diagnostic code was probably caused by a poor electrical connection and/or a short
at one of the harness connectors that was disconnected and then reconnected. Resume normal
machine operation.STOP
• NO - The diagnostic code has not been corrected. The Machine ECM has failed.
diagnostic code procedure again. Replace the ECM if the cause of the diagnostic code is not
found. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace".
STOP
Shutdown SIS
Previous Screen
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i04170113
MID 039 - CID 1178 - FMI 08

SMCS - 1439-038-BM
Boom"Overload Pressure" sensor circuit schematic
This diagnostic code is for the Boom"Overload Pressure" sensor. An FMI 08 diagnostic code means
the machine ECM has determined the sensor output signal has an abnormal frequency, pulse width, or
period.
• Failed sensor.
System Response:
B. Disconnect the machine harness connector from the Boom"Overload Pressure" sensor.
(wire H446-PK) and the contact for terminal B (wire A209-BK) in the sensor connector.
Expected Result:
Results:
Go to Test Step 3.
E. At the ECM J1 harness connector, measure the resistance between contact J1-37 (wire H446-
PK) and frame ground.
H446-PK) and all of the other contacts that are used in both the J1 and J1 ECM harness
connectors.
Expected Result:
Results:
machine harness.
Go to Test Step 3.
Expected Result:
Results:
normal operations.
STOP
STOP
Shutdown SIS
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03756751
MID 039 - CID 1522 - FMI 03

SMCS - 5479-038-CV
Schematic of the "Relief-2 Check Solenoid (attachment)"
This diagnostic code is associated with the "Relief-2 Check Solenoid (attachment)". The FMI 03
diagnostic code means that the Machine ECM has determined that the voltage is above normal.
The possible causes of the diagnostic code are listed:
• The solenoid energizer circuit of the modulating valve is shorted to the +battery circuit.
System Response:
When this diagnostic code is active, the ECM will turn off the current to the failed solenoid.
Test Step 1. CHECK THE SOLENOID ENERGIZER CIRCUIT FOR A SHORT TO THE
+BATTERY CIRCUIT
(wire K877-BU) to all contacts that are used in the machine harness connectors for the Machine
ECM.
Expected Result:
Results:
machine harness. The short is between J2-30 (K877-BU) and the circuit that has a low
STOP
Expected Result:
Results:
STOP
time.
machine operation.
STOP
Shutdown SIS
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03756769
MID 039 - CID 1522 - FMI 05

SMCS - 5479-038-CV
diagnostic code means that the Machine ECM has determined that the current is below normal.
• The solenoid energizer circuit of the modulating valve is open.
• The return circuit of the modulating valve is open.
System Response:
When this diagnostic code is active, the Machine ECM will turn off the current to the failed solenoid.
Test Step 1. CHECK THE SOLENOID
K877-BU) to contact 2 (wire 235-BK).
Expected Result:
Results:
problem.
STOP
Test Step 2. CHECK THE HARNESS FOR AN OPEN
C. The jumper wire that was installed in the previous test remains in place.
D. At the machine harness connector, measure the resistance from signal contact J2-30 (wire K877
-BU) to contact J1-2 (wire 235-BK).
E. At the machine harness connector, measure the resistance from signal contact J2-30 (wire K877
-BU) to contact J1-14 (wire 235-BK).
Expected Result:
Both resistances are less than 5.0 ohms.
Results:
• OK - Both resistances are less than 5.0 ohms. The machine harness is correct. Proceed to Test
Step 3.
• NOT OK - Either resistance is greater than 5000 ohms. The resistance measurement is not
Repair: The open is in wire K877-BU or in wire 235-BK of the machine harness. Repair the
STOP
Expected Result:
Results:
STOP
this time.
machine operation.
STOP
Shutdown SIS
Previous Screen
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03756775
MID 039 - CID 1522 - FMI 06

SMCS - 5479-038-CV
diagnostic code means that the Machine ECM has determined that the current of the solenoid is above
normal.
• The solenoid energizer circuit of the modulating valve is shorted to ground.
System Response:
Expected Result:
Results:
STOP
Test Step 2. CHECK THE SOLENOID ENERGIZER CIRCUIT FOR A SHORT TO

GROUND
K877-BU) to all contacts that are used in the machine harness connectors for the Machine
ECM.
Expected Result:
Results:
machine harness. The short is between J2-30 (wire K877-BU) and the circuit with the low
STOP
Expected Result:
Results:
STOP
this time.
machine operation.
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03756786
MID 039 - CID 1523 - FMI 03

SMCS - 5479-038-CV
• The energizer circuit of the solenoid for the modulating valve is shorted to the +battery circuit.
System Response:
+BATTERY CIRCUIT
C. At the machine harness connector for the Machine ECM, measure the resistance from contact
J2-29 (wire K876-BR) to all contacts that are used in the machine harness connectors for the
Machine ECM.
Expected Result:
Results:
machine harness. The short is between J2-29 (K876-BR) and the circuit that has a low
STOP
Expected Result:
Results:
STOP
time.
machine operation.
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03756793
MID 039 - CID 1523 - FMI 05

SMCS - 5479-038-CV
• The energizer circuit of the modulating valve for the solenoid is open.
System Response:
K876-BR) to contact 2 (wire 235-BK).
Expected Result:
Results:
problem.
STOP
-BR) to contact J1-2 (wire 235-BK).
E. At the machine harness connector, measure the resistance from signal contact J2-29 (wire K876
-BR) to contact J1-14 (wire 235-BK).
Expected Result:
Results:
Step 3.
Repair: The open is in wire K876-BR or in wire 235-BK of the machine harness. Repair the
STOP
Expected Result:
Results:
STOP
this time.
machine operation.
STOP
Shutdown SIS
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Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03756795
MID 039 - CID 1523 - FMI 06

SMCS - 5479-038-CV
normal.
System Response:
Expected Result:
Results:
STOP
• NO - The CID 1523 FMI 06diagnostic code remains active. Proceed to Test Step 2.

GROUND
K876-BR) to all contacts that are used in the machine harness connectors for the Machine
ECM.
Expected Result:
Results:
machine harness. The short is between J2-29 (wire K876-BR) and the circuit with the low
STOP
Expected Result:
Results:
STOP
this time.
machine operation.
STOP
Shutdown SIS
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03756796
MID 039 - CID 1525 - FMI 03

SMCS - 5479-038
Schematic of the "Travel Straight" Solenoid
This diagnostic code is associated with the "Travel Straight" Solenoid. The FMI 03 diagnostic code
means that the Machine ECM has determined that the voltage is above normal.
System Response:
+BATTERY CIRCUIT
B. Disconnect the machine harness connectors from the solenoid and the ECM.
C. At the machine harness connector for the ECM, measure the resistance from contact J2-1 (wire
M740-PK) to all contacts that are used in the machine harness connectors for the Machine
ECM.
Expected Result:
Results:
machine harness. The short is between J2-1 (M740-PK) and the circuit that has a low resistance
measurement.
STOP
Expected Result:
Results:
STOP
time.
machine operation.
STOP
Shutdown SIS
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03756801
MID 039 - CID 1525 - FMI 05

SMCS - 5479-038
means that the Machine ECM has determined that the current is below normal.
• The solenoid energizer circuit of the modulating valve is open.
System Response:
M740-PK) to contact 2 (wire 235-BK).
Expected Result:
Results:
problem.
STOP
D. At the machine harness connector, measure the resistance from signal contact J2-1 (wire M740-
PK) to contact J1-2 (wire 235-BK).
E. At the machine harness connector, measure the resistance from signal contact J2-1 (wire M740-
PK) to contact J1-14 (wire 235-BK).
Expected Result:
Results:
Step 3.
Repair: The open is in wire M740-PK or in wire 235-BK of the machine harness. Repair the
STOP
Expected Result:
Results:
STOP
this time.
machine operation.
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03756804
MID 039 - CID 1525 - FMI 06

SMCS - 5479-038
means that the ECM has determined that the current of the solenoid is above normal.
System Response:
Expected Result:
Results:
STOP

GROUND
M740-PK) to all contacts that are used in the machine harness connectors for the Machine
ECM.
Expected Result:
Results:
machine harness. The short is between J2-1 (wire M740-PK) and the circuit with the low
STOP
Expected Result:
Results:
STOP
this time.
machine operation.
STOP
Shutdown SIS
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Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05434610
MID 039 - CID 1590 - FMI 03

SMCS - 5479-038-FW
Schematic of the Flow Limit Pressure solenoid
This diagnostic code is associated with the Flow Limit Pressure solenoid. An FMI 03 diagnostic code
means that Machine ECM has determined the voltage in the solenoid circuit is above normal.
Possible causes for this diagnostic code are listed below:
• The Flow Limit Pressure solenoid energize circuit has shorted to a voltage source.
• The Machine ECM may have failed (unlikely).
System Response:
B. Disconnect the machine harness connector from the Flow Limit Pressure solenoid.
C. At the harness connector for the solenoid, place a jumper wire from contact 1 (M737-WH) to
contact 2 (M739-YL) on the connector.
Expected Result:
Results:
Go to Test Step 2.
• NO - The CID 1590 FMI 03 code is no longer active, and has been replaced by an active CID
1590 FMI 06 diagnostic code. The ECM has detected a valid diagnostic code.
Go to Test Step 3.
Test Step 2. CHECK THE SOLENOID ENERGIZE CIRCUIT FOR A SHORT TO A

VOLTAGE SOURCE.
B. The harness connector remains disconnected from the Flow Limit Pressure solenoid.
C. Remove the jumper wire inserted in Test Step 1.
D. Disconnect the J1 and J2 machine harness connectors from the Machine ECM.
E. At the ECM J2 harness connector, measure the resistance from contact J2-9 (M737-WH) to all
of the other contacts that are used in the machine harness connectors for the ECM.
Expected Result:
Results:
• YES - Each resistance is more than 5000 ohms. The machine harness is correct. Go to Test
Step 3.
between contact J2-9 (M737-WH) and the circuit with the low resistance.
Go to Test Step 3.
Expected Result:
The CID 1590 FMI 03 diagnostic code is no longer active.
Results:
this time.
STOP
corrected.
"Electronic Control Module (ECM) - Replace ".
STOP
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05434616
MID 039 - CID 1590 - FMI 05

SMCS - 5479-038-FW
means the ECM has determined the current of the solenoid circuit is below normal.
• The Flow Limit Pressure solenoid has failed.
• An open wire in the Flow Limit Pressure solenoid circuits.
System Response:
C. At the harness connector for the solenoid, place a jumper wire from contact 1 (M737-WH) to
contact 2 (M739-YL) on the connector.
Expected Result:
Results:
• YES - The CID 1590 FMI 05 code remains active. The jumper wire did not change the code.
The solenoid is NOT the cause of the problem.
Go to Test Step 2.
• NO - The CID 1590 FMI 05 code is NOT active, and has been replaced by an active CID 1590
FMI 06 diagnostic code. The ECM has detected a valid diagnostic code.
Go to Test Step 3.
Test Step 2. CHECK THE MACHINE HARNESS FOR AN OPEN CONNECTION.
B. The jumper wire that was placed into the Flow Limit Pressure solenoid harness connector
during Test Step 1 remains in place.
C. Disconnect the J2 machine harness connector from the machine ECM.
D. At the ECM J2 harness connector, measure the resistance from contact J2-9 (M737-WH) to
contact J2-35 (M739-YL) on the connector.
Expected Result:
Results:
• YES - The resistance is less than 5.0 ohms. The machine harness is correct. Go to Test Step 3.
• NO - The resistance is NOT less than 5.0 ohms. There is an open in the harness.
Repair: The open is in wire M737-WH or in wire M739-YL of the machine harness. Repair, or
replace, the harness.
Go to Test Step 3.
Expected Result:
Results:
this time.
STOP
corrected.
STOP
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320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05434619
MID 039 - CID 1590 - FMI 06

SMCS - 5479-038-FW
means the ECM has determined the current of the solenoid circuit is above normal.
• The Flow Limit Pressure solenoid has failed
• The Flow Limit Pressure solenoid energize circuit is shorted to ground.
System Response:
C. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine.
Expected Result:
Results:
• YES - The CID 1590 FMI 06 code remains active. Disconnecting the solenoid did not change
Go to Test Step 2.
Go to Test Step 3
GROUND.
B. The harness connector remains disconnected from the Flow Limit Pressure solenoid.
C. Disconnect the J1 and J2 machine harness connectors from the Machine ECM.
D. At the ECM J2 harness connector, measure the resistance from the signal contact J2-9 (wire
M737-WH) to all of the other contacts used in the machine harness connectors for the ECM.
Expected Result:
Results:
• YES - Each resistance is more than 5000 ohms. The harness is correct. Go to Test Step 3.
between J2-9 (M737-WH) and the circuit with the low resistance.
Go to Test Step 3.
Expected Result:
Results:
this time.
STOP
corrected.
STOP
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03757890
MID 039 - CID 1593 - FMI 03

SMCS - 5479-038-V4
Schematic of the "Attachment Valve #1 Extend Pressure" Solenoid
This diagnostic code is associated with the "Attachment Valve #1 Extend Pressure" Solenoid. The
FMI 03 diagnostic code means that the ECM has determined that the voltage is above normal.
System Response:
+BATTERY CIRCUIT
J2-38 (wire K856-PU) to all contacts that are used in the machine harness connectors for the
Machine ECM.
Expected Result:
Results:
machine harness. The short is between J2-38 (K856-PU) and the circuit that has a low
STOP
Expected Result:
Results:
STOP
time.
machine operation.
STOP
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320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03758049
MID 039 - CID 1593 - FMI 05

SMCS - 5479-038-V4
FMI 05 diagnostic code means that the Machine ECM has determined that the current is below
normal.
• The energizer circuit of the solenoid for the modulating valve is open.
System Response:
K856-PU) to contact 2 (wire K868-BR).
Expected Result:
Results:
problem.
STOP
-PU) to contact J2-19 (wire K868-BR).
Expected Result:
Results:
Step 3.
Repair: The open is in wire K856-PU or in wire K868-BR of the machine harness. Repair the
STOP
Expected Result:
Results:
STOP
this time.
machine operation.
STOP
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03758072
MID 039 - CID 1593 - FMI 06

SMCS - 5479-038-V4
Schematic of the "Attachment Valve #1 Extend Pressure" solenoid
This diagnostic code is associated with the "Attachment Valve #1 Extend Pressure" solenoid. The
FMI 06 diagnostic code means that the ECM has determined that the current of the solenoid is above
normal.
• The energizer circuit of the solenoid for the modulating valve is shorted to ground.
System Response:
Expected Result:
Results:
STOP

GROUND
K856-PU) to all contacts that are used in the machine harness connectors for the Machine
ECM.
Expected Result:
Results:
machine harness. The short is between J2-38 (wire K856-PU) and the circuit with the low
STOP
Expected Result:
Results:
STOP
this time.
machine operation.
STOP
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03758115
MID 039 - CID 1594 - FMI 06

SMCS - 5479-038-V4
Schematic of the "Attachment Valve #2 Extend Pressure" solenoid
This diagnostic code is associated with the "Attachment Valve #2 Extend Pressure" solenoid. The
FMI 06 diagnostic code means that the Machine ECM has determined that the current of the solenoid
is above normal.
System Response:
Expected Result:
Results:
STOP

GROUND
K857-WH) to all contacts that are used in the machine harness connectors for the Machine
ECM.
Expected Result:
Results:
machine harness. The short is between J2-40 (wire K857-WH) and the circuit with the low
STOP
Expected Result:
Results:
STOP
this time.
machine operation.
STOP
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03758181
MID 039 - CID 1595 - FMI 03

SMCS - 5479-038-V4
FMI 03 diagnostic code means that the Machine ECM has determined that the voltage is above
normal.
System Response:
+BATTERY CIRCUIT
(wire K858-YL) to all contacts that are used in the machine harness connectors for the Machine
ECM.
Expected Result:
Results:
machine harness. The short is between J2-42 (K858-YL) and the circuit that has a low
STOP
Expected Result:
Results:
STOP
time.
machine operation.
STOP
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03758238
MID 039 - CID 1595 - FMI 05

SMCS - 5479-038-V4
normal.
System Response:
K858-YL) to contact 2 (wire K869-BU).
Expected Result:
Results:
problem.
STOP
-YL) to contact J2-21 (wire K869-BU).
Expected Result:
Results:
Step 3.
Repair: The open is in wire K858-YL or in wire K869-BU of the machine harness. Repair the
STOP
Expected Result:
Results:
STOP
this time.
machine operation.
STOP
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03758305
MID 039 - CID 1595 - FMI 06

SMCS - 5479-038-V4
is above normal.
System Response:
Expected Result:
Results:
STOP

GROUND
K858-YL) to all contacts that are used in the machine harness connectors for the Machine
ECM.
Expected Result:
Results:
machine harness. The short is between J2-42 (wire K858-YL) and the circuit with the low
STOP
Expected Result:
Results:
STOP
this time.
machine operation.
STOP
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05434667
MID 039 - CID 1596 - FMI 03

SMCS - 5479-038-V4
Schematic of the Attachment Valve #1 Retract Pressure Solenoid
This diagnostic code is associated with the "Attachment Valve #1 Retract Pressure" Solenoid. The
normal.
For machines equipped with the E-Fence feature, reference Troubleshooting, " E-Ceiling and
• The solenoid energize circuit for the "Attachment Valve #1 Retract Pressure" is shorted to the
+battery circuit.
System Response:
+BATTERY CIRCUIT
(wire K860-BU) to all contacts that are used in the machine harness connectors for the Machine
ECM.
Expected Result:
Results:
machine harness. The short is between J2-32 (K860-BU) and the circuit that has a low
STOP
Expected Result:
Results:
STOP
time.
short at one of the disconnected and reconnected harness connectors. Resume normal machine
operation.
STOP
Shutdown SIS
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05434677
MID 039 - CID 1596 - FMI 05

SMCS - 5479-038-V4
Schematic of the "Attachment Valve #1 Retract Pressure" Solenoid
normal.
• The solenoid energize circuit for the "Attachment Valve #1 Retract Pressure" solenoid is open.
• The return circuit of the "Attachment Valve #1 Retract Pressure" solenoid is open.
• The "Attachment Valve #1 Retract Pressure" solenoid has failed.
System Response:
K860-BU) to contact 2 (wire K868-BR).
Expected Result:
Results:
Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" to verify
the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem.
STOP
B. Disconnect the machine harness connectors from the Machine ECM.
-BU) to contact J2-19 (wire K868-BR).
Expected Result:
Results:
Step 3.
Repair: The open is in wire K860-BU or in wire K868-BR of the machine harness. Repair the
STOP
Expected Result:
Results:
STOP
this time.
Repair: The diagnostic code was probably caused by a poor electrical connection that was
resolved when a harness connector was disconnected and reconnected. Resume normal machine
operation.
STOP
Shutdown SIS
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05434686
MID 039 - CID 1596 - FMI 06

SMCS - 5479-038-V4
is above normal.
• The solenoid energize circuit for the "Attachment Valve #1 Retract Pressure" solenoid is
shorted to ground.
• The "Attachment Valve #1 Retract Pressure" solenoid has failed.
System Response:
Expected Result:
Results:
STOP

GROUND
C. Disconnect the machine harness connectors from the Machine ECM.
K860-BU) to all contacts that are used in the machine harness connectors for the Machine
ECM.
Expected Result:
Results:
machine harness. The short is between J2-32 (wire K860-BU) and the circuit with the low
STOP
Expected Result:
Results:
Repair: Is unlikely that the Machine ECM has failed. Exit this procedure and perform this
STOP
this time.
Repair: The diagnostic code was probably caused by a poor electrical connection that was
resolved when a harness connector was disconnected and reconnected. Resume normal machine
operation.
STOP
Shutdown SIS
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03758399
MID 039 - CID 1597 - FMI 03

SMCS - 5479-038-V4
normal.
System Response:
+BATTERY CIRCUIT
(wire K861-GN) to all contacts that are used in the machine harness connectors for the ECM.
Expected Result:
Results:
machine harness. The short is between J2-39 (K861-GN) and the circuit that has a low
STOP
Expected Result:
Results:
STOP
time.
machine operation.
STOP
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03758410
MID 039 - CID 1597 - FMI 05

SMCS - 5479-038-V4
normal.
System Response:
K861-GN) to contact 2 (wire K868-BR).
Expected Result:
Results:
problem.
STOP
-GN) to contact J2-19 (wire K868-BR).
Expected Result:
Results:
Step 3.
Repair: The open is in wire K861-GN or in wire K868-BR of the machine harness. Repair the
STOP
Expected Result:
Results:
STOP
this time.
machine operation.
STOP
Shutdown SIS
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03758432
MID 039 - CID 1597 - FMI 06

SMCS - 5479-038-V4
is above normal.
System Response:
Expected Result:
Results:
STOP

GROUND
K861-GN) to all contacts that are used in the machine harness connectors for the Machine
ECM.
Expected Result:
Results:
machine harness. The short is between J2-39 (wire K861-GN) and the circuit with the low
STOP
Expected Result:
Results:
STOP
this time.
machine operation.
STOP
Shutdown SIS
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03758469
MID 039 - CID 1598 - FMI 03

SMCS - 5479-038-V4
normal.
System Response:
+BATTERY CIRCUIT
(wire K862-GY) to all contacts that are used in the machine harness connectors for the Machine
ECM.
Expected Result:
Results:
machine harness. The short is between J2-41 (K862-GY) and the circuit that has a low
STOP
Expected Result:
Results:
STOP
time.
machine operation.
STOP
Shutdown SIS
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03758550
MID 039 - CID 1598 - FMI 05

SMCS - 5479-038-V4
normal.
System Response:
K862-GY) to contact 2 (wire K869-BU).
Expected Result:
Results:
problem.
STOP
-GY) to contact J2-21 (wire K869-BU).
Expected Result:
Results:
Step 3.
Repair: The open is in wire K862-GY or in wire K869-BU of the machine harness. Repair the
STOP
Expected Result:
Results:
STOP
this time.
machine operation.
STOP
Shutdown SIS
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03758553
MID 039 - CID 1598 - FMI 06

SMCS - 5479-038-V4
is above normal.
System Response:
Expected Result:
Results:
STOP

GROUND
K862-GY) to all contacts that are used in the machine harness connectors for the Machine
ECM.
Expected Result:
Results:
machine harness. The short is between J2-41 (wire K862-GY) and the circuit with the low
STOP
Expected Result:
Results:
STOP
this time.
machine operation.
STOP
Shutdown SIS
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03928713
MID 039 - CID 1609 - FMI 03

SMCS - 1439-038-VL
Schematic of the "Squeeze Pressure" Sensor
This diagnostic code is associated with the "Squeeze Pressure Sensor". The FMI 03 diagnostic code
means that the Machine ECM determined that the sensor signal voltage is too high.
• The sensor signal has shorted to another power supply source.
• The sensor supply or the ground circuit in the machine harness is open.
• The signal circuit in the machine harness is open or the sensor is disconnected.
• The Machine ECM has failed, but is unlikely.
Test Step 1. CHECK THE SENSORPOWER.
B. Insert the 7X-1710 Multimeter Probe leads into the back of the sensor connector along side of
contact A (wire 308-YL) and contact B (wire A209-BK).
C. Measure the voltage (DCV) between signal contact B (wire E472-GN) and ground contact 2
(wire 235-BK).
Expected Result:
The voltage is 24 DCV.
Results:
• OK - The voltage is 24 DCV . The voltage is correct. Proceed to Test Step 2.
• NOT OK - The voltage is NOT 24 DCV. There is an open circuit.
STOP
Test Step 2. CHECK THE SIGNAL CIRCUIT FOR A SHORT.
B. The machine harness remains disconnected from the sensor.
C. Disconnect the J1 connector from the Machine ECM.
D. At the J1 connector for the Machine ECM, measure the resistance from contact J1-16 (wire
M906-BU) to all of the other J1 contacts in the connector.
Expected Result:
The resistance measurements are all greater than 5 ohms.
Results:
• YES - The resistance measurements are all greater than 5 ohms. The harness is correct. Proceed
to Test Step 3.
• NO - The resistance measurements are NOT all greater than 5 ohms. There is a short in the
harness.
Repair: The short is in the wire with the low resistance measurement. Repair the harness or
replace the harness.
STOP
Test Step 3. CHECK THE SENSOR CIRCUITS FOR AN OPEN.
A. The sensor remains disconnected.
B. The disconnect switch and the key start switch remain in the OFF position.
C. The machine harness connectors remain disconnected from the Machine ECM.
D. At the J1 connector for the Machine ECM, measure the resistance between the return contact J1
-16 (wire M906-BU) and contact C (wire M906-BU) at the sensor connector.
E. At the J1 connector for the Machine ECM, measure the resistance between the return contact J1
-18 (wire A209-BK) and contact B (wire A209-BK) at the sensor connector.
F. At the J1 connector for the Machine ECM, measure the resistance between the return contact J1
-23 (wire 308-YL) and contact A (wire 308-YL) at the sensor connector.
Expected Result:
The resistance measurements are all less than 5 ohms.
Results:
• YES - The resistance measurements are all less than 5 ohms. The harness resistance is correct.
• NO - The resistance measurements are NOT all less than 5 ohms. A sensor circuit connection
in the harness has failed.
Repair: There is an open in the sensor circuits in the harness. Repair the machine harness or
STOP
E. Check if the diagnostic code is active.
Expected Result:
The diagnostic code is NOT active.
Results:
• YES - The diagnostic code is NO longer active. The initial diagnostic code was probably
caused by a poor electrical connection that was resolved when a connector was disconnected
and reconnected. Resume normal machine operationSTOP
• NO - The diagnostic code remains active. The Machine ECM has failed.
Repair: Is unlikely that the Machine ECM has failed. Exit this procedure and perform this
procedure again. Also, recheck if the indicator is illuminated for this diagnostic code. If the
cause of the diagnostic code is not found, replace the Machine ECM. See Testing and
STOP
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i03758651
MID 039 - CID 1609 - FMI 04

SMCS - 1439-038-VL
Schematic of the "Squeeze Pressure" Sensor
sensor as being too low.
• Wire M906-BU is shorted to ground.
C. Observe the status of the diagnostic code. Disconnect the machine harness from the sensor.
Expected Result:
The diagnostic code will remain active if the sensor is not the cause of the problem. The sensor is the
cause of the problem if the diagnostic code is NO longer active.
Results:
• OK - The diagnostic code remains active. The sensor has not failed. The machine harness may
have failed or the Machine ECM may have failed. Proceed to Test Step 2.
• NOT OK - The diagnostic code is NO longer active.
Repair: The machine harness and the Machine ECM are operating properly. The sensor has
failed. Replace the sensor.
STOP
Test Step 2. CHECK THE SIGNAL CIRCUIT FOR A SHORT TO GROUND.
C. Disconnect the machine harness connector J1 and J2 from the Machine ECM.
D. At the J1 machine harness connector, measure the resistance from contact J1-16 (M906-BU) to
all source of ground.
Expected Result:
Results:
• OK - The resistance is greater than 5 ohms. The machine harness is correct. Proceed to Test
Step 3.
Repair: There is a short in the machine harness. The short is between the signal circuit (wire
M906-BU) and the circuit with the low resistance measurement. Repair the machine harness or
STOP
A. Clean the contacts of the harness connectors.
Expected Result:
Results:
• YES - The diagnostic code is NO longer active. The diagnostic code does not exist at this time.
The initial diagnostic code was probably caused by a poor electrical connection and/or a short
at one of the harness connectors that was disconnected and then reconnected. Resume normal
• NO - The diagnostic code has not been corrected. The ECM has failed.
diagnostic code procedure again. Replace the Machine ECM if the cause of the diagnostic code
is not found. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace".
STOP
Shutdown SIS
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i04170114
MID 039 - CID 1609 - FMI 08

SMCS - 1439-038-VL
"Squeeze Pressure" sensor circuit schematic
This diagnostic code is for the"Squeeze Pressure" sensor. An FMI 08 diagnostic code means the
machine ECM has determined the sensor output signal has an abnormal frequency, pulse width, or
period.
• Failed sensor.
B. Disconnect the machine harness connector from the "Squeeze Pressure" sensor.
(wire M906-BU) and the contact for terminal B (wire A209-BK) in the sensor connector.
Expected Result:
Results:
Go to Test Step 3.
E. At the ECM J1 harness connector, measure the resistance between contact J1-16 (wire M906-
BU) and frame ground.
M906-BU) and all of the other contacts that are used in both the J1 and J1 ECM harness
connectors.
Expected Result:
Results:
machine harness.
Go to Test Step 3.
Expected Result:
Results:
normal operations.
STOP
STOP
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320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05435121
MID 039 - CID 1657 - FMI 03

SMCS - 5705-038-PSN
Left Joystick Thumbwheel Modulation Control sensor circuit schematic
This diagnostic code is for the Left Joystick Thumbwheel Modulation Control sensor. An FMI 03
diagnostic code means the Machine ECM has determined the sensor output signal voltage is above
the normal limit.
• Failed sensor.
• Open sensor signal output wire.
• Failed Machine ECM, but most unlikely.
System Response:
When this diagnostic code occurs, there is no warning on the monitor. The "thumbwheel" control of
the joystick will be inoperative.
Test Step 1. VERIFY THE +8 VDC SUPPLY.
C. At the harness connector for the Left Joystick Thumbwheel Modulation Control sensor,
measure voltage from contact 1 (wire E472-GN) to contact 2 (wire 235-BK) on the sensor
connector.
Expected Result:
The voltage is 8.0 ± 0.5 VDC.
Results:
• YES - The voltage is 8.0 ± 0.5 VDC. Go to Test Step 2.
• NO - The voltage is not 8.0 ± 0.5 VDC. There is a problem with the +8 VDC power supply.
Repair: Refer to the complete electrical schematics for the machine. Investigate the ECM +8
VDC power supply problem.
After +8 VDC power supply problem is repaired, check if the 1657 FMI 03 diagnostic code is
B. Disconnect the machine harness connector from the Thumbwheel Modulation Control sensor.
(wire E474-OR) and the contact for terminal 2 (wire 235-BK) in the sensor connector.
Expected Result:
Results:
• YES - The CID 1657 FMI 03 code remains active. The sensor is not the cause of the problem.
Go to Test Step 3.
Go to Test Step 5.
D. Disconnect both the J1 and J2 harness connectors from the Machine ECM.
E. At the J1 ECM harness connector, measure resistance between contact J1-38 (wire E474-OR)
and contact J1-2 (wire 235-BK) in the connector.
Expected Result:
Results:
Go to Test Step 5.
B. The sensor, and the ECM harness connectors, remain disconnected.
D. At the J1 ECM harness connector, measure resistance from contact J1-38 (wire E474-OR) to all
Expected Result:
Results:
• NO - All measurements are not more than 5000 ohms. There is a short circuit in the machine
harness.
Go to Test Step 5.
fully seated. Observe that the clips for each connector are fastened securely.
Expected Result:
Results:
normal operations.
STOP
problem was again not found, and the original code is still active, the Machine ECM may have
may greatly reduce repair time. If the ECM needs to be replaced, see Testing and Adjusting, "
STOP
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320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03758791
MID 039 - CID 1657 - FMI 04

SMCS - 5705-038-PSN
Schematic of the "Left Joystick Thumbwheel Modulation" control
This diagnostic code is recorded when the Machine ECM reads the voltage of the circuit for the
"Thumbwheel" as being below normal. The signal circuit of the "Thumbwheel PWM" output may be
shorted to ground.
• The signal circuit for the "Thumbwheel Modulation" control is shorted to ground.
• The "Thumbwheel Modulation" control has failed.
Note: Ensure that the diagnostic code of CID 1657 FMI 04 is active before performing this
procedure.
System Response:
When this diagnostic code occurs, there is no warning on the monitor. The "Thumbwheel
Modulation" control will be inoperative.
Test Step 1. CHECK THE "THUMBWHEEL" CONTROL.
C. Observe the status of the diagnostic code. Disconnect the joystick from the machine harness.
Expected Result:
Results:
• OK - The diagnostic code remains active. The "Thumbwheel Modulation" control is correct.
• NOT OK - The diagnostic code is no longer active. The "Thumbwheel Modulation" control has
failed.
Repair: Replace the entire joystick handle.
STOP
Test Step 2. CHECK THE WIRING HARNESS OF THE "THUMBWHEEL MODULATION"

CONTROL FOR A SHORT TO GROUND.
B. Disconnect the machine harness from the joystick.
C. Disconnect machine harness connectors from the Machine ECM.
contact J1-38 (wire E474-OR) of the machine harness to all possible sources of ground.
Measure the resistance to all contacts that are used in the J1 and J2 harness connectors.
Expected Result:
Each resistance measurement should be greater than 5000 ohms.
Results:
• NOT OK - One or more resistance measurements is not correct. There is a short in the machine
harness. The short is between signal contact J1-38 (wire E474-OR) and the circuit with the low
resistance measurement. Repair the machine harness or replace the machine harness.STOP
D. Enter the service mode of the Monitoring System and clear all of the inactive diagnostic codes.
Expected Result:
Results:
• YES - The CID 1657 FMI 04 diagnostic code is not active. The diagnostic code does not exist
at this time. The initial diagnostic code was probably caused by a poor electrical connection or
a short at one of the harness connectors that was disconnected and reconnected. Resume normal
• NO - The CID 1657 FMI 04 diagnostic code is active. The diagnostic code has not been
corrected. It is unlikely that the Machine ECM has failed.
Repair: Exit this procedure and perform this procedure again. If the cause of the diagnostic
code is not found, replace the Machine ECM. See Testing And Adjusting, "Electronic Control
STOP
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320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05435128
MID 039 - CID 1657 - FMI 08

SMCS - 5705-038-PSN
Left joystick "Thumbwheel Modulation Control" sensor circuit schematic
This diagnostic code is for the left joystick "Thumbwheel Modulation Control" sensor. An FMI 08
diagnostic code means the Machine ECM has determined the sensor output signal has an abnormal
frequency, pulse width, or period.
• Failed sensor.
System Response:
When this diagnostic code occurs, there is no warning on the monitor. The function for the work tool
that is controlled by the "Thumbwheel Modulation Control" sensor will not function.
B. Disconnect the machine harness connector from the "Squeeze Pressure" sensor.
(wire E474-OR) and the contact for terminal 2 (wire 235-BK) in the sensor connector.
Expected Result:
Results:
• YES - The CID 1657 FMI 08 diagnostic code remains active. The sensor is not the cause of the
Go to Test Step 3.
D. Disconnect both the J1 and J2 harness connector from the Machine ECM.
E. At the ECM J1 harness connector, measure the resistance between contact J1-38 (wire E474-
OR) and frame ground.
E474-OR) and all of the other contacts that are used in both the J1 and J1 ECM harness
connectors.
Expected Result:
Results:
machine harness.
Go to Test Step 3.
Expected Result:
Results:
normal operations.
STOP
STOP
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320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05435133
MID 039 - CID 1658 - FMI 03

SMCS - 5705-038-PSN
Right Joystick "Thumbwheel Modulation Control" sensor circuit schematic
This diagnostic code is for the Right Joystick "Thumbwheel Modulation Control" sensor. An FMI 03
diagnostic code indicates the Machine ECM has determined the sensor output signal voltage is above
the normal limit.
• Failed sensor.
• Open sensor signal output wire.
System Response:
When this diagnostic code occurs, there is no warning on the monitor. The "thumbwheel" control of
the joystick will be inoperative.
Test Step 1. VERIFY THE +8 VDCSUPPLY.
A. Turn the disconnect switch and the key start switch to the "ON" position.
C. At the machine harness connector for the Right Joystick "Thumbwheel Modulation Control"
sensor, measure voltage from contact 1 (wire E472-GN) to contact 2 (wire 235-BK) on the
sensor connector.
Expected Result:
The voltage is 8.0 ± 0.5 VDC.
Results:
• YES - The voltage is 8.0 ± 0.5 VDC. Go to Test Step 2.
• NO - The voltage is not 8.0 ± 0.5 VDC. There is a problem with the +8 VDC power supply.
Repair: Refer to the complete electrical schematics for the machine. Investigate the ECM +8
VDC power supply problem.
After +8 VDC power supply problem is repaired, check if the 1658 FMI 03 diagnostic code is
B. Disconnect the machine harness connector from the Thumbwheel Modulation Control sensor.
(wire E473-GY) and the contact for terminal 2 (wire 235-BK) in the sensor connector.
Expected Result:
Results:
Go to Test Step 3.
Go to Test Step 5.
E. At the J1 ECM harness connector, measure resistance between contact J1-44 (wire E473-GY)
and contact J1-2 (wire 235-BK) in the connector.
Expected Result:
Results:
Go to Test Step 5.
D. At the J1 ECM harness connector, measure resistance from contact J1-38 (wire E474-OR) to all
Expected Result:
Results:
Go to Test Step 5.
Expected Result:
Results:
normal operations.
STOP
STOP
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320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05435135
MID 039 - CID 1658 - FMI 04

SMCS - 5705-038-PSN
Schematic of the "Right Joystick Thumbwheel Modulation" control
This diagnostic code is recorded when the Machine ECM reads the voltage of the circuit for the
"Thumbwheel" as being below normal. The signal circuit of the "Thumbwheel PWM" output may be
shorted to ground.
• The signal circuit for the "Thumbwheel Modulation" control is shorted to ground.
• The "Thumbwheel Modulation" control has failed.
• The ECM has failed. This situation is unlikely.
Note: Ensure that the diagnostic code of CID 1658 FMI 04 is active before performing this
procedure.
System Response:
When this diagnostic code occurs, there is no warning on the monitor. The "Thumbwheel
Modulation" control will be inoperative.
Test Step 1. CHECK THE "THUMBWHEEL" CONTROL
C. Observe the status of the diagnostic code. Disconnect the joystick from the machine harness.
Expected Result:
Results:
• OK - The diagnostic code remains active. The "Thumbwheel Modulation" control is correct.
• NOT OK - The diagnostic code is no longer active. The "Thumbwheel Modulation" control has
failed.
Repair: Replace the entire joystick.
STOP
Test Step 2. CHECK THE WIRING HARNESS OF THE "THUMBWHEEL MODULATION"

CONTROL FOR A SHORT TO GROUND
B. Disconnect the machine harness from the joystick.
C. Disconnect machine harness connectors from the Machine ECM.
contact J1-44 (wire E473-GY) of the machine harness to all possible sources of ground.
Measure the resistance to all contacts that are used in the J1 and J2 harness connectors.
Expected Result:
Each resistance measurement should be greater than 5000 ohms.
Results:
• NOT OK - One or more resistance measurements are not correct. There is a short in the
machine harness. The short is between signal contact J1-44 (wire E473-GY) and the circuit
with the low resistance measurement. Repair the machine harness or replace the machine
harness.STOP
D. Enter the service mode of the "Monitoring System" and clear all of the inactive diagnostic
codes.
Expected Result:
Results:
• YES - The CID 1658 FMI 04 diagnostic code is not active. The diagnostic code does not exist
at this time. The initial diagnostic code was probably caused by a poor electrical connection or
a short at one of the disconnected and reconnected harness connectors. Resume normal machine
operation.STOP
• NO - The CID 1658 FMI 04 diagnostic code is active. The diagnostic code has not been
corrected. A failure of the Machine ECM is unlikely.
Repair: Exit this procedure and perform this procedure again. If the cause of the diagnostic
code is not found, replace the Machine ECM. See Testing And Adjusting, " Electronic Control
STOP
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320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05435139
MID 039 - CID 1658 - FMI 08

SMCS - 5705-038-PSN
Right joystick "Thumbwheel Modulation Control" sensor circuit schematic
This diagnostic code is for the right joystick "Thumbwheel Modulation Control" sensor. An FMI 08
• Failed sensor.
System Response:
When this diagnostic code occurs, there is no warning on the monitor. The function for the work tool
that is controlled by the right joystick "Thumbwheel Modulation Control" will not function.
B. Disconnect the machine harness connector from the right joystick "Thumbwheel Modulation
Control" sensor.
(wire E473-GY) and the contact for terminal 2 (wire 235-BK) in the sensor connector.
Expected Result:
Results:
Go to Test Step 3.
E. At the ECM J1 harness connector, measure the resistance between contact J1-44 (wire E473-
GY) and frame ground.
E473-GY) and all of the other contacts that are used in both the J1 and J1 ECM harness
connectors.
Expected Result:
Results:
machine harness.
Go to Test Step 3.
Expected Result:
Results:
normal operations.
STOP
STOP
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i03758889
MID 039 - CID 1665 - FMI 03

SMCS - 5571-038
Schematic of the "Variable Relief Valve #1 Pressure" solenoid
This diagnostic code is associated with the "Variable Relief Valve #1 Pressure" solenoid. The FMI 03
System Response:
+BATTERY CIRCUIT
J2-18 (wire K864-PK) to all contacts that are used in the machine harness connectors for the
Machine ECM.
Expected Result:
Results:
machine harness. The short is between J2-18 (K864-PK) and the circuit that has a low
STOP
Expected Result:
The CID 1665FMI 03 diagnostic code is active.
Results:
STOP
time.
machine operation.
STOP
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i03758961
MID 039 - CID 1665 - FMI 05

SMCS - 5571-038
Schematic of the "Variable Relief Valve #1 Pressure" Solenoid
This diagnostic code is associated with the "Variable Relief Valve #1 Pressure" Solenoid. The FMI 05
System Response:
K864-PK) to contact 2 (wire M739-YL).
Expected Result:
Results:
problem.
STOP
-PK) to contact J2-35 (wire M739-YL).
Expected Result:
Results:
Step 3.
Repair: The open is in wire K864-PK or in wire M739-WH of the machine harness. Repair the
STOP
Expected Result:
Results:
STOP
this time.
machine operation.
STOP
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320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03759031
MID 039 - CID 1665 - FMI 06

SMCS - 5571-038
normal.
System Response:
Expected Result:
Results:
STOP

GROUND
K864-PK) to all contacts that are used in the machine harness connectors for the Machine
ECM.
Expected Result:
Results:
machine harness. The short is between J2-18 (wire K864-PK) and the circuit with the low
STOP
Expected Result:
Results:
STOP
this time.
machine operation.
STOP
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i03759052
MID 039 - CID 1666 - FMI 03

SMCS - 5571-038
means that the Machine ECM has determined that the voltage is above normal.
System Response:
+BATTERY CIRCUIT
J2-28 (wire K865-PU) to all contacts that are used in the machine harness connectors for the
Machine ECM.
Expected Result:
Results:
machine harness. The short is between J2-28 (K865-PU) and the circuit that has a low
STOP
Expected Result:
Results:
STOP
time.
machine operation.
STOP
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i03759090
MID 039 - CID 1666 - FMI 05

SMCS - 5571-038
System Response:
K865-PU) to contact 2 (wire M739-YL).
Expected Result:
Results:
problem.
STOP
-PU) to contact J2-35 (wire M739-YL).
Expected Result:
Results:
Step 3.
Repair: The open is in wire K865-PU or in wire M739-WH of the machine harness. Repair the
STOP
Expected Result:
Results:
STOP
this time.
machine operation.
STOP
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320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03759729
MID 039 - CID 1666 - FMI 06

SMCS - 5571-038
means that the Machine ECM has determined that the current of the solenoid is above normal.
System Response:
Expected Result:
Results:
STOP

GROUND
K865-PU) to all contacts that are used in the machine harness connectors for the Machine
ECM.
Expected Result:
Results:
machine harness. The short is between J2-28 (wire K865-PU) and the circuit with the low
STOP
Expected Result:
Results:
STOP
machine operation.
STOP
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i03759752
MID 039 - CID 1931 - FMI 03

SMCS - 5479-038
Schematic of the "Auxiliary Circuit Flow Combining" solenoids
This diagnostic code is associated with the auxiliary circuit for the Solenoid Valves (Flow
Combining). The FMI 03 means that the Machine ECM has determined that the voltage of the
solenoid circuit is above normal.
• One or both solenoids has failed.
• The energize circuit of the solenoids is shorted to the +battery circuit.
Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOIDS FOR A SHORT TO
B. Disconnect the machine harness connectors from the solenoids and the Machine ECM.
J2-10 (wire K871-WH) to all contacts that are used in the machine harness connectors for the
ECM.
Expected Result:
Results:
machine harness. The short is between J2-10 (K871-WH) and the circuit that has a low
STOP
Expected Result:
Results:
STOP
time.
machine operation.
STOP
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i03759773
MID 039 - CID 1931 - FMI 05

SMCS - 5479-038
Schematic of the "Auxiliary Circuit Flow Combining" Solenoids
This diagnostic code is associated with the auxiliary circuit for the solenoid valves (flow combining).
The FMI 05 diagnostic code means that the Machine ECM has determined that the current of the
solenoids is below normal.
• The energize circuit of the solenoids is open.
• The ground circuit of the solenoids is open.
Test Step 1. CHECK THE SOLENOIDS.
B. Disconnect the solenoids with the active diagnostic code from the machine harness.
C. At the machine harness connector for one of the solenoids, place a jumper wire from contact 1
(wire K871-WH) to contact 2 (wire 235-BK).
Expected Result:
Results:
• NO - The diagnostic is no longer active. One or both solenoids have failed.
Repair: A solenoid has failed. Repeat this Test Step "CHECK THE SOLENOIDS" in order to
verify the solenoid failure. Replace the failed solenoid. Verify that the new solenoid corrects
the problem.
STOP
-WH) to ground (wire 235-BK).
Expected Result:
Results:
3.
Repair: The open is in wire K871-WH or in wire 235-BK of the machine harness. Repair the
STOP
Expected Result:
Results:
STOP
this time.
machine operation.
STOP
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i03759790
MID 039 - CID 1931 - FMI 06

SMCS - 5479-038
Schematic of the "Auxiliary Circuit Flow Combining" Solenoids
This diagnostic code is associated with the auxiliary circuit for the solenoid valves (flow combining).
The FMI 06 means that the Machine ECM has determined that the current of the solenoids is above
normal.
• The energize circuit of the solenoids is shorted to ground.
Test Step 1. CHECK THE SOLENOIDS.
C. Disconnect the solenoids with the active diagnostic code from the machine harness.
Expected Result:
solenoids are disconnected.
Results:
when the solenoids are disconnected. The circuit is correct.
Repair: One or both solenoids have failed. Repeat this test "CHECK THE SOLENOIDS" in
order to verify the solenoid failure. Replace the failed solenoid.
STOP
• NO - The CID 1931 FMI 06 remains active. Proceed to Test Step 2.
Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOIDS FOR A SHORT TO
GROUND.
ECM.
Expected Result:
Results:
STOP
Expected Result:
Results:
STOP
this time.
machine operation.
STOP
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320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05435581
MID 039 - CID 2265 - FMI 03

SMCS - 1439-038-NP
"Hydraulic Pump #1 Outlet Pressure" sensor circuit schematic
This diagnostic code is for the "Hydraulic Pump #1 Outlet Pressure" sensor. An FMI 03 indicates the
Machine ECM has determined the voltage of the sensor output signal is above normal.
• Failed sensor.
• The Machine ECM has failed (unlikely).
been corrected.
Test Step 1. CHECK SENSOR POWER.
B. Do not disconnect any machine harness connectors at this time.
C. At the "Hydraulic Pump #1 Outlet Pressure" sensor, measure a DC voltage from contact A
(wire 308-YL) to contact B (wire A209-BK) on the sensor connector.
Expected Result:
The voltage is equal to system voltage.
Results:
• YES - The voltage is equal to system voltage. Go to Test Step 2.
• NO - The voltage is not equal to system voltage. There is a problem with the machine system
voltage.
Repair: Refer to the complete Electrical System Schematic of the machine. Investigate and
repair the system voltage problem.
After the system voltage supply problem has been repaired, check if the 2265 FMI 03
diagnostic code is still active. If the diagnostic code is still active, go to Test Step 2.
B. Disconnect the machine harness connector from the "Hydraulic Pump #1 Outlet Pressure"
sensor.
(wire K904-GN) and the contact for terminal 2 (wire A209-BK) in the sensor connector.
Expected Result:
Results:
Go to Test Step 3.
Go to Test Step 5.
Test Step 3. CHECK THE SENSOR CIRCUIT FOR AN OPEN WIRE.
C. The wire jumper remains in the connector.
E. At the J1 ECM harness connector, measure resistance between contact J1-34 (wire K904-GN)
and contact J1-18 (wire A209-BK) in the connector.
Expected Result:
Results:
Go to Test Step 5.
D. At the J1 ECM harness connector, measure resistance from contact J1-34 (wire K904-GN) to
all the other contacts used in both the J1 and J2 ECM harness connectors.
Expected Result:
Results:
Go to Test Step 5.
Expected Result:
Results:
normal operations.
STOP
of the machine wiring harness, using the Cat® Electronic Technician (Cat ET) service tool. The
STOP
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i05435627
MID 039 - CID 2265 - FMI 04

SMCS - 1439-038-NP
Schematic of the "Hydraulic Pump 1 Outlet Pressure" sensor
This diagnostic code is associated with the "Hydraulic Pump 1 Outlet Pressure" sensor. This
diagnostic code is recorded when the Machine ECM reads the sensor signal voltage and the voltage is
too low.
The possible causes of this failure are listed below:
A. Disconnect the machine harness from the sensor.
Expected Result:
The diagnostic code changes from CID 2265 FMI 04 to CID 2265 FMI 03.
Results:
• OK - The diagnostic code changed to CID 2265 FMI 03. This change indicates that the failure
is no longer present. The sensor has failed.
STOP
• NOT OK - The diagnostic code CID 2265 FMI 04 remained active. This change indicates that
the failure remains present. The sensor is not the cause of the failure. Proceed to Test Step 2.
B. Disconnect the J1 machine harness connector from the Machine ECM.
C. At the harness connector for the sensor, measure the resistance between the signal contact C
(wire K904-GN) and frame ground.
Expected Result:
Results:
• OK - The resistance is greater than 5000 ohms. The harness circuit resistance is correct. The
Machine ECM may have failed.
diagnostic code procedure again. If the failure is not found, replace the Machine ECM. See the
Testing and Adjusting, "Electronic Control Module (ECM) - Replace " section of this manual.
STOP
short between frame ground and the signal circuit in the machine harness.
STOP
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i05435678
MID 039 - CID 2265 - FMI 08

SMCS - 1439-038-NP
This diagnostic code is associated with the "Hydraulic Pump #1 Outlet Pressure" sensor. An FMI 08
• Failed sensor.
• Failed Machine ECM (unlikely).
sensor.
(wire K904-GN) and the contact for terminal B (wire A209-BK) in the sensor connector.
Expected Result:
Results:
Go to Test Step 3.
E. At the ECM J1 harness connector, measure the resistance between contact J1-34 (wire K904-
GN) and frame ground.
K904-GN) and all of the other contacts that are used in both the J1 and J2 ECM harness
connectors.
Expected Result:
Results:
machine harness.
Go to Test Step 3.
Expected Result:
Results:
normal operations.
STOP
STOP
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i05435784
MID 039 - CID 2266 - FMI 03

SMCS - 1439-038-NP
This diagnostic code is for the "Hydraulic Pump #2 Outlet Pressure" sensor. An FMI 03 indicates the
Machine ECM has determined the voltage of the sensor output signal is above normal.
• Failed sensor.
been corrected.
Test Step 1. CHECK SENSOR POWER.
B. Do not disconnect any machine harness connectors at this time.
C. At the "Hydraulic Pump #2 Outlet Pressure" sensor, measure a DC voltage from contact A
(wire 308-YL) to contact B (wire A209-BK) on the sensor connector.
Expected Result:
The voltage is equal to system voltage.
Results:
• YES - The voltage is equal to system voltage. Go to Test Step 2.
• NO - The voltage is not equal to system voltage. There is a problem with the machine system
voltage.
Repair: Refer to the complete Electrical System Schematic of the machine. Investigate and
repair the system voltage circuit.
After the system voltage supply problem has been repaired, check if the 2266 FMI 03
diagnostic code is still active. If the diagnostic code is still active, go to Test Step 2.
sensor.
(wire T967-YL) and the contact for terminal 2 (wire A209-BK) in the sensor connector.
Expected Result:
Results:
Go to Test Step 3.
Go to Test Step 5.
Test Step 3. CHECK THE SENSOR CIRCUIT FOR AN OPEN WIRE.
C. The wire jumper remains in the connector.
E. At the J1 ECM harness connector, measure resistance between contact J1-35 (wire T967-YL)
and contact J1-18 (wire A209-BK) in the connector.
Expected Result:
Results:
Go to Test Step 5.
D. At the J1 ECM harness connector, measure resistance from contact J1-35 (wire T967-YL) to all
Expected Result:
Results:
Go to Test Step 5.
Expected Result:
Results:
normal operations.
STOP
STOP
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320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05435805
MID 039 - CID 2266 - FMI 04

SMCS - 1439-038-NP
Schematic of the "Hydraulic Pump 2 Outlet Pressure" sensor
This diagnostic code is associated with the "Hydraulic Pump 2 Outlet Pressure" sensor. This
diagnostic code is recorded when the Machine ECM reads the sensor signal voltage and the voltage is
too low.
The possible causes of this failure are listed below:
• The Machine ECM has failed, however this situation is unlikely.
A. Disconnect the machine harness from the sensor.
Expected Result:
The diagnostic code changes from a CID 2266 FMI 04 diagnostic code to a CID 2266 FMI 03
diagnostic code.
Results:
• OK - The diagnostic code changed to CID 2266 FMI 03. This change indicates that the failure
is no longer present. The sensor has failed.
STOP
• NOT OK - The diagnostic code CID 2266 FMI 04 remained active. This change indicates that
the failure remains present. The sensor is not the cause of the failure. Proceed to Test Step 2.
B. Disconnect the J1 machine harness connector from the Machine ECM.
C. At the harness connector for the sensor, measure the resistance between the signal contact C
(wire T967-YL) and frame ground.
Expected Result:
Results:
• OK - The resistance is greater than 5000 ohms. The harness circuit resistance is correct. The
Machine ECM may have failed.
Repair: A failure of the ECM is unlikely. Exit this procedure and perform this diagnostic code
procedure again. If the failure is not found, replace the Machine ECM. See the Testing and
Adjusting, "Electronic Control Module (ECM) - Replace " section of this manual.
STOP
short between frame ground and the signal circuit in the machine harness.
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05435815
MID 039 - CID 2266 - FMI 08

SMCS - 1439-038-NP
This diagnostic code is associated with the "Hydraulic Pump #2 Outlet Pressure" sensor. An FMI 08
• Failed sensor.
• Failed Machine ECM (unlikely).
sensor.
(wire T967-YL) and the contact for terminal B (wire A209-BK) in the sensor connector.
Expected Result:
Results:
Go to Test Step 3.
E. At the ECM J1 harness connector, measure the resistance between contact J1-35 (wire T967-
YL) and frame ground.
T967-YL) and all of the other contacts that are used in both the J1 and J1 ECM harness
connectors.
Expected Result:
Results:
machine harness.
Go to Test Step 3.
Expected Result:
Results:
normal operations.
STOP
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03760672
MID 039 - CID 2275 - FMI 03

SMCS - 5479-038-RJ
Schematic of the "1 Way/2 Way Change Solenoid" applicable to machine models 322D, 324D, 325D, 328D and 330D.
Schematic of the "Hammer Return To Tank Solenoid" applicable to machine models 320D and 323D.
This diagnostic code is associated with the "Hammer Return To Tank Solenoid or the 1 Way/2 Way
Change Solenoid". The FMI 03 diagnostic code means that the Machine ECM has determined that the
voltage of the solenoid circuit is above normal.
System Response:
ECM .
The hammer function will be disabled.
THE +BATTERY CIRCUIT
J1-11 (wire K866-WH) to all contacts that are used in the machine harness connectors for the
ECM.
Expected Result:
Results:
machine harness. The short is between J1-11 (K866-WH) and the circuit that has a low
STOP
C. Turn the disconnect switch and the starter keyswitch to the ON position.
Expected Result:
Results:
STOP
time.
machine operation.
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03760755
MID 039 - CID 2275 - FMI 06

SMCS - 5479-038-RJ
Schematic of the "1 Way/2 Way Change Solenoid " applicable to machine models 322D, 324D, 325D, 328D and 330D.
Schematic of "Hammer Return To Tank Solenoid" applicable to machine models 320D and 323D.
This diagnostic code is associated with the "Hammer Return To Tank Solenoid or the 1 Way/2 Way
Change Solenoid". The FMI 06 diagnostic code means that the Machine ECM has determined that the
current of the solenoid is above normal.
System Response:
ECM.
The hammer function will be disabled when the CID 2275 FMI 06 diagnostic code is active.
Expected Result:
Results:
STOP
GROUND
ECM.
Expected Result:
Results:
STOP
Expected Result:
Results:
STOP
this time.
machine operation.
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03760836
MID 039 - CID 2280 - FMI 03

SMCS - 4493-038
Schematic Of The "Travel Alarm" relay
This diagnostic code is associated with the "Travel Alarm" relay.
This diagnostic code is recorded when the Machine ECM reads the voltage of the circuit for the relay
as above normal.
• The harness is shorted.
Test Step 1. CHECK THE SIGNAL CIRCUIT FOR A SHORT
B. Disconnect the machine harness from the relay.
C. Disconnect the machine harness connectors C1 and C2 from the Machine ECM.
D. At machine harness connector C2, measure the resistance from the signal contact C2-15 (wire
331-OR) to all other C1 and C2 connector contacts.
Expected Result:
Each resistance should be greater than 5000 ohms.
Results:
• YES - Each resistance is greater than 5000 ohms. The machine harness is correct. Proceed to
Test Step 2.
• NO - There is a short in the machine harness.
Repair: The short is between the signal contact C2-15 (wire 331-OR) and the circuit with the
low resistance measurement. Repair the machine harness or replace the machine harness.
STOP
E. Check if the diagnostic code for the relay is present.
Expected Result:
The diagnostic code for the relay is no longer present.
Results:
• YES - The diagnostic code is not present. The diagnostic code does not exist at this time. The
initial diagnostic code was probably caused by a poor electrical connection or a short at one of
the harness connectors that was disconnected and reconnected. Resume normal machine
operation.STOP
• NO - The diagnostic code has not been corrected.
Repair: It is unlikely that the Machine ECM is faulty. Exit this procedure and perform this
procedure again. Also, recheck if the diagnostic code is active. If the cause of the diagnostic
code is not found, replace the ECM. See Testing And Adjusting, "Electronic Control Module
(ECM) - Replace".
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i04648089
MID 039 - CID 2420 - FMI 03

SMCS - 5479-038-BCD
Schematic of the "Boom Cylinder Extend Limit" Solenoid
This diagnostic code is associated with the "Boom Cylinder Extend Limit" Solenoid. The FMI 03
diagnostic code means the Machine ECM has determined that the voltage of the solenoid circuit is
above normal.
Conditions that can cause this diagnostic code are listed below:
• The energize circuit of the solenoid is shorted to another voltage source.
• The Backup switch may have failed.
all of the connections in the circuit are clean, secure, and in good condition. If a problem with a
connection is found, correct the problem and verify that this diagnostic code is active before
performing this procedure.
codes and clear these diagnostic codes when the original diagnostic code has been corrected.
Note: The resistance of the solenoid coil should be 8.7 ± .4 ohms at 25 °C (77.0 °F).
Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT
A. Turn the key start switch and the disconnect switch OFF.
B. Disconnect the machine harness connector from the solenoid. Disconnect the machine harness
connectors J1 and J2 from the Machine ECM.
C. At the harness connector J1, measure the resistance from contact J2-12 (wire K950-YL) to all
J1 and J2 contacts on the ECM.
Expected Result:
Results:
machine harness. The short is between wire K950-YL and the circuit that has a low resistance
measurement.
Repair: For information on testing for short circuits and finding short circuits, refer to Testing
and Adjusting, "Wiring Harness (Short Circuit) - Test". Repair the machine harness or replace
STOP
Test Step 2. CHECK THE OPERATION OF THE BACKUP SWITCH
The disconnect switch and the key start switch remain OFF. The machine harness connectors for the
solenoid and the ECM remain disconnected.
A. Remove the "Backup Crane" switch from the wiring harness.
B. Measure the resistance between pin 11 and pin 12 of the switch.
C. Toggle the switch to the ON position.
D. Measure the resistance between pin 11 and pin 12 of the switch.
E. Toggle the switch to the OFF position.
F. Measure the resistance between pin 11 and pin 12 of the switch.
G. Reconnect the switch to the wiring harness.
Expected Result:
The switch should be open in the OFF position and closed in the ON position.
Results:
• OK - The switch operates as expected. Proceed to Test Step 3.
• NOT OK - The switch is either open for both positions or closed for both positions.
STOP
Test Step 3. CHECK THE OPERATION OF THE ECM
A. At the harness connector J1, use a 151-6320 Removal Tool to remove wire K950-YL and
socket at contact J2-12 from the harness connector.
B. Reconnect the machine harness J1 and J2 connectors to the ECM.
C. Turn the disconnect switch and the key start switch ON.
D. Observe the status of the active CID 2420 FMI 03 diagnostic code.
Expected Result:
The CID 2420 FMI 03 diagnostic code is no longer active. A CID 2420 FMI 05 diagnostic code is
now active.
Results:
• YES - The CID 2420 FMI 03 diagnostic code is no longer active. A CID 2420 FMI 05
diagnostic code has been activated after the solenoid energize circuit was disconnected. The
ECM has responded correctly to the open circuit condition in the solenoid circuit.
Reinstall the disconnected solenoid energize wire back into the correct space in the ECM
connector before proceeding to the next test step.
• NO - The CID 2420 FMI 03 diagnostic code remains active. The status of the active diagnostic
code did not change when the solenoid energize wire was disconnected from the ECM.
Repair: The ECM has not responded correctly to the open condition in the solenoid circuit.
The operation of the ECM is not correct.Prior to replacing an ECM, always contact the
Technical Communicator at your dealership for possible consultation with Caterpillar. This
consultation may greatly reduce repair time. If the ECM must be replaced, refer to Testing and
STOP
Test Step 4. CHECK THE STATUS OF THE DIAGNOSTIC CODE
A. Inspect the harness connectors and clean the contacts of the harness connectors. Check the
wires for damage to the insulation that is caused by excessive heat, battery acid, or chafing.
B. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit.
D. Turn the disconnect switch and the key start switch ON.
F. Determine if the CID 2420 FMI 03 diagnostic code is active.
Expected Result:
Results:
• YES - The CID 2420 FMI 03 diagnostic code is active.
Repair: Check the circuit again. Use the "Cat Electronic Technician (ET)" service tool to
perform a Wiggle Test on the machine wiring harness. The wiggle test can detect a momentary
or intermittent shorts or opens in the machine wiring harness.If the problem remains, the ECM
may have failed. A failure of the ECM is unlikely. The ECM detected the open circuit condition
in the solenoid circuit and activated the FMI 05 diagnostic code when the solenoid energize
wire was disconnected.Verify that all possible causes of the diagnostic code have been
investigated. If the cause of the failure is not found, contact the Technical Communicator at
your dealership for possible consultation with Caterpillar. This consultation may greatly reduce
repair time. If the cause of the diagnostic code is not found, replace the ECM. Refer to Testing
STOP
• NO - The CID 2420 FMI 03 code is not active. The problem does not exist at this time.
short at one of the harness connectors. Resume normal machine operation.
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i04959751
MID 039 - CID 2420 - FMI 05

SMCS - 5479-038-BCD
diagnostic code means that the Machine ECM has determined that the current for the solenoid circuit
is below normal.
Some possible causes of this diagnostic code are listed below:
• The Backup Crane switch has failed.
all connections in the circuit are clean, secure and in good condition. If a problem with a
A. Disconnect the solenoid from the machine harness.
B. At the machine harness connector for the solenoid, place a jumper wire from contact 1 (wire
K950-YL) to contact 2 (wire K952-BR).
C. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine.
Expected Result:
The active diagnostic code changes from an FMI "05" to an FMI "06" diagnostic code when the
jumper wire is installed.
Results:
• YES - The active diagnostic code changes from an FMI "05" to an FMI "06" diagnostic code
when the jumper wire is installed. The solenoid has failed.
Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" to verify
the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem.
STOP
• NO - The CID 2420 FMI 05 diagnostic code remains active. The jumper wire does not affect
the status of the diagnostic code. The solenoid is not the cause the problem. Proceed to Test
Step 2.
Test Step 2. CHECK THE "BACKUP CRANE" SWITCH AND THE RETURN CIRCUIT.
B. Remove the jumper that was placed in the previous test.
C. Disconnect the machine harness connector J2 from the Machine ECM and the machine harness
from the "Boom Extend" solenoid.
D. Use the Electronic System Schematic to locate the "Backup Crane" switch.
E. Place the "Backup Crane" switch in the ON position.
F. At the machine harness connector, measure the resistance from contact J2-35 (wire M739-YL)
to the connector contact 2 of the solenoid (wire K952-BR).
Expected Result:
Results:
• OK - The resistance is less than 5.0 ohms. The machine harness and the "Backup Crane" switch
are correct. Proceed to Test Step 3.
• NOT OK - The resistance is greater than 5.0 ohms. There is an open circuit in the machine
harness or the "Backup Crane" switch has failed. Proceed to Test Step 3.
Test Step 3. CHECK THE RETURN CIRCUIT FOR AN OPEN
B. Disconnect the machine harness connector J2 from the ECM.
C. Disconnect the wires at pins 11 and 12 of the switch. Install a jumper wire between M739-YL
and K952-BR at the switch.
D. At the machine harness connector J2 for the ECM, measure the resistance from the return
contact J2-35 (wire M739-YL) to the energize contact J2-12 (wire K950-YL ).
Expected Result:
The resistance measurement is less than 10 ohms.
Results:
• OK - The resistance that is measured is less than 10 ohms. The circuit is not open in the
machine harness. The Backup Crane Switch has failed.
Repair: Replace the Backup Crane Switch.
STOP
• NOT OK - The resistance measurement is greater than 5000 ohms. The resistance
measurement is not correct. There is an open or a bad connection in the machine harness. A
resistance over 5 ohms but under 5000 ohms indicates a connection point in the circuit is not
open but not a good connection.
Repair: The open or possible poor connection is in supply wire K950-YL or in return wire
M739-YL of the machine harness. Refer to the complete machine Electrical System Schematic.
Check all of the connectors that are in the solenoid circuit. Ensure that all connections are
clean, secure and in good condition. Repair the machine harness or replace the machine
harness.
STOP
Test Step 4. CHECK THE OPERATION OF THE ECM
The disconnect switch and the key start switch remain in the OFF position. The machine harness
connector for the solenoid and the ECM J1 connector remain disconnected.
A. Remove the jumper wire that was installed in the last test step.
B. At the machine harness connector J1 for the ECM, use a 151-6320 Removal Tool to remove the
solenoid energize wire K950-YL and socket at contact J2-12 from the harness connector.
C. Reconnect the machine harness J2 connector to the ECM.
E. Use a 7X-1710 Multimeter Probe that is not connected to a multimeter or a similar device.
Contact the ECM pin at J2-12 through the vacant space in the J2 connector.
F. While observing the status of the active CID 2420 FMI 05 diagnostic code, ground the other
end of the 7X-1710 Multimeter Probe to frame ground.
Expected Result:
The CID 2420 FMI 05 diagnostic code is no longer active. A CID 2420 FMI 06 diagnostic code
becomes active when the ECM pin at J2-12 is grounded.
Results:
• YES - The CID 2420 FMI 05 diagnostic code is no longer active. A CID 2420 FMI 06
diagnostic code has been activated after the ECM pin is grounded. The ECM has responded
correctly to the grounded circuit condition in the solenoid circuit. The ECM is most likely not
the cause of the problem.
Reinstall the disconnected solenoid energize wire back into the correct spot in the ECM
connector before proceeding to the next test step.
• NO - The CID 2420 FMI 05 diagnostic code remains active. The status of the active diagnostic
code does not change when the ECM pin for the solenoid is grounded.
Repair: The ECM has not responded correctly to the grounded condition in the solenoid
circuit. The operation of the ECM is not correct.Prior to replacing an ECM, always contact the
Technical Communicator at your dealership for possible consultation with Caterpillar. This
consultation may greatly reduce repair time. If the ECM must be replaced, refer to Testing and
STOP
for damage to the insulation that is caused by excessive heat, battery acid, or chafing.
B. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the sensor circuit.
Expected Result:
Results:
Repair: Check the circuit again. Use the Cat Electronic Technician (ET)"" service tool to
perform a Wiggle Test on the machine wiring harness. The wiggle test can detect momentary or
intermittent shorts or opens in the machine wiring harness.If the cause of the problem is not
found, the ECM may have failed.A failure of the ECM is unlikely. The ECM responded
correctly to the grounded condition in the last test step.Verify that all possible causes of the
diagnostic code have been investigated. If the cause of the failure is not found, replace the
ECM. Prior to replacing an ECM, always contact the Technical Communicator at your
STOP
this time.
operation.
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i04649533
MID 039 - CID 2420 - FMI 06

SMCS - 5479-038-BCD
diagnostic code means that the Machine ECM has determined that the current of the solenoid circuit
is above normal.
Some possible causes of this diagnostic code are listed below:
• The Backup Crane switch has failed.
all connections in the circuit are clean, secure and in good condition. If a problem with a
C. Disconnect the solenoid from the machine harness.
Expected Result:
The active CID 2420 FMI 06 diagnostic code changes to a CID 2420 FMI 05 diagnostic code when
the solenoid is disconnected.
Results:
• YES - The active CID 2420 FMI 06 diagnostic code changes to a CID 2420 FMI 05 diagnostic
code when the solenoid is disconnected. The circuit is correct.
STOP
• NO - The CID 2420 FMI 06 remains active when the solenoid is disconnected. The solenoid is
not the cause of the problem. Proceed to Test Step 3.
Test Step 2. CHECK THE OPERATION OF THE BACKUP CRANE SWITCH
A. Remove the "Backup Crane" switch from the wiring harness.
B. Measure the resistance between pin 11 and pin 12 of the switch.
C. Toggle the switch to the ON position.
D. Measure the resistance between pin 11 and pin 12 of the switch.
E. Toggle the switch to the OFF position.
F. Measure the resistance between pin 11 and pin 12 of the switch.
G. Reconnect the switch to the wiring harness.
Expected Result:
The switch should be open in the OFF position and closed in the ON position.
Results:
• OK - The switch operates as expected. Proceed to Test Step 3.
• NOT OK - The switch is either open for both positions or closed for both positions.
STOP
GROUND
C. Disconnect the machine harness connectors J1 and J2 from the ECM.
D. At the machine harness ECM connectors, measure the resistance from the contact J2-12 (wire
K950-YL) to frame ground. Measure the resistance from the contact J2-12 (wire K950-YL) to
all of the other J1 and J2 contacts that are used in the ECM connectors.
Expected Result:
Results:
• NOT OK - One or more of the resistance measurements is less than 5000 ohms. There is a
short in the machine harness. The short is between wire K950-YL and the circuit with the low
STOP
for damage to the insulation that is caused by excessive heat, battery acid, or chafing.
B. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the sensor circuit.
Expected Result:
The CID 2420 FMI 06 diagnostic code is still active.
Results:
• YES - The CID 2420 FMI 06diagnostic code is still active. The diagnostic code has not been
corrected.
Repair: Check the circuit again. Use the Caterpillar Electronic Technician (ET) service tool to
perform a "Wiggle Test" on the machine wiring harness. The wiggle test can detect momentary
or intermittent shorts or opens in the machine wiring harness.If the cause of the problem is not
found, the ECM may have failed.A failure of the ECM is unlikely. Verify that all possible
causes of the diagnostic code have been investigated. If the cause of the failure is not found,
replace the ECM. Prior to replacing an ECM, always contact the Technical Communicator at
your dealership for possible consultation with Caterpillar. This consultation may greatly reduce
STOP
short at one of the harness connectors. Resume normal machine operation.
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i04650451
MID 039 - CID 2425 - FMI 03

SMCS - 1439-038-BM
Connections for the Boom Angle sensor
This diagnostic code is associated with the Boom Angle sensor. An FMI 03 diagnostic code indicates
the Machine ECM has determined the sensor circuit voltage is above normal.
• The sensor power supply has failed.
• The sensor output circuit is open.
• The sensor output is shorted to the power supply.
Test Step 1. CHECK THE SENSOR POWER SUPPLY
B. At the machine harness connector for the Boom Angle sensor, measure the voltage between
contact A (wire A760-GY) and contact B (wire A209-BK).
Expected Result:
Results:
• YES - The voltage is 5 VDC. Proceed to Test Step 2.
• NO - The voltage is not 5 VDC.
Repair: There is a problem with the 5 VDC power supply from the machine ECM. Use MID
039 CID 0262 FMI 06 to troubleshoot this power supply problem. After the 5 VDC power
supply problem is corrected, check if the CID 2425 FMI 03 diagnostic code is active.
If the diagnostic code is active, go to Test Step 2.
B. Disconnect the machine harness connector from the Boom Angle sensor.
C. At the sensor harness connector, insert a jumper wire between the contact for C (wire E441-
GN) and the contact for B (wire A209-BK) in the sensor harness connector.
Expected Result:
The CID 2425 FMI 03 diagnostic code stays active.
Results:
• YES - The CID 2425 FMI 03 diagnostic code stays active. The sensor is not the cause of the
problem. Proceed to Test Step 3.
• NO - The CID 2425 FMI 03 diagnostic code is no longer active and has been replaced by a
CID 2425 FMI 04 diagnostic code.
Repair: The sensor has failed. Replace the sensor. The new sensor will need to be calibrated.
Test Step 3. CHECK THE SENSOR CIRCUIT FOR AN OPEN.
B. The sensor harness connector remains disconnected.
C. The jumper wire remains in the sensor harness connector.
D. Disconnect both the J1 and J2 machine harness connectors from the Machine ECM.
E. At the ECM J1 harness connector, measure the resistance from contact J1-5 (wire E441-GN) to
contact J1-18 (wire A209-BK) in the J1 harness connector.
Expected Result:
The resistance measured is less than 5 ohms.
Results:
• YES - The resistance measured is less than 5 ohms. Go to Test Step 4.
• NO - The resistance measured is not less than 5 ohms. There is an open in the harness.
Repair: The open is in either wire E441-GN or in wire A209-BK. Repair or replace the
machine harness.
Go to Test Step 5.
Test Step 4. CHECK THE SENSOR CIRCUIT FOR A SHORT.
A. The key start switch and the disconnect switch stay in the OFF position.
B. Both the J1 and J2 ECM harness connectors stay disconnected.
C. The sensor remains disconnected from the harness connector.
D. Remove the jumper wire from the connector.
E. At the ECM harness connectors, measure the resistance from the contact J1-05 (wire E441-GN)
to all of the other contacts that are used in both the J1 and J2 ECM harness connectors.
Expected Result:
Each resistance measured is more than 5000 ohms.
Results:
• YES - Each resistance measured is more than 5000 ohms. The machine harness is correct.
• NO - A resistance measured is not more than 5000 ohms. There is a short in the machine
harness. The short is between J1-5 (wire E441-GN) and the circuit with the low resistance.
the clips on each connector are fastened securely.
Expected Result:
Results:
Repair: The cause for the problem has been repaired. Return the machine to normal operation.
STOP
of the machine wiring harness, using the Cat Electronic Technician (Cat ET) service tool. The
Observe that the clips for each connector are fastened securely. Prior to replacing an ECM,
always contact the Technical Communicator at your Dealership for possible consultation with
Caterpillar. This consultation may greatly reduce repair time. If the ECM needs to be replaced,
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i04650534
MID 039 - CID 2425 - FMI 04

SMCS - 1439-038-BM
Schematic for the Boom Angle sensor
This diagnostic code is associated with the Boom Angle sensor. An FMI 04 diagnostic code indicates
the Machine ECM has determined the sensor circuit voltage is below normal.
• Sensor power supply failure.
• Sensor output shorted to ground.
Test Step 1. CHECK THE SENSOR POWER SUPPLY
B. At the machine harness connector for the Boom Angle sensor, measure the voltage between
contact A (wire A760-GY) and contact B (wire A209-BK).
Expected Result:
Results:
• YES - The voltage is 5 VDC. Go to Test Step 2.
• NO - The voltage is not 5 VDC.
Repair: There is a problem with the 5 VDC power supply from the Machine ECM. Use MID
039 CID 0262 FMI 06 diagnostic code to troubleshoot the power supply. After the supply is
corrected, check if the CID 2425 FMI 04 diagnostic code is active.
If the diagnostic code is active, go to Test Step 2.
B. Disconnect the machine harness connector from the Boom Angle sensor.
Expected Result:
Results:
• NO - The CID 2425 FMI 04 diagnostic code has been replaced by the CID 2425 FMI 03
diagnostic code. The sensor has failed.
Repair: Replace the sensor. The new sensor may require calibration.
Go to Test Step 4.
Test Step 3. CHECK THE SENSOR CIRCUIT FOR A SHORT.
C. Disconnect both the J1 and J2 harness connector from the Machine ECM.
D. At the J1 machine harness connector, measure the resistance from contact J1-5 (wire E441-GN)
to all contacts used in the J1 and J2 ECM harness connectors.
Expected Result:
The all measurements are more than 5000 ohms.
Results:
• YES - The measurements are all more than 5000 ohms. The harness is correct. Proceed to Test
Step 4.
• NO - A measurement is less than 5000 ohms. There is a short in the harness.
Repair: The short is from wire E441-GN to the wire with the low resistance measurement.
Go to Test Step 4.
the clips on each connector are fastened securely.
Expected Result:
Results:
STOP
caused by excessive heat, battery acid, or chafing. Perform a 45 N (10 lb.) pull test on each of
of the machine wiring harness, using the "Cat Electronic Technician (Cat ET)" service tool. The
Observe that the clips for each connector are fastened securely.Prior to replacing an ECM,
always contact the Technical Communicator at your Dealership for possible consultation with
Caterpillar. This consultation may greatly reduce repair time. If the ECM needs to be replaced,
STOP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i04650551
MID 039 - CID 2425 - FMI 13

SMCS - 1439-038-BM
Schematic of the "Boom Angle" potentiometer
This diagnostic code is recorded when the ECM records a signal from the potentiometer for the boom
angle that is out of calibration. The output of the potentiometer is voltage. The signal wire for the
potentiometer connects to contact J1-5 (wire E441-GN) of the ECM.
• New software has been installed, and the sensor has not been calibrated.
• The position sensor is above or the position sensor is below the calibration range for more than
3 seconds.
System Response:
The machine response is listed below:
• The implement features will not work.
• The calibration procedure for the boom angle will not work properly.
• The calibration procedure for the boom angle may not function properly.
Note: Ensure that the diagnostic code is active and that the diagnostic code indicator is active.
Test Step 1. CHECK CALIBRATION
A. Calibrate the "Boom Angle" position sensor. Refer to the Testing and Adjusting, "Calibration"
procedure. Verify that the new potentiometer corrects the problem.
C. Observe the status of the diagnostic code as the boom angle is fully raised and fully lowered.
Expected Result:
The diagnostic code is inactive.
Results:
• YES - The diagnostic code is inactive.
Repair: The diagnostic code is inactive now. Calibration corrected the diagnostic code. Clear
the diagnostic code.
STOP
• NO - The diagnostic code is active.
Repair: The diagnostic code remains active. Is unlikely that the ECM has failed. Perform
calibration for the "Boom Angle" sensor again. Also, ensure that the diagnostic code indicator
is active for this diagnostic code. If the cause is not found, replace the potentiometer and
perform the calibration again. If that does not eliminate the diagnostic code, replace the ECM.
If a fault becomes active, is possible that the mounting for the sensor may be loose. The
mounting should be checked. See Testing and Adjusting, "Module - Replace".
STOP
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Product: EXCAVATOR
Specifications
i04407660
Oil Filter (Hydraulic) - Case Drain

SMCS - 5068; 5093
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TMF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 289-8194 Oil Filter Gp
- - - Rated flow is 90 L/min to 24 US gpm.
- - - Maximum pressure is 981 kPa (142 psi).
- - - Oil temperature range is -30 to 90 °C to -22 to 194 °F.
Cracking pressure for the bypass relief valve is
- - -
147.0 ± 29.4 kPa (21.3 ± 4.3 psi).
Torque for the oil filter element assembly
- - -
13.7 ± 2.0 N·m (121.3 ± 17.7 lb in).
Shutdown SIS
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Product: EXCAVATOR
Specifications
i04404008
Oil Filter (Hydraulic)

SMCS - 5068; 5093
S/N - A6F1-UP
S/N - A8F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - RAR1-UP
S/N - SDC1-UP
S/N - SDZ1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 188-4142 Oil Filter Gp , and 173-3511 Oil Filter Gp
1 1 137-3626 Special Bolt Torque to 3.9 ± 0.4 N·m (34.5 ± 3.5 lb in).
Torque to
2 1 9s-4180 Plug
8.8 ± 0.9 N·m (77.9 ± 8.0 lb in).
Torque to
3 8 137-3624 Screw
0.40 ± 0.04 N·m (3.54 ± 0.35 lb in).
Torque to
4 6 173-3529 Bolt
4.0 ± 1.0 N·m (35.4± 8.9 lb in).
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Specifications
i04638213
Oil Filter (Return)

SMCS - 5068-RJ
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - RAR1-UP
S/N - SDC1-UP
S/N - SDZ1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 158-9005 Oil Filter Gp, and 188-4140 Oil Filter Gp
Torque to
1 4 6V-4298 Bolt
3 ± 1 N·m (27 ± 9 lb in).
Torque to
2 8 8T-4194 Bolt
30 ± 5 N·m (266 ± 44 lb in).
Torque to
3 4 8T-6693 Screw
3 ± 1 N·m (27 ± 9 lb in).
Shutdown SIS
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Product: EXCAVATOR

i03108265
Overload Warning - Set - If Equipped

SMCS - 1408; 5472; 7490
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - KHR1-UP
S/N - LMA1-UP
S/N - NBT1-UP
S/N - TMF1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
The overload warning device is a system that warns the operator that the pump pressure for the boom
cylinder lines has exceeded a set value. The set value for the overload warning device varies because
of the machine configuration and the attachments that are installed. The alarm setting for the overload
warning device on your machine should be checked for the proper adjustment. Use the information
that follows in order to calculate the correct value and reset the parameter for the overload warning
device.
the engine speed that was used for this test.
Calculation Of The Threshold Pressure For The Overload

Warning Device
Use the information that follows in order to calculate the correct value of the threshold pressure for
the overload warning device on your machine.
Basic position of the machine
(A) Full extension of bucket cylinder
(B) Full retraction of stick cylinder
(C) Position of the pin in the boom foot
(D) Position of the track
(E) Secured position of the bucket
(F) Position of the pin in the stick nose
1. Position the machine. Refer to Illustration 1.
2. Stop the engine.
3. Connect the linkage and a stationary object with a suitable lifting device (E) . Make sure that
the pin in stick nose (F) is the same distance from the ground as the pin for the boom foot (C) .
Note: Make sure that the boom is positioned perpendicular to the track. The machine should be
configured with the boom, the stick, and the attachments that will be used.
rpm settings.
7. Access the "PERFORMANCE" menu with the monitor in order to measure the pump pressure
during boom operation. The "PERFORMANCE" menu allows the user to view data for a list of
system parameters. The data allows the user to monitor machine systems during machine
operation. Use Illustration 2 in order to navigate the monitor.
(1) Up key
(2) Right key
(3) Home key
(4) Main menu key
(5) Left key
(6) Down key
(7) Cancel key or back key
(8) OK key
8. From the default screen, press the main menu key (4) .
Typical example of the "MAIN MENU" for the monitor
9. The "PERFORMANCE" menu option is entered by selecting "PERFORMANCE" from the

"MAIN MENU". Press the left key (5) or the right key (2) until "PERFORMANCE" is
highlighted in order to select this option. Then press the OK key (8) . Refer to Illustration 3.
Typical example of the "PERFORMANCE" menu for the monitor
10. From the "PERFORMANCE" menu, use the appropriate up key (1) or down key (6) to scroll
through the listed parameters for the system components. Find the parameter for the pump
pressure.
Position of the machine for the measurement of the pump pressure
(G) Extension of boom cylinder
(H) Track at the rear or the machine
(J) Free space between the track and the ground
11. Slowly extend the boom cylinders. Extend the boom cylinders until the track that is under the
rear side of the machine is above the ground. Refer to Illustration 5.
12. Record the measured pump pressure from the display on the monitor in the cab in Table 1.
13. Slowly retract the boom cylinder. Retract the boom cylinder until the track that is under the rear
side of the machine is on the ground.
14. The value of the threshold pressure for the overload warning device is 70% of the recorded
pump pressure from Step 12. This calculation is shown in Table 1.
Table 1
Calculation for Overload Warning Device (OLWD)
Pump Pressure (PP)
OLWD Pressure = PP x 0.7
Input The Value Of The Threshold Pressure For The Overload

Warning Device
(1) Up key
(2) Right key
(3) Home key
(4) Main menu key
(5) Left key
(6) Down key
(7) Cancel key or back key
(8) OK key
1. In order to access the "OVER LOAD WARNING" parameter, you must first enter the
"SERVICE" mode on the monitor.
2. Use the following procedure to access the "SERVICE" screen on the monitor.
a. From the default screen, press the main menu key (4) .
b. From the "MAIN MENU" screen, use the right key (2) to scroll through the menu
options.
c. When the "SERVICE" option is highlighted, press the OK key (8) .
d. When "PASSWORD" screen appears, use the right key (2) and the left key (5) in order to
scroll through the characters. When the desired character is highlighted, press the OK key
(8) . Enter the password for service FFF2 in order to continue to the "SERVICE" screen.
e. After the password has been entered the "SERVICE" screen should appear. Refer to
Illustration 9.
Typical example of the "SERVICE" menu for the monitor
3. From the "SERVICE" menu, use the up key (1) or the down key (6) in order to move the
highlighted line.
4. When the "CONFIGURATIONS" menu option is highlighted, press the OK key (8) .
Typical example of the "CONFIGURATIONS" screen
5. After the OK key (8) is pressed the "CONFIGURATIONS" screen will appear. From the
"CONFIGURATIONS" menu, highlight "PARAMETER SETTING".
6. When the "PARAMETER SETTING" option is highlighted, press the OK key (8) .
Typical example of the "PARAMETER SETTING" screen
7. After the OK key is pressed the "PARAMETER SETTING" menu will appear. From the
"PARAMETER SETTING" menu, highlight "OVER LOAD WARNING".
8. When "OVERLOAD WARNING" option is highlighted, press the OK key (8) .
Typical example of the "OVER LOAD WARNING" screen
9. After the OK key is pressed the "OVER LOAD WARNING" parameter will appear.
10. Press the up key (1) or the down key (6) in order to highlight the desired setting to change.
Press the OK key (8) in order to highlight the value of the data.
11. Press the up key (1) or the down key (6) in order to change the value. Press the OK key (8) in
order to set the value into memory.
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Specifications
i05535126
Pilot Lines - Joystick and Pedals

SMCS - 5057-PS
S/N - -
Top view
Table 1
Specification for 248-9825 Pilot Lines Gp
Item Qty
7K-1181 Cable Strap Sharp corners at the cutting edge of each cable strap shall
1 5
not be allowed.
309-5769 Pressure
2 3 Torque is 29 ± 3 N·m (257 ± 27 lb in).
Switch
Torque is
3 2 323-7770 Adapter
22.5 ± 2.0 N·m (199.1 ± 17.7 lb in).
Right side view
Table 2
Torque is
4 3 164-5628 Connector As
24 ± 3 N·m (212 ± 27 lb in).
Torque is
24 ± 3 N·m (212 ± 27 lb in).
Torque is
6 4 148-8378 Elbow As
24 ± 3 N·m (212 ± 27 lb in).
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Specifications
i04631282
Pilot Lines - Main Control Valve

SMCS - 5057-PS
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - RAR1-UP
S/N - SDC1-UP
S/N - SDZ1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Top view
Right side view
Table 1
Specification for 266-0962 Pilot Lines Gp, 376-6309 Pilot Lines Gp and 248-9850 Pilot Lines
Gp
Item Qty
Sharp corners at the cutting edge of each cable strap shall not be allowed.
Before assembly, apply Loctite Spray Adhesive in order to
1 4 -
secure four grommets to the swing frame.
148-8378 Torque to
2 6
Elbow As 29 ± 2 N·m (257 ± 18 lb in).
148-8435 Tee Torque to
3 6
As 29 ± 2 N·m (257 ± 18 lb in).
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Specifications
i04655050
Pilot Lines - Main Control Valve

SMCS - 5057-PS
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KHR1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Top view
Table 1
Torque to
1 2 187-7070 Hose As
76 ± 4 N·m (56 ± 3 lb ft).
Table 2
Item Qty

2 1
As 76 ± 4 N·m (56 ± 3 lb ft).
202-4004 Before assembly, apply Loctite Spray Adhesive in order to
3 1
Grommet secure the grommet to the swing frame.
7Y-8487 Hose Torque to
4 1
As 76 ± 4 N·m (56 ± 3 lb ft).
5 1
As 76 ± 4 N·m (56 ± 3 lb ft).
Section D-D
Table 3
If manufactured from aluminum, then torque to
6 2 148-8378 Elbow As
24 ± 2 N·m (212 ± 18 lb in).
24 ± 2 N·m (212 ± 18 lb in).
8 1 164-5639 Elbow As
41 ± 5 N·m (30 ± 4 lb ft).
9 4 148-8407 Plug As
24 ± 2 N·m (212 ± 18 lb in).
41 ± 5 N·m (30 ± 4 lb ft).
11 4 148-8353 Elbow As
24 ± 2 N·m (212 ± 18 lb in).

12 1 148-8364 Elbow As
41 ± 5 N·m (30 ± 4 lb ft).
13 3 8T-4192 Bolt
50 ± 10 N·m (37 ± 7 lb ft).
Front bottom view
Table 4
Torque to
29 ± 3 N·m (257 ± 275 lb in).
Torque to
15 1 148-8435 Tee As
29 ± 3 N·m (257 ± 275 lb in).
Torque to
16 1 148-8378 Elbow As
40 ± 5 N·m (30 ± 4 lb ft).
Torque to
40 ± 5 N·m (30 ± 4 lb ft).
Torque to
18 2 148-8407 Plug As
29 ± 3 N·m (257 ± 275 lb in).
Torque to
19 2 148-8378 Elbow As
29 ± 3 N·m (257 ± 275 lb in).
Torque to
20 1 148-8353 Elbow As
29 ± 3 N·m (257 ± 275 lb in).
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Product: EXCAVATOR
Specifications
i05987936
Pilot Lines
SMCS - 5057-PS
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KHR1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PJP1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Table 1
Item Qty
1 1 178-5955 Hose As Torque to 160 ± 16 N·m (118 ± 12 lb ft).
Torque to
2 1 366-1059 Hose As
76 ± 4 N·m (56 ± 3 lb ft).
Before assembly, apply thin hydraulic oil to surface of
434-3436 Pressure the male sensor.
3 2
Sensor Torque to
100 ± 10 N·m (74 ± 7 lb ft).
Torque to
4 1 148-8354 Elbow As
32.4 ± 3.0 N·m (286.8 ± 26.6 lb in).
Torque to
5 1 5I-3121 Hose As
160 ± 16 N·m (118 ± 12 lb ft).
Torque to
6 1 153-6237 Elbow As
68.6 ± 7.0 N·m (50.6 ± 5.2 lb ft).
Torque to
7 1 148-8347 Elbow As
95.0 to 104.5 N·m (70.1 to 77.1 lb ft).
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Specifications
i04637749
Pilot Oil Filter and Relief Valve

SMCS - 5072; 5092
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TMF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 158-8987 Pilot Oil Filter and Valve Gp, and 289-7836 Pilot Oil Filter and
Valve Gp
Tighten the nut to
1 1 -
49.0 ± 4.9 N·m (36.1 ± 3.6 lb ft).
Torque to
2 1 215-4909 Pilot Relief Valve Gp
117.6 ± 9.8 N·m (86.7 ± 7.2 lb ft).
Torque to
3 1 5I-8670 Oil Filter
34.3 ± 4.9 N·m (303.6 ± 43.4 lb in).
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Specifications
i04367396
Pilot Valve (Boom Drift Reduction)

SMCS - 5059
S/N - -
Table 1
Specification for 255-5683 Load Control Valve Gp

Item Qty
352-7123 Relief Valve Torque for the relief valve group to

1 1
Gp 95 ± 14 N·m (70 ± 10 lb ft).
Torque the connector to
2 1 190-7865 Connector
48 ± 5 N·m (35 ± 4 lb ft).
Torque for plug assemblies to
3 2 225-4818 Plug As
10 ± 1 N·m (89 ± 9 lb in).
Length under test force
33.0 mm (1.30 inch).
Test force
23.128 ± 1.850 N (5.199 ± 0.416 lb).
4 1 5I-8511 Spring
Free length after test
61.4 mm (2.42 inch).
Outside diameter
13.2 mm (0.52 inch).
Torque for the plug assembly to
5 1 148-8395 Plug As
40 ± 7 N·m (30 ± 5 lb ft).
52.0 mm (2.00 inch).
Test force
12.858 N (2.891 lb).
6 1 087-5166 Spring
70.0 mm (2.80 inch).
Outside diameter
21.8 mm (0.86 inch).
095-1594 O-Ring Seal Lubricate the bore of the O-ring seal with the lubricant
7 1
that is being sealed.
8 1 148-8407 Plug As
48 ± 5 N·m (35 ± 4 lb ft).
Torque for the bolts to
9 4 8T-4136 Bolt
55 ± 10 N·m (41 ± 7 lb ft).
Lubricate the bore of the ring with the lubricant that is
10 1 095-1789 Ring
being sealed.
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Specifications
i04397720
Pilot Valve (Joystick)

SMCS - 5059
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BZP1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBT1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBE1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - SDC1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TMF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 297-0529 Pilot Valve Gp , and 310-0382 Pilot Valve Gp
Item Qty
Before assembly, apply red Loctite 271 between the threads

131-5915 Special
1 1 part of the joint and the special nut.
Nut
Torque to 68.6 ± 4.9 N·m (50.6 ± 3.6 lb ft).
Before assembly, apply red Loctite 271 between the threads
part of the joint and the plate.
2 1 165-9431 Plate
Torque to
68.6 ± 4.9 N·m (50.6 ± 3.6 lb ft).
Torque to
3 1 4I-6365 Joint
47.1 ± 2.9 N·m (34.7 ± 2.1 lb ft).
118-4087 Spring Free length is
4 4
10.6 mm (0.42 inch).
5 2
29.7 mm (1.17 inch).
6 2
31.1 mm (1.22 inch).
As required, use the following washers:

Thickness of one, number 1 washer is
099-6137
7 4 0.2 mm (0.01 inch).
Washer
Thickness of one, number 2 washer is
0.4 mm (0.02 inch).
8 4
41.9 mm (1.65 inch).
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Specifications
i04367392
Pilot Valve (Stick Drift Reduction)

SMCS - 5059
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - RAR1-UP
S/N - SDC1-UP
S/N - SDZ1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 255-5680 Load Control Valve Gp
Item Qty
Torque for plug assemblies to

1 2 225-4818 Plug As
10 ± 1 N·m (89 ± 9 lb in).
Torque for the bolts to
2 4 8T-4136 Bolt
55 ± 10 N·m (41 ± 7 lb ft).
Torque for the plug to

3 1 147-4184 Plug
35 ± 4 N·m (26 ± 3 lb ft).
352-7123 Relief Torque for the relief valve group to
4 1
Valve Gp 95 ± 14 N·m (70 ± 10 lb ft).
Lubricate the bore of the ring with the lubricant that is
5 1 095-1789 Ring
being sealed.
095-1594 O-Ring Lubricate the bore of the O-ring seal with the lubricant
6 1
Seal that is being sealed.
52.0 mm (2.00 inch).
Test force
12.858 N (2.891 lb).
7 1 087-5166 Spring
70.0 mm (2.80 inch).
Outside diameter
21.8 mm (0.86 inch).
8 1 162-0177 Plug As
40 ± 7 N·m (30 ± 5 lb ft)
33.0 mm (1.30 inch).
Test force
23.128 ± 1.850 N (5.199 ± 0.416 lb).
9 1 5I-8511 Spring
61.4 mm (2.42 inch).
Outside diameter
13.2 mm (0.52 inch).
10 1 148-8395 Plug As
50 ± 7 N·m (37 ± 5 lb ft).
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Specifications
i04786012
Pilot Valve (Travel)

SMCS - 5059
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TMF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 369-8502 Pilot Valve Gp
Torque to
1 4 8T-4133 Nut
33.3 ± 3.4 N·m (294.7 ± 30.1 lb in).
Torque to
2 2 369-8568 Bolt
39.8 ± 4.0 N·m (29.4 ± 3.0 lb ft).
Free length is
3 4 126-1865 Spring
33.0 mm (1.30 inch).
Free length is
4 4 126-1866 Spring
54.0 mm (2.13 inch).
Torque to
5 1 8T-6759 Pipe Plug
6.9 ± 1.0 N·m (61.1 ± 8.9 lb in).
Free length is
6 4 131-5818 Spring
40.2 mm (1.58 inch).
Free length is
7 4 270-5950 Spring
59.9 mm (2.36 inch).
Torque to
8 2 095-1260 Socket Setscrew
6.9 ± 1.0 N·m (61.1 ± 8.9 lb in).
Torque to
9 2 8C-6965 Bolt
8.8 ± 1.0 N·m (77.9 ± 8.9 lb in).
Torque to
10 2 6V-8202 Bolt
20.6 ± 1.5 N·m (182.3 ± 13.3 lb in).
Torque to
11 2 369-8507 O-Ring Plug
11.8 ± 1.0 N·m (104.4 ± 8.9 lb in).
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Specifications
i04047904
Piston and Rings

SMCS - 1214; 1215
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - KBS1-UP
S/N - KHR1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Typical example
(1) Top compression ring
The shape of the top compression ring ... Keystone with a barrel face
Width of the top compression ring ... tapered
Ring gap ... 0.30 to 0.45 mm (0.0118 to 0.0177 inch)
Note: When you install a new top compression ring, make sure that the word "TOP" is facing the top
of the piston. New top piston rings for turbocharged engines have a yellow identification mark which
must be on the left of the ring end gap when the top piston ring is installed on an upright piston.
(2) Intermediate compression ring
The shape of the intermediate compression ring ... Internal chamfer in the bottom edge with a
tapered face
Width of intermediate compression ring ... 2.470 to 2.495 mm (0.0972 to 0.0982 inch)
Clearance between the intermediate compression ring and the piston groove ... 0.065 to 0.110
mm (0.0026 to 0.0043 inch)
Note: When you install a new intermediate compression ring, make sure that the word "TOP" is
facing the top of the piston. New intermediate rings for turbocharged engines have a blue
identification mark which must be on the left of the ring end gap when the top piston ring is installed
on an upright piston.
(3) Oil control ring
Shape of oil control ring ... a two-piece coil that is spring loaded
Width of oil control ring ... 2.97 to 2.99 mm (0.1169 to 0.1177 inch)
Note: A pin is used in order to hold both ends of the spring of the oil control ring in position. The
ends of the spring of the oil control ring must be installed opposite the end gap of the oil control ring.
Note: Ensure that the ring end gaps of the piston rings are spaced 120 degrees from each other.
Piston
Note: An arrow which is marked on the piston crown must be toward the front of the engine.
Piston height above cylinder block ... 0.41 to 0.55 mm (0.01614 to 0.02165 inch)
Width of top groove in piston ... Tapered
Width of second groove in piston ... 2.56 to 2.58 mm (0.1008 to 0.1016 inch)
Width of third groove in piston ... 3.02 to 3.04 mm (0.1189 to 0.1197 inch)
Piston pin
Diameter of a new piston pin ... 39.694 to 39.700 mm (1.5628 to 1.5630 inch)
Diameter of the bore for the piston pin ... 39.703 to 39.709 mm (1.5631 to 1.5633 inch)
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Specifications
i03520280
Piston Cooling Jet

SMCS - 1331
S/N - -
(1) Installed piston cooling jets
The valve must move freely. Torque for the bolt ... 9 N·m (7 lb ft)
Piston Cooling Jet Alignment
(2) Piston cooling jet
(3) Rod
(4) Cylinder block
Use the following procedure in order to check the alignment of the piston cooling jet.
1. Insert rod (3) into the end of the piston cooling jet (2). Rod (3) has a diameter of 1.70 mm
(0.067 inch). Rod (3) must protrude out of the top of the cylinder block.
2. Dimension (A) is 58.5 mm (2.30315 inch) and dimension (B) is 13.5 mm (0.53150 inch).
Dimension (A) and dimension (B) are tangential to the cylinder bore (4) .
3. The position of the rod (3) must be within dimension (C). Dimension (C) is 10 mm (0.39370
inch).
Note: Ensure that the rod (3) can not damage the piston cooling jet when the alignment is checked.
The piston cooling jets can not be adjusted. If a piston cooling jet is not in alignment the piston
cooling jet must be replaced.
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i02656275
Piston Height - Inspect

SMCS - 1214-040
Table 1
Required Tools
A 1P-2403 Dial Indicator 1
B 1P-2402 Gauge body 1
If the height of the piston above the cylinder block is not within the tolerance that is given in
Specifications, "Piston and Rings", the bearing for the piston pin must be checked. Refer to Systems
Operation, Testing and Adjusting, "Connecting Rod - Inspect". If any of the following components
are replaced or remachined, the piston height above the cylinder block must be measured:
• Crankshaft
• Cylinder head
• Connecting rod
• Bearing for the piston pin
The correct piston height must be maintained in order to ensure that the engine conforms to the
standards for emissions.
Note: The top of the piston should not be machined. If the original piston is installed, be sure that the
original piston is assembled to the correct connecting rod and installed in the original cylinder.
Three grades of length of connecting rods determine the piston height above the cylinder block. The
grade of length of a connecting rod is identified by a letter or a color. The letter or the color is marked
on the side of the connecting rod. Refer to Systems Operation, Testing and Adjusting, "Connecting
Rod - Inspect" and Specifications, "Connecting Rod" for additional information.
Typical example
1. Use Tooling (A) and Tooling (B) in order to measure the piston height above the cylinder
block. Use the cylinder block face to zero Tooling (A) .
2. Rotate the crankshaft until the piston is at the approximate top center.
3. Position Tooling (B) and Tooling (A) in order to measure the piston height above the cylinder
block. Slowly rotate the crankshaft in order to determine when the piston is at the highest
position. Record this dimension. Compare this dimension with the dimensions that are given in
Specifications, "Piston and Rings".
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i02675721
Piston Ring Groove - Inspect

SMCS - 1214-040
Table 1
Required Tools
A 8H-8581 Feeler Gauge 1
Inspect the Piston and the Piston Rings

1. Check the piston for wear and other damage.
2. Check that the piston rings are free to move in the grooves and that the rings are not broken.
Inspect the Clearance of the Piston Ring

1. Remove the piston rings (2) . Refer to Disassembly and Assembly Manual, "Pistons and
Connecting Rods - Disassemble" for the correct procedure. Clean the grooves (1) and the piston
rings (2) .
(A) Feeler gauge
(1) Piston grooves
(2) Piston ring
2. Fit new piston rings (2) in the piston grooves (1) . Refer to Disassembly and Assembly Manual,
"Pistons and Connecting Rods - Assemble" for the correct procedure.
3. Check the clearance for the piston ring by placing Tooling (A) between piston groove (1) and
the top of piston ring (2) . Refer to Specifications, "Piston and Rings" for the dimensions.
Inspect the Piston Ring End Gap
(A) Feeler Gauge
(2) Piston ring
(3) Cylinder ring ridge
1. Clean all carbon from the top of the cylinder bores.
2. Place each piston ring (2) in the cylinder bore just below the cylinder ring ridge (3) .
3. Use Tooling (A) to measure piston ring end gap. Refer to Specifications, "Piston and Rings" for
the dimensions.
Note: The coil spring must be removed from the oil control ring before the gap of the oil
control ring is measured.
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Specifications
i04404255
Pressure Reducing Valve (Boom and Stick Priority)

SMCS - 5467-PS
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - RAR1-UP
S/N - SDC1-UP
S/N - SDZ1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 232-4102 Pressure Reducing Valve and 310-0210 Pressure Reducing Valve

Torque to
1 2 111-9998 Plug
73.6 ± 4.9 N·m (54.0 ± 4.0 lb ft)
Torque for the port adapter is

2 - -
36 ± 2 N·m (27 ± 2 lb ft)
Free length is
3 2 171-0128 Spring
42.7 mm (1.68 inch)
Torque to
4 2 171-0123 Plug
128 ± 10 N·m (94 ± 7 lb ft)
Torque to
5 2 5C-7261 Nut
17.0 ± 2.5 N·m (150.0 ± 22.0 lb in)
Maximum adjustment range is
A 2 171-0124 Setscrew
9.0 ± 1.1 mm (0.35 ± 0.04 inch)
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Specifications
i05496798
Pressure Reducing Valve (Boom and Stick Priority)

SMCS - 5467-PS
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TMF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 310-0210 Pressure Reducing Valve
Torque to
1 2 111-9998 Plug
73.6 ± 4.9 N·m (54.0 ± 4.0 lb ft)
Free length is
2 2 171-0128 Spring
42.7 mm (1.68 inch)
Torque to
3 2 171-0123 Plug
128 ± 10 N·m (94 ± 7 lb ft)
Torque to
4 2 5C-7261 Nut
17.0 ± 2.5 N·m (150.0 ± 22.0 lb in)
Maximum adjustment range is
A 2 171-0124 Setscrew
9.0 ± 1.1 mm (0.35 ± 0.04 inch)
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Product: EXCAVATOR

i03327200
Pump Control (Negative Flow) - Adjust

SMCS - 3222-025-FW
Pump regulator (drive pump)
(1) Bolt
(2) Cover
(3) Seal
(4) Spring seat
(5) Spring
(6) Shim
Perform the following steps in order to adjust the drive pump.
1. Remove two bolts (1) .
2. Remove cover (2) and seal (3) .
3. Remove spring seat (4) and spring (5) .
4. Add shims (6) in order to increase the negative flow. Remove shims (6) in order to decrease the
negative flow. Refer to Table 1 for available shims and shim thickness.
Note: A change of 0.1 mm (0.0039 inch) in shim thickness will change the negative flow rate 3
L/min (0.8 US gpm) at a negative flow control pressure of 2350 kPa (340 psi).
Table 1
Available Shims
Part Number Shim Thickness
099-3669 Shim
1.00 mm (0.0394 inch)
099-6109 Shim
1.05 mm (0.0413 inch)
099-6110 Shim
1.10 mm (0.0433 inch)
099-6111 Shim
1.15 mm (0.0453 inch)
099-6112 Shim
1.20 mm (0.0472 inch)
099-6113 Shim
1.25 mm (0.0492 inch)
099-6115 Shim
1.30 mm (0.0512 inch)
099-6117 Shim
1.35 mm (0.0531 inch)
099-6118 Shim
1.40 mm (0.0551 inch)
099-6119 Shim
1.45 mm (0.0571 inch)
099-6120 Shim
1.50 mm (0.0591 inch)
099-6121 Shim
1.55 mm (0.0610 inch)
099-6122 Shim
1.60 mm (0.0630 inch)
099-6123 Shim
1.65 mm (0.0650 inch)
099-6124 Shim
1.70 mm (0.0669 inch)
099-6125 Shim
1.75 mm (0.0689 inch)
099-6126 Shim
1.80 mm (0.0709 inch)
099-6127 Shim
1.85 mm (0.0728 inch)
099-6128 Shim
1.90 mm (0.0748 inch)
099-3670 Shim
1.95 mm (0.0768 inch)
5. Install shims (6) in the pump regulator.
6. Install spring (5) . Install spring seat (4) .
7. Install cover (2) and seal (3) .
Note: Inspect seal (3) . If the seal is damaged, replace the damaged seal with a new seal.
8. Install bolts (1) . Tighten bolts (1) to a torque of 55 ± 10 N·m (40 ± 7 lb ft).
Adjust the idler pump in the same manner as the drive pump.
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i05134188
Pump Control (Negative Flow) - Test

SMCS - 3222-081-FW
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - KHR1-UP
S/N - LMA1-UP
S/N - NBT1-UP
S/N - TMF1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
These tests measures individual pump flow at the pump while a fixed negative flow control pressure
is sent to the main pump regulator. Each pump is tested individually for an output flow rate at a
specified delivery pressure and a specified negative flow control pressure.
(1) Swing motor
(4) Makeup Line (swing motor)
(23) Drive pump
(24) Idler pump
(29) 1U-8303 Fitting
(31) 5P-0201 Hose
(32) 5P-1010 Sleeve
(42) 1P-3703 Rectangular Seal
(46) 8T-4184 Bolt
(47) 8T-4223 Hard Washer
(48) 6V-0400 Half Flange
(49) 1U-8292 Adapter
Circuit diagram
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(5) Main control valves
(7) Plug
(8) Pressure tap (delivery pressure for the idler pump)
(9) Pressure gauge
(15) Tees
(16) Pressure tap (delivery pressure for the drive pump)
(17) Blocking cover
(18) Test line
(20) Pressure gauge
(21) Engine
(23) Drive pump
(24) Idler pump
(40) Elbow
Drive Pump
NOTICE

containing fluids.

Cat products.
Note: Perform each test for the drive pump and the test for the idler pump one at a time.
Pump compartment
(16) Pressure tap (delivery pressure for the drive pump)
(23) Drive pump
(24) Idler pump
2. Stop the engine.
hydraulic system.
5. Install the following tools in accordance with the circuit diagram. Refer to Illustration 1 and
Illustration 2.
a. Disconnect delivery line (12) from drive pump (23) .
b. Install seal (42), half flanges (48) and blocking cover (17) to the end of delivery line (12)
c. Assemble and install seal (42), adapter (49), seals (34), fitting (29) and nipple assembly
(36) on drive pump (23) by using half flanges (48), bolts (46) and washers (47) .
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(40) Elbow
e. Assemble and install seals (30), tee (3), swivel elbow (40) and coupling (37) to connector
g. Connect portable hydraulic tester (10) and the test hoses between nipple assembly (36) at
h. Connect 60000 kPa (8700 psi) pressure gauge (9) to pressure tap (16) for delivery
pressure for the drive pump.
i. Install multitach group (22) on engine (21). This is used to monitor engine speed.
Tool setup
(15) 8T-8902 Tee
(18) 177-7860 Hose Assembly
(19) Idler pump regulator
(23) Drive pump
(24) Idler pump
(27) 6V-9829 Cap
(41) 6V-3965 Fitting
(43) 6V-4143 Coupler
(44) Test hose
j. Disconnect negative flow control line (6) from drive pump (23). Install seal (25) and plug
(7) to the end of negative flow control line (6) .
k. Connect two tees (15) to the elbow at the negative flow signal pressure port of drive
pump (23). Install cap (27) to tee (15) .
l. Remove 311-1362 Vacuum Cap and install the filler plug for the hydraulic tank.
m. Connect one end of test hose (18) to tee (15) .
n. Connect the other end of test hose (18) to pressure tap (14) for the power shift pressure.
o. Connect one end of test hose (44) to tee (15) .
p. Connect 6000 kPa (870 psi) pressure gauge (20) to the other end of test hose (44) .
Idler Pump
NOTICE

containing fluids.

Cat products.
Pump compartment
(8) Pressure tap (delivery pressure for the idler pump)
(23) Drive pump
(24) Idler pump
2. Stop the engine.
hydraulic system.
5. Install the following tools in accordance with the circuit diagram. Refer to Illustration 1 and
Illustration 2.
a. Disconnect delivery line (11) from idler pump (24) .
b. Install seal (42), half flanges (48) and blocking cover (17) to the end of delivery line (11)
c. Assemble and install seal (42), adapter (49), seals (34), fitting (29) and nipple assembly
(36) to idler pump (24) by using half flanges (48), bolts (46) and washers (47) .
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(40) Elbow
e. Assemble and install seals (30), tee (3), swivel elbow (40) and coupling (37) to connector
g. Connect portable hydraulic tester (10) and the test hoses between nipple assembly (36) at
idler pump (24) and coupling (37) at the swing motor.
h. Connect 60000 kPa (8700 psi) pressure gauge (9) to pressure tap (8) for delivery pressure
for the idler pump.
i. Install multitach group (22) on engine (21). This is used to monitor engine speed.
Tool setup
(15) 8T-8902 Tee
(18) 177-7860 Hose Assembly
(19) Idler pump regulator
(20) 8T-0855 Pressure Gauge
(23) Drive pump
(24) Idler pump
(27) 6V-9829 Cap
(43) 6V-4143 Coupler
(44) Test hose
j. Disconnect negative flow control line (13) from idler pump (24). Install seal (25) and
plug (7) to the end of negative flow control line (13) .
k. Connect two tees (15) to the elbow at the negative flow signal pressure port of idler pump
(24). Install cap (27) to tee (15) .
l. Remove 311-1362 Vacuum Cap and install the filler plug for the hydraulic tank.
m. Connect one end of test hose (18) to tee (15) .
n. Connect the other end of test hose (18) to pressure tap (14) for the power shift pressure.
o. Connect one end of test hose (44) to tee (15) .
p. Connect 6000 kPa (870 psi) pressure gauge (20) to the other end of test hose (44) .
Test


Monitor
(A) Display
(B) Keypad
(C) Up key
(D) Left key
(E) Down key
(F) Right key
(G) Cancel key
(H) Home key
(I) OK key
(J) Menu key
Note: Perform each test for both of the fixed power shift pressures one pump at a time.
3. Start Service Mode and input a fixed power shift pressure located in tables. 1,2
Note: If more than 30 seconds pass between pushing the keys on the keypad, the menu
"SERVICE" screen.
display.
high idle.
for power shift pressure. For the first specification look in table 1, the actual power shift
pressure must be 3200 kPa (464 psi) on the pressure gauge. For the second specification
look in table 2, the actual power shift pressure must be 3920 kPa (568 psi) on the
pressure gauge.
position.

Service Mode.
(22) Multitach
(26) Valve
4. Turn valve (26) on portable hydraulic tester (10) clockwise until the pump delivery pressure is
7000 kPa (1015 psi).
5. Record the negative flow rate in Tables. 1,2
Pressure/Flow characteristic curve
Table 1
Negative Flow Control
Power Shift Pressure
3200 kPa (464 psi)
Drive pump
Oil Temperature °C (°F)
Idler pump
Drive pump
Engine speed (rpm)
Idler pump
Drive pump
Idler pump
Drive pump
Idler pump
Specification for negative flow rate liter/min (US gpm) New

50 ± 10 (13 ± 2.6)
Table 2
Negative Flow Control
Power Shift Pressure
3920 kPa (568 psi)
Drive pump
Oil Temperature °C (°F)
Idler pump
Drive pump
Engine speed (rpm)
Idler pump
Drive pump
Idler pump
Drive pump
Idler pump
Specification for negative flow rate liter/min (US gpm) New

28 ± 5 (7 ± 1.3)
Note: Specifications for flow rates are based on an engine speed of 1700 rpm. To get more accurate
test results, measured flow should be corrected with the following calculation.
Table 3
Corrected flow =
Measured rpm
Flow measurements must be done in pressure rise.
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i05131194
Pump Control (Output Flow) - Adjust

SMCS - 3222-025-FW
Adjust the pump output flow if the flow test results differ greatly from the specifications.
Adjustment of Pump Output Flow (Constant Horsepower

Control)
Main pump compartment
(21) Locknut
(23) Locknut
(25) Locknut
(27) Locknut
Adjust the flow of the drive pump for the first stage of the constant horsepower control. The idler
pump must be at no-load condition.
1. Loosen locknut (23) .
2. Turn adjustment screw (22) in order to adjust the output flow of the pump. Turning adjustment
screw (22) clockwise will increase the output flow of the pump. Turning adjustment screw (22)
counterclockwise will decrease the output flow of the pump. A 1/4 turn of adjustment screw
(22) will change the output flow of the pump at the following pressure.
◦ Output flow of the pump will change approximately 18 L/min (4.8 US gpm) if the output
flow is adjusted in the pressure range of 11800 kPa (1700 psi) to 19600 kPa (2850 psi).
The pump is operating in the first stage of the constant horsepower control.
3. Tighten locknut (23) to a torque of 98 ± 10 N·m (72 ± 7 lb ft).
Adjust the flow of the drive pump for the second stage of the constant horsepower control. The idler
pump must be at no-load condition.
2. Turn adjustment screw (20) in order to adjust the output flow of the pump. Turning adjustment
screw (20) clockwise will increase the output flow of the pump. Turning adjustment screw (20)
counterclockwise will decrease the output flow of the pump. A 1/4 turn of adjustment screw
(20) will change the output flow of the pump at the following pressure.
◦ Output flow of the pump will change approximately 12 L/min (3.2 US gpm) if the output
flow is adjusted in the pressure range of 25000 kPa (3625 psi) to 35000 kPa (5076 psi).
The pump is operating in the second stage of the constant horsepower control.
Adjust the idler pump in the same manner as the drive pump. Use locknut (27) and adjustment screw
(26) in order to adjust the first stage of the constant horsepower control. Use locknut (25) and
adjustment screw (24) in order to adjust the second stage of the constant horsepower control.
Adjustment of the Maximum Output Flow of the Pump
Main pump compartment
(29) Locknut
(30) Locknut
Adjust the maximum output flow of the drive pump.
2. In order to adjust maximum output flow, turn adjustment screw (31). Turning adjustment screw
(31) clockwise will decrease the maximum output flow of the pump. Turning adjustment screw
(31) counterclockwise will increase the maximum output flow of the pump. A 1/4 turn of
adjustment screw (31) will change the maximum output flow approximately 5 L/min (1.3 US
gpm).
Adjust the maximum output flow of the idler pump in the same manner as the drive pump. Use
locknut (29) and adjustment screw (28) in order to adjust the maximum output flow of the idler pump.
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Product: EXCAVATOR
Specifications
i05241743
Pump Coupling
SMCS - 5062
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - KBS1-UP
S/N - KHR1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Right side view
Table 1
Specification for 374-6000 Pump Coupling Gp
Item Qty
Remove the rust prevention of flywheel surface and install

1 - -
coupling.
During the installation, pay attention to the pin position on the
2 - -
flywheel and coupling face in assembling insert.
Torque to
3 4 287-0047 Bolt
320 ± 10 N·m (236 ± 7 lb ft).
279-7871 Assemble the flexible coupling group so that the flexible
4 1 Flexible Coupling coupling group is flush with the end of the pump shaft before
Gp tightening the socket setscrews.
7Y-0466 Socket Torque to
5 2
Setscrew 110 ± 10 N·m (81 ± 7 lb ft).
Torque to
6 4 7Y-0467 Bolt
320 ± 10 N·m (236 ± 7 lb ft).
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Specifications
i04654313
Pump Head (Main) - Drive

SMCS - 3222-MV
S/N - A6F1-UP
S/N - A8F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - RAC1-UP
S/N - RAR1-UP
S/N - SDC1-UP
S/N - SDZ1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 256-0093 Pump Head Gp
Item Qty
Lubricate the sliding surfaces lightly with the hydraulic oil.

Before assembly, apply blue Loctite High Flex GM to the
1 10 094-1882 Plug
threads.
Torque to
13 ± 2 N·m (115 ± 18 lb in).
3J-1907 O-Ring Lubricate the bore lightly with the lubricant that is being
2 2
Seal sealed.
Table 2
Item
285-4470 O-Ring Lubricate the bore lightly with the lubricant that is being
3 1
Seal sealed.
4 1
Seal sealed.
Before assembly, apply Loctite 241 to the threads of the
piston.
5 1 173-3384 Piston
Torque to
350 ± 30 N·m (258 ± 22 lb ft).
6 1
Seal sealed.
Torque to
7 2 096-4878 Nut
177 ± 15 N·m (131 ± 11 lb ft).
Extension of the dowel from the surface of the pin is
D 1 094-1875 Dowel
2.35 to 2.60 mm (0.093 to 0.102 inch).
8 1
Seal sealed.
43.0 mm (1.69 inch).
Test force is
9 1 200-3244 Spring
100 ± 5 N (22 ± 1 lb).
47.200 mm (1.8583 inch).
33.5 mm (1.32 inch).
Test force is
10 1 200-3245 Spring
31.0 ± 1.6 N (7.0 ± 0.4 lb).
34.0 mm (1.34 inch).
14.5 mm (0.57 inch).
Test force is
11 1 099-3671 Spring
8.8 ± 0.7 N (2.0 ± 0.2 lb).
26.5 mm (1.04 inch).
As required, use the following shims in order to adjust the test force of the spring (13) for
12
flow setting of the negative flow control (NFC):
Thickness is
2 099-3669 Shim
1.0 mm (0.04 inch).
Thickness is
2 099-6109 Shim
1.05 mm (0.041 inch).
Thickness is
2 099-6110 Shim
1.1 mm (0.04 inch).
Thickness is
2 099-6111 Shim
1.15 mm (0.045 inch).
Thickness is
2 099-6112 Shim
1.2 mm (0.05 inch).
Thickness is
2 099-6113 Shim
1.25 mm (0.049 inch).
Thickness is
2 099-6115 Shim
1.3 mm (0.05 inch).
Thickness is
2 099-6117 Shim
1.35 mm (0.053 inch).
Thickness is
2 099-6118 Shim
1.4 mm (0.06 inch).
Thickness is
2 099-6119 Shim
1.45 mm (0.057 inch).
Thickness is
2 099-6120 Shim
1.5 mm (0.06 inch).
Thickness is
2 099-6121 Shim
1.55 mm (0.061 inch).
Thickness is
2 099-6122 Shim
1.6 mm (0.06 inch).
Thickness is
2 099-6123 Shim
1.65 mm (0.065 inch).
Thickness is
2 099-6124 Shim
1.7 mm (0.07 inch).
Thickness is
2 099-6125 Shim
1.75 mm (0.069 inch).
Thickness is
2 099-6126 Shim
1.8 mm (0.07 inch).
Thickness is
2 099-6127 Shim
1.85 mm (0.073 inch).
Thickness is
2 099-6128 Shim
1.9 mm (0.07 inch).
Thickness is
2 099-3670 Shim
1.95 mm (0.077 inch).
42.5 mm (1.67 inch).
Test force is
13 1 200-3246 Spring
115.0 ± 5.8 N (25.9 ± 1.3 lb).
43.400 mm (1.7087 inch).
Torque to
14 1 8T-4133 Nut
45 ± 5 N·m (33 ± 4 lb ft).
Torque to
15 1 200-3255 Nut
100 ± 10 N·m (74 ± 7 lb ft).
16 1
Seal sealed.
17 1
Seal sealed.
18 3
Seal sealed.
19 1
Seal sealed.
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Product: EXCAVATOR
Specifications
i04654328
Pump Head (Main) - Driven

SMCS - 3222-MV
S/N - A6F1-UP
S/N - A8F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - RAC1-UP
S/N - RAR1-UP
S/N - SDC1-UP
S/N - SDZ1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Item Qty
Lubricate the sliding surfaces lightly with the hydraulic oil.

094-1882 Plug threads.
1 9
Torque to
13 ± 2 N·m (115 ± 18 lb in).
Table 2
Item
2 1
Seal sealed.
3 1
Seal sealed.
Before assembly, apply Loctite 241 to the threads of the
4 1 173-3384 Piston
piston.
Torque to
350 ± 30 N·m (258 ± 22 lb ft).
5 1
Seal sealed.
Torque to
6 2 096-4878 Nut
177 ± 15 N·m (131 ± 11 lb ft).
3J-1907 O-Ring Seal Lubricate the bore lightly with the lubricant that is being
7 1
sealed.
Extension of the dowel from the surface of the pin is
D 1 094-1875 Dowel
2.35 to 2.60 mm (0.093 to 0.102 inch).
8 1
Seal sealed.
43.0 mm (1.69 inch).
Test force is
9 1 200-3244 Spring
100 ± 5 N (22 ± 1 lb).
47.200 mm (1.8583 inch).
33.5 mm (1.32 inch).
Test force is
10 1 200-3245 Spring
31.0 ± 1.6 N (7.0 ± 0.4 lb).
34.0 mm (1.34 inch).
14.5 mm (0.57 inch).
Test force is
11 1 099-3671 Spring
8.8 ± 0.7 N (2.0 ± 0.2 lb).
26.5 mm (1.04 inch).
As required, use the following shims in order to adjust the test force of the spring (13) for
flow setting of the negative flow control (NFC):
Thickness is
12 2 099-3669 Shim
1.0 mm (0.04 inch).
Thickness is
2 099-6109 Shim
1.05 mm (0.041 inch).
Thickness is
2 099-6110 Shim
1.1 mm (0.04 inch).
Thickness is
2 099-6111 Shim
1.15 mm (0.045 inch).
Thickness is
2 099-6112 Shim
1.2 mm (0.05 inch).
Thickness is
2 099-6113 Shim
1.25 mm (0.049 inch).
Thickness is
2 099-6115 Shim
1.3 mm (0.05 inch).
Thickness is
2 099-6117 Shim
1.35 mm (0.053 inch).
Thickness is
2 099-6118 Shim
1.4 mm (0.06 inch).
Thickness is
2 099-6119 Shim
1.45 mm (0.057 inch).
Thickness is
2 099-6120 Shim
1.5 mm (0.06 inch).
Thickness is
2 099-6121 Shim
1.55 mm (0.061 inch).
Thickness is
2 099-6122 Shim
1.6 mm (0.06 inch).
Thickness is
2 099-6123 Shim
1.65 mm (0.065 inch).
Thickness is
2 099-6124 Shim
1.7 mm (0.07 inch).
Thickness is
2 099-6125 Shim
1.75 mm (0.069 inch).
Thickness is
2 099-6126 Shim
1.8 mm (0.07 inch).
Thickness is
2 099-6127 Shim
1.85 mm (0.073 inch).
Thickness is
2 099-6128 Shim
1.9 mm (0.07 inch).
Thickness is
2 099-3670 Shim
1.95 mm (0.077 inch).

42.5 mm (1.67 inch).
Test force is
13 1 200-3246 Spring
115.0 ± 5.8 N (25.9 ± 1.3 lb).
43.400 mm (1.7087 inch).
Torque to
14 1 8T-4133 Nut
45 ± 5 N·m (33 ± 4 lb ft).
Torque to
15 1 200-3255 Nut
100 ± 10 N·m (74 ± 7 lb ft).
16 1
Seal sealed.
17 1
Seal sealed.
18 3
Seal sealed.
19 1
Seal sealed.
Shutdown SIS
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Product: EXCAVATOR
Specifications
i05860992
Pump Lines (Main)

SMCS - 5057-MV
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KHR1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PJP1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Right side view
Table 1
Specification for 376-6313 Pump Lines Gp
Torque to
1 1 155-3624 Plug As
14 ± 2 N·m (124 ± 18 lb in).
Shutdown SIS
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Product: EXCAVATOR
Specifications
i04557186
Recoil Spring
SMCS - 4158
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - RAR1-UP
S/N - SDC1-UP
S/N - SDZ1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 239-4389 Track Adjuster and Recoil Gp
Item Qty
Use any one of the following springs:

Length under test force is 550 mm (21.7 inch).
Test force is
239-4350
156900 ± 10000 N (35273 ± 2248 lb).
Spring
664.9 mm (26.18 inch).
1 1
550 mm (21.7 inch).
Spring 156900 ± 12600 N (35273 ± 2833 lb).
665 mm (26.2 inch).
239-4384
2 1 Install the spacer with the direction of chamfer, as shown.
Spacer
Before assembly, apply coat of 1U-8801 Rust Preventive Oil to
3 1 239-4382 Nut
the threads.
4 2 7X-2536 Bolt Apply blue Loctite 242 to the threads.
Shutdown SIS
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Product: EXCAVATOR

i05984959
Relief Valve (Crossover) - Test and Adjust

SMCS - 5069-036
Specification
Table 1
"Relief Valve (Crossover) - Test and Adjust"
Date Machine Serial Number
Engine Speed
Main Relief Pressure (1)
Machine Speed Dial

Settings Implement
"10" 35000 ±500 kPa ( 5076 ± 73
AEC switch psi)
OFF Travel
Item Direction Relief Pressure Setting Actual
Forward
Left Travel 37500 ± 500 kPa (5439 + 73
Reverse psi)
Forward
Right Travel 37500 ± 500 kPa (5439 + 73
Reverse psi)
(1)
System pressure setting before temporary setting adjustment
Introduction
The crossover relief valves are located on the travel counterbalance valves. The following procedure
will determine if the crossover relief valves are out of adjustment.
Required Tools
Tooling group "B"
198-4240 Digital Pressure Indicator Gp
Track Block
Table 2
Tool Item Part Number Description Qty

B 198-4240 Digital Pressure Indicator Gp
B1 198-4234 Indicator 1
Pressure Sensor
B2 198-4239 2
41,368 kPa (6,000 psi)
B3 198-4236 Extension Cable 2
G 418-3611 Track Block 1
Machine Preparation
1. Position the machine on level ground and stop the engine.
2. Release the pressure in the hydraulic system. Refer to Testing and Adjusting, "System Pressure
- Release".
Pump compartment
3. Attach both 41,368 kPa (6,000 psi) pressure sensors to pressure tap (1) and pressure tap (2) .
Test Procedure
Note: A temporary setting of the right forward travel crossover relief is required before the temporary
setting of the main relief.
Note: A temporary setting of the main relief valve is required before any crossover relief valves can
be adjusted. Refer to Table 3 for temporary main relief setting for the function being tested.
Note: A continuous relief of the valve for more than 10 seconds is not allowed.
Table 3
Function Temporary Main Relief Setting
Left Travel Forward and Reverse

37500 ± 500 kPa (5439 ± 73 psi)
Right Travel Forward and Reverse

37500 ± 500 kPa (5439 ± 73 psi)
Table 4
Relief Valve Pressure Change With One Turn Of Adjustment Screw
Main relief valve

4430 kPa (650 psi)
Crossover relief valves

4230 kPa (625 psi)
Note: Pressure values in Table 4 are approximate values. Use a pressure gauge for adjustment.
Travel brake valve (left side)
(18) Locknut
(20) Crossover relief valve (forward left travel)
(21) Crossover relief valve (reverse left travel)
(22) Locknut
Sprocket (left track)
(16) Sprocket
(G) 418-3611 Track Block
1. Mark the original position of the right forward travel crossover relief valve.
2. Loosen the locknut for the right forward travel crossover relief valve. Turn the adjustment
screw clockwise by one half turn. Tighten the locknut.
3. Place track block (G) in sprocket in order to block forward right travel.
rpm settings.
8. Slowly move the right travel control lever to full FORWARD position.
9. Check the main relief valve pressure setting at pressure tap (1) or pressure tap (2) . The main
relief valve pressure setting should be 35000 ± 500 kPa (5076 ± 73 psi).
Main relief valve (standard)
(A) Adjustment screw
(L) Locknut
10. Loosen the locknut. Set the temporary main relief pressure to 37500 ± 500 kPa (5439 ± 73 psi).
Tighten the locknut.
Note: Turn the adjustment screw clockwise in order to increase the pressure. Turn the
adjustment screw counterclockwise in order to decrease the pressure.
Note: Always make final pressure adjustments on pressure rise.
11. Place track block (G) in sprocket (16) in order to block forward left travel. Refer to illustration
5
12. Slowly move the left travel control lever to full FORWARD position.
13. Check the pressure setting of the left forward travel crossover relief (20) .
14. Loosen the locknut of the left forward travel crossover relief valve (20) . Turn adjustment screw
of the left forward travel crossover relief valve until the pressure reading at pressure tap (2) is
35000 kPa (5076 psi).
15. Slowly move the left travel control lever to full FORWARD position.
16. Check the pressure setting of the left forward travel crossover relief (20) .
17. Loosen the locknut of the left forward travel crossover relief valve (20) . Turn adjustment screw
of the left forward travel crossover relief valve until the pressure reading at pressure tap (2) is
37500 kPa (5439 psi).
Note: In order to prevent over setting, the adjustment should be stopped immediately
after the pressure becomes within specification.
18. Remove track block (G) from sprocket (16) .
19. Place track block (G) in sprocket in order to block reverse left travel.
20. Slowly move the left travel control lever to full REVERSE position.
21. Check the pressure setting of the left reverse travel crossover relief (21) .
22. Loosen the locknut of the left reverse travel crossover relief valve (21) . Turn adjustment screw
of the left reverse travel crossover relief valve until the pressure reading at pressure tap (2) is
35000 kPa (5076 psi).
23. Slowly move the left travel control lever to full REVERSE position.
24. Check the pressure setting of the left reverse travel crossover relief (21) .
25. Loosen the locknut of the left reverse travel crossover relief valve (21) . Turn adjustment screw
of the left reverse travel crossover relief valve until the pressure reading at pressure tap (2) is
37500 kPa (5439 psi).
26. In order to adjust the crossover relief valves on the right travel motor, place the track block (G)
in the sprocket in order to block right travel. Use the pressure tap (1) in order to monitor the
crossover relief valve pressure settings for the right travel motor.
27. Return the main relief valve pressure to the specified setting after crossover relief valve
pressure setting is attained. Refer to Testing and Adjusting, "Relief Valve (Main) - Test and
Adjust".
Adjustment Procedure
Crossover relief valve
(L) Locknut
1. Loosen locknut and turn adjustment screw in order to increase or decrease pressure.
Note: Turn the adjustment screw clockwise in order to increase pressure. Turn adjustment
screw counterclockwise in order to decrease pressure.
Note: Always make final pressure adjustments on the pressure rise.
2. Tighten the locknut to specification once all adjustments are complete.
Shutdown SIS
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Product: EXCAVATOR

i05258921
Relief Valve (Line) - Test and Adjust

SMCS - 5117-025-L9; 5117-081-L9
Specification
Table 1
"Relief Valve (Line) - Test and Adjust"
Machine Settings
Main Relief Pressure (1)
Standard lift
35000 ± 500 kPa (5076 ± 73 psi)
Heavy lift
(If Equipped) 36000 ± 500 kPa (5221 ± 73 psi)
Cylinder Cylinder Position Actual
Engine Speed Relief Pressure Setting
Extended 39500 ± 500 kPa (5729 ± 73

Speed Dial "10" psi)
Boom (2) AEC switch OFF
Retracted 38000 ± 500 kPa (5511 ± 73

psi)
Speed Dial "10"
Stick (2) Extended AEC switch OFF 38500 ± 500 kPa (5584 ± 73
psi)
Retracted 39500 ± 500 kPa (5729 ± 73

psi)
Extended Speed Dial "10"

Bucket (2)
AEC switch OFF 38000 ± 500 kPa (5511 ± 73
Retracted psi)
(1)
System pressure setting before temporary setting adjustment
(2)
Heavy lift and Standard lift use the same line relief settings.
Introduction
The line relief valves are located between each cylinder and the respective control valve. The line
relief valve limits the overload pressures that can be created in the implement cylinders. The line
relief valves are located on the left side and right side of the main control valve. The line relief valves
are accessible from above the main control valve and below the machine after removal of the access
plate.
Required Tools
Tooling group "B"
Table 2
Tool Item Part Number Description Qty
Pressure Sensor
B2 198-4239 2
41,368 kPa (6,000 psi)
Machine Preparation
2. Release the pressure in the hydraulic system. Refer to Testing and Adjusting, "System Pressure
- Release".
Pump compartment
3. Attach both 41,368 kPa (6,000 psi) pressure sensors to pressure tap (1) and pressure tap (2) .
Test Procedure
Note: A temporary setting of the main relief valve is required before any line relief valves can be
adjusted. Refer to Table 3 for temporary main relief setting for the function being tested.
Table 3
Function Temporary Main Relief Setting
Boom Cylinder Head End
Stick Cylinder Rod End 39500 ± 500 kPa (5729 ± 73 psi)

38500 ± 500 kPa (5584 ± 73 psi)
Boom Cylinder Rod End
Bucket Cylinder Head End
38000 ± 500 kPa (5511 ± 73 psi)
Bucket Cylinder Rod End
Table 4
Relief Valve Pressure Change With One Turn Of Adjustment Screw
Main relief valve

14400 kPa (2100 psi)
Line relief valves

19800 kPa (2871 psi)
Bucket Cylinder Head End, Bucket Cylinder Rod End, and Boom Cylinder Rod
End
Main control valve
(3) Line relief valve for the boom cylinder rod end
(4) Line relief valve for the bucket cylinder head end
(5) Main relief valve
(6) Line relief valve for the stick cylinder head end
(7) Line relief valve for the boom cylinder head end
(8) Line relief valve for the bucket cylinder rod end
(9) Line relief valve for the stick cylinder rod end
rpm settings.
5. Move the joystick for the stick until the stick is at the full STICK OUT position (full retraction
of the stick cylinder).
6. Check the main relief valve pressure setting at pressure tap (1) or pressure tap (2). The main
relief valve pressure setting should be 35000 ± 500 kPa (5076 ± 73 psi).
(L) Locknut
Main relief valve (heavy lift) (If Equipped)
(L) Locknut
7. Loosen the locknut. Set the main relief pressure to 38000 ± 500 kPa (5511 ± 73 psi). Tighten
the locknut.
8. Verify the temporary main relief pressure setting with a second function. Move the joystick for
the boom until the boom is at full BOOM RAISE position (full extension of the boom
cylinder). The main relief pressure should be 38000 ± 500 kPa (5511 ± 73 psi).
9. Mark the original position of the line relief for the bucket cylinder head end (4) .
10. Move the joystick for the bucket until the bucket is at the full BUCKET CLOSE position (full
extension of bucket cylinder).
11. Check the pressure setting of the line relief for the bucket cylinder head end (4) .
12. Loosen the locknut of the bucket line relief valve. Turn adjustment screw of the bucket line
relief valve until the pressure reading at pressure tap (1) is 36000 kPa (5221 psi).
13. Move the joystick for the bucket until the bucket is at the full BUCKET CLOSE position (full
extension of bucket cylinder).
14. Check the pressure setting of the line relief for the bucket cylinder head end (4) .
15. Turn the adjustment screw of the bucket line relief valve until the pressure reading at pressure
tap (1) is 38000 ± 500 kPa (5511 ± 73 psi).
16. Repeat Step 9 to Step 15 for the following line relief valves:
◦ Line relief valve for bucket cylinder rod end
◦ Line relief valve for boom cylinder rod end
17. Reset main relief valve pressure setting to the normal operating condition after the completion
of the line relief test and adjust. Refer to Testing and Adjusting, "Relief Valve (Main) - Test
and Adjust".

Main control valve
1. Mark the original position of the line relief valve for the stick cylinder head end (6) .
2. Loosen the locknut for line relief valve (6). Turn the adjustment screw clockwise by one quarter
turn. Tighten the locknut.
rpm settings.
7. Move the joystick for the stick until the stick is at the full STICK IN position (full extension of
stick cylinder).
relief pressure setting should be 35000 ± 500 kPa (5076 ± 73 psi).
(L) Locknut
(L) Locknut
the locknut.
stick cylinder).
11. Check the pressure setting of the line relief for the stick cylinder head end (6) .
12. Loosen the locknut for the stick line relief valve (6). Turn adjustment screw of the stick line
relief valve counterclockwise until the pressure reading at pressure tap (1) is 36500 kPa (5294
psi).
stick cylinder).
14. Check the pressure setting of the line relief for the stick cylinder rod end (6) .
15. Turn the adjustment screw of the stick line relief valve until the pressure reading at pressure tap
(1) is 38500 ± 500 kPa (5584 ± 73 psi).
and Adjust".
Boom Cylinder Head End, and Stick Cylinder Rod End

Main control valve
1. Mark the original position of the line relief valve for the stick cylinder rod end (9) .
2. Loosen the locknut for line relief valve (9). Turn the adjustment screw clockwise by one quarter
turn. Tighten the locknut.
rpm settings.
of stick cylinder).
relief pressure setting should be 35000 ± 500 kPa (5076 ± 73 psi).
(L) Locknut
(L) Locknut
the locknut.
of stick cylinder).
11. Check the pressure setting of the line relief for the stick cylinder head end (9) .
12. Loosen the locknut for the stick line relief valve (9). Turn adjustment screw of the stick line
relief valve counterclockwise until the pressure reading at pressure tap (1) is 37500 kPa (5439
psi).
of stick cylinder).
14. Check the pressure setting of the line relief for the stick cylinder rod end (9) .
15. Turn the adjustment screw of the stick line relief valve until the pressure reading at pressure tap
(1) is 39500 ± 500 kPa (5729 ± 73 psi).
16. Repeat Step 10 to Step 15 for the following line relief valves:
◦ Line relief valve for boom cylinder head end
and Adjust".
Line relief valve (typical example
(L) Locknut
1. Loosen locknut and turn adjustment screw in order to increase or decrease pressure.
Note: Turn the adjustment screw clockwise in order to increase pressure. Turn adjustment
screw counterclockwise in order to decrease pressure.
2. Tighten the locknut to specification once adjustments are complete.
Shutdown SIS
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Product: EXCAVATOR

i05786594
Relief Valve (Main) - Test and Adjust - Heavy Lift

SMCS - 5069-025; 5069-081
Specification
Table 1
"Relief Valve (Main) - Test and Adjust (Heavy Lift)"
Machine Settings Actual
Item Specification
Speed Dial "10" 35000 ± 500 kPa (5076 ± 73 psi)

Standard
AEC switch OFF
Heavy Lift (1)(If Equipped) Speed Dial "10"

36000 ± 500 kPa (5221 ± 73 psi)
AEC switch OFF
(1)
The main relief valve should have a 1000 kPa (145 psi) pressure difference between heavy lift mode and standard lift
mode.
Required Tools
Tooling (B) 198-4240 Digital Pressure Indicator Gp
Table 2
Tool Item Qty Part Number Description
B1 1 198-4234 Indicator
Pressure Sensor
B2 1 198-4239
41,368 kPa (6,000 psi)
B3 1 198-4236 Extension Cable
Machine Preparation
Pump compartment
3. Attach a 41,368 kPa (6,000 psi) pressure sensor to pressure tap (1) .
Test Procedure
Note: The main relief valve should have a 1000 kPa (145 psi) pressure difference between heavy lift
mode and standard lift mode.
rpm settings.
Switch panel
(9) Heavy lift switch
3. Set heavy lift switch (9) to the ON setting. Make sure that the indicator light is on.
5. Raise the boom until the boom cylinder rods are at full extension.
6. Check the pressure setting of the heavy lift at pressure tap (1) .
7. Return the joystick for the boom to the NEUTRAL position.
(5) Locknut for the heavy lift
(6) Adjustment screw for the heavy lift
(7) Locknut for the main relief valve
(8) Adjustment screw for the main relief valve
Note: When the main relief setting is adjusted, the heavy lift setting is not affected. When
adjustment screw (8) is turned counterclockwise in order to decrease the main relief setting the
pressure difference between the main relief setting and heavy lift setting will increase. When
adjustment screw (8) is turned clockwise in order to increase the main relief setting the pressure
difference between the main relief setting and heavy lift setting will decrease.
Note: When the heavy lift setting is increased, the main relief setting is also increased. When
the heavy lift setting is decreased, the main relief setting is also decreased.
8. The relief valve pressure setting for heavy lift should be 36000 ± 500 kPa (5221 ± 73 psi). If
the relief valve pressure setting for heavy lift is not within the specification, adjust the relief
valve pressure setting for heavy lift.
a. Loosen locknut (5) in order to adjust the relief valve for the heavy lift. Adjust the
pressure by turning adjustment screw for the heavy lift (6) until the pressure gauge
reading at pressure tap (1) is 36000 ± 500 kPa (5221 ± 73 psi).
Note: Turning adjustment screw (6) clockwise increases the pressure. Turning
adjustment screw (6) counterclockwise decreases the pressure.
b. Tighten locknut (5) to a torque of 70 ± 10 N·m (50 ± 7 lb ft).
Note: Confirm the heavy lift pressure by raising the boom until the boom cylinder rods
are at full extension.
9. Set heavy lift switch (9) to the OFF setting. The indicator light should not be illuminated.
10. Open the bucket until the bucket cylinder rod is at full retraction.
11. Check the main relief valve pressure setting at pressure tap (1) .
12. Return the joystick for the bucket to the NEUTRAL position.
13. The main relief valve pressure setting should be 35000 ± 500 kPa (5076 ± 73 psi). If the main
relief valve pressure setting is not within the specification, adjust the main relief valve pressure
setting.
Note: During adjustment of screw (8) , do not allow screw (6) to move.
14. In order to adjust the main relief valve, loosen locknut (7) and turn adjustment screw (8) until
the pressure gauge reading at pressure tap (1) is 35000 ± 500 kPa (5076 ± 73 psi).
Note: Turning adjustment screw (8) clockwise increases the pressure. Turning adjustment
screw (8) counterclockwise decreases the pressure.
Note: If the pilot line for heavy lift prevents proper adjustment of the relief valve settings, the line can
be removed in order to make the adjustments. The machine will need to be off and the hydraulic
system pressure will need to be released in order to remove the pilot line for heavy lift. Make
adjustments to the relief valves and reconnect the pilot line before starting the machine and checking
the pressure settings.
Temporary Setting of the Main Relief Valve

Note: In order to adjust line relief valve pressure settings, the main relief valve must be temporarily
adjusted to a higher setting since the line relief valve pressure settings are higher than the main relief
valve pressure setting.
Switch Panel
(9) Heavy lift switch
1. Set the heavy lift switch (9) to the ON setting. Make sure that the indicator light is ON.
2. The main relief valve pressure setting should be 36000 ± 500 kPa (5221 ± 73 psi) when the
heavy lift mode is on. If the main relief valve is not within the specification, adjust the main
relief valve pressure setting to the correct pressure specification before performing Step 3.
Refer to Testing and Adjusting, "Relief Valve (Main) - Test and Adjust (Heavy Lift)".
(5) Locknut for the heavy lift
(6) Adjustment screw for the heavy lift
(7) Locknut for the main relief valve
(8) Adjustment screw for the main relief valve
4. Turn screw (6) clockwise by one half turn. Tighten locknut (5) while screw (6) is secured.
5. Perform the desired steps for Testing and Adjusting the line relief valves.
6. Reset main relief valve pressure setting to the normal operating condition. Refer to Testing and
Adjusting, "Relief Valve (Main) - Test and Adjust (Heavy Lift)".
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Specifications
i04358630
Relief Valve (Main)

SMCS - 5069
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BZP1-UP
S/N - CXY1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - XBB1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Table 1
Specification for 310-0395 Relief Valve Gp and 352-7116 Relief Valve Gp
Item Qty
352-7114 Control Torque to

1 1
Valve Gp 135 ± 10 N·m (100 ± 7 lb ft).

24.6 mm (0.97 inch).
Test force is
2 1 6I-6795 Spring
21.47 ± 1.72 N (4.83 ± 0.40 lb).
30.0 mm (1.20 inch).
095-1786 Backup Lubricate the bore of the backup ring lightly with the
3 1
Ring lubricant that is being sealed.
32.200 mm (1.2677 inch).
Test force is
4 1 4I-3510 Spring
218.676 ± 10.934 N (49.200 ± 2.500 lb).
35.600 mm (1.4016 inch).
Torque to
5 1 171-0035 Holder
75 ± 10 N·m (55 ± 7 lb ft).
Torque to
6 1 4I-7714 Nut
50 ± 10 N·m (37 ± 7 lb ft).
095-1587 O-Ring
7 1
Seal
095-1590 O-Ring Lubricate the bore of O-ring seals lightly with the
8 1
Seal lubricant that is being sealed.
095-1579 O-Ring
9 1
Seal
Shutdown SIS
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Product: EXCAVATOR
Specifications
i05004215
Relief Valve (Main)

SMCS - 5069
S/N - A6F1-UP
S/N - A8F1-UP
S/N - BYM1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - RAR1-UP
S/N - SDC1-UP
S/N - SDZ1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 360-4599 Relief Valve Gp
1 - - Apply red Loctite 272 to the threads of orifice.
Torque to
2 1 7Y-8437 Nut
92.2 ± 8.3 N·m (68.0 ± 6.1 lb ft).
Shutdown SIS
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Product: EXCAVATOR
Specifications
i04635609
Relief Valve (Pilot) - Front Lines

SMCS - 5072; 5117
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - RAR1-UP
S/N - SDC1-UP
S/N - SDZ1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 255-5661 Relief Valve Gp, 255-5662 Relief Valve Gp, 259-7646 Relief Valve
Gp, and 352-7123 Relief Valve Gp
Torque the locknut to
1 - -
19.6 ± 2.0 N·m (173.5 ± 17.7 lb in).
Torque the nut to
2 - -
58.8 ± 5.9 N·m (43.4 ± 4.4 lb ft).
Shutdown SIS
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Product: EXCAVATOR

i05954301
Relief Valve (Pilot) - Test and Adjust

SMCS - 5072-036
Specification
Note: Certain machines will default to "Economy Mode" at machine startup. Change to "High
Hydraulic Power Mode" before performing the test procedure.
Table 1
"Relief Valve (Pilot) - Test and Adjust"
Engine Speed
Machine Settings Speed Dial "10"
AEC switch OFF
Item Specification Actual
Pilot relief valve pressure 4100 ± 200 kPa (595 ± 29 psi)
Introduction
The pilot relief valve is located on the mounting base for the pilot oil filter. The pilot relief valve
limits the pressure in the pilot system. The pilot relief valve setting is adjustable.
Required Tools
Tooling (A) 198-4240 Digital Pressure Indicator Gp
Table 2
A 198-4240 Digital Pressure Indicator Gp
A1 1 198-4234 Digital Pressure Indicator
Pressure Sensor
A2 1 198-4238
34,450 kPa (5,000 psi)
A3 1 198-4236 Adapter Cable As
Machine Preparation
2. Stop the engine.
Pilot relief valve (located in pump compartment)
(1) Locknut
(3) Pressure tap
(4) Pilot filter
4. Connect a 34,450 kPa (5,000 psi) pressure sensor to pressure tap (3) .
Test Procedure
rpm settings.
4. Check the pilot relief valve setting at pressure tap (3) .
5. The pilot relief valve setting should be 4100 ± 200 kPa (595 ± 29 psi). If the pilot relief valve
setting is not within the specification, then adjust the pilot relief valve.
1. In order to adjust the pilot relief valve, loosen locknut (1) .
2. Turn adjustment screw (2) until the pressure reading at pressure tap (3) is within the
specification.
Note: Turn adjustment screw (2) clockwise in order to increase the pressure. Turn adjustment
screw (2) counterclockwise in order to decrease the pressure.
4. Test the pressure setting again. Refer to "Test Procedure".
Note: Normal operation of the engine and pumps are necessary for the pressure adjustment. If the
results of the pressure adjustments are not correct, then check the engine and the pump characteristic
curve.
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Specifications
i04807887
Relief Valve (Pilot)

SMCS - 5072; 5117
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TMF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 215-4909 Pilot Relief Valve Gp
Item Qty
215-4909 Pilot Relief Valve Gp Torque to 117.6 ± 9.8 N·m (86.7 ± 7.2 lb ft).
1 1
Torque the nut to

2 - -
49.0 ± 4.9 N·m (36.1 ± 3.6 lb ft).
Shutdown SIS
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Product: EXCAVATOR
Specifications
i04637750
Relief Valve (Pilot)

SMCS - 5072; 5117
S/N - A6F1-UP
S/N - A8F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TMF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 158-8987 Pilot Oil Filter and Valve Gp, and 177-2576 Pilot Relief Valve Gp

Tighten the nut to
1 1 -
49.0 ± 4.9 N·m (36.1 ± 3.6 lb ft).
Torque to
2 1 215-4909 Pilot Relief Valve Gp
117.6 ± 9.8 N·m (86.7 ± 7.2 lb ft).
Torque to
3 1 5I-8670 Oil Filter
34.3 ± 4.9 N·m (303.6 ± 43.4 lb in).
Shutdown SIS
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Product: EXCAVATOR

i05259362
Relief Valve (Swing) - Test and Adjust

SMCS - 5454-036
Specification
Table 1
"Relief Valve (Swing) - Test and Adjust"
Engine Speed
Machine Settings Engine speed dial "10"
AEC switch OFF
Item Specification Actual
Right Swing
26000 ± 1000 kPa (3770 ± 145 psi)
Left Swing
26000 ± 1000 kPa (3770 ± 145 psi)
Required Tools
Table 2
B1 1 198-4234 Indicator
Pressure Sensor
B2 1 198-4239
41,368 kPa (6,000 psi)
B3 1 198-4236 Extension Cable
Machine Preparation
2. Stop the engine.
Pump compartment
4. Connect a 41,368 kPa (6,000 psi) pressure sensor to pressure tap (2) .
Pilot oil manifold
(4) Connector
(5) Swing brake solenoid valve
5. Disconnect connector (4) from swing brake solenoid valve (5) .
Test Procedure
OFF.
ReferenceRefer to Testing and Adjusting, "Engine Performance - Test (Engine Speed)" for
engine rpm settings.
3. Move the swing joystick slowly and ensure that the swing parking brake is operating properly.
Swing motor
(6) Adjustment plug
(7) Locknut
(8) Relief valve (right swing)
(9) Relief valve (left swing)
(10) Adjustment plug
(11) Locknut
4. Slowly move the swing joystick for a full SWING RIGHT operation and check the pressure for
relief valve (8) at pressure tap (2) .
5. Return the swing joystick to the NEUTRAL position.
6. The pressure setting of the swing relief valve is 26000 ± 1000 kPa (3770 ± 145 psi). If the
pressure reading at pressure tap (2) is not within the specification, adjust the swing relief valve.
7. In order to adjust the swing relief valve, loosen locknut (7). Turn adjustment plug (6) until the
pressure gauge reading at pressure tap (2) is 26000 ± 1000 kPa (3770 ± 145 psi).
Note: Turning adjustment plug (6) clockwise increases the pressure. Turning adjustment plug
(6) counterclockwise decreases the pressure.
9. Slowly move the swing joystick for a full SWING LEFT operation and check the pressure for
relief valve (9) at pressure tap (2) .
10. Return the swing joystick to the NEUTRAL position.
11. The pressure setting of the swing relief valve is 26000 ± 1000 kPa (3770 ± 145 psi). If the
pressure reading at pressure tap (2) is not within the specification, adjust the swing relief valve.
12. In order to adjust the swing relief valve, loosen locknut (11). Turn adjustment plug (10) until
the pressure gauge reading at pressure tap (2) is 26000 ± 1000 kPa (3770 ± 145 psi).
Note: Turning adjustment plug (10) clockwise increases the pressure. Turning adjustment plug
(10) counterclockwise decreases the pressure.
14. After completing the test and/or the adjustment procedures for the swing relief valves, stop the
engine.
16. Connect connector (4) to the solenoid valve for swing parking brake (5) .
Shutdown SIS
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Product: EXCAVATOR
Specifications
i04585935
Return Lines - Hydraulic Tank

SMCS - 5057-QN
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CXY1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PCM1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Right side view
Table 1
Specification for 248-9853 Return Lines Gp
Item Qty
164-5608 Connector
1 1 Torque to 41 + 4 N·m (30 + 3 lb ft).
As
148-8358 Elbow As Torque to
2 1
70 + 7 N·m (52 + 5 lb ft).
Torque to
3 1 307-5097 Tee As
70 + 7 N·m (52 + 5 lb ft).
7K-1181 Cable Strap Sharp corners at the cutting edge of each cable strap shall
4 2
not be allowed.
Rear view
Table 2
Specification for 248-9853 Return Lines Gp
Torque to
5 1 176-4770 Hose As
160 + 16 N·m (118 + 12 lb ft).
Torque to
95 + 8 N·m (70 + 6 lb ft).
Torque to
7 1 268-1621 Fitting As
95 + 8 N·m (70 + 6 lb ft).
Torque to
8 1 8T-4956 Bolt
50 ± 10 N·m (37 ± 7 lb ft).
Torque to
9 1 275-1361 Hose As
76 ± 4 N·m (56 ± 3 lb ft).
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Product: EXCAVATOR
Specifications
i04048891
Rocker Shaft
SMCS - 1102
S/N - -
Typical example
(1) Washer
(2) Circlip
(3) Rocker arm bore
Diameter of the rocker arm bore for the bushing ... 25.01 to 25.05 mm (0.9847 to 0.9862 inch)
Rocker arm bushing
Clearance between the rocker arm bushing and the rocker shaft ... 0.03 to 0.09 mm (0.0010 to
0.0035 inch)
Maximum permissible clearance between the rocker arm bushing and the rocker shaft ... 0.17
mm (0.007 inch)
(4) Rocker arm
(5) Rocker shaft
Diameter of the rocker shaft ... 24.96 to 24.99 mm (0.9827 to 0.9839 inch)
(5) In order to install the rocker shaft assembly, ensure that the machined square is to the top of the
rocker shaft.
(6) Locknut
Torque for the locknut ... 27 N·m (20 lb ft)
(7) Tighten the bolts to the following torque. ... 35 N·m (26 lb ft)
Typical example
Note: The shaft has a seat that has been cut into the top of the shaft for the bolt head.
Note: Refer to illustration 2, in order to tighten the bolts in the correct sequence.
(8) Spring
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05137355
Service Tools
SMCS - 0785
The following service tools should be used to aid in troubleshooting the electrical system.
• Version 3.2 or later version of the Caterpillar Electronic Technician (ET)
• 146-4080 Digital Multimeter or equivalent
• 9U-7330 Digital Multimeter or equivalent
• 7x-1710 Multimeter Probe
• 8T-8726 Adapter Cable
• 4C-3406 Connector Repair Kit
• 276-7273 Sensor Test Box
Note: The Sensor Test Box is an instrument used to test Caterpillar Cylinder Position sensors.
Refer Troubleshooting, "Using Caterpillar Electronic Technician (Cat-ET) to Determine Diagnostic

Codes" for more information about the Cat-ET. Service Tool.
Use a digital multimeter in order to check the continuity or the voltage. See the following Special
Instruction for more information about the use of the 6V-7070 Digital Multimeter . See Special
Instruction, SEHS7734, "Use Of The 6V-7070 And 6V-7800 Multimeter". The 7X-1710 Multimeter
Probe is used in order to make a measurement at the connector without disconnecting the connector.
The probes are pushed into the back of the connector alongside the wire. The 8T-8726 Adapter Cable
is a "3 pin" breakout harness that is used to make measurements in sensor circuits.
Except for harness tests, the use of certain test equipment is not recommended for use on modern
Caterpillar electrical circuits. Such testers include the following examples: the 8T-0500 Continuity
Tester and 5P-7277 Voltage Tester .
Note: A procedure has been developed to test "In Cylinder" Position Sensors. Reference Special
Instruction REHS7338, "Procedure to Test the Position Sensor of a Hydraulic Cylinder".
Shutdown SIS
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Specifications
i04374293
Shuttle Valve (Pilot Lines)

SMCS - 5059; 5079
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TMF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 185-0462 Shuttle Valve Gp
1 4 7I-8084 Plug Torque to 6.9 ± 1.0 N·m (61.1 ± 8.9 lb in).
Torque to
2 7 107-6479 Plug
27.0 ± 2.5 N·m (239.0 ± 22.1 lb in).
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Specifications
i04397658
Shuttle Valve (Pilot Lines)

SMCS - 5059; 5079
S/N - -
Table 1
Specification for 164-6979 Shuttle Valve Gp
1 2 175-4430 Connector As Torque to 35 ± 3 N·m (26 ± 2 lb ft).
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Specifications
i04603218
Solenoid Valve - Straight Travel

SMCS - 5479
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - RAR1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TMF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 121-1491 Solenoid Valve Gp
Torque to
1 1 114-0623 Nut
7.4 ± 0.5 N·m (65.5 ± 4.4 lb in).
Nominal voltage is 24 VDC.
Allowable voltage range is 18 to 32 VDC.
- - - Resistance of coil at
20 °C (68 °F) is 32.0 ± 3.2 ohms.
Operating temperature range is
−40° to 121°C (−40° to 250°F).
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Specifications
i04395850
Solenoid Valve (Proportional Reducing)

SMCS - 5479
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TMF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 111-9916 Solenoid Valve Gp
1 1 114-0623 Nut Torque to 7.4 ± 0.5 N·m (65.5 ± 4.4 lb in).
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i05259741
Specifications
SMCS - 5050
Relief valve locations
(A) Boom cylinder line (rod end)
(B) Bucket cylinder line (head end)
(C) Main relief valve
(D) Stick cylinder line (head end)
(E) Boom cylinder line (head end)
(F) Bucket cylinder line (rod end)
(G) Stick cylinder line (rod end)
(H) Swing motor
(J) Swing (left)
(K) Swing (right)
(L) Pilot filter
(M) Pilot relief valve
(N) Travel motor (right)
(P) Right travel crossover relief valve for forward travel (upper valve)
(Q) Right travel crossover relief valve for reverse travel (lower valve)
(R) Left travel crossover relief valve for forward travel (upper valve)
(S) Left travel crossover relief valve for reverse travel (lower valve)
(T) Travel motor (left)
Table 1
Specifications
Torque for
Relief Valve New
Service Limit (3) Locknut
Rebuilt (2)
35000 ± 500 kPa 33000 to 35500 kPa 50 ± 10 N·m (37 ±

(5076 ± 73 psi) (4785 to 5150 psi) 7 lb ft)
(C) Main relief valve

36000 ± 500 kPa
(5221 ± 73 psi) 34000 to 36500 kPa 69 ± 10 N·m (51 ±
(Heavy Lift (if (4930 to 5300 psi) 7 lb ft)
equipped))
(E) Boom cylinder line
(head end)
39500 ± 500 kPa 32800 kPa (4757 psi)
(G) Stick cylinder line (rod (5729 + 73 psi)
end)
20 ± 2 N·m (14 ±
(A) Boom cylinder line (rod 1 lb ft)
end)
38000 ± 500 kPa 32800 kPa (4757 psi)
(B) Bucket cylinder line (5511 ± 73 psi)
(head end)
(F) Bucket cylinder line

(rod end)
(D) Stick cylinder line

38500 ± 500 kPa 32800 kPa (4757 psi)
(head end)
(5584 ± 73 psi)
(K) Swing relief pressure
(right)
120 ± 10 N·m (85
(J) Swing relief pressure 26000 ± 1000 kPa (3770 ± 145 psi)
± 7 lb ft)
(left)
(R) Left travel crossover
relief valve (forward)
(S) Left travel crossover
relief valve (reverse)
37500 ± 500 kPa 32800 kPa (4757 psi) 130 ± 13 N·m (95
(P) Right travel crossover (5439 ± 73 psi) ± 10 lb ft)
relief valve (forward)
(Q) Right travel crossover
relief valve (reverse)
(M) Pilot relief valve 50 ± 5 N·m (36 ±

4100 ± 200 kPa (595 ± 29 psi)
4 lb ft)
(2)
A New specification is the performance that can be expected for a new machine. A Rebuild specification is the
performance that can be expected after rebuilding the components of a system.
(3)
Performance beyond Service Limit specifications is an indication of these problems: improper adjustment, wear,
damage of relief valves and damage of pumps.
Table 2
Required Tools
9U-7400 Multitach Tool Group 1
8T-0470 Thermometer Group 1
Table 3
Relief Valves Pressure change With One Turn Of Adjustment Screw
Main valves
14400 kPa (2100 psi)
Line relief valve

11000 kPa (1600 psi)
Swing relief valve

6800 kPa (985 psi)
Travel crossover relief valve

3050 kPa (440 psi)
Pilot relief valve

620 kPa (90 psi)
Note: Normal operations of the engine and pumps are necessary for the pressure adjustments. If the
results of the pressure adjustment are not correct, then check the engine and the pump characteristic
curve. Slow output flow from the pump is an indication of air in the hydraulic system. Make sure that
no air is present in the hydraulic system. Refer to Testing and Adjusting, "Main Hydraulic Pump Air -
Purge".
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320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05258671
Speed Sensor - Adjust

SMCS - 1907-025
Installation of the speed sensor
(1) Speed Sensor
(2) Locknut
(3) Magnetic Pickup
(4) Flywheel Gear
(5) Flywheel Housing
Perform the following procedure to replace and/or adjust the speed sensor.
1. Turn the key start switch and the battery disconnect switch to the OFF position.
2. Loosen locknut (2) and remove speed sensor (1) . Inspect the sensor for damage. Replace the
sensor if magnetic pickup (3) is damage or has metal embedded into the tip.
Note: Inspect the connector, see Testing and Adjusting , "Electrical Connector - Inspect ".
3. Inspect the gear train for damage by looking through the speed sensor hole and flywheel
housing cover. Rotate the gear train to inspect all the teeth. After inspection, ensure that a tooth
is aligned with the speed sensor hole.
Note: Use a 9S-9082 Engine Turning Tool and 1/2 inch drive ratchet wrench to turn the engine
flywheel. Turn the flywheel in the direction of engine rotation, counterclockwise, as viewed
from the flywheel end. A 178-8615 Socket may be used to turn the crankshaft if access to the
flywheel housing cover is limited.
Note: If damage can be seen to the gear teeth, remove the pump for further inspection of the
flywheel. Refer to Disassembly and Assembly, "Pump Drive Group - Remove".
4. Measure distance between flywheel tooth and the sensor base on the flywheel housing. From
the pickup end of the sensor, mark that distance on the sensor body. This measurement will
help ensure that the sensor stops on the tooth and not because the sensor becomes stuck on the
threads.
5. By hand, screw speed sensor (1) into the threaded opening in flywheel housing (5) until
magnetic pickup (3) contacts a tooth on flywheel gear (4) .
6. Turn speed sensor (1) approximately 3/4 of a rotation in the counterclockwise direction. This
rotation sets the air gap between magnetic pickup (3) and flywheel gear (4) . The air gap
specification is 0.53 mm (0.021 inch) to 0.83 mm (0.033 inch).
7. Temporarily tighten locknut (2) .
Note: Do not allow speed sensor (1) to turn as locknut (2) is tightened.
8. Position the Engine Speed Dial at position 1 (LOW IDLE position). Refer to Testing and
Adjusting , "Engine Performance - Test - Engine Speed" for the Low Idle rpm specification.
9. Turn the key start switch and the battery disconnect switch to the ON position and start the
engine.
10. Calibrate the Engine Speed. Refer to Troubleshooting, "Calibration" in this manual.
11. Observe the "Performance " menu in the monitor and verify that the correct engine rpm is
displayed. Refer to Testing and Adjusting , "Engine Performance - Test - Engine Speed" for the
Low Idle rpm specification.
12. If the correct rpm is displayed, tighten locknut (2) to a torque of 25 N·m (18.4 lb ft). Sensor
adjustment is complete.
Note: Do not allow speed sensor (1) to turn as locknut (2) is tightened.
13. If the correct rpm is not displayed, the sensor requires readjustment. Stop the Engine.
14. Loosen the locknut on the speed sensor. Turn the speed sensor clockwise 1/4 turn.
Note: The air gap must not decrease below 0.53 mm (0.021 inch).
15. Repeat 2 through 12 until the correct rpm is displayed.
Note: If diagnostic code 190-8 "Engine Speed Sensor - Abnormal Frequency, Pulse Width, or
Period" becomes active after adjustment, refer to Troubleshooting, "MID 039 - CID 0190 - FMI
08" in this manual.
Note: If diagnostic code 190-8 persists, after all steps are performed, remove the pump and
inspect the rear gear train for visible wear or damage Refer to Disassembly and Assembly,
"Pump Drive Group - Remove"
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Specifications
i05881717
Sprocket
SMCS - 4164
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - RAR1-UP
S/N - SDC1-UP
S/N - SDZ1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 145-3042 Sprocket Gp
Item Qty
Before assembly, apply blue Loctite 243 to the threads of the

447-1717 Bolt
1 16 bolts.
Torque to 520 ± 70 N·m (384 ± 52 lb ft).
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Specifications
i04608631
Stick - 2.920 m (9.5801 ft)

SMCS - 6502
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - FAL1-UP
S/N - GBA1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - RAR1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
(2) Bucket cylinder group
(3) Stick cylinder group
(4) Bucket linkage group
(5) Bucket group
(6) Boom group
Table 1
Specification for 241-7303 Hoe Stick Gp , 290-9210 Hoe Stick Gp , 294-1486 Hoe Stick Gp ,
294-1483 Hoe Stick Gp , 324-0967 , 324-0980 Hoe Stick Gp , and 324-0981 Hoe Stick Gp
Item Qty
All bores must be free of paint. Use 5P-0960 Grease Cartridge in order to coat all bores for the
pins, the bucket, and the cylinder pin bores.
The stick cylinder must be assembled in order to orient the grease

1 - -
zerk, as shown.
7 1
As 69.850 ± 0.025 mm (2.7500 ± 0.0010 inch).
8 1
As 79.850 ± 0.025 mm (3.1437 ± 0.0010 inch).
166-1495
9 2 Lip Type
Seal
235-7679
10 2 Lip Type
Seal
166-1494
11 2 Lip Type
Seal
Install the bushing in the bore so that the part number of the bushing is facing outward.
Bushing (12) is one of the following part numbers:
Inside diameter before assembly is
228-5615 90.25 ± 0.04 mm (3.553 ± 0.002 inch).
2
12
9.5 ± 0.8 mm (0.37 ± 0.03 inch).
244-4277 90.16 ± 0.02 mm (3.550 ± 0.001 inch).
2
9.5 ± 0.8 mm (0.37 ± 0.03 inch).
Install the bushing in the bore so that the part number of the bushing
is facing outward.
229-1096 Inside diameter before assembly is
13 2
Bushing 70.17 ± 0.04 mm (2.763 ± 0.002 inch).
9.5 ± 0.8 mm (0.37 ± 0.03 inch).
Install the bushing in the bore so that the part number of the bushing
is facing outward.
240-2913 Inside diameter before assembly is
14 2
Bushing 80.20 ± 0.04 mm (3.157 ± 0.002 inch).
9.5 ± 0.8 mm (0.37 ± 0.03 inch).
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Specifications
i05864768
Stick Cylinder
SMCS - 5458
S/N - BZP1-UP
S/N - DFM1-UP
S/N - FAL1-UP
S/N - KBS1-UP
S/N - KHN1-UP
S/N - MDJ1-UP
S/N - TMF1-UP
S/N - XBB1-UP
Table 1
Specification for 364-0937 Hydraulic Cylinder Gp
Item Qty
During press fit, insert the bushing in the cap assembly and rod assembly with the tapered
side first.
Bore diameter before installation is
1 80.120 ± 0.020 mm (3.1543 ± 0.0008 inch).
241-7381 Bushing Installation depth of the bushing in the cap assembly is
2
9.85 ± 0.30 mm (0.388 ± 0.012 inch).
Installation depth of the bushing in the rod assembly is
10.0 ± 0.3 mm (0.39 ± 0.01 inch).
Before assembly, lubricate the face and the threads with 309
123-2060 Locknut -6932 Hydraulic Oil.
2 1
Torque to
7900 ± 400 N·m (5827 ± 295 lb ft).
Lubricate the inside diameter and the outside diameter with
3 2 158-9065 Ring
clean grease.
Lubricate the inside diameter and the outside diameter of the
4 1 9X-3598 Seal As
seal assembly with clean grease.
Lubricate the inside diameter and the outside diameter with

5 1 179-9667 Ring
clean grease.
323-3830 Cylinder Diameter is
A 1
As 139.2 ± 0.3 mm (5.48 ± 0.01 inch).
289-7937 Rod As Diameter is
B 1
99.93 ± 0.03 mm (3.934 ± 0.001 inch).
Bore of the head over two lands is
C 1 087-5434 Head
100.63 ± 0.03 mm (3.962 ± 0.001 inch).
Free linear movement of stop after assembly is
6 1 103-8380 Stop
0.50 ± 0.26 mm (0.020 ± 0.010 inch).
Maximum outside diameter of two retaining rings after
095-0929 Retaining
7 2 assembly is
Ring
70.4 mm (2.77 inch).
247-8791 Seal Ring The slit of the seal ring must turn in the direction of the
8 1
piston.
Outside diameter is
114-0757 Bushing 105.148 ± 0.032 mm (4.1397 ± 0.001 inch).
9 1
Thickness is
2.475 ± 0.025 mm (0.0974 ± 0.0010 inch).
377-6022 Buffer Lubricate the sealing lip lightly with the lubricant that is
10 1
Seal being sealed.
377-6019 U-Cup Lubricate the sealing lip lightly with the lubricant that is
11 1
Seal being sealed.
364-0955 Lip Type Lubricate the sealing lip lightly with the lubricant that is
12 1
Seal being sealed.
Before assembly, apply green Loctite 609 to the wiper seal
13 - -
groove.
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Specifications
i04573592
Stick Cylinder Lines

SMCS - 5057-JJ
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - FAL1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBT1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAR1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 242-6735 Stick Cylinder Lines Gp and 266-8024 Stick Cylinder Lines Gp
Item Qty
6V-8200
1 4 Torque to 92.4 ± 17.5 N·m (68.2 ± 13.0 lb ft).
Bolt
Distance from the center of the mounting pin to the center of the
A - - support assembly is
305 mm (12.0 inch).
B - - Orient the support assemblies to an angle of 45 degrees.
8T-4910 Torque to
2 1
Bolt 56.9 ± 10.7 N·m (42.0 ± 8.0 lb ft).
8T-4196 Torque to
3 2
Bolt 31.50 ± 5.88 N·m (278.80 ± 52.04 lb in).
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Specifications
i04629785
Stick Cylinder Lines

SMCS - 5057-JJ
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - FAL1-UP
S/N - GDP1-UP
S/N - JLG1-UP
S/N - KBS1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KLM1-UP
S/N - LFL1-UP
S/N - MCH1-UP
S/N - MDJ1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PHX1-UP
S/N - RAC1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TMF1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - YSD1-UP
S/N - ZMF1-UP
Table 1
Specification for 248-9925 Stick Cylinder Lines Gp
Item Qty
B - - Orient the support assemblies to the angle of 30 ± 3 degrees.

C - - assemblies (2) is
390.0 ± 2.0 mm (15.35 ± 0.08 inch).
1 4
39 ± 8 N·m (29 ± 6 lb ft).
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Specifications
i05707692
Stick Cylinder
SMCS - 5458
S/N - DFM1-UP
S/N - FAL1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - MZD1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - PJP1-UP
S/N - RAR1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
Table 1
Specification for 341-2802 Stick Cylinder and Seal Gp and 341-2807 Stick Cylinder and Seal
Gp
Item Qty
Inside diameter before assembly is 80.20 ± 0.04 mm

(3.157 ± 0.002 inch).
1 1 240-2914 Bushing
10 mm (0.4 inch).
Torque to
2 12 4I-3628 Bolt
367 ± 55 N·m (271 ± 41 lb ft).
352-1098 Stick Bore diameter is
A 1
Cylinder As 140 mm (5.5 inch).
Diameter is
B 1 352-1104 Rod As
100 mm (3.9 inch).
During press fit, insert the bushing with the taper side
first.
3 2 357-5711 Bushing
80.36 ± 0.03 mm (3.164 ± 0.00 inch).
10 mm (0.4 inch).
3B-8489 Grease Torque to
4 1
Fitting 9.32 ± 4.90 N·m (82.49 ± 43.37 lb in).
105 mm (4.1 inch).
5 1 096-5625 Bushing
Thickness is
2.47 mm (0.097 inch).
Torque to
6 1 247-8873 Piston
8890 ± 440 N·m (6557 ± 325 lb ft).
Torque to
096-6210 Socket 56.9 ± 10.7 N·m (42.0 ± 7.9 lb ft).
7 1
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i05985516
Swing Bearing Movement - Measure

SMCS - 7063-082
Specification
Table 1
"Swing Bearing Movement - Measure"
Specification For Vertical Movement Of The Swing Bearing
Item Specification Actual Average
1.
New 2.0 mm (0.08 inch) 2.
3.
1.
Service Limit 2.
4.0 mm (0.16 inch)
3.
Specification For Circular Movement Of The Swing Bearing
Item Specification Actual Average
1.
2.
New
4.5 mm (0.18 inch) 3.
4.
1.
2.
Service Limit
13.5 mm (0.53 inch) 3.
4.
Introduction
Use the procedures that follow in order to check the vertical movement and the circular movement of
the swing bearing. Two dial indicators with magnetic bases are required for the procedures.
Required Tools
Table 2
Tool Description Qty
A Dial Indicator 2
Procedure To Measure Vertical Movement Of The Swing

Bearing
1. Place the machine on level ground.
2. Empty the bucket.
3. Position the upper structure parallel with the tracks.
4. Inspect the static torque of the bolts in the swing bearing in order to make sure that the bolts are
tightened properly.
a. Set the torque wrench to a torque value of 509 N·m (375 lb ft).
b. Make a mark on the head of the bolt that is relative to the carbody or the bearing race.
c. Apply the specified torque to the bolt.
d. If the head of the bolt does not move, the torque is within the specification.
e. If the head of the bolt moves, replace the bolt.
(A) Dial indicator
(B) Dial indicator
(C) Outer race of the swing bearing
(D) Inner race of the swing bearing
(F) Carbody
5. Refer to Illustration 1. Position dial indicator (A) between the carbody and the outer race of the
swing bearing (C) . Position dial indicator (B) between the carbody and the outer race of the
swing bearing (C) .
Note: Position the dial indicators at the front center of the carbody and at the rear center of the
carbody.
6. Position the machine as shown in Illustration 2.
7. Adjust both dial indicators to "zero".
8. Position the machine as shown in Illustration 3. The angle between the ground and the track
should be approximately 15 degrees.
9. Calculate the total distance of movement between dial indicator (A) and dial indicator (B) .
Record the total distance movement of in Table 1.
Note: This measurement is one of three measurements of the vertical swing bearing movement
to be used in Step 14.
10. Reposition the machine as shown in illustration 2.
11. Note the distance movement of both of the dial indicators. Calculate the difference for each dial
indicator and the measurement at the zero point that was measured in Step 7.
Note: The difference calculated for each dial indicator should be less than ± 0.05 mm (± 0.002
inch). A greater distance may indicate the dial indicator has moved out of the original zero
position This greater distance also indicates that the measurement from Step 9 is not a valid
measurement and additional vertical swing bearing movement measurements are necessary.
Repeat Steps 6 through 11.
12. Remove the dial indicators. Rotate the upper structure three times in a clockwise direction.
Rotate the upper structure three times in a counterclockwise direction.
13. Repeat Steps 5 through 12 three times.
14. Calculate the average of the values that were recorded in Step 9. Compare this average to the
service limit specifications are shown in Table 1.
Procedure To Measure Circular Movement Of The Swing

Bearing
1. Place the machine on level ground.
(E) 1000 mm (39.4 inch)
3. Position the upper structure parallel to the tracks. Refer to Illustration 4 for the correct position
of the boom, of the stick, and of the bucket.
4. Stop the engine.
(A) Dial indicator
(C) Outer race of swing bearing
(D) Inner race of swing bearing
(F) Magnet
5. Position dial indicator (A) on the outer race of swing bearing (C) . Position a magnet (F) on the
inner race of swing bearing (D) . The value for the measurement will be the average of four
readings.
6. By hand, push the side of the bucket in order to rotate the upper structure in a counterclockwise
direction as far as possible. Hold the upper structure in that position while the dial indicator is
set to "zero".
7. By hand, push the side of the bucket in order to rotate the upper structure in a clockwise
direction as far as possible. Record the dial indicator reading.
8. Remove the dial indicator. Rotate the upper structure three times in a clockwise direction.
Rotate the upper structure three times in a counterclockwise direction.
9. Perform Step 5 through 8 for each machine position that is shown in Illustration 6. The
evaluation of the movement of the bearing is based on the average value of the four
measurements at the four positions shown in Illustration 6.
If the measurements for the circular movement of the swing bearing exceed the specifications that are
listed in Table 1, check the following components for improper function, wear and/or failure:
• swing gear teeth
• pinion gear in the swing drive
• swing drive
• swing motor
• swing brake valve
• swing control valve
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Specifications
i04374345
Swing Cushion Valve - Fine Swing

SMCS - 5480
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - FAL1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - RAR1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Typical example
Table 1
Specification for 322-8716 Swing Cushion Valve Gp
Torque to
69.0 ± 6.9 N·m (51.0 ± 5.1 lb ft).
Torque to
2 2 8T-0288 Bolt
7.0 ± 0.7 N·m (62.0 ± 6.2 lb in).
Apply blue Loctite 242 to the threads.
3 2 133-6788 Orifice Torque to
6.9 ± 0.7 N·m (61.1 ± 6.2 lb in).
Torque to
7.0 ± 0.7 N·m (62.0 ± 6.2 lb in).
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Specifications
i04374359
Swing Cushion Valve

SMCS - 5480
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - MDE1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - SED1-UP
S/N - TDH1-UP
S/N - TMF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 158-9085 Swing Cushion Valve Gp

Torque to
69.0 ± 6.9 N·m (50.8 ± 5.1 lb ft)
Torque to
7.0 ± 0.7 N·m (62.0 ± 6.2 lb in)
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Specifications
i04556670
Swing Drive - Without Motor

SMCS - 5459
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - RAR1-UP
S/N - SDC1-UP
S/N - SDZ1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 148-4644 Swing Drive Gp and 199-4701 Swing Drive Gp
Item Qty
Apply 4C-5599 Anti-Seize Compound to the inside diameter,

1 - - outside diameter of the roller bearing and to the surfaces of the
mating parts.
6V-7238 Torque to 28 to 31 N·m (248 to 274 lb in).

2 1 Shutoff Valve When the valve shutting off, tighten to
2.9 ± 0.5 N·m (25.7 ± 4.4 lb in).
After installation, make the stake marks near the opening of each
spring pin hole.
B - -
Distance from the edge of the spring pin hole to the stake mark is
2.25 ± 0.75 mm (0.089 ± 0.030 inch).
Lubricate the sealing lip lightly with the lubricant that is being
199-4561 Lip
3 2 sealed. Lubricate the circumference of lip type seals with grease
Type Seal
when the seal is installed in the cage.
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Specifications
i04647090
Swing Gear and Bearing

SMCS - 7063
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CXY1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PCM1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Top view
Table 1
Specification for 227-6147 Swing Gear and Bearing Gp and 267-6801 Swing Gear and
Bearing Gp
Item Qty
Note : Position "S" that is on inner race (8) relative to the carbody assembly (1) and bearing
stopper (2). Refer to Illustration 1.
096-4902
3 1 Apply Loctite C5A Cooper antiseize to dowel holes.
Dowel
7Y-1650
Torque to
4 1 Hose Clamp
5.39 ± 0.49 N·m (47.71 ± 4.34 lb in).

8T-4136
5 8 Torque to
Bolt
37 ± 4 N·m (27 ± 3 lb ft).
Apply blue Loctite High Flex GM between the mating surfaces of the
1U-8846
gear group and upper frame assembly. Apply blue Loctite High Flex
6 - Gasket
GM between the mating surfaces of the gear group and carbody
Sealant
assembly.
8T-4136
7 4 Torque to
Bolt
20 ± 2 N·m (177 ± 18 lb in).
Apply Loctite C5A Cooper antiseize to the threads of bolts. Do not
apply Loctite C5A Cooper antiseize to the seats of the bolts or to the
washer faces.
The five holes which are marked "Y" are not for use.
37 8T-0362 Use the following torque in order to tighten the bolts:

9
Bolt Torque for the bolts except for the Akashi facility is
568 ± 59 N·m (419 ± 44 lb ft).
Torque for the bolts for the Akashi facility is
294 ± 29 N·m (217 ± 21 lb ft).
Additionally tighten the bolts for Akashi facility by 50 ± 5 degrees.
Apply Loctite C5A Cooper antiseize to the threads of bolts. Do not
apply Loctite C5A Cooper antiseize to the seats of the bolts or to the
washer faces.
The five holes which are marked "Y" are not for use.
40 8T-0360 Use the following torque in order to tighten the bolts:

10
Bolt Torque for the bolts except for the Akashi facility is
568 ± 59 N·m (419 ± 44 lb ft).
Torque for the bolts for the Akashi facility is
294 ± 29 N·m (217 ± 21 lb ft).
Additionally tighten the bolts for Akashi facility by 50 ± 5 degrees.
8T-4137
11 2 Torque to
Bolt
37 ± 4 N·m (27 ± 3 lb ft).
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i05294473
Swing Motor - Test - Measurement of Case Drain Oil

SMCS - 5058-081-ZW
Specification
Table 1
"Swing Motor - Test (Measurement of Case Drain Oil)"
Swing Relief Pressure Engine Speed
26000 ± 1000 kPa (3770 ± 145 psi) AEC Switch OFF
Item Specification (1) Actual
1.
New Swing Motor 2.
30 L/min (7.9 US gpm)
3.
1.
Rebuilt Swing Motor 2.
3.
(1)
Maximum acceptable flow
Required Tools
Tooling group "B"
Tooling group (D)
Table 2
Required Tools
Part
Tool Item Description Qty
Number
B 198-4240 Digital Pressure Indicator Gp 1
Pressure Sensor
B2 198-4239 1
41,368 kPa (6,000 psi)

Flow Meter
D1 6V-7788 1
5 to 60 L/min (2 to 15 US gpm)
D2 8C-6874 Reducer 1
D3 6V-9746 O-Ring Seal 1
D4 124-1901 Permanent Coupling 1
D
D5 122-6870 Bulk Hydraulic Hose 3 ft
D6 124-2147 Permanent Coupling 1
D7 6V-8942 O-Ring Reducer 1
D8 6V-8556 Nut 1
D9 6V-8398 O-Ring Seal 1
F 311-1362 Vacuum Cap 1
Machine Preparation
NOTICE

containing fluids.

Cat products.
1. Stop the engine.
hydraulic system.
Swing motor compartment
(1) Case drain hose
(2) Adapter
4. Disconnect case drain hose (1) from adapter (2) .
Flow Meter Tool Layout
Tooling D
(1) Case drain hose
(2) Adapter
(3) Swing motor
(4) Swivel
5. Connect the flow meter assembly (D) between adapter (2) and case drain hose (1). Refer to
Illustration 4.
Note: Correct orientation of the flow meter is necessary. The oil flows from swing motor (3) to
swivel (4) .
6. Swing solenoid valve location.
Pilot manifold
(5) Connector
(6) Solenoid valve for swing parking brake
7. Disconnect connector (5) from the solenoid valve for swing parking brake (6) .
8. Remove 311-1362 Vacuum Cap and install the filler plug for the hydraulic tank.
Test Procedure
2. Place the engine speed dial at position "10" and AEC switch OFF.
ReferenceRefer to Testing and Adjusting, "Engine Performance - Test (Engine Speed)" for
engine rpm settings.
4. Slowly move the swing joystick and make sure that the swing parking brake is activated.
5. Move the swing joystick fully for 1 minute. Measure the case drain oil.
6. Stop the engine.
7. Connect connector (5) to the solenoid valve for swing parking brake (6) .
8. Repeat this test procedure three times in order to obtain three measurements. For each test
procedure, swing the upper structure to a different position.
The following values specify the maximum acceptable flow of case drain oil when the swing relief
pressure is set at 26000 ± 1000 kPa (3770 ± 145 psi).
New swing motor ... 30 L/min (7.9 US gpm)

Rebuilt swing motor ... 35 L/min (9.2 US gpm)
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Specifications
i04597411
Swing Motor
SMCS - 5058
S/N - BYM1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - RAR1-UP
S/N - SDC1-UP
S/N - SDZ1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
NOTICE
To prevent damage to the motor, the case must be filled with hydraulic
oil at least to the fill port before operation.
Table 1
Specification for 334-9968 Swing Motor Gp
Free length is
37.5 mm (1.48 inch).
1 20 126-2055 Spring
Outside diameter is
17.9 mm (0.70 inch).
Torque to
2 2 110-5525 Plug
59.0 ± 5.9 N·m (43.5 ± 4.4 lb ft).
Torque to
3 4 7Y-5221 Bolt
430 ± 43 N·m (317 ± 32 lb ft).
Free length is
48.5 mm (1.91 inch).
4 2 7Y-4268 Spring
Outside diameter is
18.7 mm (0.74 inch).
Torque to
5 2 094-1900 Plug
334.0 ± 33.4 N·m (246.4 ± 24.6 lb ft).
Torque to
176 ± 10 N·m (130 ± 7 lb ft).
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i02808845
Swing Speed and Overswing on Level Ground - Check

SMCS - 5058-535-ZW
Measuring the swing speed and the overswing of the machine will determine if there is a need to
check the swing motor or the anti-reaction valve. The fine swing control switch (if equipped) must be
in the OFF position.
Table 1
Required Tools
Description Qty
Measuring Tape 1
Stopwatch 1
1. Position the machine on level ground. Refer to Illustration 1.
2. Stop the engine.
(A) Upper frame
(B) Undercarriage frame
(C) Marking
3. To indicate the relationship of the two positions, put a mark (C) on the inner race and the outer
race of the swing bearing. The mark will be used as a target to stop the swing operation. Refer
to Illustration 2.
5. Move the swing joystick in either direction until the machine completes a 180 degree swing
operation away from the target.
6. Move the swing joystick in either direction until the machine completes a 180 degree swing
operation toward the target. Return the swing joystick to the NEUTRAL position at the target.
7. Measure the amount of overswing by measuring the distance between the marks on the swing
bearing. Refer to Illustration 2.
Note: Use a point that is visible from the operator seat as a reference point for the target.
Table 2
Overswing
Right Swing
1100 mm (43.3 inch) or
1200 mm (47.2 inch) or 1400 mm (55.1 inch) or
Left Swing less
less less
8. Move the swing joystick in each direction and measure the time that is required to complete a
180 degree swing operation.
Table 3
Swing Time
Right Swing
4.2 seconds or less 4.6 seconds or less 5.2 seconds or less
Left Swing
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i05597269
Swing Speed and Swing Drift on a Slope - Check

SMCS - 5058-535-ZW
Measuring the swing speed on a slope will determine if there is a need to check the swing motor and
the anti-reaction valve. Measuring the swing drift on a slope will determine if there is a need to check
the swing parking brake.
Table 1
Required Tools
Description Qty
Measuring Tape 1
Stopwatch 1
Swing Speed (Empty Bucket)

2. Position the machine on a slope of 12 degrees. Refer to Illustration 1.
3. Position the implements at maximum reach and close the bucket. Position the bucket above the
ground so that the bucket will not come in contact with any obstacles.
4. Position the upper structure at position (A). The upper structure should be at a 90 degree angle
to the lower structure. Refer to Illustration 2.
5. Measure the time that is required to swing the upper structure from position (A) to position
(B) .
6. Position the upper structure at position (C). The upper structure should be at a 90 degree angle
to the lower structure.
7. Measure the time that is required to swing the upper structure from position (C) to position (B).
Table 2
Swing Time (seconds)
Right Swing
4.1 or less 4.6 or less 5.4 or less
Left Swing
Swing Drift (Loaded Bucket)

1. Load the bucket.
Weight of bucket load
Standard Undercarriage ... 1050 kg (2310 lb)

Long Undercarriage ... 1200 kg (2640 lb)
2. Position the machine on a slope of 12 degrees. Refer to Illustration 1.
3. Position the implements at maximum reach and close the bucket. Position the bucket above the
ground so that the bucket will not come in contact with any obstacles.
4. Position the upper structure at position (A). The upper structure should be at a 90 degree angle
(A) Upper frame
(B) Undercarriage frame
(C) Marking
5. To indicate the relationship of the two positions, put a mark (C) on the inner race and the outer
race of the swing bearing. Refer to Illustration 4.
6. Stop the engine.
7. Leave the machine in this position for three minutes. Measure the swing drift on the
circumference of the swing bearing.
9. Position the upper structure at position (C). The upper structure should be at a 90 degree angle
10. Repeat Steps 5 through 7.
Table 3
Swing Drift mm (inch)
Right Swing
0 0 0
Left Swing
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Specifications
i05223349
Swivel
SMCS - 5060
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - RAR1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Typical example
Table 1
Specification for 234-4440 Swivel Gp , 225-4547 Swivel Gp , 162-4695 Swivel Gp , and 162-
4696 Swivel Gp
Item Qty
159-7782 Seal Lubricate the O-ring seals and the shaft lightly with the lubricant
1 5
that is being sealed or with clean grease.
095-1625 O- Lubricate the O-ring seals and the shaft lightly with the lubricant
2 3
Ring Seal that is being sealed or with clean grease.
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05895988
Symptom Troubleshooting
SMCS - 7000-035
Use the following guidelines when troubleshooting a symptom.
Know the Machine

Understand the operation of the machine. Know if the symptom is a characteristic of normal operation
or if the symptom is a failure.
Read the Systems Operation information to understand the systems of the machine. Understand the
interaction of the machine systems.
Understand the Symptom

Speak with the operator about the symptom. Inspect the machine and look for problems. Notice any
unusual odors in the air. Listen for unusual noises. Acquire the following Information:
• The performance of the machine prior to the failure
• First occurrence of the symptom
• The operating conditions at the time of the failure
• The sequence of events prior to the failure (order of the occurrences)
• The troubleshooting steps that have been taken
• The history of repairs of the machine
• The preventive maintenance of the machine
• Related service information about current problems that affect the serial number of the machine
Perform the "Visual Inspection" steps.
Verify the Symptom

When possible, attempt to duplicate the symptom. Operate the machine and repeat the conditions that
caused the failure. Check the gauges inside the cab. Notice any unusual odors in the air. Listen for
unusual noises.
Determine if the ECM has detected any faults. A diagnostic code is used to specify each detected
fault.
Determine Possible Causes

Use the information from the operator and your inspection. Attempt to identify a common cause if
there is more than one symptom.
If the problem is not resolved after troubleshooting the diagnostic codes, continue troubleshooting
using the "Symptom Troubleshooting" section of this manual. Identify the component that is the most
probable cause of the symptom.
Test and Repair the System

Use the tests and procedures in this manual to verify the cause of the symptom. Once the cause has
been identified, repair the failure. Test the system again to verify that the symptom is resolved.
Provide Feedback to Caterpillar

Share your troubleshooting information with Caterpillar. Use the form in "SIS" or "CBT" feedback to
write a brief description about the symptom, testing, and repair. Include your phone number or e-mail
address so that you can be contacted. This feedback information helps Caterpillar improve service
information.
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320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i04647970
System Schematic
SMCS - 7566-MCH
These simplified schematics of the machine control system are electrically correct. These schematics
do not show all possible harness connections. Always see the "Electrical System Schematic" in the
Service Manual for the machine for a complete schematic of a particular machine.
320D, 321D, 323D
Connector J1 connections of the Machine Electronic Control Module ( 320D, 321D, 323D)
Connector J2 connections of the Machine Electronic Control Module for ( 320D, 321D, 323D)
324D, 325D, 328D, 329D, 330D, 336D
Connector J1 connections of the Machine Electronic Control Module for ( 324D, 325D, 328D, 329D, 330D, 336D)
Connector J2 connections of the Machine Electronic Control Module ( 324D, 325D, 328D, 329D, 330D, 336D)
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Specifications
i04629912
Track Adjuster
SMCS - 4157
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - RAR1-UP
S/N - SDC1-UP
S/N - SDZ1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 239-4390 Track Adjuster and Recoil Gp
Item Qty
239-4392 Cylinder Lubricate the inside diameter and the seal groove of the
1 1
cylinder with 5P-0960 Grease Cartridge.
357-7540 Fill Torque to
2 1
Valve 34 ± 5 N·m (301 ± 44 lb in).
Lubricate the outside diameter and the seal grooves of the
3 1 145-3031 Piston
piston with 5P-0960 Grease Cartridge.
2S-5926 Relief Torque to
4 1
Valve 34 ± 5 N·m (301 ± 44 lb in).
093-1436 Lip Installation depth is
A 1
Type Seal 0.5 ± 0.5 mm (0.02 ± 0.02 inch).
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Specifications
i04404520
Travel Counterbalance Valve

SMCS - 5051-KV; 5811-KV
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - RAR1-UP
S/N - SDC1-UP
S/N - SDZ1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 322-8714 Travel Counterbalance Valve Gp
Item Qty
360-4588 Relief Valve Gp Torque to 270.0 ± 27.0 N·m (199.1 ± 19.9 lb ft).
1 2
Torque for the nuts of the relief valve groups is

2 - -
68.6 ± 7.0 N·m (50.6 ± 5.2 lb ft).
Torque to
3 8 8T-7811 Bolt
78.5 ± 8.0 N·m (57.9 ± 5.9 lb ft).
Torque to
4 2 102-0818 Plug
32.0 ± 3.0 N·m (283.2 ± 26.6 lb in).
49.2 mm (1.94 inch).
Test force is
5 2 360-4583 Spring
280 N (63 lb).
68.2 mm (2.69 inch).

28.5 mm (1.12 inch).
Test force is
6 2 360-4587 Spring
4.63 ± 0.50 N (1.04 ± 0.11 lb).
47.2 mm (1.86 inch).
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i05259682
Travel Motor - Test - Measurement of Case Drain Oil

SMCS - 4351-081
Specification
Table 1
"Travel Motor - Test (Measurement of Case Drain Oil)"
Crossover Relief Pressure Engine Speed
37500 ± 500 kPa (5439 ± 73 psi)
AEC switch OFF
Item Specification (1) Left Travel Right Travel
1. 1.
New Travel Motor 2. 2.
3. 3.
1. 1.
Rebuilt Travel Motor 2. 2.
3. 3.
(1)
Maximum acceptable flow
Required Tools
Tooling group (D)
Table 2
Required Tools
Part
Tool Item Qty Description
Number
A 198-4240 Digital Pressure Indicator Gp
A1 1 198-4234 Indicator
Pressure Sensor
A2 1 198-4237
3447 kPa (500 psi)
Pressure Sensor
A2 1 198-4239
41,368 kPa (6,000 psi)
A3 2 198-4236 Extension Cable
Flow Meter
D1 1 6V-7788
5 to 60 L/min (2 to 15 US gpm)
D2 1 8C-6874 Reducer
D3 1 6V-9746 O-Ring Seal
D4 1 124-1901 Permanent Coupling
D
D5 3 ft 122-6870 Bulk Hydraulic Hose
D6 1 124-2147 Permanent Coupling
D7 1 6V-8942 O-Ring Reducer
D8 1 6V-8556 Nut
D9 1 6V-8398 O-Ring Seal
F 1 311-1362 Vacuum Cap
G 1 418-3611 Track Block
Machine Preparation
NOTICE

containing fluids.

Cat products.
Sprocket (left travel)
(G) Track block
(1) Sprocket
2. Place track block (G) in sprocket (1) in order to block forward left travel. Refer to Illustration 3.
3. Stop the engine.
hydraulic system.
Flow Meter Tool Layout
Tooling (D)
(2) Case drain hose
(3) Connector
(4) Travel motor
6. Install the following tools in accordance with the flow meter tool layout. Refer to Illustration 4.
7. Disconnect case drain hose (2) from connector (3) .
8. Connect the flow meter assembly (D) between connector (3) and case drain hose (2) .
Note: Correct orientation of the flow meter is necessary. The oil flows from travel motor (4) to
case drain hose (2) .
9. Remove 311-1362 Vacuum Cap and install the filler plug for the hydraulic tank.
Test Procedure
rpm settings.
4. Move the left travel lever to full FORWARD position and check the flow of oil through the
flow meter.
5. Remove track block (G) from sprocket (1) .
6. Move the left travel lever in order to reposition the travel motor.
7. Place track block (G) in sprocket (1) in order to block forward left travel.
8. Repeat Steps 4 through 7 in order to obtain three measurements of case drain oil.
The following values specify the maximum acceptable flow of case drain oil when the travel
crossover relief valves are set at 37500 ± 500 kPa (5439 ± 73 psi).
New travel motor ... 15 L/min (4.0 US gpm)

Rebuilt travel motor ... 18 L/min (4.8 US gpm)
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Specifications
i05981768
Travel Motor and Mounting

SMCS - 79PC-MT
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - RAR1-UP
S/N - SDC1-UP
S/N - SDZ1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Typical example
Table 1
Specification for 334-9988 Travel Motor and Mounting Gp and 334-9986 Travel Motor and
Mounting Gp
1 6 8C-8729 Bolt Torque to 80 ± 8 N·m (59 ± 6 lb ft).
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Specifications
i05861013
Travel Motor Guard

SMCS - 7163
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - FAL1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFZ1-UP
S/N - JLG1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - RAR1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 166-1478 Travel Motor Guard Gp , 163-3754 Travel Motor Guard Gp , 178-
0809 Travel Motor Guard Gp , 184-5713 Travel Motor Guard Gp , 184-5790 Travel Motor
Guard Gp , 220-3606 Bottom Guard Gp , 178-0895 Travel Motor Guard Gp , and 184-5714
Travel Motor Guard Gp
1 8 - Tighten the bolts to 130 ± 10 N·m (96 ± 7 lb ft).
Shutdown SIS
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Product: EXCAVATOR
Specifications
i04631340
Travel Motor Lines

SMCS - 5057-TV
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - RAR1-UP
S/N - SDC1-UP
S/N - SDZ1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Typical example
Table 1
Specification for 239-1717 Travel Motor Lines Gp, 266-0980 Travel Motor Lines Gp, 239-
1716 Travel Motor Lines Gp, and 269-5175 Travel Motor Lines Gp, 286-6861 Travel Motor
Lines Gp, 286-6869 Travel Motor Lines Gp, and 296-7360
Item Qty
Torque to
1 2 -
76 ± 4 N·m (56 ± 3 lb ft).
8T-4136
2 6 Apply blue Loctite 242 to the threads of bolts.
Bolt
Apply blue Loctite High Flex GM between the mating surfaces of
3 - -
the swivel group and the cover of the undercarriage.
Torque to
4 1 -
76 ± 4 N·m (56 ± 3 lb ft).
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Specifications
i04406804
Travel Motor
SMCS - 4351; 5058
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TMF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
NOTICE
To prevent damage to the motor, the case must be filled with hydraulic
oil at least to the fill port before operation.
Table 1
Specification for 215-9952 Travel Motor Gp
Item Qty
095-7384 O-
1 1 Lubricate the sliding surfaces lightly with clean hydraulic oil.
Ring Seal
095-7383 O-
Ring Seal
096-4377 O-
Ring Seal
095-1572 O-
Ring Seal
087-4743 Stop
5 2 Torque to 140 ± 14 N·m (103 ± 10 lb ft).
346-1340
Piston
122-5114 Ball
Guide
147-5860
Piston
234-4629
Barrel
13 mm (0.5 inch).
10 1
Spring 14.3 ± 1.5 N (3.2 ± 0.3 lb).
15.000 mm (0.5905 inch).
To ensure that the following conditions are fulfilled, install
shims (12) :
When parking brake release port (11) is vented to the air, the
motor output shaft does not rotate with a torque of
11 - - 440 N·m (320 lb ft) or less.
When pressure at parking brake release port (11) is
780 kPa (115 psi), the motor output shaft rotates with a torque of
49 N·m (36 lb ft) or less. Both the inlet port and the outlet port
must be open to the hydraulic tank.
As required, use the following shims:
096-1521 Shim Thickness is
1
12 1.00 mm (0.039 inch).
1
1.20 mm (0.047 inch).

1
1.40 mm (0.055 inch).
1
1.60 mm (0.063 inch).
1
1.80 mm (0.071 inch).
1
2.00 mm (0.079 inch).
Torque to
13 10 8T-4944 Bolt
177 ± 18 N·m (131 ± 13 lb ft).
095-1586 O-
Ring Seal
31 mm (1.2 inch).
15 9
Spring 360 ± 49 N (81 ± 11 lb).
33.7 mm (1.33 inch).
094-1882 Plug threads of the plug. The plug is not required for optional design.
16 1
Torque to
13 ± 2 N·m (115 ± 18 lb in).
094-1882 Plug threads of the plug.
17 10
Torque to
13 ± 2 N·m (115 ± 18 lb in).
096-4376 Lip Apply blue Loctite High Flex GM to the mating surfaces of the
18 1
Type Seal lip type seal and the body.
7Y-4216 Spool

24.0 mm (0.95 inch).
20 1
Spring 74 ± 8 N (17 ± 2 lb).
34.700 mm (1.3661 inch).
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i05106914
Travel on Level Ground - Test - Optional Test

SMCS - 4351-081
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - KBS1-UP
S/N - KHR1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - YBE1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Note: When the procedure for the Testing and Adjusting, "Travel on Level Ground - Test" cannot be
performed, this test may be used as a substitute.
Table 1
Required Tools
Description Qty
Stopwatch 1
4. Raise a track off the ground. Refer to Illustration 1.
5. Put a mark on a shoe of the raised track.
6. Place the machine controls at the following settings: Engine speed dial "10" and AEC switch
OFF.
7. Place the travel speed control switch in HIGH position.
8. Move the travel lever of the raised track to full travel position.
9. Measure the time that is required for the raised track to make three complete revolutions.
Measure the time that is required in each direction.
10. Place the travel speed control switch in the LOW position and repeat Steps 8 through 9.
Table 2
Time For Three Revolutions (time in seconds)
Standard Undercarriage
Forward
Reverse
Forward
Reverse
Table 3
Time For Three Revolutions (time in seconds)
Long Undercarriage
Forward
Reverse
Forward
Reverse
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i05182663
Troubleshooting
SMCS - 1000
Introduction
Troubleshooting can be difficult. To make a repair to a problem, refer to the possible cause and the
corrective action. The most common problems are identified in this troubleshooting manual. The
symptoms, causes, and guidance for solving the problems are given.
The list of problems, causes, and corrections will only give an indication of the location of a possible
problem. There is also a list that shows some of the repairs that are required.
Sometimes additional repair work is required beyond the repair which is recommended. Frequently, a
problem does not exist in isolation. The problem can be a result of wear or of damage to several parts
which operate together as part of a system.
Service personnel may remember similar complaints which were corrected by a previous method of
troubleshooting. A similar complaint can have a different cause.
Get a good description of the problem from the operator and/or the person that owns the vehicle.
Knowing the details of the problem can save time. This will make the repair job faster and easier.
All possible problems and the probable causes cannot be listed. The technician must follow a logical
process of eliminating possible causes and of identifying the specific causes of the problems.
Troubleshooting The Fuel Injection Nozzles On The Engine

Note: Be careful when you are handling the fuel injection nozzles in order to prevent damage to the
orifices, the threads, and other surfaces. When a fuel injection nozzle is installed, make sure that all
surfaces and threads are clean.
Only personnel that have the proper training should disassemble the fuel injection nozzles. Only
personnel that have the proper training should perform repairs to the fuel injection nozzle.
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i05182663
Troubleshooting
SMCS - 1000
Introduction
Troubleshooting can be difficult. To make a repair to a problem, refer to the possible cause and the
corrective action. The most common problems are identified in this troubleshooting manual. The
symptoms, causes, and guidance for solving the problems are given.
The list of problems, causes, and corrections will only give an indication of the location of a possible
problem. There is also a list that shows some of the repairs that are required.
Sometimes additional repair work is required beyond the repair which is recommended. Frequently, a
problem does not exist in isolation. The problem can be a result of wear or of damage to several parts
which operate together as part of a system.
Service personnel may remember similar complaints which were corrected by a previous method of
troubleshooting. A similar complaint can have a different cause.
Get a good description of the problem from the operator and/or the person that owns the vehicle.
Knowing the details of the problem can save time. This will make the repair job faster and easier.
All possible problems and the probable causes cannot be listed. The technician must follow a logical
process of eliminating possible causes and of identifying the specific causes of the problems.
Troubleshooting The Fuel Injection Nozzles On The Engine

Note: Be careful when you are handling the fuel injection nozzles in order to prevent damage to the
orifices, the threads, and other surfaces. When a fuel injection nozzle is installed, make sure that all
surfaces and threads are clean.
Only personnel that have the proper training should disassemble the fuel injection nozzles. Only
personnel that have the proper training should perform repairs to the fuel injection nozzle.
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i04046709
Turbocharger - Inspect
SMCS - 1052-040
Hot engine components can cause injury from burns. Before

performing maintenance on the engine, allow the engine and the
components to cool.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE

containing fluids.

Cat products.
Before you begin inspection of the turbocharger, be sure that the inlet air restriction is within the
specifications for your engine. Be sure that the exhaust system restriction is within the specifications
for your engine. Refer to Systems Operation, Testing and Adjusting, "Air Inlet and Exhaust System -
Inspect".
The condition of the turbocharger will have definite effects on engine performance. Use the following
inspections and procedures to determine the condition of the turbocharger.
• Inspection of the compressor wheel and the compressor housing
• Inspection of the turbine wheel and the turbine housing
• Inspection of the wastegate
Inspection of the Compressor Wheel and the Compressor

Housing
Typical example
(1) Turbine housing
(2) Compressor housing
1. Remove the air cleaner from the compressor inlet.
2. Inspect compressor wheel for damage from a foreign object. If there is damage, determine the
source of the foreign object. As required, clean the inlet system and repair the intake system.
Replace the turbocharger. If there is no damage, go to Step 4.
3. Turn the rotating assembly by hand. While you turn the assembly, push the assembly sideways.
The assembly should turn freely. Compressor wheel (2) should not rub compressor housing (1).
The turbocharger must be replaced if the compressor wheel rubs the compressor housing. If
there is no rubbing or scraping, go to Step 4.
4. Inspect compressor wheel (2) and compressor housing (1) for oil leakage. An oil leak from the
compressor wheel may deposit oil in the aftercooler (if equipped). Drain and clean the
aftercooler if you find oil in the aftercooler.
a. Check the oil level in the crankcase. If the oil level is too high, adjust the oil level.
b. Inspect the air cleaner element for restriction. If restriction is found, correct the problem.
c. Inspect the engine crankcase breather. Clean the breather or replace the breather if the
breather is plugged.
d. Remove the oil drain tube. Inspect the oil drain hole and the oil drain tube for oil sludge.
Inspect the area between the bearings of the rotating assembly shaft. If necessary, clean
the rotating assembly shaft, the oil drain hole, and the oil drain tube.
e. If Steps 4.a through 4.d did not reveal the source of the oil leakage, the turbocharger has
internal damage. Replace the turbocharger.
Inspection of the Turbine Wheel and the Turbine Housing
Typical example
(1) Turbine housing
(2) Turbine wheel
1. Remove the air piping from the turbine housing.
2. Inspect turbine wheel (2) for damage by a foreign object. If there is damage, determine the
source of the foreign object. Replace the turbocharger. If there is no damage, go to Step 3.
3. Clean turbine wheel (2) and turbine housing (1) if you find buildup of carbon or foreign
material. If there is no buildup of carbon or foreign material, go to Step 4.
4. Turn the rotating assembly by hand. While you turn the assembly, push the assembly sideways.
The assembly should turn freely. Turbine wheel (2) should not rub turbine housing (1). Replace
the turbocharger if the turbine wheel rubs the turbine housing. If there is no rubbing or
scraping, go to Step 5.
5. Inspect turbine wheel (2) and turbine housing (1) for oil leakage and oil coking. Some oil
coking may be cleaned. Heavy oil coking may require replacement of the turbocharger. If the
oil is coming from the turbocharger center housing go to Step 5.a. Otherwise go to "Inspection
of the Wastegate".
a. Remove the oil drain tube. Inspect the oil drain hole and the oil drain tube for oil sludge.
Inspect the area between the bearings of the rotating assembly shaft. If necessary, clean
the rotating assembly shaft, the oil drain hole, and the oil drain tube.
b. If crankcase pressure is high, or if the oil drain is restricted, pressure in the center
housing may be greater than the pressure of turbine housing (1). Oil flow may be forced
in the wrong direction and the oil may not drain. Check the crankcase pressure and
correct any problems.
c. If the oil drain tube is damaged, replace the oil drain tube.
d. Check the routing of the oil drain tube. Eliminate any sharp restrictive bends. Make sure
that the oil drain tube is not too close to the engine exhaust manifold.
e. If Steps 5.a through 5.d did not reveal the source of the oil leakage, the turbocharger has
internal damage. Replace the turbocharger.
Inspection of the Wastegate

The wastegate controls the amount of exhaust gas that is allowed to bypass the turbine side of the
turbocharger. This valve then controls the rpm of the turbocharger.
When the engine operates in conditions of low boost (lug), a spring presses against a diaphragm in the
canister. The actuating rod will move and the wastegate will close. Then, the turbocharger can operate
at maximum performance.
When the boost pressure increases against the diaphragm in the canister, the wastegate will open. The
rpm of the turbocharger becomes limited. The rpm limitation occurs because a portion of the exhaust
gases bypass the turbine wheel of the turbocharger.
The following levels of boost pressure indicate a problem with the wastegate:
• Too high at full load conditions
• Too low at all lug conditions
The boost pressure controls the maximum rpm of the turbocharger, because the boost pressure
controls the position of the wastegate. The following factors also affect the maximum rpm of the
turbocharger:
• The engine rating
• The horsepower demand on the engine
• The high idle rpm
• Inlet air restriction
• Exhaust system restriction
Check the Wastegate for Proper Operation

Table 1
Required Tools
Tool Part Number Part Description QTY
A 8T-5096 Dial Indicator Group 1
Note: The turbocharger is a nonserviceable item. The pressure for the wastegate can be checked, but
not adjusted.
1. Remove the heat shield from the turbocharger. Remove the guard for the wastegate.
Typical example
2. Remove the boost line (3) from the wastegate (2). Connect an air supply to the wastegate that
can be measured accurately.
3. Fasten a dial indicator to the turbocharger so that the end of the actuator rod (1) is in contact
with the dial indicator. This will measure axial movement of the actuator rod.
4. Slowly apply air pressure to the wastegate (2) so that the actuator rod (1) moves 1.0 mm (0.039
inch). The air pressure should be within 107 to 117 kPa (15.5 to 17.0 psi). Ensure that the dial
indicator returns to zero when the air pressure is released. Repeat the test several times. This
will ensure that an accurate reading is obtained.
5. If the operation of the wastegate (2) is incorrect then the turbocharger must be renewed.
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Specifications
i04048910
Turbocharger
SMCS - 1052
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - KBS1-UP
S/N - KHR1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Typical example
(1) Turbocharger
(2) Actuator rod (if equipped)
(3) Actuator (if equipped)
The maximum test pressure for the wastegate (if equipped) ... 125 kPa (18 psi)
The movement for the rod actuator (if equipped) ... 3 mm (0.118 inch)
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i04000853
Using Caterpillar Electronic Technician to Determine

Diagnostic Codes
SMCS - 0785-UE; 7569
Connect the Caterpillar ET to the machine. Turn the key switch to the RUN position. Start the Cat
ET. The Cat ET will initiate communications with the Electronic Control Modules on the machine.
After communication has been established, the Cat ET will list the Electronic Control Modules.
Choose the desired Electronic Control Module. After the diagnostic codes have been determined with
the Cat ET, see the test procedure for the corresponding diagnostic code.
ReferenceTroubleshooting, "Service Tools"
Active Diagnostic Codes
Typical Cat ET screen for active diagnostic codes
The following procedures may cause new diagnostic codes to be logged. Therefore, before any
procedures that are performed, make a list of all the active diagnostic codes in order to determine the
system problems. Clear the diagnostic codes that were caused by the procedure, when each procedure
is complete.
Note: Before performing a procedure, always check all the circuit breakers. Repair the cause of any
circuit breaker that is tripped.
A screen is provided in Cat ET for active diagnostic codes. The screen will display the diagnostic
codes that are active. Active diagnostic information shall include a component identifier (CID), a
failure mode identifier (FMI) and a text description of the problem.
Logged Diagnostic Codes
Typical Cat ET screen for logged diagnostic codes
A screen is provided in Cat ET for logged diagnostic codes. The screen will display diagnostic codes
that are logged. The Cat ET will log diagnostic codes that are intermittent. The logged diagnostic data
shall include a component identifier (CID), a failure mode identifier (FMI), and a text description of
the problem. Also, the logged diagnostic data shall include the number of occurrences of the problem
and two time stamps. The time stamp displays the first occurrence of the problem and the time stamp
displays the most recent occurrence of the problem.
Diagnostics are logged in non-volatile memory. On powerup, the ECM will clear any diagnostic
codes that have not been detected or active within the last 150 hours of machine operation.
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Troubleshooting
320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i03928529
Using the Operator Monitor to Determine Diagnostic Codes

SMCS - 7490
Use the following illustration to operate the monitor.
(1) Up key
(2) Right key
(3) Home key
(4) Main menu key
(5) Left key
(6) Down key
(7) Back key
(8) OK key
The "DIAGNOSTIC" menu option is entered by selecting "DIAGNOSTIC" from the "SERVICE"
menu. Press the up key (1) or down key (6) until "DIAGNOSTIC" is highlighted in order to select
this option. Then press the "OK" key (8). Refer to Illustration 1.
Note: Refer to Systems Operation, RENR8068, "Service Mode" for instructions to get to the
"SERVICE" menu.
When "DIAGNOSTIC" is selected, the diagnostic information can be checked. The "DIAGNOSTIC"
menu has the following options:
• ACTIVE ERROR
• LOGGED ERROR
• LOGGED EVENT
The "ACTIVE ERROR" menu displays active errors in the MID: CID - FMI format. Press the up key
(1) or down key (6) in order to scroll through the active errors.
The "LOGGED ERROR" menu displays logged errors in the MID: CID - FMI format. Press the up
key (1) or down key (6) in order to highlight the desired item. Press the "OK" key (8) in order to see
the detail of the logged error. The detail of a logged error will display the following items:
MID - Control module ID of the ECM that detected the error.
CID - Component ID that is in error status.
FMI - Failure mode ID
OCC - The number of times the error occurred.
FIRST - The first time the error occurred.
LAST - The last time the error occurred.
When the detailed view of the "LOGGED ERROR" view is displayed as in Illustration 4, the logged
errors can be deleted. Press the "OK" key (8) in order to delete the logged error. The delete
confirmation screen will appear. To confirm the delete request move the cursor to the "YES" option
and press the "OK" key (8). Refer to Illustration 5.
The "LOGGED EVENT" menu displays logged events in the MID: EID - LEVEL format. Press the
up key (1) or down key (6) in order to highlight the desired item. Press the "OK" key (8) in order to
see the detail of the logged event. The detail of a logged event will display the following items:
MID - Control module ID of the ECM that detected the error.
EID - Event ID
LEVEL - Warning Level
OCC - The number of times the error occurred.
FIRST - The first time the error occurred.
LAST - The last time the error occurred.
When the detailed view of the "LOGGED EVENT" menu is displayed as in Illustration 6, the logged
events can be deleted. Press the "OK" key (8) in order to delete the logged error. The delete
confirmation screen will appear. To confirm the delete request move the cursor to the "YES" option
and press the "OK" key (8). Refer to Illustration 7
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i04046712
Valve Depth - Inspect

SMCS - 1105-040
Table 1
Required Tools
A 8T-0455 Liner Projection Tool Group 1
(1) Dial indicator
(2) Gauge body
(3) Gauge block
1. Use the Tooling (A) to check the depths of the inlet valves and the exhaust valves below the
face of the cylinder head. Use the gauge block (3) to zero the dial indicator (1) .
2. Ensure that the face of the valves are clean. Ensure that the bottom face of the cylinder head is
clean. Ensure that the cylinder head is not distorted. Refer to Systems Operation, Testing and
Adjusting, "Cylinder Head - Inspect" for the procedure to measure flatness of the cylinder head.
Typical example
Measurement of the valve depth
(1) Dial indicator
(2) Gauge body
3. Position gauge body (2) and dial indicator (1) in order to measure the valve depth. Measure the
depth of the inlet valve and the exhaust valve before the valve springs are removed.
4. For the minimum and maximum limits for a new engine for the inlet valves and the exhaust
valves, refer to Specifications, "Cylinder Head".
5. Service wear occurs on an engine which has been in operation. If the valve depth below the
cylinder head face on a used engine exceeds the specification for service wear, the following
components must be replaced.
◦ Valves
◦ Valve inserts
For the wear limits for the inlet valves and exhaust valves, refer to Specifications, "Cylinder
Head".
6. Check each valve for cracks. Check the stems of the valves for wear. Ensure that the valves are
the correct fit in the valve guides. Refer to Systems Operation, Testing and Adjusting, "Valve
Guide - Inspect" for the procedure to inspect the valve guides.
7. Check the load on the valve springs. Refer to Specifications, "Cylinder Head Valves" for the
correct lengths and specifications for the valve springs.
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i04046714
Valve Guide - Inspect

SMCS - 1104-040
Perform this test in order to determine if a valve guide should be replaced.
Measure the radial movement of the valve in the valve guide.
(1) Valve guide
(2) Radial movement of the valve in the valve guide
(3) Valve stem
(4) Dial indicator
(5) Valve head
1. Place a new valve in the valve guide.
2. Place a dial indicator with a magnetic base on the face of the cylinder head.
3. Lift the edge of the valve head to a distance of 15.0 mm (0.60 inch).
4. Move the valve in a radial direction away from the dial indicator. Make sure that the valve
moves away from the dial indicator as far as possible. Position the contact point of the dial
indicator on the edge of the valve head. Set the position of the needle of the dial indicator to
zero.
5. Move the valve in a radial direction toward the dial indicator as far as possible. Note the
distance of movement which is indicated on the dial indicator. If the distance is greater than the
maximum clearance of the valve in the valve guide, replace the valve guide. Refer to
Specifications, "Cylinder Head Valves" for the clearances.
When new valve guides (1) are installed, new valves and new valve seat inserts must be installed. For
more information, contact your distributor or your dealer.
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Specifications
i04164800
Valve Mechanism Cover

SMCS - 1107
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - KBS1-UP
S/N - KHR1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Typical example
Tighten the bolts for the valve mechanism cover in the sequence that is shown in illustration 1 to the
following torque. ... 22 N·m (16 lb ft)
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i04046787
V-Belt - Test
SMCS - 1357-025; 1357-081; 7320-081-BE
Table 1
Required Tools
A 144-0235 Belt Tension Gauge 1
Table 2
Belt Tension Chart
Gauge Reading
Size of Belt Width of Belt
Initial Belt Tension (1) Used Belt Tension (2)
1/2
13.89 mm (0.547 inch) 535 N (120 lb) 355 N (80 lb)
Measure the tension of the belts.
(1)
Initial Belt Tension refers to a new belt.
(2)
Used Belt Tension refers to a belt that has been in operation for 30 minutes or more at the rated speed.
Install Tooling (A) at the center of the longest free length of belt and check the tension on both belts.
Check and adjust the tension on the tightest belt. To adjust the belt tension, refer to Disassembly and
Assembly, "Alternator - Install".
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i04047270
Vibration Damper - Check

SMCS - 1205-535
The vibration damper is installed on the front of the crankshaft. The vibration damper is installed in
order to help remove torsional vibration in the engine.
Vibration damper with hub assembly
(1) Damper setscrews
(2) Vibration damper
(3) Setscrews for the adapter
(4) Crankshaft adapter and pulley
Replace the vibration damper if any of the following conditions exist:
• There is any impact damage to the outer casing.
• There is leakage of the viscous fluid from the cover plate.
• There is movement of the pulley or the outer ring on the hub.
• There is a large amount of gear train wear that is not caused by lack of oil.
• Analysis of the engine oil has revealed that the front main bearing is badly worn.
• The engine has had a failure because of a broken crankshaft.
Check the areas around the holes for the bolts in the vibration damper for cracks or for wear and for
damage.
Use the following steps in order to check the alignment and the runout of the vibration damper:
1. Remove any debris from the front face of the vibration damper. Remove any debris from the
circumference of the vibration damper.
2. Mount the dial indicator on the front cover. Use the dial indicator to measure the outer face of
the vibration damper. Set the dial indicator to read 0.00 mm (0.00 inch).
3. Rotate the crankshaft at intervals of 45 degrees and read the dial indicator.
4. The difference between the lower measurements and the higher measurements that are read on
the dial indicator at all four points must not be more than 0.18 mm (0.007 inch).
If the reading on the dial indicator is more than 0.18 mm (0.007 inch), inspect the pulley and
the vibration damper for damage. If the pulley or the vibration damper are damaged, use new
parts for replacement.
5. Move the dial indicator so that the dial indicator will measure the circumference of the
vibration damper. Set the dial indicator to read 0.00 mm (0.00 inch).
6. Slowly rotate the crankshaft in order to measure the runout of the circumference of the
vibration damper. Use the highest reading and the lowest reading on the dial indicator. The
maximum and the minimum readings on the dial indicator should not vary more than 0.12 mm
(0.005 inch).
If the reading on the dial indicator is more than 0.12 mm (0.005 inch), inspect the pulley and
the vibration damper for damage. If the pulley or the vibration damper are damaged, use new
parts for replacement.
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Specifications
i04051330
Vibration Damper and Pulley

SMCS - 1205
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - KBS1-UP
S/N - KHR1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Typical example
(1) Tighten the damper setscrews to the following torque. ... 115 N·m (84 lb ft)
(2) Vibration damper
(3) Tighten the setscrews for the adapter to the following torque. ... 40 N·m (30 lb ft)
(4) Crankshaft adapter and pulley
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i01134573
Visual Inspection
SMCS - 5050-040
A visual inspection of the system is the first step in order to troubleshoot a problem. Shut off the
engine and lower all implements to the ground before performing the visual inspection.
1. Check the oil level in the hydraulic tank. Slowly loosen the fill/vent plug and release the
pressure before the fill/vent plug is removed.
NOTICE

containing fluids.

2. Remove the hydraulic filter elements. Inspect the hydraulic filters for material that would give
an indication of damage to a component.
3. Inspect all lines and connections for damage or leaks.
4. Inspect control linkages for bent components, broken components or damaged components.
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Specifications
i02363605
Water Pump
SMCS - 1361
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - KBS1-UP
S/N - KHR1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Tightening sequence
Tighten the setscrews in the numerical sequence that is shown in illustration 1 to the following torque.
... 22 N·m (16 lb ft)
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i02414647
Water Temperature Regulator - Test

SMCS - 1355-081-ON; 1355-081
Personal injury can result from escaping fluid under pressure.
If a pressure indication is shown on the indicator, push the release valve

in order to relieve pressure before removing any hose from the radiator.
1. Remove the water temperature regulator from the engine. Refer to Disassembly and Assembly
Manual, "Water Temperature Regulator - Remove and Install".
2. Heat water in a pan until the temperature of the water is equal to the fully open temperature of
the water temperature regulator. Refer to Specifications, "Water Temperature Regulator" for the
fully open temperature of the water temperature regulator. Stir the water in the pan. This will
distribute the temperature throughout the pan.
3. Hang the water temperature regulator in the pan of water. The water temperature regulator must
be below the surface of the water. The water temperature regulator must be away from the sides
and the bottom of the pan.
4. Keep the water at the correct temperature for ten minutes.
5. After ten minutes, remove the water temperature regulator. Immediately measure the opening
of the water temperature regulator. Refer to Specifications, "Water Temperature Regulator" for
the minimum opening distance of the water temperature regulator at the fully open temperature.
If the distance is less than the amount listed in the manual, replace the water temperature regulator.
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Specifications
i02953189
Water Temperature Regulator and Housing

SMCS - 1355; 1393
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - KBS1-UP
S/N - KHR1-UP
S/N - LCA1-UP
S/N - LMA1-UP
S/N - MDJ1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - PBB1-UP
S/N - RAR1-UP
S/N - SDZ1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Typical example
(1) Tighten the bolts that fasten the housing to the following torque. ... 44 N·m (32 lb ft)
(2) Water temperature regulator housing
(3) Water temperature regulator
Opening temperature ... 82° to 87°C (180° to 189°F)

Full opening temperature ... 95 °C (203 °F)
Minimum stroke at full temperature ... 9 mm (0.3543 inch)
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320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05812177
Wiring Harness (Open Circuit) - Test

SMCS - 1408-081
An open circuit is a failure that results in no current flow. An open circuit can be caused by:
• Poor connections
• Broken wires
Open Circuit Test

Table 1
Values
Troubleshooting Steps Results
1. Identify Open Circuit OK - The resistance

is < 5 Ω.
A. Identify the connectors and wires in the suspect circuits. The circuit is not
Use the machine Electrical Schematic. open.
B. Turn off the keyswitch and the disconnect switch. <5Ω STOP
C. Disconnect the component and the ECM from the harness. Not OK - The
resistance is ≥ 5K Ω.
D. At one of the disconnected harness connections, place a The circuit is open (2).
jumper wire from the suspect wire contact to frame ground.
Repair:
Repair or replace the

E. At the other connector of the harness, measure the resistance
harness.
from the suspect wire contact to frame ground (1).
STOP
(1)
Use a calibrated digital multimeter for this check.
(2)
A resistance ≥ 5 Ω but < 5K Ω, indicates a loose or corroded connection. A resistance ≥ 5K Ω indicates an open.
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320D, 320D2, 321C, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2,
i05817010
Wiring Harness (Short Circuit) - Test

SMCS - 1408-081
A short circuit is a circuit failure resulting in undesired current, usually a circuit bypass across a load.
For example: a short across the circuit wires for a lamp produces too much current in the wires, but no
current to the lamp. The lamp circuit is shorted.
Note: Normal circuit resistance can vary, but the normal resistance between a particular circuit and
other unrelated circuits is always ≥ 5K Ω.
Short Circuit Test

Table 1
Values
Troubleshooting Test Steps Results
1. Identify Short Circuit

OK - All resistance is ≥ 5K Ω.
A. Identify the connectors and wire numbers of
STOP
the suspect circuits (1).
≥ 5K Ω Not OK - A resistance is < 5 Ω .
B. Turn off the keyswitch and disconnect
There is a short between the suspect
switch.
wire and the low resistance wire (2).
C. Disconnect the component and ECM from
Repair:
the harness.
D. At the harness connector for the ECM, place
a multimeter probe on the suspect wire contact.
E. Use the other multimeter probe to check the

STOP
resistance across all other ECM connector
contacts and frame ground.
(1)
Use the machine Electrical Schematic.
(2)
A resistance ≥ 5 Ω but < 5K Ω , indicates a loose or corroded connection. A resistance ≥ 5K Ω indicates an open.
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Specifications
i03907004
Accessory Drive
SMCS - 1207
S/N - DFM1-UP
S/N - DNP1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - KHR1-UP
S/N - LMA1-UP
S/N - NBT1-UP
S/N - TMF1-UP
S/N - XBB1-UP
S/N - YEA1-UP
S/N - ZCS1-UP
Typical example
(1) Tighten the allen head screws to the following torque. ... 22 N·m (16 lb ft)
(2) Tighten the allen head screws to the following torque. ... 78 N·m (58 lb ft)
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i05865063
Accumulator (Pilot) - Test and Charge

SMCS - 5077-081-PS; 5077-081-PX; 5077-045-PS
Pressurized System!
Hydraulic accumulators contain gas and oil under high pressure. DO

NOT disconnect lines or disassemble any component of a pressurized
accumulator. All gas pre-charge must be removed from the
accumulator as instructed by the service manual before servicing the
accumulator or any accumulator component.
Failure to follow the instructions and warnings could result in personal

injury or death.
Only use dry nitrogen gas to recharge accumulators. See your Cat
dealer for special equipment and detailed information for accumulator
service and charging.
NOTICE

containing fluids.

Cat products.
Specification
Gas pressure is variable with temperature. Check the temperature of the air around the accumulator.
In order to check the amount of charge in an accumulator, the accumulator must be at the same
temperature as the surrounding air.
Note: The temperature of the accumulator may change as the accumulator is being charged due to the
expansion or compression of the nitrogen charge. It may be necessary to charge the accumulator in
several steps in order to ensure a correct charge.
Table 1
Charge Pressures and Temperatures
Temperature Pressure
−25°C (−13°F) 1490 kPa (216 psi)
−20°C (−4°F) 1520 kPa (220 psi)
−15°C (5°F) 1550 kPa (225 psi)
−10°C (14°F) 1580 kPa (229 psi)
−5°C (23°F) 1610 kPa (233 psi)
0°C (32°F) 1640 kPa (238 psi)
5°C (41°F) 1670 kPa (242 psi)
10°C (50°F) 1700 kPa (247 psi)
15°C (59°F) 1730 kPa (251 psi)
20°C (68°F) 1760 kPa (255 psi)
25°C (77°F) 1790 kPa (260 psi)
30°C (86°F) 1820 kPa (264 psi)
35°C (95°F) 1850 kPa (268 psi)
40°C (104°F) 1880 kPa (273 psi)
45°C (113°F) 1910 kPa (277 psi)
50°C (122°F) 1940 kPa (281 psi)
Introduction
The accumulator stores pilot pressure oil for use at the main control valves. During multiple
operations, the pilot system will demand more oil in order to maintain valve operation. The
accumulator provides pilot pressure oil to the pilot system, when the pilot pump flow is inadequate.
Inadequate flow will cause sluggish implement control.
Required Tools
Tooling (A)
This tooling group is used to test the pressure in the pilot manifold.
Table 2
Pressure Gauge
A1 1 8T-0856
(0 to 6,000 kPa (0 to 870 psi))
A A2 1 6V-3989 Fitting
A3 2 6V-4143 Quick Connect Coupler
A4 1 177-7860 Hose As
F1 1 6V-3965 Fitting
F
F2 1 3J-1907 O-Ring Seal
Test Procedure
Preliminary Test
1. Start the engine. Place the hydraulic lockout lever in the UNLOCKED position.
2. Position the implements 1 m (3.3 ft) from the ground.
3. Shut off the engine by turning the start switch to the OFF position. When the engine has
stopped, return the start switch to the ON position.
4. Move the joysticks in order to lower the implements. When the accumulator circuit is
functioning properly, there will be enough stored energy for approximately 20 seconds after a
power loss in order to lower the implements to the ground safely.
5. If the preliminary test fails and the implements are unable to be lowered to the ground safely
after a power loss, proceed to test the accumulator circuit. Refer to "Testing the Accumulator
(Nitrogen Gas Charge)".
Testing the Accumulator (Nitrogen Gas Charge)

Note: Some accumulators do not have a charge pressure port. This type of accumulator cannot be
recharged. The accumulator must be replaced. Replacement accumulators are equipped with a charge
pressure port.
Cap for charging port on accumulator
1. Refer to Special Instruction, REHS5464, "Accumulator Discharging and Charging Procedures"

for the testing and charging procedure.
Note: If the pressure reading is within the specifications of Table 1, continue to test the operation of
the check valve within the pilot manifold. Refer to "Testing the Check Valve (Pilot Manifold)".
Testing the Check Valve (Pilot Manifold)
Typical example 1
Location of the check valve in the pilot manifold
Typical example 2
Location of the check valve in the pilot manifold
If the check valve does not close properly during a loss of pilot pressure, the accumulator precharge
pressure will exhaust before being able to provide lowering of the implements.
Note: Make sure that the accumulator has a proper nitrogen gas charge before attempting to test the
check valve. An improperly charged accumulator may give indications of a problem with the check
valve.
1. Stop the engine. Release the pressure from the pilot hydraulic system. Refer to Testing and
Adjusting, "Hydraulic System Pressure - Release".
2. Connect a 6000 kPa (800 psi) pressure gauge to port "PSA2" on the pilot manifold. Use tooling
group (A) and tooling group (F) .
3. Start the engine and place the hydraulic lockout lever in the UNLOCKED position.
4. Shut off the engine by turning the start switch to the OFF position. When the engine has
stopped, return the start switch to the ON position.
5. After the power loss, the accumulator will still have pilot system pressure. Use the stopwatch to
observe the pilot pressure. The pilot pressure should stay above 1035 kPa (150 psi) within 20
seconds. This pressure ensures that enough stored energy is available to lower the implements
to the ground.
Note: When the pilot pressure in the accumulator is approximately 860 kPa (125 psi), the
pressure will suddenly drop to zero. This sudden drop occurs because no oil is left in the
accumulator.
6. If the pilot pressure in the accumulator is below 1035 kPa (150 psi) or the pilot supply is
exhausted in less than 20 seconds, the check valve within the pilot manifold is not working
properly.
7. Move the joysticks in order to release any pilot hydraulic pressure in the accumulator.
8. Turn the start switch to the OFF position.
9. Clean the check valve. The check valve is located behind the plug on the pilot manifold. Repeat
steps 3 through 5. If the test fails, replace the check valve.
Charge Procedure
1. Refer to Special Instruction, REHS5464, "Accumulator Discharging and Charging Procedures".
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Specifications
i04400546
Accumulator (Pilot)
SMCS - 5077-PS
S/N - A6F1-UP
S/N - A8F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DFM1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DNP1-UP
S/N - EKT1-UP
S/N - FAL1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - HDM1-UP
S/N - JEG1-UP
S/N - JFM1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - JZA1-UP
S/N - KBS1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KHR1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - KZF1-UP
S/N - LCA1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MDJ1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NBF1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBB1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - RAC1-UP
S/N - RAR1-UP
S/N - SDC1-UP
S/N - SDZ1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - TDN1-UP
S/N - TMF1-UP
S/N - WBF1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - XBB1-UP
S/N - XBK1-UP
S/N - YCR1-UP
S/N - YEA1-UP
S/N - YSD1-UP
S/N - ZCS1-UP
S/N - ZMF1-UP
Table 1
Specification for 4I-1536 Hydraulic Accumulator Gp and 199-7447 Hydraulic Accumulator
Gp
1 1 4I-5862 Cap Torque to 10 ± 1 N·m (89 ± 9 lb in).

SM Cat 320d2 Full

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320D2 Excavator DFM00001-UP (MACHINE) POWERED BY C7.1 Engine(SEBP6240...

Tighten the clamp to

Testing and Adjusting

Air in Fuel - Test

2P-8278 Tube As (Sight Gauge)

(3) Excessive air bubbles in the fuel are not acceptable.

Testing and Adjusting

Air Inlet and Exhaust System - Inspect

Hot engine components can cause injury from burns. Before

When working on an engine that is running, avoid contact with hot

Testing and Adjusting

3. Start the engine and run the engine at full throttle.

Less than the Replace the Turn on all accessories. If -

◦ The battery charge

◦ The ambient temperature

◦ The speed of the engine

Refer to the Fault Conditions And Possible Causes in Table 1.

Alternator and Regulator

12 Volt and 24 Volt Alternator

Rotation ... clockwise

Polarity ... Negative earth

Testing and Adjusting

The charging unit will be damaged if the connections between the

Boom - 5.675 m (18.6188 ft)

(1) Stick cylinder group

(2) Stick group

(3) Boom cylinder group

Boom Cylinder Lines

Distance from the centerline of the mounting pin to the center

Boom Cylinder Lines

Right side view

Bore before assembly is

Bore before assembly is

202-6996 Hose Torque to

Distance between the center of the mounting bolts and the

Right side view

Bucket Cylinder Lines

Distance from the centerline of the mounting pin to the support

Bucket Cylinder Lines

9X-6032 Bolt Torque to

Bucket Cylinder Lines

5I-4216 Hose As Torque to

Inside diameter before assembly 80.20 ± 0.04 mm (3.157

3B-8489 Grease Torque to

Bucket Linkage - B1 Family

Testing and Adjusting

Using Caterpillar Electronic Technician

Location of the ET Connector

(Behind Operator Seat, Below Right Console)

(2) Right Console

(3) Back of Operator Seat (Shifted Forward for access)

(4) Backup Control Switches

1. Select the Machine ECM.

Typical screen for accessing calibrations

2. Select "Service" from the main menu.

3. Select "Calibrations" from the "Service" drop-down menu.

◦ "PRV - Main Pump Flow Limitation Pressure Calibration"

◦ "PRV - Power Shift Pressure Calibration"

◦ "Modulation Input Calibration"

◦ "PRV - Variable Relief Pressure Calibration"

◦ "PRV - Attachment Valves Pressure Calibration"

◦ "Engine Speed Calibrations"

5. Follow the instructions that are provided on the screen.