Engine and Pump Control - Systems Operation, Testing and Adjusting 320 C

RENR3814-04
CATERPILLAR November 2001
312C, 315C, 320C, 322C,

325C and 330C Excavators
Engine and Pump Control
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to. other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as
"DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below.
WARNING
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Caterpillar is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Caterpillar dealers have the most current information available. For a list of the most
current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.
WARNING
When replacement parts are required for this
product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
3
Table of Contents
Table of Contents Warning "Fuel Leftover Is Little" Is Displayed -

Troubleshoot (CID 96) , 123
Warning "Engine Coolant Temperature Is High" Is
Displayed-Troubleshoot (CID 110) 130
Systems Operation Section Warning "Hydraulic Oil Temperature Is High" Is
Displayed - Troubleshoot (CID 600) 138
Electrical System
Warning "Engine Oil Pressure Is Low" Is Displayed -
General Information (Electrical System) 5
Troubleshoot (CID 286 (325C and 330C)) 146
Power Circuit 9
Warning "Air Cleaner Filter Is Clogged" Is Displayed -
Start and Stop Circuit 14
Troubleshoot 152
Starting Aid Circuit 19
Warning "Engine Coolant Level Is Low" Is Displayed -
Charging Circuit 22
Troubleshoot 157
Low Current Circuit 25
Warning "Hydraulic Oil Level Is Low" Is Displayed -
Troubleshoot 162
Electronic Control System
Warning "Engine Oil Level Is Low" Is Displayed -
General Information (Electronic Control System).. 26
Troubleshoot 168
Engine and Pump Regulation 33
Warning "Return Filter Is Clogged" Is Displayed -
Pump Regulation 34
Troubleshoot 175
Engine Speed Control 35
Warning "Battery Charge Is Abnormal" Is Displayed
Automatic Engine Control 36
While Engine Is Running - Troubleshoot (CID
One Touch Low Idle 37
167) 182
Tool Control 38
Check of Speed Sensor - Troubleshoot (CID
Straight Travel Control . 39
190) 185
Engine Speed Protection 40
Battery Voltage Is Abnormal - Troubleshoot (CID
Swing Lock System 42
Backup System 43
168) 188
Engine Speed Dial Does Not Work - Troubleshoot
Monitoring System 44
(CID 586) 196
Engine and Hydraulic Pump Controller 46
Low Idle Switch Does Not Work - Troubleshoot.. 206
Operator Monitor 52
AEC Is Abnormal - Troubleshoot 213
Switches 53
Check of Governor Actuator - Troubleshoot (CID 91
Sensors 56
(325C)) 220
Senders 57
Check of Feedback Signal From Governor Actuator -
Solenoid Valves 58
Troubleshoot (CID 587) 223
Governor Actuator Control 59
Check of Fault Alarm - Troubleshoot (CID 2002 for
Related Components 60
320C and 322C or CID 271 for312C, 315C, 325C
and 330C) 232
Testing and Adjusting Section Travel Alarm Is Abnormal - Troubleshoot (CID
376) 238
Testing and Adjusting Automatic Travel Speed Change Is Abnormal -
General Information 61 Troubleshoot (CID 0598, CID 1161, and CID
Service Tools 61 1162) 249
Electrical Components And Connector Swing Is Inoperable - Troubleshoot (CID 374) .... 278
Locations 62 Check of Straight Travel Proportional Reducing Valve
Harness and Wire Identification 62 -Troubleshoot (CID 1525) 304
Using Service Mode 63 Check of Proportional Reducing Valve - Troubleshoot
Adjust Clock Mode 66 (CID 581) 308
ECM Summary Mode 67 Warning "Water Separator Has Water" Is Displayed -
Switch Status Mode 68 Troubleshoot 319
Status Mode 70 Warning "Water Separator Has Water" Is Abnormal -
Configuration Mode 71 Troubleshoot 319
Active Error Mode .... 74 Charging System - Test 326
Logged Error Mode 75 Device Test . 337
Logged Event Mode 76 Governor Actuator Sweep - Test 341
Initial Troubleshooting Procedure 77 Governor Actuator - Replace 343
Using Caterpillar Electronic Technician 78 Governor Actuator - Calibrate 346
Troubleshooting Diagnostic Codes 84 Proportional Reducing Valve Sweep - Test (Power
Check of Controller LED Indicator - Troubleshoot.. 86 Shift) ... 351
No Power Supply to Controller - Troubleshoot 87 Proportional Reducing Valve - Calibrate (Power
Engine Controller Is Abnormal - Troubleshoot Shift) 352
(590) 105 Speed Sensor - Replace 353
Communication Problem Between Controller and Controller- Replace , 355
Monitor - Troubleshoot ("CID 248" and "CID Controller Connector Contact Identification.......... 355
588") 110 Controller Input and Output Values 357
4
Table of Contents
System Schematic 361
Index Section
Index 368
5
Systems Operation Section
Electrical System
General Information (Electrical

System)
SMCSCode: 1406; 1450
ILlustration 1
Schematic Of The Electrical Circuit For The 312C And The 315C
(1) Disconnect switch (12) Neutral start switch (22) Horn
(2) Battery (13) Cab heater (23) Controller
(3) Power circuit (14) Air conditioner (24) Switch panel
(4) Breaker for the alternator (15) Lights (25) Governor actuator
(5) Main relay (16) Windshield wiper (26) Heater control unit
(6) Fuse panel (17) Windshield washer (27) Air heater
(7) Low current circuit (18) Start/stop circuit (28) Charging circuit
(9) Cigar lighter (19) Starter motor (29) Timer relay
(10) Starter control relay (20) Starter relay (30) Neutral start relay
(11) Starter switch (21) Alternator (31) Heater relay
6
Illustration 2
Schematic Of The Electrical Circuit For The 320C Series
(1) Disconnect switch (13) Cab heater (24) Switch panel
(2) Battery (14) Air conditioner (25) Engine shutdown timer
(3) Power circuit (15) Lights (26) Heater control unit
(4) Breaker for the alternator (16) Windshield wiper (27) Air heater
(5) Main relay (17) Windshield washer (28) Charging circuit
(6) Fuse panel (18) Start/stop circuit (29) Timer relay
(7) Low current circuit (19) Starter motor (30) Neutral start relay
(9) Cigar lighter (20) Starter relay (31) Heater relay
(10) Starter control relay (21) Alternator (32) Engine shutdown solenoid
(11) Starter switch (22) Horn
(12) Neutral start switch (23) Controller
7
Illustration 3
Schematic Of The Electrical Circuit For The 322C
(1) Disconnect switch (13) Cab heater (24) Switch panel
(2) Battery (14) Air conditioner (25) Engine coolant temperature switch
(3) Power circuit (15) Lights (26) Start aid solenoid
(4) Breaker for the alternator (16) Windshield wiper (27) Start aid switch
(5) Main relay (17) Windshield washer (28) Charging circuit
(6) Fuse panel (18) Start/stop circuit (29) Timer relay
(7) Low current circuit (19) Starter motor (30) Neutral start relay
(9) Cigar lighter (20) Starter relay (31) Governor actuator
(10) Starter control relay (21) Alternator (32) Heater control unit
(11) Starter switch (22) Horn (36) Heater relay
(12) Neutral start switch (23) Controller (37) Air heater
8
Illustration 4
(1) Disconnect switch (12) Light (23) Neutral Start Switch
(2) Battery (13) Cigar Lighter (24) Start/stop Circuit
(3) Alternator Circuit Breaker (14) Cab Heater (25) Engine Controller
(4) Power Circuit (15) Air Conditioner (26) Heater Relay
(5) Main relay (16) Controller (27) Air heater
(6) Fuse panel (17) Horn (28) Fuel Pump Relay
(7) Low current circuit (18) Timer Relay (29) Fuel Pump
(8) Switch Panel (19) Starter Switch (30) Charge Circuit
(9) Radio (20) Neutral Start Relay (31) Alternator
(10) Wiper (21) Starter Relay
(11) Washer (22) Starter Motor
9
Illustration 5
(1) Disconnect switch (12) Light (23) Neutral Start Switch
(2) Battery (13) Cigar Lighter (24) Start/stop Circuit
(3) Alternator Circuit Breaker (14) Cab Heater (25) Engine Controller
(4) Power Circuit (15) Air Conditioner (26) Heater Relay
(5) Main relay (16) Controller (27) Air heater
(6) Fuse panel (17) Horn (28) Fuel Pump Relay
(7) Low current circuit (18) Timer Relay (29) Fuel Pump
(8) Switch Panel (19) Starter Switch (30) Charge Circuit
(9) Radio (20) Neutral Start Relay (31) Alternator
(10) Wiper (21) Starter Relay (32) Emergency Stop Switch
(11) Washer (22) Starter Motor
The electrical system consists of the following

circuits:
Power Circuit
• Power circuit
SMCSCode: 1401; 1408
• Stop/start circuit
The power circuit supplies electrical power to
• Charging circuit the electrical components of the machine. The
components that are included are listed: the battery,
• Low current circuit the disconnect switch, breaker for the alternator,
and main relay.
10
Illustration 6
Schematic Of The Power Circuit For The 312C And 315C
(1) Batteries (5) Timer relay
(2) Circuit breaker for alternator (6) Start switch
(3) Alternator (7) Fuse panel
(4) Fuse panel (8) Main relay
11
•us&ation7
Schematic Of The Power Circuit For The 320C Series
( 2)Circuit breaker for alternator (6) Start switch
(4)Fuse panel (8) Main relay
12
Illustration 8
Schematic Of The Power Circuit For The 322C
(2) Circuit breaker for alternator (6) Start switch
(4) Fuse panel (8) Main relay
13
lllustration 9
Schematic Of The Power Circuit For The 325C And 330C
(2) Batteries (19) Starter Switch (33) Fuse
(3) Circuit breaker for alternator (31) Alternator
(5) Main Relay (32) Fuse
14
Start and Stop Circuit

SMCSCode: 1450
Illustration 10
Schematic Of The Start/Stop Circuit For The 315C
(1) Batteries (5) Engine shutdown solenoid (9) Neutral start switch
(2) Alternator (6) Timer relay (10) Starter solenoid
(3) Starter relay (7) Starter switch (11) Starter motor
(4) Starter control relay (8) Neutral start relay (12) Engine shutdown timer
15
Illustration 11
Schematic Of The Start/Stop Circuit For The 312C and 320C Series
(1) Batteries (5) Governor actuator (9) Neutral start switch
(2) Alternator (6) Timer relay (10) Starter solenoid
(3) Starter relay (7) Starter switch (11) Starter motor
(4) Starter control relay (8) Neutral start relay
16
Illustration 12
Schematic Of The Start/Stop Circuit For The 322C
(1) Batteries (6) Timer relay (9) Neutral start switch
(2) Alternator (7) Starter switch (10) Starter solenoid
(3) Starter relay (8) Neutral start relay (11) Starter motor
17
Illustration 13
Schematic Of The Start/Stop Circuit For The 325C and 330C
(18) Timer Relay (21) Starter Relay g00824743
(19) Starter Switch (22) Starter Motor (25) Engine Controller
(20) Neutral Start Relay (23) Neutral Start Switch (28) Fuel Pump Relay
(29) Fuel Pump
The start/stop circuit is used to start the engine and • Neutral start relay
the start/stop circuit is used to stop the engine. The
following items are included in the start/stop circuit: • Neutral start switch
• Starter control relay The start/stop circuit also includes a circuit for an
air heater in order to help the engine start in cold
• Starter relay weather. The circuit for the air heater includes the
following items: an air heater, an air heater control
• Starter motor unit, and heater relay.
• Timer relay
• Start switch
• Governor actuator
18
Current is allowed to flow through the timer relay

and the neutral start switch to the neutral start relay
when the starter switch is placed in the ON position
and the control lever is in the LOCKED position. The
coil of the neutral start relay is energized. Current
flows through the neutral start relay to the starter
relay when the starter switch is placed in the START
position. The contacts of the starter relay close and
current flows to terminal "S" of the starter solenoid
from the starter relay.
<
Note: Current will not pass through the starter relay
if the starter switch is placed in the ON position and
the control lever is NOT in the LOCKED position.
Current from the battery will flow through the starter

solenoid to the starter motor when the contacts of
the starter solenoid are closed.
After the engine has started, the alternator will begin

to produce electricity. A current signal is sent from
the "P" terminal of the alternator to the "P" terminal
of the starter relay. Terminal "S" of the starter control
relay will open and the coil of the starter relay will
be deactivated. Then, the starter motor will stop
operating. This action is designed to prevent the
starter motor from rotating too fast.
The timer relay will supply power for a specific

amount of time after the start switch is placed in the
OFF position. The cable of the governor actuator
will move in order to prevent fuel from entering the
engine for a period of 10 seconds. The engine
should stop. After a period of 10 seconds has
elapsed, the cable of the governor actuator will
move allowing fuel to flow to the engine. This action
will allow restarting of the engine. Before the period
of 10 seconds has elapsed and the start switch is
moved to the ON position, the governor actuator
will allow fuel to flow to the engine. The engine may
remain running.
19
Starting Aid Circuit

SMCS Code: 1456
Illustration 14
Schematic For The Circuit Of The Starting Aid For The 312C And 315C
(1) Heater relay (3) Starter switch
(2) Air heater (4) Heater control unit
20
Illustration 15
Schematic For The Circuit Of The Starting Aid For The 320C Series
(1) Heater relay (3) Starter switch
(2) Air heater (4) Heater control unit
21
Illustration 16
Schematic For The Circuit Of The Starting Aid For The 322C Series
(1) Heater relay (4) Heater control unit (7) Start aid switch
(2) Air heater (5) Engine coolant temperature switch
(3) Starter switch (6) Start aid solenoid
22
Illustration 17
Schematic For The Circuit Of The Starting Aid For The 325C and 330C Series
(19) Starter Switch (21) Heater Relay
(25) Engine Controller (27) Air Heater
The circuit for the starting aid is an auxiliary circuit.

This circuit is used to aid the engine in starting i01620312
during cold weather below 10 °C (50 °F).
Charging Circuit
After the starter switch is moved to the ON position, SMCS Code: 1406
the time for preheating is determined by the heater
control unit. The time for preheating is determined The charging circuit of the machine uses an
according to the temperature of the coolant in the alternator to charge the battery during normal
engine. Power is sent to the air heater relay for the operations. The charging circuit also supplies the
amount of time that is determined by the heater low current circuit with power through the fuse
control unit. The contacts of the air heater relay panel.
close and power is sent to the air heater. The
monitor will indicate "Air Heater Operating". This
indication will disappear when heating is no longer
operating. The air heater will also operate with the
starter switch in the "START" position.
23
Illustration 18
Schematic Of The Charging Circuit 312C, 315C, and 320C Series
(1) Batteries (2) Alternator (3) Breaker for the alternator
24
lllustration 19
Schematic Of The Charging Circuit For The 322C
(1) Batteries (2) Alternator (3) Breaker for the alternator
25
Illustration 20
Schematic Of The Charging Circuit For The 325C and 330C
(2) Batteries (3) Breaker for the alternator (31) Alternator
The current from terminal +B of the alternator • The circuit for cigar lighter
travels through the breaker for the alternator and
to the batteries. The alternator supplies current to • The circuit for the washer fluid
the electrical components of the electrical system
through the fuse panel.
Low Current Circuit

SMCSCode: 1400
The low current circuit consists of the following

circuits:
• The circuit for the lights and windshield wiper
• The circuit for the air conditioner
• The circuit for the cab heater
• The circuit for the horn

26
i01620367
General Information
(Electronic Control System)
SMCSCode: 1931
The engine and pump controller will monitor the

machine continuously. The controller will adjust the
speed of the engine and the flow of the hydraulic
pump according to the machine conditions and
the selections of the operator. The control system
consists of the following components: engine and
pump control (controller), tool electronic control,
monitor panel, various switches, relays, sensors,
solenoids, lamps, and alarms.
The engine and pump controller communicates with

the monitor panel via the CAT data link. The monitor
panel will provide the following information to the
operator and/or service persons: the conditions of
the machine systems, diagnostic information, and
adjustment information. The monitor panel is also
used by the operator to select operational functions.
The controller changes the output of the hydraulic

pump according to the load on the machine. This
process is designed to improve the rate of fuel
consumption. The controller will adjust the flow of
hydraulic oil to a tool according to the rate of flow
that is required by the specific tool.
27
lustration 21
Block Diagram Of The Engine And Pump Control System (312C)
28
Illustration 22
29
Illustration 23
Btock Diagram Of The Engine And Pump Control System (320C and 320CU)
30
Illustration 24
31
I g00775375
32
Illustration 25
33
Block Diagram Of The Engine And Pump Control System (325C and330C)
Engine and Pump Regulation

SMCSCode: 1931
Illustration 26
Diagram of Inputs and Outputs for Engine and Pump Regulation
Models 312-322 Illustration 27
(1) Engine speed dial This diagram is of Inputs and Outputs for the 325C and 330C.
(2) Engine and Pump Controller (1) Engine speed dial
(3) Engine (2) Engine and Pump Controller
(4) Speed Sensor (3) Engine
(5) Pump (4) Speed Sensor
(6) Monitor (5) Pump
(7) Governor lever (6) Engine Controller
(8) Hydraulic pump pressure sensor (right) (7) Shift valve
(9) Governor actuator (8) Monitor
(10) Feedback sensor (9) Hydraulic pump pressure sensor (right)
(11) Hydraulic pump pressure sensor (left) (10) Hydraulic pump pressure sensor (left)
(12) Shift valve
Note: The Engine Controller and the Pump Controller
Use Separate Speed Sensors. The Engine ECM
Uses a Separate Speed Sensor.
The controller (2) will determine the power shift

pressure in order to control the pump. The controller
determines the power shift pressure according
to the position of the engine speed dial (1), the
delivery pressure and the engine speed. When the
power shift pressure is high, the output of the pump
will decrease. When the power shift pressure is low,
the output of the pump will increase. The power
shift pressure will remain constant when the engine
speed dial is set between 9 to 5. The power shift
pressure will increase in increments as a setting
of 4 or lower is selected. The power shift pressure
will increase as the engine speed dial is set to a
position lower than 5. The control of an underspeed
condition is performed in the position of 10 of the'
engine speed dial.
34
Control Of An Underspeed
Pump Regulation Condition
SMCSCode: 1931 The underspeed condition is associated with a
position of 10 of the engine speed dial. The 10
position of the engine speed dial is used when
Constant Control of Horsepower a large amount of horsepower is required or a
high travel speed is requested. In this case, it
Constant control of the horsepower is associated is necessary to utilize the underspeed feature
with the 1 to 9 setting of the engine speed dial. when the engine is being operated at a maximum
The flow of the pump is controlled by the power horsepower. The underspeed feature will maintain
shift pressure when the engine speed dial is in the the speed of the engine at approximately maximum
9 through 1 position. The hydraulic output will be power. The controller reads the engine speed and
set according to the position of the engine speed the controller will adjust the power shift pressure in
dial. Control of the pump will be adjusted from one order to regulate the engine speed. The controller
of the following set points: low pressure and middle controls the power shift pressure in the underspeed
pressure high pressure. Even though the pump condition. The engine maintains a speed of
is delivering the maximum flow, the controller will approximately 1950 rpm for the 312C series, 2150
correct the power shift pressure in order to maintain rpm for the 315C series, 1800 rpm for the 320C and
the maximum amount of flow, when the delivery 322C series, and 1800 rpm for the 325C and 330C
pressure of the pump is too low and the proper series in order to achieve the maximum horsepower.
setting of horsepower can not be reached. During Therefore, when the engine speed is higher than the
the delivery of middle pressure and high pressure, full load speed, the output of the pump will increase
the horsepower of the main pump is controlled in and the power shift pressure will decrease. Also,
order to prevent high horsepower of the pump with when the engine speed is lower than the target
lower engine horsepower. The controller receives speed, the output of the pump will decrease and
feedback from the engine speed sensor. The power the power shift pressure will increase.
shift pressure is proportional to the target flow. The
target flow is calculated from the setting of the
engine speed and the pressure of the delivery pump The horsepower of the engine may decrease under
pressure sensor. Thus, the power shift pressure the following conditions:
will vary according to the position of the engine
speed dial and the pressure of the delivery pump. • The engine becomes worn.
The antistall feature for the engine is used in order
to prevent the engine from stalling. The antistall • The quality of the fuel is poor.
feature will be activated, if the speed of the engine
decreases 250 rpm below the position of the dial in • The engine is operating at a high altitude.
comparison to the setting of the engine speed dial.
The controller will decrease the output of the pump
and the controller will increase the power shift
The powershift pressure is fixed for the positions pressure in order to reduce the load on the engine
of 1 through 9 until the underspeed feature is without reducing the engine speed. This condition
activated. The positions of 1 through 4 of the engine occurs if the speed of the engine decreases below,
speed dial have a different power shift pressure for full load speed.
each setting. The engine speed dial will set the
desired RPM, which will produce the desired flows.
The positions of 5 through 9 of the engine speed
dial have a common power shift pressure that is
fixed. The positions 1 through 9 use engine speed,
the position of the engine speed dial, and the pump
pressure to set a fixed output. The output is fixed
until a decrease of 250 RPM below the target RPM.
At a RPM of 250 below the target RPM, the. engine
controller will adjust the power shift pressure in
order to maintain engine RPM within 250 RPM of
the target RPM.
35
Engine Speed Control

SMCS Code: 1931
Illustration 31
(4) Electronic Engine Control
The controller converts the signal from the engine

speed dial (3) into a pulse width modulated
Illustration 28
signal. Then, the controller will send a signal to the
Governor Actuator for 312C governor actuator(1). The governor actuator will
(1) Governor actuator adjust the engine speed for the 10 positions of the
(2) Governor cables engine speed dial switch. The governor actuator
(3) Control Connector will use two cables (2) to increase the engine speed
and the cables are used to decrease the engine
speed.
Note: The 325C series uses the ADEM III controller

for the HEUI system.
lustration 29
Governor Actuator for 315C
(1) Governor actuator
(2) Governor cables
(3) Control Connector
Illustration 32 g00686200
Engine Speed Dial Switch
(3) Engine speed dial switch
The engine speed dial (3) is divided into 10

positions. The governor lever position is determined
in response to the position of the engine speed
dial. The dial position is displayed on the character
display of the monitor panel. The speed of the
engine with no load for each dial position is shown
in the following chart.
lustration 30
Governor Actuator for 320C series and 322C
(2) Governor cables
36
Table 1
R P M For The Engine Speed Dial Switch
"Pos" 312C 315C 320C 322C 325C/

330C
1 800 930 900 800 800
2 1100 1100 1020 1020 1020
3 1250 1300 1160 1160 1160
4 1400 1500 1300 1300 1300
5 1550 1650 1470 1470 1470
6 1700 1800 1590 1590 1590
7 1850 1950 1700 1700 1700
8 1950 2100 1800 1800 1800
9 2050 2250 1900 1900 1900
10 2150 2380 1970 1970 1980
Automatic Engine Control

SMCSCode: 1931
Illustration 34 900822672
This is a diagram of the 325C and 330C Automatic Engine Control.
(1) Engine and pump controller
(2) Switch panel
(3) Engine
(4) Speed sensor
(5) Monitor
(6) Electronic control module
The AEC will lower the engine speed if no load

on the machine continues for approximately three
seconds or a light load on the machine continues
for ten seconds when the engine speed dial is set
in a position of 5 to 10. This process is designed to
reduce the noise and fuel consumption. The AEC
has settings in two stages. The AEC can be set by
the switch on the right console. The indicator of
the switch will illuminate during the second setting
of the AEC . The second setting of the AEC is
available immediately after the engine start switch
is turned to the ON position. The AEC can be set in
Illustration 33 the first stage and the second stage by alternately
pressing the switch .
Diagram of Automatic Engine Control (AEC)
(2) Switch panel First Setting Of The AEC
(3) Engine
(4) Speed sensor
(5) Monitor The first setting of the AEC will lower the speed
(6) Governor lever of the setting of the engine speed dial by
(7) Governor actuator approximately 100 rpm in the "no load" or the "light
(8) Feedback sensor load" condition.
37
Second Setting Of The AEC

The second setting of the AEC will reduce the
engine speed to approximately 1300 rpm in the "no
load" condition. The AEC will lower the speed of the
setting of the engine speed dial by approximately
100 rpm in the "light load" condition. The AEC will
not function if the backup switch (MAN) is being
operated.
One Touch Low Idle

SMCSCode: 1931
Illustration 36
This Diagram Is For The 325C and 330C One Touch Low Idle
Control.
(1) Engine speed dial
(3) Engine
(4) One-touch low idle switch
(5) Implement swing pressure switch
(6) Travel pressure switch (right)
(7) Travel pressure switch (left)
(8) Electronic control module
(10) Travel pressure switch (left)
When the one-touch low idle switch (4) is pressed

and the* machine is not under a load, the engine
speed can be lowered by more than the speed of
the setting of the second stage of the AEC. When
lustration 35 normal operations have resumed, the engine speed
Diagram For The One Touch Low Idle Control for the dial setting will return the corresponding
(1) Engine speed dial RPM.
(3) Engine
f») One-touch low idle switch Start-up Of The One-touch Low Idle
(5) Governor lever
(6) Implement swing pressure switch The one touch low idle feature will activate during
(B) Governor actuator
all "stopped" conditions of the implement, swing,
0) Feedback sensor travel and tools. The following components are in
|10) Travel pressure switch (left) the OFF position: implement swing pressure switch
(6), the travel pressure switch (right) (10), the travel
pressure switch (left) (7), the attachment pedal
pressure switch, and the straight travel pressure
switch. However, when the one-touch low idle switch
is pressed, the control will lower the engine speed
to the speed of the "2" setting of the engine speed
dial (approximately 1100 rpm for the 312C and
315C, 1020 rpm for the 320C, 322C, and 325C).
This control overrides the AEC.
Note: The 312C has only one travel pressure switch

and the 315C has only one travel pressure switch.
38
Release Of The One-touch Low Idle Selection Of A Tool

The one-touch low idle will be released, if any of the There are five types of tools. The operator selects
following conditions occur: the type of tool by the monitor. The following
parameters are examples of some parameters
• The one-touch low idle switch (4) is pressed that can be adjusted in order to accommodate a
again. particular tool:
• The implement swing pressure switch is set to • Setting of the engine speed dial
the ON position.
• Pump flow in the single operation
• A travel pressure switch is set to the ON position.
• Pump flow in the simultaneous operation
• A pressure switch that is related to a tool is set
to the ON position. • The setting of the horsepower for the attachment
pump.
The engine speed is different after the switch has
been released. The different speed will depend on
the conditions of the release.
When the pedal is operated, the actual setting of
1. The engine speed will be set to the setting of the engine speed dial is compared to the position
the engine speed dial, when the feature for of the engine speed dial that was set by the
one-touch low idle has been released by an parameter. The engine speed control will lower the
operation of the implement, swing, etc.. engine speed to the selected engine speed that
was set in the adjustable parameter. When the tool
2. The engine speed will be set by the AEC, is deactivated, the speed of the engine will return to
when the feature of one-touch low idle has the actual speed of the setting of the engine speed
been released by using the one-touch low idle dial. When the attachment tool is being operated,
switch. The engine speed will be affected by the the AEC and the one-touch low idle are released.
following conditions:
a. When the first setting of the AEC is selected, Main Pump Flow Control
the engine speed will be set to the speed
of the first setting of the AEC. The speed is If the pedal is operated for a tool that uses the flow
approximately 100 rpm lower than the setting of the main pump, the pressure switch detects the
of the engine speed dial. change. A flow control restricts the main pump
flow. The shuttle valve selects the higher pressure
b. When the second AEC is selected, the engine between the pressure in the control valve and the
speed will be set to the speed of the setting pressure from the proportional reducing valve. This
of the second AEC. signal restricts the pump flow to a lower pressure.
The main pump flow is then reduced.
c. The engine speed will be set to the speed of
the engine speed dial if the engine speed is This process results in better simultaneous operation
lower than the setting of the second AEC. The of the tool and operation of the implement.
setting of this speed is not based on a setting
of the AEC. Main Pump Control During Use Of
The Attachment Pump
101621280
The controller detects an attachment pump section.
Tool Control This offsets the load of the attachment pump. This
process also prevents a decrease of the engine
SMCS Code: 5700
speed. If an attachment pump is operated with 30
percent of the rated load and the main pumps are
When an attachment tool is being operated, the
operated at the same time, a reduction in engine
engine speed and the pump flow are controlled
speed is prevented.
according to the type of tool. For more information,
refer to the appropriate service manual for the tool
control of the machine that is being serviced.
39
(01621594 S/N: BBL1-Up

Straight Travel Control S/N:G1L1-Up
SMCSCode: 1931 S/N: BKMT-Up
S/N: APA1-Up S/N: BMM1-Up
S/N: BEA1-Up S/N: BTM1-Up
S/N: BLA1-Up S/N: CAM 1-Up
S/N: CYA1-Up S/N: CLM1-Up
S/N: HAA1-Up S/N: S3M1-Up
S/N: MCA1-Up S/N: BCN1-Up
S/N: ANB1-Up S/N: BFN1-Up
S/N: BCB1-Up S/N: BNN1-Up
S/N: BDB1-Up S/N: BLP1-Up
S/N: BGB1-Up S/N: CAP1-Up
S7N:CRB1-Up S/N: BER1-Up
S/N: JAB1-Up S/N: BGR1-Up
S/N: AMC1-Up S/N: BPR1-Up
S/N: BBC1-Up S/N: BKT1-Up
S/N: BDC1-Up S/N: CBT1-Up
S/N: BTD1-Up S/N: BKW1-Up
S/N: CCD1-Up S/N:ALX1-Up
S/N: KDD1-Up S/N: BFX1-Up
S/N: BDE1-Up S/N: BLX1-Up
S/N: BFE1-Up S/N: BMX1-Up
SM:ALF1-Up S/N: BRX1-Up
S/N: BEF1-Up S/N: GKX1-Up
S/N: GAG 1-Up S/N: BNY1-Up
S/N:AKH1-Up S/N:CBY1-Up
S/N:AMH1-Up S/N: DKY1-Up
S/N: BKH1-Up S/N: CGZ1-Up
S/N: BPH1-Up S/N: CLZ1-Up
S/N: RBH1-Up Note: The following models have straight travel

control: 318C, 320C, 322C, 325G, and 330C.
S/N: BKJ1-Up
S/N: CSJ1-Up
S/N: BFK1-Up
S/N:BKK1-Up
S/N: M2K1-Up
40
• The pressure switch for the straight travel pedal

(5) and the implement swing pressure switch (2)
are simultaneously activated.
Engine Speed Protection

SMCSCode: 1931
Memory Function
After one of the following events has occurred, the
engine will operate at the 10 position of the engine
speed dial when the engine is restarted:
• The engine was stopped with the AEC switch in

the ON position (1300 rpm) and the engine speed
dial was in the 10 position.
• The engine was stopped at a low idle and the

Illustration 37
engine speed dial was in the 2 position.
This diagram is for the 320C and 322C series.
(1) Controller
(2) Implement swing pressure switch
Function
(4) Travel pressure switch (left) The position of the governor actuator is stored in
(5) Pressure switch for the straight travel pedal the memory when the starter switch is turned to the
(6) Straight travel solenoid OFF position (engine OFF). After the key is turned
to the OFF position, the governor actuator will move
to the maximum position of the AEC side for 10
seconds in order to stop the engine. Then, the
governor actuator will return to the stored position.
Unless the governor actuator is moved by one of
the following operations, the engine will start at the
speed that was previously stored in the memory.
1. Release of AEC and one-touch low idle by

operating the control levers and the pedals.
2. The engine speed dial is operated.
3. The AEC switch is operated.

Illustration 38
4. The one-touch low idle switch is operated.
This diagram is for the 325C and 330C series.
(1) Controller Note: The 325C does this function with the ADEM.
(2) Swing pressure switch
(3) Right travel pressure switch
(4) Left travel pressure switch Prevention Of Overspeed During
(5) Straight travel solenoid valve
Low Engine Oil Pressure
The straight travel solenoid (6) is energized and the
hydraulic circuit for straight travel is open when one This function is designed to prevent the engine
of the following conditions occur: from starting at a high speed during a condition
of low oil pressure. After the engine oil filter is
• The travel pressure switch (right), the travel replaced, a long time may be required before the
pressure switch (left) and the implement swing engine oil pressure will reach the specified level.
pressure switch are simultaneously activated. The turbocharger may be damaged, if the engine
runs at the speed dial position of 10. The following
information describes this function.
The engine speed will be limited to the position of
5, if the engine oil pressure switch is open. The
engine speed will also be limited to the position
of 5, if the governor actuator was held in the high
speed position before the stopping of the engine.
The engine will start at the speed of the 5 position.
Prevention Of Overspeed During

Overheating Condition
This function is designed to prevent damage to
the engine that is caused by overspeed during
an overheating condition. Work that requires high
pressure will be restricted during an overheating
condition. The engine and other components are
protected during this condition. The engine speed
will be decreased to the second setting of the AEC
(1300 rpm).
Control Of The Hydraulic Oil At

Low Temperatures
When the conditions of the climate are cold and the
temperature of the hydraulic oil is low, the machine
may not operate smoothly. The output of the pump
will decrease by a small amount. This allows the
operations to be smoother until the temperature of
the oil rises. When the hydraulic oil temperature
sensor has detected an oil temperature below 15 °C
(59 °F) the system limits hydraulic pump output
pressure to 80% of maximum hydraulic horsepower.
When the hydraulic oil temperature sensor detects
an oil temperature that has risen above 20 °C
(68 °F), normal control of the hydraulic oil will begin
again.
42
Swing Lock System

SMCSCode: 1931
Illustration 39
The swing parking brake is released immediately

after any control lever of the boom, stick, bucket,
swing or attachment is operated. The swing parking
brake is engaged 6.5 seconds after all the control
levers return to the neutral position. The swing
parking brake is not released while the hydraulic
activation control lever is placed to the locked
position. The swing parking brake is released by
turning the fine swing switch to the ON position, if
the fine swing attachment is installed. The swing
parking brake is released electrically when the
backup switch is placed into the "MAN" side.
43
Backup System
SMCS Code: 1931
Illustration 40
Schematic of the backup switch
Illustration 41
(1) Starter Switch
(2) Engine and pump controller This diagram is for the 325C and 330C backup switch.
(3) Engine speed switch (1) Starter Switch
(4) Main relay (2) Engine and Pump Controller
(5) Timer relay (3) Speed Change Switch
(6) Circuit for the governor actuator (4) Main relay
(7) Governor actuator (5) Electronic Control Module
(B) Drive circuit for the proportional reducing valve (6) Backup Register
(9) Backup resistor (7) Proportional Reducing Solenoid Valve
(10) Proportional reducing valve for the power shift (8) Swing Brake Solenoid
(11) Circuit of the swing brake (9) Backup Switch
(12) Backup switch for EPC (10) Engine Speed Control Circuit
(13) Swing brake solenoid (11) Proportional reducing valve
(12) Swing Brake Circuit
The backup system is used when the controller

is not able to control the machine properly. The
backup system is provided so that the machine
can be moved or an operation can be performed.
The monitor will indicate when the backup system
is active.

The speed of the engine can also be controlled by
using the engine speed change switch. When the
switch is placed in the rabbit position, the engine
speed will be increased. When the switch is placed
in the tortoise position the engine speed will be
decreased.
44
Pump Control • Allowing the operator and/or service person to

input information to the controller
The output of the pump will be reduced to 60% to
80% of the rated output. The power shift pressure The monitor panel is used to enter commands into
is fixed. Care should be taken in order to prevent the controller. Some examples of these operations
the engine from stalling. This condition could occur are included: selecting operator modes, selecting
during machine operation while the engine speed service modes, changing parameters, and many
dial is in a low position or the output of the engine other operations
has been decreased significantly.
Warning Operation
Swing Parking Brake
There are three types of warnings that will be
The swing parking brake can be released during displayed:
a backup condition. However, the brake is under
activation when the hydraulic oil supply is stopped. Warning 1 -This warning is displayed on the liquid
The hydraulic oil supply is stopped when the engine crystal display only. This is low level warning.
is stopped or the hydraulic lock lever is moved to
the lock position. Warning 2 - This warning is displayed on the liquid
crystal display and the action lamp will illuminate.
This level of a warning will require the operation to
be stopped and necessary actions should be taken.
Monitoring System Warning 3 - This warning will display the following
indications: a warning on the liquid crystal display,
SMCS Code: 7490
illumination of the action lamp, and sounding of the
action alarm. This level of a warning will require all
operations (engine OFF) to be immediately stopped
and the necessary actions be taken.
Warnings
The following list contains examples of these
warnings.
Warning for decreasing engine oil pressure
This warning warns the operator about an abnormal

decrease in the engine oil pressure. During the
abnormality, the action lamp will illuminate and the
action alarm will sound.
Warning for high engine coolant temperature
This warning warns the operator about an

abnormally high temperature of coolant. The
temperature of the coolant is above 105 °C (221 °F).
Warning for high hydraulic oil temperature
This warning warns the operator about an

abnormally high temperature of hydraulic oil. The
dangerous temperature is over 95 °C (203 °F).
Illustration 42
Monitor panel Warning for backup switch
The monitor panel has two functions: This warning warns the operator when the backup
switch is operated in the MAN position.
• Displaying information by using gauges and
indicators
45
Warning for an abnormal battery charging • Secondary fuel filter
This warning warns the operator about an abnormal • Water separator

battery charging while the engine is running.
• Oil for the swing motor
Warning for abnormal condition in the controller
• Pilot filter
This warning warns the operator about an abnormal
condition in the monitor. • Drain filter
Warning for a return filter that is clogged • Return filter
This warning warns the operator about a return • Final drive oil
fitter that is clogged. When this warning occurs,
turn the key to the OFF position. Then, when the • Hydraulic oil
key is turned to the ON position again, verify that
the warning is present. Verify that this warning • Coolant
is occurring during travel on level ground. The
filter should be changed when the warning occurs
during travel on level ground. Machine Information
The monitor will display the following information
Warning for a air filter that is clogged
about the status of the machine:
This warning warns the operator that the air filter is
• Engine RPM
clogged. Clean the air filter or replace the air filter.
• Delivery pressure of the main pump (driver side)
Warning for a fuel filter that is clogged
• Main pump delivery pressure (idle side)
This warning warns the operator that the fuel filter
is clogged. Replace the fuel filter.
• Power shift pressure for the main pump
Warning for water separator (320C series, 322C
series, 325C series, and 330C series) Monitor Operation
This warning warns the operator when the water in 1. The operation procedure for the monitor is
the water separator is over the specified level. Drain listed below.
the water separator of water.
a. Display the "MAIN MENU" screen from the
Waning for low fuel normal display screen.
This warning warns the operator when the remaining b. Select "SPECIAL SETTINGS" from the "main
fuel is low. Fill the tank with fuel. menu" screen.
Warning for air heater in operation c. The screen will change and the screen will
display the "PASSWORD" screen. Input the
This warning warns the operator that the air heater password for the dealer (0001).
is operating. Start the engine after this warning
goes off. d. The screen will change to the "SPECIAL
SETTINGS" screen. Select "MACHINE INFO".
Warning for usage of oil and filter
e. The screen will change to the "MACHINE
The usage and the recommended interval for INFO" screen. You may choose the desired
exchangrig the filter and oil is displayed on the option.
monitor. The used time can be reset from the
monitor. It is necessary to reset the used time after Working Hour
exchanging the filter. The following list contains
examples of oil and filters: The monitor is capable of displaying the operating
* Engine oil time of the following components:
*Engine oil filter
*Primary fuel filter • Engine
• Main pump
46
• Travel motor Travel Alarm

• The tool for the "INSTALL TOOL #1" through the When the travel pressure switch is in the ON
"INSTALL TOOL #5" display position, the travel alarm will sound in order to call
attention to the machine. When the travel alarm
Monitor Operation cancel switch is pressed during the activation of
the travel alarm, the alarm will be silenced. This
1. The operation procedure for the monitor is action is effective until the machine completely
listed below. stops. After the machine has momentarily stopped
and the machine begins to travel again, the alarm
a. Display the "MAIN MENU" screen from the will sound.
normal display.
[01621857
b. Select "SPECIAL SETTING" from the "MAIN
MENU" screen. Engine and Hydraulic Pump
c. The screen will change to the "PASSWORD" Controller
screen. Input the password for the dealer
(0001). SMCS Code: 1931; 7610-NP
d. The screen will change to the "SPECIAL

SETTINGS" screen. Select "MACHINE INFO".
e. The screen will change to the "MACHINE

INFO" screen. Select the desired option.
2. The procedure that is used to reset the

operating hours is listed below.
a. The operating hours should be displayed.

Press the "MENU" key in order to display the
screen that will reset the total time.
b. Press the "SET" key in order to reset the hours.
c. Confirm the reset by pressing the "OK" key.
d. The operating hours have been reset. The

screen should return to the default display.
Note: The screen will return to the default display

unless the "cancel" key is pressed or no key is
pressed within twenty seconds of confirming a reset
of the operating hours.
Tools
The monitor will display the currently selected tool
and the pressure setting for hydraulics of the tool.
47
Illustration 43
Diagram Of Inputs And Outputs Of The 312C, 3150, 320C, and 3220 Controller
(1) Controller (18) Fuel level sensor (33) Solenoid valve for travel speed
(2) Fuse Box (19) Alternator (34) Solenoid valve for the swing parking
(3) Engine (20) Engine oil pressure switch brake
(4) Governor lever (21) One touch low idle switch (35) Travel alarm
(5) Hydraulic Pump (22) Engine oil level switch (36) Air heater indicator
(6) Battery (23) Hydraulic oil level switch (37) Switch (Clogged air filter)
(7) Start switch (24) Water separator level switch (38) Switch (Clogged hydraulic oil filter)
(8) Speed sensor (25) Swing pressure switch for the implement (39) Engine coolant level switch
(9) Backup switch (26) Travel pressure switch (40) Pressure switch for the attachment
(10) Governor actuator (27) Travel pressure switch pump
(11) Feedback sensor (28) Pressure switch for the straight travel (41) Pressure switch for the attachment
(12) Monitor pedal pedal
(13) Action alarm (29) Pump pressure sensor (42) Pressure switch for the attachment
(14) Engine speed dial (30) Pump pressure sensor pedal (2)
(15) Switch panel (31) Proportional reducing valve for the (43) Proportional reducing valve for the
(16) Engine coolant temperature sensor power shift pressure auxiliary hydraulics (Attachment)
(17) Hydraulic oil temperature sensor (32) Solenoid valve for straight travel
48
Illustration 44
Diagram Of Inputs And Outputs Of The 325C and 330C Controller
(1) Engine and Pump Controller (17) Fuel Level Sensor (31) Travel Speed Solenoid Valve
(2) Starter Switch (18) Alternator (32) Swing Parking Brake Solenoid Valve
(3) Fuse Box (20) One-touch Low Idle (33) Travel Alarm
(4) Battery (21) Engine Oil Level Switch (35) Clogged Air Filter Switch
(5) Engine (22) Hydraulic Oil Level Switch (36) Clogged Hydraulic Oil Filter Switch
(7) Pump (23) Implement Swing Pressure Switch (37) Engine Coolant Level Switch
(8) Speed sensor (24) Travel Pressure Switch (right) (38) Implement Pressure Switch
(10) Electronic Control Module (25) Travel Pressure Switch (left) (39) Attachment Pedal Pressure Switch
(11) Backup Switch (26) Pump Pressure Sensor (40) Row Control Valve
(12) Action Alarm (27) Pump Pressure Sensor (41) Water Separator Level Switch
(13) Engine Speed Dial (28) Monitor (42) Straight Travel Control
(14) Switch Panel (29) Proportional Reducing Valve (43) Attachment Pedal Pressure Switch
(16) Hydraulic Oil Temperature Sensor (30) Straight Travel Solenoid Valve
49
Note: The 312C and 315C have only one travel (Table 2, contd)
pressure switch. 7 Pressure Switch for Switch Input
320C and 320CU
Note: The Engine Control Module is on the 325C.
8 Hammer Switch for Switch Input
The controller is connected to the machine through 320C and 320CU
two 54-pin connectors. The controller will monitor 9 Engine Speed Dial 1 Operational Switch
the system through the inputs and the controller Input
will make adjustments to the system through the
outputs. The controller will control the hydraulic 10 Engine Speed Dial 2 Operational Switch
output of the pump by adjusting the speed of the Input
engine according to the load on the machine. 11 One-touch Low Idle Switch Input
Switch
12 Mode Switch for the Switch Input
AEC
13 +Battery Power
14 Ground Ground
16 Overload protection Switch Input
17 Implement Pressure Switch Input
Switch for 312C and
315C
18 Implement Control Line Output
2
19 Engine Speed Dial 3 Operational Switch
Input
20 Engine Speed Dial 4 Operational Switch
Input
21 Travel Mode Switch Switch Input
22 Travel Alarm Switch Switch Input
23 Key Start Switch Switch Input
28 Implement Status 1 Output
29 Control Lever Pressure Switch Input
Switch 320C and 322C
30 Left Travel Pressure Switch Input
Switch 312C and 315C
31 Coolant Level Switch Switch Input
32 Hydraulic Oil Level Switch Input
Switch
33 Data Link + Input/Output
Illustration 45
39 Right Travel Pressure Switch Input
Engine and Pump Controller (ECM)
Switch
(44) Controller
(45) Connector 2 40 Engine Oil Level Switch Switch Input
(46) Connector 1
41 Engine Oil Pressure Switch Input
Table 2 Switch
Engine And Hydraulic Pump Control (Connector 1)(1) 42 Clogged Air Filter Switch Input
Indicator
No.1 Function Type
43 Data Link Negative Input/Output
1 +Unswitched Battery Power
2 Ground Ground
4 Air Heater Relay Solenoid Output
(continued)
50
(Table 2, contd) (Table 3, contd)

47 Water Separator Level Switch Input 37 Main Pump Pressure Sensor Input (PWM)
Switch Sensor
48 Clogged Filter Switch Input 39 Hydraulic Oil Sensor Input (PWM)
Temperature Sensor
53 Straight Travel Solenoid Switch Input
for 320C 44 Governor Sensing Sensor Input (Voltage)
(1) The connector contacts that are not listed are not used. The 45 Pump Delivery Sensor Input (PWM)
connector has 54 contacts. Pressure
Table 3 46 Boom Hold Sensor Input (PWM)
(1)
Engine And Hydraulic Pump Control (Connector 2) 47 Backup Switch Switch Input
No.1 Function Type 52 +Battery for 320C, Power
320CU and 322C
1 Straight Travel Solenoid Solenoid Output
320C, 320CU and (1) The connector contacts that are not listed are not used. The
322C connector has 54 contacts.
2 Travel Speed Solenoid Solenoid Output When the controller determines that it is necessary
to change the speed of the engine and the output
of the hydraulic pump, the controller will actuate the
4 Swing Brake Solenoid Solenoid Output
governor actuator and the proportional reducing
valve. Each input and output of the controller is
6 Fine Swing Switch Switch Input connected to the machine harness through two
54-pin connectors.
7 Power Shift Solenoid Solenoid Output
8 Pump Flow Limitation
Valve Solenoid
Solenoid Output Input/Output
9 Priority Control Valve Solenoid Output The data link is a bidirectional component. The data
link allows the controller to receive information and
13 Travel Alarm Output the controller can send information. The data link
14 Mode Indicator for the Output is designed to allow communication between the
AEC controller and the monitor. The data link is not a
visible component. The data link consists of internal
15 Travel Mode Indicator Output control circuits and the connecting harness wiring.
16 Negative Speed Sensor Return The controller sends information through the data
Sensor link to the monitor panel. The following list contains
some examples: fuel level and engine coolant
17 Neutral Start Relay for Solenoid Output temperature. The controller also receives requested
322C information from the monitor panel.
19 Solenoid Return Ground
20 Solenoid Return Ground Input
21 Solenoid Return Ground
Each input will describe the status of the machine
22 Solenoid Return Ground system. Two types of inputs exist: switch type and
sensor type. Switches and harnesses provide an
23 Action Alarm Output open or ground to the controller. Sensors and
24 Travel Alarm Indicator Output harnesses provide a signal that changes to the
controller.
25 Engine Speed Sensor Input
29 Coolant Temperature Sensor Input Switch Input (Keyswitch)
Sensor
30 Fuel Level Sensor Sensor Input (PWM) The input of the key start switch connects to the
controller through connector 1 and contact 23. The
35 Alternator Terminal "R" Sensor Input (Voltage) key start switch will provide input information to the
36 Feedback from the Sensor Input (PWM) controller about the status of the key start switch.
Governor The input for the key start switch is + battery when
the key start switch is placed in the ON position.
(continued)
51
Switch Input (Operational Type) Output

Each switch input will provide information about The controller responds to decisions by sending
operator requests and machine systems. The electrical signals through the various outputs. The
condition of the system is sent to the controller outputs will create an action or the outputs will
through each input. The status of each input will provide information. Three status indicators inside
be grounded, open or +battery. Each input of the the controller that are connected to the monitor
controller will receive information from the switches panel are outputs of the controller. These outputs
that are located in the machine systems (pressure are additional to the outputs that are listed in the
and temperature). table for the descriptions of the connector contacts.
The monitor panel shows the operating status of the
Sensor Input (Frequency) engine and pump control system and diagnostic
information. This action could be energizing a
An AC signal is present for the input of the frequency solenoid, sounding an alarm or activating a motor.
sensor. The AC signal is used to represent the The controller will send an output to the following
speed of a machine system. For example, the components:
engine speed sensor provides an AC signal to the
controller. The controller measures the frequency • Governor actuator
(Hz) of the AC signals. The resulting speed is used
by the controller to make decisions. • Proportional reducing valve for the power shift
pressure
Sensor Input (Alternator) • Travel speed solenoid
The sensor input for the alternator connects to
• Action alarm
connector contact 2-35. A square wave signal
is present at this input. The signal is used to
• Travel alarm
represent the speed of the alternator. The controller
measures the frequency (Hz) of the square wave
signal. The controller uses this information to • Swing parking brake solenoid
make determinations and the controller uses this
information to monitor the output of the alternator. • Proportional reducing valve for the tool mode
When an abnormal condition exists, the controller
will alert the operator. • Straight travel solenoid
Sensor Input (PWM)

The controller receives a PWM signal from the
sensor. This signal will represent the condition of
a machine system. For example, the controller
can monitor pressure. PWM sensors provide this
information. The controller measures the duty cycle
of the PWM signal. This signal will represent the
information that is measured. The controller will
use this information to perform decisions. When an
abnormal condition exists, the controller will alert
the operator.
Sensor Input (Voltage)

For example, contact 2-35 is an input for voltage
sensing. A voltage is present. This voltage will
represent the condition of a machine system. For
example, the level of voltage is a condition that
is monitored by the controller. Analog sensors or
senders provide this information. The controller
measures the voltage, which represents the
measured information. The controller uses this
information to make decisions. The controller also
uses this information to monitor machine systems.
When an abnormal condition exists the controller
alerts the operator.
52
Operator Monitor
SMCS Code: 7490
Illustration 46
Monitor Panel
Illustration 47
(1) Fuel gauge
(2) Engine coolant temperature gauge Monitor Panel
(3) Action lamp (7) "Up" key
(4) Engine speed dial indicator (8) "Left" key
(5) Hydraulic oil temperature gauge (9) "Right" key
(6) Message center (10) "Down" key
(11) "Cancel" key
The liquid crystal display panel will display various (12) "Setting" key
warnings and information. The monitor panel (13) "Menu" key
(14) "OK" key
includes the following components: three gauges,
an action lamp, the engine speed dial indicator, a
message center, and eight switches.
53
The information about the condition of the machine One Touch Low Idle Switch
from the controller is displayed on the monitor. The
monitor has three gauges and a number of alert The one touch low idle switch is incorporated into
indicators. Each gauge is dedicated to a parameter the top section of the lever on the right console.
within a machine system. Some of the possible When the switch is in the ON position, the engine
parameters of the machine systems are listed: fuel speed is decreased to 1020 rpm.
level, engine coolant temperature, and hydraulic
oil temperature. The gauges receive information
from sensors or senders that are connected to Pressure Switch
the controller. The controller uses the information
from each sensor input to calculate the value that
is shown on the gauges. The alert indicators will
notify the operator of an abnormal condition in a
machine system. The controller uses information
from pressure switches, sensors and other inputs in
order to determine when an abnormal condition is
present. The controller will send a message to the
monitor panel. Then, the monitor panel FLASHES
the alert indicator for the machine system with the
abnormal condition. The controller will process
information from the switches of the monitor panel.
The switches are used in order to select various
functions. The controller will receive this information
and the controller will perform the requested
operation or mode of operation.
Travel Pressure Switch And Implement/Swing Pressure Switch
Left Travel Pressure Switch, Right Travel

Switches Pressure Switch, Straight Travel Pressure
Switch and Implement/Swing Pressure
SMCS Code: 1435; 7332 Switch
Engine Speed Dial Switch The travel pressure switch and the implement/swing
pressure switch will monitor the hydraulic system.
This switch is normally open. These switches will
inform the controller about the status of the hydraulic
demands. When there is no hydraulic demand these
switches are open. The function of the automatic
engine speed control (ECM) of the controller will
use these switches to determine operation. These
switches are in the normally open position, when
the switches are not installed on the machine. The
implement/swing pressure switch releases the swing
brake. If the implement/swing pressure switch and
the travel pressure switch are in the closed position
the swing brake will be released.
Illustration 48
Engine Speed Dial Switch
The positions of the engine speed dial switch is

designed to inform the controller about the speed
that is desired by the operator. The engine speed
dial switch has ten positions: 1 to 10. Each position
of the switch has a unique combination of connector
contacts that close to contact 1. A combination of
contact 2 through contact 5 will close to contact
1. This switch will ground a unique combination
of inputs for the engine speed dial switch to the
controller.
54
Engine Oil Pressure Switch Note: After the key start switch is initially turned to
the START position, the switch will not return to the
START position from the ON position. The switch
must be turned to the OFF position first. Then, the
switch can be turned to the START position.
Air Filter Switch
Illustration 50
Engine Oil Pressure Switch
During normal operation, the engine oil pressure

switch is closed to ground. This switch is normally
open. The switch opens when engine oil pressure
is less than the specified value for the switch. If Illustration 52
the switch is in the open position, the controller will Air Filter Switch
notify the operator that the engine oil pressure is
insufficient. This switch is normally open, when the The air filter switch will open, if the air filter is
switch is not installed on the machine. blocked with debris. This switch is normally closed.
A warning will be displayed on the monitor. However,
Key Start Switch when a warning of higher priority is occurring at the
same time, the warning with the higher priority will
be displayed.
Hydraulic Oil Filter Switch

When the hydraulic oil filter is clogged, the hydraulic
oil filter switch will be open. A warning will be
displayed on the monitor.
Engine Coolant Level Switch

The engine coolant level switch is an electronic
switch that is activated by the coolant. The coolant
level switch is closed to ground during normal
Illustration 51 operation. The switch opens when the coolant level
is too low. The open switch informs the controller
Key Start Switch
that the coolant level is too low in the cooling
system.
The key start switch is an input of the engine and
pump controller. The key start switch informs the
ECM of an attempt to start the engine. Then, the
ECM initiates the start procedure.
During normal machine operation, the start terminal

of the key start switch is open. If the key start switch
is placed in the START position the start terminal
will close. +Battery voltage is supplied to the start
terminal. When all starting conditions are satisfied,
the ECM sends a +battery signal to the start relay
and engine cranking begins.
55
Hydraulic Level Switch and Engine When the volume of water that has been separated
by the water separator reaches a specified volume,
Oil Level Switch the switch is closed. The controller reads the input
from the water separator switch. The controller
will display a warning on the monitor. The water
separator should be inspected. The water separator
should be drained.
Switch Panel Assembly
Illustration 53
Hydraulic Oil Level Switch
The hydraulic oil level switch monitors the hydraulic

oi level after the starter key switch is held in the
ON position for 2 seconds or more. The controller
checks hydraulic oil level with the switch. The switch
closes when the hydraulic oil level is below the
normal operating level. This switch is in the normally
open position, when the switch is not installed on
t i e machine.
Water Separator Level Switch (320C

Series and 322C Series)
Illustration 55
Switch Panel
(1) Travel alarm cancel switch
(2) Automatic engine control switch (AEC)
(3) Travel Speed Switch
Travel Alarm Cancel Switch

When the travel alarm cancel switch (1) is activated
and the machine is in motion, the travel alarm will
temporarily stop until the machine has stopped.
When the machine begins to travel again, the travel
alarm will sound again. The indicator will illuminate
while the switch is being pressed.
Automatic Engine Control Switch (AEC)

Illutration 54
Water Separator Level Switch Either "AEC 1" or "AEC 2" is set by pressing the
Automatic Engine Control switch (2). The indicator
will illuminate when "AEC 2" has been selected.
56
Travel Speed Switch Frequency - T h e sensor will produce an AC signal

(sine wave or square wave) that varies in frequency
When the travel speed switch (3) is pressed, the (Hz) as the condition changes.
travel control is set in the position of automatic
two-speed or the position of fixed low speed. Pulse Width Modulated - The sensor produces a
The indicator will illuminate when the position of digital signal (PWM) that varies the duty cycle as
automatic two-speed has been selected. the condition changes. The frequency of the signal
will remain constant.
Pressure Switch
Engine Speed Sensor
Illustration 57
Engine Speed Sensor
The engine speed sensor is located on the flywheel

housing. An AC voltage is produced as the gear
Illustration 56 teeth of the flywheel pass the tip of the sensor.
Attachment Pedal Pressure Switch (Hammer) The frequency of the voltage is proportional to the
speed of the gear teeth as the teeth pass the tip of
the sensor. The controller uses this signal to make
Attachment Pedal Pressure Switch decisions for the hydraulic pump and the engine.
(Hammer)
This pressure switch is in the closed position when Feedback Sensor
the attachment pedal is being operated and the
pedal is using the main pump. This switch is utilized
for control of the engine speed and control of the
pump. This switch is normally open.
Attachment Pump Pressure Switch

This pressure switch is in the closed position when
Illustration 58
the attachment pedal is being operated and the
pedal is using the attachment pump. This switch Feedback Sensor Inside The Governor Actuator
is utilized for the engine speed control and pump
control. This switch is normally open. Note: The 325C Series does not have a governor
actuator.
The feedback sensor is incorporated in the govern

101611016 actuator. The sensor sends a PWM signal to the
controller. The PWM signal informs the controller
Sensors about the position of the governor lever. The
SMCS Code: 1931-NS controller will stop the activation of the governor
actuator when the controller determines that the
Sensors provide information to the controller about information from the feedback sensor matches the
changing conditions. Some types of information selected setting of the engine speed dial and the
are listed: speed, temperature, and fluid level. The engine RPM.
sensor signal changes in a proportional manner.
This change will represent the changing condition.
The controller will recognize the following types of
sensor signals:
57
Pressure Sensor The fuel level sender is attached to a float in the

fuel tank. As the fuel level changes, the float inside
the tank moves. The movement of the float will
change the resistance of the sender. The voltage at
the input to the controller for the sender will change
as the resistance of the sender changes. The
controller will monitor this voltage and the controller
will compare this voltage to values that are known.
This comparison will determine the level of fuel in
lustration 59 the tank.
Pump Discharge 1 (Drive) and Pump Temperature Sender

Discharge 2 (Idle)
These sensors send a signal to the controller. The
controller will use the signal to modify the following
terns:
• Adjusting the horsepower
• Changing the travel speed
• Determining light load and "AEC" level 1
Senders Illustration 61
SMCS Code: 1931-UN

Engine Coolant
Fuel Level Sender The resistance of the sender will change as the
temperature of the coolant changes. The voltage at
the input to the controller for the sender will change
as the resistance of the sender changes. The
This comparison will determine the temperature of
the coolant.
Hydraulic Oil
The resistance of the sender will change as the
temperature of the fluid changes. The voltage at the
input to the controller for the send'er will change
as the resistance of the sender effanges. The
This comparison will determine the temperature of
the hydraulic oil.
Illustration 60
Fuel Level Sender
58
Pressure Solenoid For Power Shift

i01622062
Solenoid Valves
SMCS Code: 5479
Proportional Reducing Solenoid

Valve (Power Shift)
The proportional reducing solenoid valve changes
the electrical signal from the controller into a
hydraulic signal for the hydraulic pump. The
hydraulic signal (power shift pressure) is used to
regulate the output of the hydraulic pump. The
controller varies the current (PWM signal) to the
solenoid and the solenoid valve modulates the Illustration 63 900778231
power shift pressure. The controller varies the Pressure Solenoid For Power Shift for 312C and 315C (1)
current to the solenoid according to the engine
speed.
Solenoid Valve
Illustration 62
Schematic Symbol
Illustration 64
The solenoid valve is designed to direct the flow
Power Shift Solenoid (1)
of hydraulic oil through the hydraulic system. The
controller will activate the proper solenoid valves Photo for 320C, 322C, 325C, and 330C
according to the input from switches on the monitor
panel and the pressure switches in the hydraulic The controller adjusts the current that drives the
system of the machine. When the solenoids are solenoid according to the following conditions:
activated, a solenoid receives ground from the
controller. The travel speed solenoid is activated • The position of the engine speed dial
when "HIGH" is selected in the travel speed mode.
The "rabbit" travel speed indicator is illuminated • The actual engine speed
when this mode is active.
• The delivery pressure of the pump
The solenoids have a connector with two contacts.
One contact receives a ground signal from the • The pressure of the circuit for power shift
corresponding connector contact of the controller.
The other solenoid contacts are connected to a
+battery source in the fuse panel.
59
Travel Speed Solenoid and Swing The travel speed solenoid changes the speed of
the travel motor from high speed to low speed
Parking Brake Solenoid Valve and vice versa. When the low speed mode has
been selected, the solenoid is not energized. The
displacement of the travel motor is controlled by
the travel speed solenoid. If the travel motor is in
the high speed mode and the controller detects a
pressure that is too high, the travel speed solenoid
will be de-energized and the" travel motor will now
be in the low speed mode.
The swing parking brake solenoid valve is energized

in order to release the brakes, when the implement,
the swing or the tool is operated. The swing parking
brake solenoid valve will be de-energized and the
brakes will be applied 6.5 seconds after a control
lever has been operated.
Illustration 65
Travel Speed Solenoid (2) and Swing Parking Brake Solenoid
Valve (3) for 312C
Illustration 66 Straight Travel Solenoid (4) for 320C, 322C, 325C, and 330C
Travel Speed Solenoid (2) for 315C
The straight travel solenoid is energized, when the
right travel pedal, the left travel pedal and other
actuators are operated at an identical time.
Governor Actuator Control

SMCS Code: 1716
Illustration 67
Travel Speed Solenoid (2) and Swing Parking Brake Solenoid
Vaive (3)
Illustration 69
Photo for 320C, 322C, 325C, and 330C
Governor Actuator
Note: The 325C and 330C do not have governor

actuators.
60
The operator selects an engine speed by placing Action Alarm

the engine speed dial in one of the ten positions.
The controller will determine if the engine is The action alarm connects to connector contact
operating at the speed that was selected by 2-23 of the controller. The SOUNDING of the action
comparing the engine speed w i t h the engine speed alarm will alert the operator when a high emergency
sensor. If the engine is not operating at the selected condition is present. For example, the engine oil
speed the controller activates the governor actuator pressure decreases below a set value.
which moves the governor lever. The controller
uses the governor feedback sensor to place the
governor lever in a position that corresponds to Travel Alarm
the selected engine speed. The governor actuator
uses a cable(s) to rotate the pulley. If the pulley is The travel alarm connects to connector contact
rotated counterclockwise, the governor lever that is 2-13 of the controller. The SOUNDING of the travel
connected to the pulley will move in the accelerate alarm will alert the area that the machine is moving.
direction. If the pulley is rotated clockwise, the
governor lever will-move in the decelerate direction. Input for Air Heater Indicator
If the machine is equipped with an air heater, the
air heater will be activated by the key start switch.
The air heater will only activate if the temperature of
Related Components the engine coolant is low. The controller will send
a signal to the monitor. The monitor wilLshow an
SMCS Code: 1931
indication that the air heater is active.
Alternator
The frequency output terminal of the alternator
is connected to connector contact 2-35 of the
controller. The controller will monitor the signal on
this circuit. This signal informs the controller about
the relative speed that the alternator is rotating. The
frequency output terminal of the alternator is the
"R" terminal.
Data Link
The data link is an input and an output of the
controller. The data link connects to the controller
at connector contact 1-33 and 1-43. The data link
is designed to carry communications between the
controller and the monitor. The data link is not a
visible component. The data link consists of internal
control circuits and a harness wiring. The data link is
bidirectional. The controller can receive information
and the controller can send information through the
data link. The controller sends information about the
fuel level, engine coolant temperature and many
other signals to the monitor panel.
Action Lamp
The FLASHING of the action lamp is designed to
inform the operator about a condition that exists
that requires a change in the operation of the
machine. The controller will instruct the monitor
panel to FLASH the action lamp when the controller
determines that a warning category of 2 or 3 is
present.
61
Testing and Adjusting Section
Testing and Adjusting The action alarm indicators, that are on the
monitor panel, alert an operator to a problem in
Section the electronic system. The service program of the
controller "Service Mode" can also be used to
identify the problems. See Testing And Adjusting,
"Using Service Mode". The monitoring system will
Testing and Adjusting monitor the system for problems. The monitor will
display the problems on the character display, if
the "Service Mode" is activated during the machine
operation. Existing problems and problems that
i01313182 have not been corrected are shown on the character
General Information display, if the "Service Mode" is activated during
the stopping of the machine. In order to activate
SMCS Code: 1931 the "Service Mode" of the controller, refer to Testing
And Adjusting, "Using Service Mode". According to
Troubleshooting the electronic control system will
the number of diagnostic codes, machine operation
require additional information from the Service
Manual of the machine . The reference material and machine control may not be possible, if the
should be consulted: the Electrical System "Service Mode" is being serviced.
Schematic, the Parts Manual, and the Operation
And Maintenance Manual. As a reference, a typical
system schematic is included at the end of this i01548282
manual. For an accurate representation of the
machine that is being diagnosed, see the Testing Service Tools
And Adjusting, "System Schematic". You should SMCS Code: 0785
use the Electrical System Schematic in the Service
Manual of the machine in order to trace the circuit, The following service tools should be used in order
if a troubleshooting procedure instructs you to to troubleshoot the electrical system easily:
REPAIR THE HARNESS". The continuity checks
should be performed at the connectors in order • 146-4080 Digital Multimeter
to locate a failure in the harness. At a component
connector, always check the ground circuit. Less • 8T-3224 Needle Tip (Multimeter)
than five ohms of resistance is required from the
ground contacts to frame ground. A problem can • 7X-1710 Multimeter Probe
be incorrectly diagnosed, if an excessive resistance
that is greater than 5 ohms is present in the • 8T-8726 Adapter Cable (3 Pin Breakout)
ground circuit. During a troubleshooting procedure,
you should inspect all component and harness • 40-4892 ORFS Fittings Group
connections before a component is replaced. If
these connections are not clean and tight, the • 6V-3000 Connector Repair Kit (Sure Seal)
connection can cause an electrical problem. The
problem can be permanent or the problem can • 40-3406 Connector Repair Kit (Deutsch)
be intermittent. Ensure that the wires are pushed
into the connectors completely. Make sure that
Use the 146-4080 Digital Multimeter or use an
the connections are tight before other tests are
equivalent multimeter in order to make continuity
performed. A failure of an electrical component can
checks and voltage measurements. The 7X-1710
cause a failure of another component or a failure
Multimeter Probe is used to perform measurements
can be caused by the failure of other components.
at connectors without the need to disconnect the
You should always attempt to find a failure and you
connector. The probes are pushed into the back
should correct the cause of a failure in the electrical
side of the connector and alongside the wire. The
system before you replace a component.
8T-8726 Adapter Cable (3 Pin Breakout)is used
to perform measurements in the circuits for the
sensors.
Note: Unless you are testing a harness, the
The monitor and the controller are the main
8T-0500 Continuity Test Light or the 5P-7277
components of the electronic control system. The
Voltage Tester is not recommended for use on
monitor and the controller have a self-diagnostic
electrical circuits.
function. The first components of the electrical
system that should be checked are listed: monitor
controller, and communication lines.
62
Table 4
F01313171
Symbol Color
Electrical Components And BK BLACK
Connector Locations BU BLUE
SMCS Code: 7553-546-WW
BR BROWN
The following references should be used to locate GY GRAY
the components and connectors for the machine
that is being serviced: Electrical System Schematic, GN GREEN
Parts Manual, and Operation And Maintenance OR ORANGE
Manual.
PK PINK
The following information is found on the back of PU PURPLE
the Electrical System Schematic: the "Harness
Connector and Component Locations", the machine RD RED
profile, and area views. The following information WH WHITE
explains the use of the information on the back of
the System Schematic. YL YELLOW
• "Chart Of Component Locations" The following example will explain the wire
identification:
The component location chart uses white circles
as location labels in the machine profile and the • An example is listed. 308-YL-18
area views. Alphabetical letters in the column for
the connector location and the machine location are 308 - The identification of the circuit
used in order to indicate the location in the area
views. YL - The color of the wire
• "Chart Of Harness Connector Location" 18 - This number represents the size of the wire
(AWG) according to the standards that are set by
The chart for the location of a harness connector the American Wiring Gauge. The gauge of the wire
uses white circles for the location labels in the will be No. 16, if the gauge has not been specified.
general view and the area views. Alphabetical
letters in the column for the location of the harness
connector and the machine location indicate the
area views for the location of the components.
i01305773
Harness and Wire Identification

SMCS Code: 1408-546; 7556-546
The colors and the sizes of the wires that are shown
in the Electric Circuit Diagram are identified and
described in the following chart:
9
Illustration 70 °0663"
Partial Diagram Of An Electrical Circuit
(1) Harness symbol for harness "A"
(2) Harness symbol for harness "L"
The harness symbol (1) or symbol (2) is shown on

the connector or the terminal of a component. Th
symbol "A" identifies harness "A" and the symbol
"L" identifies harness "L".
63
J01548283
Using Service Mode

SMCS Code: 7569
lllustration 71 900684315
Monitor Panel
(1) Fuel gauge
(2) Engine coolant temperature gauge Monitor Panel
P) Action lamp (7) "Up" key
(4) Engine speed dial indicator (8) "Left" key
(5) Hydraulic oil temperature gauge (9) "Right" key
(6) Message center (10) "Down" key
(11) "Cancel" key
(12) "Setting" key
(13) "Menu" key
(14) "OK" key
The information from the controller is displayed on

the monitor. The following service programs and
functions are available from the controller:
• The controller informs the monitor about the

condition of the machine. Some examples are
listed: hydraulic oil temperature, engine coolant
temperature, and fuel level.
• The controller informs the monitor about any

existing and/or past failures of the electronic
control system.
• Various settings of the controller are performed.
• Adjustment and testing of the electronic control

system are performed.
64
Start-Up Of The Service Mode "Menu" key

The "menu" key (13) is used to access the main
menu.
"Cancel" key
The "cancel" key (11) is used to cancel the
immediate selection and the key is used to exit the
menu screen. The screen of normal operation will
be displayed when the "cancel" key is pressed
during the menu screen.
"OK" key
The "OK" key (14) is used to select the item that is
being highlighted in the message area.
Start-Up Of The Service Mode
Illustration 73 900685772
Monitor Panel
(7) "Up" key
(8) "Left" key
(9) "Right" key
(10) "Down" key
(11) "Cancel" key
(12) "Setting" key
(13) "Menu" key
(14) "OK" key The above screen should be displayed. Then, pre
the "menu" key (13).
The keys of the keypad are used to enter the service
mode. The keys are used to change the modes.
Next, the appropriate key is pressed until the
desired mode is displayed on the message center.
"Up" key and "Down" key

The "up" key (7) is used and the "down" key (10)
is used to scroll up and down through the items in
the message area.
"Left" key and "Right" key

The "left" key (8) is used and the "right" key (9) is
used to scroll to the left and to the right through the Illustration 75
items in the message area.
The "down" key should be pressed. Highlight the
"Setting" key "PREFERENCES" setting. Press the "OK" key.
The "setting" key (12) is used to set the menu that

is being displayed in the message area.
65
Illustration 76 900764425 Illustration 79

Typical example of a display
The above screen should be displayed.
The above screen should be displayed if the correct
password is entered.
lustration 77
Illustration 80
The above screen should be displayed if the

password that was entered is not correct.
Exiting The Service Mode

Two methods are capable of terminating the service
mode.
1. The service mode will be terminated 10 seconds

after the start switch is turned to the OFF position.
lllustration 78
The keys for direction are used to input the

password. Input the password and press the "OK"
key.
Illustration 81
66
2. Highlight "SERVICE" in the first line of the display.

Adjust Clock Mode
SMCSCode: 1931
Adjustment Of The Clock
Illustration 82
3. The "left" key and the "right" key is used to scroll

through the display. The display should show
"EXIT" in the first line.
Illustration 84
1. At the above menu screen, press the "menu" key.
Illustration 83
4. The service mode will be terminated and the

display will return to the above display when the
"setting" key is pressed at the "exit" screen.
Illustration 85
2. Select the "PREFERENCES" option. Press the

"OK" key.
Illustration 86
67
3. Select the "ADJUST CLOCK" option. Press the

"OK" key.
Illustration 89
Typical monitor display
lustration 87
While the third line is highlighted, use the left
4. The keys for direction are used in order to adjust arrow key and the right arrow key to change the
the time. After the time has been set, press the ID number. This action will change the display of
"setting" key. the fourth line. The following table will describe the
information that is being displayed.
Table 5
ECM Summary Mode Machine Information For 312C and 315C

ID Description
SIICS Code: 1931
1 Machine model
The ECM summary mode is used to display the 2 Respective information for
software that is installed on the machine. Perform machine
fie following procedure in order to access this
mode. 3 Part number for the
standard controller
4 Serial number of the
standard controller
5 Machine specifications
6 Part number for the
software
7 Date of the software
8 Type of engine and pump
101 Model of tool
102 Part number for the
attachment controller
lllustation 88 103 Specifications for the tool

Tipical example of the display with the latest software 104 Serial number of the
attachment controller
Enter the service mode. Use the arrow keys to
105 Part number for the flash
highlight "ECM SUMMARY" in the second line of file
the display.
106 Date of the flash file
Note: See the appropriate service manual for the

tool control for IDS that are not listed.
68
(Table 6, contd)
2 Air heater relay "HEATING/OFF
Switch Status Mode HEATING during
preheating,
SMCSCode: 1931 OFF during NO
preheating
The switch status mode is used to display the "ON"
status or "OFF" status of various switches in the 3 Fine swing "FINE/OFF"
(320C, 322C switch
machine.
ONLY) Fine in switch
ON, OFF in
switch OFF
4 Cranking signal ON/OFF
(322C ONLY) input
ON when
cranking, OFF
in switch OFF
position.
5 Quick coupler ON/OFF
switch
ON in switch ON
position
OFF in switch
OFF position
Illustration 90 6 One-touch low "ON/OFF"
idle switch
1. Enter the service mode. Scroll to the above ON when
display by using the keys for direction. pressed, OFF
when not
pressed
7 AEC mode "ON/OFF"
switch
ON when
pressed, OFF
when not
pressed
8 Travel mode "ON/OFF"
switch
ON when
pressed, OFF
when not
pressed
9 Travel alarm "ON/OFF"
Illustration 91
cancel switch
ON when
2. The above illustration shows the "ID" status of pressed, OFF
the switch and the respective "ID" numbers. The when not
following table should be used to identify the pressed
switch and the display. Highlight the third line.
10 Pressure switch "HIGH PRESS/
Use the directional keys in order to change the
for the joystick LOW PRESS"
"ID". The example above shows the pressure HIGH PRESS
switch for the joystick in the ON position. when pressure
is generated in
Table 6 the switch circuit.
Status Of The Switch LOW PRESS
when pressure is
ID Switch Display not available
1 Position of the "1-10" (continue)
engine speed
dial
(continued)
69

11 Travel pressure "HIGH PRESS/ 19 Automatic "NOT
(312Cand315C switch (left) LOW PRESS" greasing failure. DISABLED/
have only one HIGH PRESS NOT INSTALLED NORMAL/
press switch) when pressure for non-equipped FAULT'
is generated in machine. In
the switch circuit. equipped
LOW PRESS machine,
when pressure is NORMAL in
i not available. normal condition.
FAULT when
12 Travel pressure "HIGH PRESS/ failed.
(320C, 320CU, switch (right) LOW PRESS"
322C ONLY) HIGH PRESS 20 Overload switch "ALARM
when pressure cancel switch CANCEL/OFF"
is generated in ON when
the switch circuit. pushed. OFF
LOW PRESS when not
when pressure is pushed.
not available.
21 Implement HIGH PRESS/
13 Engine oil level "NORMAL/LOW (312Cand315C pressure switch LOW PRESS
switch LEVEL" ONLY) HIGH PRESS
NORMAL when when pressure
oil level is setting is generated in
level or higher. switch circuit.
LOW LEVEL LOW PRESS
when the oil level when pressure is
is lower than the not available.
setting level.
24 ATT stem "ON/OFF"
14 Coolant level "NORMAL/LOW Aux. tool 1 activation
switch LEVEL" status ON when
i
NORMAL when operation status
the coolant level of attachment
is setting levelor system is ON.
higher. OFF when status
is OFF.
15 Hydraulic oil level "NORMAL/LOW
switch LEVEL" 25 ATT stem "ON/OFF"
NORMAL when Aux. tool 2 activation
hydraulic oil level status ON when
is setting level operation status
or higher. LOW of attachment
LEVEL when system is ON.
hydraulic oil level OFF when status
is lower than the is OFF.
setting level.
26 ATT stem "ON/OFF"
16 Engine oil "HIGH PRESS/ Aux. tool 3 activation
pressure switch LOW PRESS" status ON when
HIGH PRESS operation status
during engine of attachment
running. LOW system is ON.
PRESS during a OFF when status
engine stop. is OFF.
If 17 Return filter "NORMAL/ 27 ATT stem "ON/OFF"

switch is clogged CLOGGED" Aux. tool 4 activation
PLUGGED status ON when
when clogged. operation status
NORMAL when of attachment
normal. system is ON.
OFF when status
I 18 Air heater "HEATING/OFF is OFF.
controller
HEATING during (continued)
preheating.
OFF during no
preheating.
(continued)
70
(Table 6, contd) i01548894
28 Water separator
Draining demand
"NOT
DISABLED/
Status Mode
NOT INSTALLED NORMAL/
for non-equipped FAULT" SMCS Code: 1931
machine. An
equipped The status mode will display the parameters of the
machine, components of the machine.
NORMAL
in normal
condition. FAULT
in draining
demand.
29 Air cleaner "NORMAL/

Air cleaner PLUGGED"
switch is
PLUGGED
when clogged.
NORMAL when
normal
30 First fuel filter "DISABLED/
First fuel filter NORMAL/
switch is clogged PLUGGED"
NOT INSTALLED Illustration 92
for non-equipped
machines. 1. Enter the service mode. Select "STATUS" from
Equipped
the menu by using the keys for direction.
machines
NORMAL
when normal.
PLUGGED when
clogged.
31 Second fuel filter "DISABLED/
Second fuel filter NORMAL/
switch PLUGGED"
NOT INSTALLED
for non-equipped
machines.
NORMAL when
normal.
PLUGGED when
clogged.
32 Special filter "DISABLED/
switch NORMAL/ Illustration 93
NOT INSTALLED PLUGGED"
for non-equipped 2. The third line of the display will show the status
machines. "ID" and the respective "ID" numbers. The
NORMAL meaning of the "ID" numbers are listed in the
for normal following chart of parameters. The illustration
conditions. above shows that the engine speed is 1948 rpm.
PLUGGED when
clogged. Table 7
33 Pressure switch "HIGH PRESS/ Parameters
(320C, 320CU, for straight travel LOW PRESS"
322C ONLY) HIGH PRESS ID Status Display
when pressure 1 Governor actuator unit [%]
is generated in
feedback signal
switch circuit.
LOW PRESS 2 Drive pump delivery unit [kPa]
when the pressure
pressure is not
available. (continued)
71

3 Idle pump delivery unit [kPa] 29 Temperature condition Low temp, mode:
pressure control status COLD MODE
Normal temp, mode:
4 Boom hold pressure unit [kPa] NORMAL MODE
(Attachment) Derating mode:
5 Backup switch status . BACK UP / CONTROL DERATE MODE
7 Fuel level unit [mm] 30 Speed setting status of unit [rpm]

engine speed dial
8 Coolant temperature unit [°C]
9 Hydraulic oil unit [°C]
temperature
10 Power supply voltage unit [V] Configuration Mode
11 . Engine speed unit [rpm]
SMCSCode: 1931
12 Alternator status CHARGE/
NO CHARGE The configuration mode will display information
about the machine and changes in various values.
13 Supply condition of +12 ON / OFF
V power supply voltage
14 Required speed unit [rpm]
15 AEC mode selection First stage: OFF
status Second stage: ON
16 Travel mode selection First speed: SLOW

status Second speed: FAST
17 Travel alarm cancel CANCEL/ALARM
status
19 Travel mode switching First speed: SLOW
status Second speed: FAST
Illustration 94
20 Activation status of, ON/OFF
action alarm 1. Enter the service mode. Select the
"CONFIGURATION" option from the menu by
21 Activation status of ON/OFF
using the keys for direction.
travel alarm
22 Activation status of ON / OFF
straight travel control
23 Unloading valve status ON/OFF/
ATTACHMENT
24 Release condition of Release: FREE Brake:
swing brake BRAKE
25 Power shift pressure unit [kPa]/DISABLED
26 Negative Flow Control unit [kPa]/DISABLED
Pressure Reducing
Valve
(Attachment)
27 Negative Flow Control unit [kPa]/DISABLED
Pressure Reducing Illustration 95
Valve
(Attachment optional)
(continued)
72
2. The third line in the above illustration indicates (Table 8 contd)

the configuration ID. The settings that correspond 1 Model information Display only (Model
to the respective ID numbers are listed in the name- Model type)
following table. Each respective ID is classified
in either the "display only" or the setting for the 2 Type of hydraulic oil Mineral oil: MINERAL
ID. In order to change the ID, use the keys for Vegetable oil: BIO OIL
direction and highlight the fourth line. After the 3 Travel alarm status Equipped: INSTALLED
ID has been changed, press the "setting" key. Non-equipped: NOT
When the area that is highlighted moves to the INSTALLED
third line, the change has been completed.
4 Water separator NORMALLY OPEN
Contact type of level NORMALLY CLOSE
switch Non-equipped: NOT
INSTALLED
5 Contact type of NO. 1 NORMALLY OPEN
fuel filter switch NORMALLY CLOSE
Non-equipped: NOT
INSTALLED
6 Contact type of NORMALLY OPEN
clogged second fuel NORMALLY CLOSE
filter switch Non-equipped: NOT
INSTALLED
clogged special filter NORMALLY CLOSE
switch Non-equipped: NOT
Illustration 96 INSTALLED
3. In order to clear the setting, highlight the word NORMALLY CLOSE
automatic greasing
"STANDBY" in the fourth line and press the failure switch Non-equipped: NOT
"setting" key. INSTALLED
9 Overload warning Equipped: INSTALLED
sensor status Non-equipped: NOT
INSTALLED
10 Pressure of overload Upper limit: 40000 kPa
warning (5801 psi)
Units: kPa (PSI) Lower Limit: 0 Kpa
(0 psi)
1 step: 100 kPa (14 psi)
301 Switching pressure to Upper limit: 40000 kPa
low speed of automatic (5801 psi)
travel speed change Lower Limit: 0 Kpa
Units: kPa (PSI) (0 psi)
1step:100kPa(14psi)
302 Switching pressure Upper limit: 40000 kPa
Illustration 97 to high speed of (5801 psi)
automatic travel speed Lower Limit: 0 Kpa
4. The above illustration shows the screen that change (0 psi)
confirms the "clear" operation. When "CLEAR?" Units: kPa (PSI) 1step:100kPa(14psj)
is being displayed, press the "OK" key. This
operation has been completed. 303 Switching time to low Upper limit: 25.0 sec
speed of automatic Lower limit: 0.0 sec
travel speed change 1 step: 0.1 sec
Note: See the appropriate service manual for the Units: Second
tool control for the parameters that are not listed.
304 Switching time to high Upper limit: 25.0 sec
Table 8 speed of automatic Lower limit: 0.0 sec
travel speed change 1 step: 0.1 sec
(continued)
(continued)
73

305 Setting speed of Upper limit: Initial 405 Swing drive oil Upper limit: 25500
one-touch low idle speed at Dial position recommended hours
Units: rpm 10 replacement time Lower limit: 0 hours
Lower limit: Initial Units: Hours 1 step: 100 hours
speed at Dial position 1 "0 hour" is used as
1 step: 10 rpm non-equipped.
306 AEC 2nd stage setting Upper limit: Initial rpm 406 Pilot oil filter Upper limit: 25500
speed at Dial position 10 recommended hours
Units: rpm Lower limit: Initial rpm replacement time Lower limit: 0 hours
at Dial position 1 Units: Hours 1 step: 100 hours
1 step: 10 rpm "0 hour" is used as
non-equipped.
307 AEC 2nd stage Upper limit: 25.0 sec
operation time Lower limit: 0.0 sec 407 Drain oil filter Upper limit: 25500
Units: Second 1 step: 0.1 sec recommended hours
replacement time Lower limit: 0 hours
308 Setting change of Upper limit: One step Units: Hours 1 step: 100 hours
setting speed for up dial setting less than "0 hour" is used as
current Dial position -50 rpm non-equipped.
Units: rpm Lower limit: One step
down setting speed 408 Hydraulic return Upper limit: 25500
over +50 rpm filter recommended hours
Max. value: Initial rpm replacement time Lower limit: 0 hours
at Dial position 10 Units: Hours 1 step: 100 hours
Min. value: Initial rpm "0 hour" is used as
at Dial position 1 non-equipped.
1 step: 10 rpm
409 Final drive oil change Upper limit: 25500
309 Setting change of 0.1% unit display using time hours
torque distribution the decimal point Units: Hours Lower limit: 0 hours
for the current Dial Upper limit value: 1 step: 100 hours
position 100.0% "0 hour" is used as
Units: % Lower limit value: 0.0% non-equipped.
1 step: 1.0%
Reset operation is 410 Hydraulic oil Upper limit: 25500
possible recommended change hours
time Lower limit: 0 hours
401 Engine oil Upper limit: 25500 Units: Hours 1 step: 100 hours
recommended change hours "0 hour" is used as
time Lower limit: 0 hours non-equipped.
Units: Hours 1 step: 100 hours
"0 hour" is used as 411 Coolant recommended Upper limit: 25500
non-equipped. change time hours
Units: Hours Lower limit: 0 hours
402 Engine oil filter Upper limit: 25500 1 step: 100 hours
recommended change hours "0 hour" is used as
time Lower limit: 0 hours non-equipped.
Units: Hours 1 step: 100 hours
"0 hour" is used as 501 Adjustment of load Upper limit: 128
non-equipped. input Lower limit: -127
Power shift response 1 step: 1
403 Fuel filter Upper limit: 25500 hour
recommended Lower limit: 0 hour 502 Memory mode setting At memory mode:
replacement time 1 step: 100 hours of automatic engine ENABLE
Units: Hours "0 hour" is used as speed control when At AEC: OFF
non-equipped. key is in the ON
position.
404 Primary filter Upper limit: 25500
recommended hours 601 Clear engine speed Normal: Standby
replacement time Lower limit: 0 hours dial #'s back to default In clear demand:
Units: Hours 1 step: 100 hours setting CLEAR?
"0 hour" is used as Refer to ID 308 After performing clear:
non-equipped. CLEARED
(continued) 602 All clear of dial torque Normal: STANDBY
distribution setting In clear demand:
change CLEAR?
Refer to ID 309 After performing clear:
CLEARED
(continued)
74
(Table 8, contd)
603 All clear of operating Normal: STANDBY
time In clear demand:
NOTE: Please use CLEAR?
care when using this After performing clear:
feature. CLEARED ,
604 All clear of elapsed Normal: STANDBY
time for filter/fluid In dear demand:
NOTE: Please use CLEAR?'
care when using this After performing clear:
feature. CLEARED
605 All clear of logged error Normal: STANDBY
In clear demand:
CLEAR?
After performing clear: Illustration 99
CLEARED
2. The area that is highlighted in the illustration is
showing the number of the error out of the total
number of errors that are present.
i01622507
Active Error Mode

SMCS Code: 1931
The active error mode will be displayed on the

monitor panel. The active error codes correspond
to an abnormal condition that is detected by the
controller.
Illustration 100
The left arrow key and the right arrow key is used
to display the error codes that are active. These
keys are used to scroll through the codes. The
illustration above shows the "MID-CID-FMI". The
"69" is the MID. The "1162" is the CID and the
"04" is the FMI. The arrow keys are used to scroll
Illustration 98 through the active diagnostic codes.
Table 9
1. Enter the service mode. Select the "ACTIVE
ERROR" option on the second line by using the Module Identification (MID)
keys for direction.
Number For The Module Module
69 Engine and Pump
Controller
6A Tool Controller
1E Monitoring System
24 Engine ECM
75
Table 10 Table 11
Component Identifier (CID) Failure Mode identifier

CID Number Name Of Component FMI Description
91 Throttle position signal 00 Above Normal Data is valid but above normal.
96 Fuel level sensor 01 Below Normal Data is valid but below normal.
110 Engine coolant temperature sensor 02 Incorrect Signal Data is erratic, intermittent,
or incorrect.
167 Alternator
03 Voltage Above Normal
168 Voltage of the power supply
(keyswitch) 04 Voltage Below Normal
190 Speed sensor 05 Current Below Normal
248 Cat data link 06 Current Above Normal
320C and 322C
Series ONLY 07 Improper Mechanical Response
254 Electronic Control Module (ECM) 08 Abnormal Signal

312C and 315C 09 Abnormal Update
ONLY
10 Abnormal Rate of Change
271 Action Alarm
312Cand315C 11 Failure Mode Identifier
ONLY
12 Failed Component
286 Signal for low engine oil pressure
13 Out of Calibration
374 Swing brake solenoid
376 Travel alarm The MID is the code for the module identifier. The
CID is the code for the component identification.
581 Proportional reducing valve for the
power shift pressure The FMI is the failure mode identifier.
586 Engine speed dial

587 Feedback sensor for the governor ••• r i01298451
actuator
Logged Error Mode
588 Communication problem between
312C and 315C controller and monitor SMCS Code: 1931
ONLY
Trie logged error mode allows a person to view a
590 Engine controller logged diagnostic code or an error code that was
598 Travel speed solenoid cleared previously.
600 Hydraulic oil temperature sensor

1161 Pump delivery pressure
1162 Pump delivery pressure
1525 Straight travel solenoid
2002 Action alarm
320C and 322C
Series ONLY
Illustration 101
1. Enter the service mode. Highlight the second line

and scroll through the display by using the keys
for direction until the display reads "LOGGED
ERROR". See the illustration above.
76
2. The third line will display the errors that were 5. The display will change to read "CLEAR?"
previously logged. when the setting key is pressed. See the above
illustration. Then, press the "OK" key. The error
code has been erased and the screen will show
the next error. The logged error can also be
erased from the screen for setting configurations.
i01548897
Logged Event Mode

SMCS Code: 1931
The logged event mode will log a condition of the

machine that is out of the normal range without the
failure of a component. This condition is logged as
an "event".
Illustration 102
3. Highlight the displayed number by using the

keys for direction. The area that is highlighted
in the illustration shows the number of the error
out of the total number of errors. The keys for
direction are used in order to scroll through the
logged errors.
Illustration 105
1. Enter the service mode. Highlight the second

line by using the keys for direction. The third line
of the illustration shows the number of the total
number of logged events.
Illustration 103
4. The area that is highlighted in the above

illustration shows the code for the CID and the
FMI on the fourth line.
Illustration 106
Illustration 104
77
2. The fourth line of the display indicates "MID

: EID". The MID is a code for the module
identification that can identify the electronic
control module that has detected the abnormality.
SeeTesting And Adjusting, "Active Error Mode".
The EID is a code for identifying the event. This
code can identify various events. See table 12
for a description of the events.
Table 12
Event Identifier (EID)
Event Description
17 Coolant overheat
43 Abnormal battery charge (Voltage to power Illustration 108
supply low)
50
4. Press the "OK" key when the display shows
Abnormal battery charge (Voltage to power
supply high "CLEAR?". The logged events are erased one
at a time.
59 Insufficient level of coolant
95 Fuel filter is clogged
100 Engine oil pressure is low
Initial Troubleshooting
119 Fuel level is low
Procedure
171 Engine oil level is low
SMCS Code: 7569
179 Abnormal battery charge (Charging is
abnormal)
232 Water separator draining demand
235 Hydraulic oil level is low The monitor and the controller are the main
components of the electronic control system. The
236 Hydraulic oil filter is clogged monitor and the controller have a self-diagnostic
237 Overload warning function. The monitor will display any active warning
to the operator.
272 Air filter is clogged
600 Hydraulic oil overheat
862 Special filter is clogged
863 Automatic greasing failure
Illustration 107
3. In order to clear the event, highlight the fourth

line and press the "setting" key.
78
You should determine if the problem with the

machine is still present. You should use the i01548898
monitor and the "Service Mode" function in order
to determine if any system failures are detected Using Caterpillar Electronic
in the electronic system. If there are any error Technician
codes, follow the procedure for the error code. See SMCS Code: 0785-UE; 7569
the topic Testing and Adjusting, "Troubleshooting
Diagnostic Codes". Otherwise, the problem is
not likely to be in the electronic control system.
Perform the operational tests for the machine that
is being serviced. Follow the procedures that are
described in the "Testing And Adjusting" section
of the service manual for the Hydraulic System.
Compare the results of the operational tests with
the specifications in order to determine the extent
of the problem. You should determine whether the
hydraulic force is adequate or the implement speed
is a problem, when you use an operational test.
These problems can involve the entire machine or
the problem can affect only a specific operation.
The overall performance of the machine will be
decreased, if any failures occur in the circuits of
Illustration 109
the main pump or the pilot pumps and the control
valves. This type of problem in the hydraulic system Connections for the Electronic Technician (ET)
is nqt detected by self-diagnostics of the control The components that are needed to use CAT Electronic Technician
system. To detect such a problem, it is necessary to determine diagnostic codes are listed here:
to check the flow characteristics of the pumps, the (1) An IBM-COMPATIBLE personal computer with an installed
main relief pressure, pilot pressure, etc. current version of Caterpillar Electronic Technician software
(2) 139 - 4166 Data Link Cable or 7X -1570 Data Link Cable
(3) 7X-1425 Cable and 4C-6805 Adapter
(4) Special Publication, JEBD3003, Special Publication,
JERD2124, Special Publication, JERD2129; Caterpillar
Electronic Technician software
(5) 7X-1700 Communication Adapter Tool with Special
Publication, NEXG4323, "Communications Adapter Software"
Note: Caterpillar Electronic Technician (ET) is a

software program that can be used on an IBM
compatible personal computer.
In order to use the Caterpillar Electronic

Technician (ET), order the following materials:
Special Publication, JERD2124, "ET Single Use
Program License", Special Publication, JEHP1026,
"Information and Requirements Sheet", 7X-1425
Data Link Cable and the Data Subscription, and
Special Publication, JERD2142, "Data Subscription".
The Special Publication, JEHP1026, "Information
and Requirements Sheet" lists the required
hardware and the features of the ET.
The Electronic Technician (ET) is not required in

order to determine the diagnostic codes and the
ET is not required in order to clear the diagnostic
codes. However, the process of determining the
diagnostic codes is easier and faster by using the
ET. The ET can also display information on the
history of a diagnostic code and the parameter
status of diagnostic codes. These features allow the
ET to be a useful tool for troubleshooting.
79
The ET connects to the machine diagnostic

connector and the ET communicates with the
electronic control modules over the data link.
For. more information and the locations of the
connectors, see Testing and Adjusting, "Electrical
Components and Connector Locations" and the
Electrical System Schematic in your machines
Service Manual.
Connect the ET to the machine. Turn the key start

switch to the RUN position. Start the ET. The ET
will initiate communications with the electronic
control modules on the machine. The ET will list the
available electronic control modules on the machine
after communication has been established. Choose
the menu item "Engine And Pump". Use the ET in
order to determine the diagnostic codes. Follow the
troubleshooting procedures that correspond to the
diagnostic codes. See Troubleshooting Procedures.
Status Groups For Electronic

Technician
Summary Of The Status Groups
Illustration 110
Typical display of the status groups
80
The following illustrations are only typical examples

of status groups. Groups may vary from one
machine to another machine.
Calibrations By Using The

Electronic Technician
Calibration For The Automatic Governor
Actuator
The ET can be used to perform the calibration
procedure for the governor actuator. See the
following illustrations for the example.
Illustration 111
ET screen for the calibration of the automatic governor actuator
Calibration For The Proportional

Reducing Valve
The ET can be used to perform the calibration
procedure for the proportional reducing valve. See
the following illustration for the example.
81
Illustration 112
ET screen for the calibration of the proportional reducing valve
Diagnostic Tests
"Engine Speed Test"
The ET can be used to perform the "engine speed
test". See the following illustration for the example.
82
Illustration 113
ET screen for the engine speed test
"Power Shift Pressure Test"

The ET can be used to perform the "power shift
pressure test". See the following illustration for the
example.
83
Illustration 114
ET screen for the power shift pressure test
84
'101595597
Troubleshooting Diagnostic
Codes
SMCS Code: 7569
Table 13
Component Identification (CID)
CID No. Name Of Component
91 Throttle position signal
96 Fuel level sensor
110 Engine coolant temperature sensor
167 Alternator
168 Voltage to the power supply (keyswitch)
190 Speed sensor
248 Cat Data Link
320C and
322C Series
254 Electronic Control Module (ECM)
312C and
315C
271 Action Alarm
312C and
315C
286 Signal for engine oil pressure decrease
374 Swing brake solenoid
376 Travel alarm
581 Proportional reducing valve for the power
shift pressure
586 Engine speed dial
587 Feedback of the governor actuator
588 Communication problem between
312C and controller and monitor
315C
590 Engine controller
598 Automatic travel speed solenoid
600 Hydraulic oil temperature sensor
1161 Pressure sensor for the delivery pump (1)
1162 Pressure sensor for the delivery pump (2)
1525 Straight travel solenoid
2002 Travel alarm
320C and
322C Series
85
Illustration 115
Diagram Of A Typical Troubleshooting Procedure
(1) Preparations (3) Error code on the display (5) Probable cause and solution
(2) Description of the problem (4) Items that require checking
• "C-ground": Ground terminal for the chassis
• "P-ground" : Ground terminal for the

platform
• "R-ground" : Ground terminal for the relay

panel
Illustration 116 • "Cab-ground" : Ground terminal for the cab

Diagram Of Terminology For The Troubleshooting Procedures
(6) Number of the terminal in the connector Preliminary Check
(7) Indication of the short circuit
(8) Number of the connector a. Connector
(9) "M" Male "P Female
Check the connection of the connector before
1. Description (Items that require checking) a troubleshooting procedure is performed.
Inspect the connector for moisture. Moisture
2. Measurement of Voltage in a connector can cause a poor connection.
Ensure that the connectors are mating
• (A) - (B) : 24V correctly. Ensure that the pins in the connector
are secure.
Voltage is measured at the later terminal. For
example, the red test pin + is connected to b. Continuity
terminal "A" and the black test pin - is connected
to terminal "B". Ensure that continuity is present between the
following items:
3. Meaning of Symbols
• "C-ground" - "P-ground"
a. The following list describes the meaning of
specific symbols: • "C-ground" - "R-ground"
86
• "P-ground" - "Cab-ground" Table 14

Normal Indications Of The LED
Turn the disconnect switch to the OFF position
before you perform the continuity checks. The Key Green Yellow Red Remarks
power is OFF in order to prevent damage to Start LED LED LED
the tester and the circuit. Switch
ON ON OFF OFF The red LED
5. Preparation will momentarily
illuminate when the
a. Turn the key start switch to the OFF position. key start switch is
turned from the OFF
b. The hydraulic control lever is in the LOCKED position to the ON
position. position.
OFF OFF OFF OFF The green LED will
c. Ensure that the controller, the harnesses and remain illuminated
the connectors are connected. for approximately 10
seconds after the key
Note: Ensure that disconnected wires do not contact start switch is turned
the machine in order to avoid damage to electrical to the OFF position.
components when power is applied.
Table 15
Indications Of The LED For A Malfunction
Check of Controller LED LED Display Description and Action
Indicator - Troubleshoot No LED is illuminated. Power is not supplied to

the controller. Perform
Testing And Adjusting, "No
SMCSCode: 1931-035; 7610-035-NP Power Supply to Controller
- Troubleshoot".
The yellow LED is Communications
illuminated. between the controller
and the monitor have
malfunctioned. Perform
Testing And Adjusting, "No
Power Supply to Controller
- Troubleshoot".
The red LED is flashing or The controller has
illuminated. malfunctioned. Replace
the controller. See Testing
And Adjusting, "Controller
- Replace".
Illustration 117
Controller At The Rear Of The Cab
(1) Green LED
(2) Yellow LED
(3) Red LED
(4) Controller
87
No Power Supply to Controller

- Troubleshoot
SMCSCode: 1931-035; 7610-035-NP
No Power Supply To Controller.
Illustration 118
Diagram for 312C and 315C
88
Illustration 119
Diagram for 320C, 322C, 325C, and 330C
89
Check Of Power Supply Line

(101-RD)
Chcek Of Power Supply Line (101-RD)
Illustration 120
90

(112-PU) For 312C And 315C
91
Illustration 121
92

(112-PU) For 320C Series
93
Illustration 122
Diagram for 320C Series
94

(112-PU) For 322C
Illustration 123
Diagram for 322C
95

(112-PU) For 325C and 330C
Illustration 124
96

(109-RD) For 322C,325C,and 330C
Check of Power Supply Line (109-RD).
Illustration 125
97
Schematic Of Power Supply For

312C
Illustration 126
98

315C
Illustration 127
99

320C Series
Illustration 128
100

322C
Illustration 129
101

325C and 330C
Illustration 130
102
Check Of Starter Switch
Illustration 131
109
Schematic Of Starter Switch For

312C
Illustration 132

315C
Illustration 133
104

320C Series
Illustration 134

322C
Illustration 135
105

325C and 330C
Illustration 136
S/N: CAP1-Up
i01591724
S/N: BGR1-Up
Engine Controller Is Abnormal
- Troubleshoot S/N: BKT1-Up
(590) S/N: CBT1-Up
SMCSCode: 1900-035 S/N: BKW1-Up
S/N: BLA1-Up S/N: BLX1-Up
S/N:CYA1-Up S/N:GKX1-Up
S/N: MCA1-Up S/N: DKY1-Up
S/N: CRB1-Up S/N: CGZ1-Up
S/N: BTD1-Up
S/N: BFE1-Up
S/N: GAG1-Up
S/N:AMH1-Up
S/N: BKH1-Up
S/N: CSJ1-Up
S/N: BFK1-Up
S/N: M2K1-Up
S/N:G1L1-Up
S/N: BMM1-Up
S/N: S3M1-Up
S/N: BNN1-Up
106
The Engine Controller Is Abnormal
g00825381
Illustration 137
107
Illustration 138
108
Illustration 139
109
Illustration 140
110
i01623236
Communication Problem
Between Controller and
Monitor - Troubleshoot
("CID 248" and "CID 588")
SMCSCode: 1931-035; 7490-035; 7610-035-NP
Communication Problem Between

Controller And Monitor (312C And
315C)
Illustration 141
111

Controller And Monitor (320C
Series)
Communication Problem Between Controller And Monitor.
Illustration 142
Diagram for 320C series
1.12

Controller And Monitor (322C)
Communication Problem Between Controller And Monitor.
Illustration 143
Diagram for 322C
113

Controller And Monitor (325C and
330C)
Illustration 144
114
"Monitor Is Abnormal"
Illustration 145
115
"Monitor is Abnormal" (325C and

330C)
Illustration 146
116
Check Of Power Supply To Monitor
Check Of Power Supply To Monitor.
Illustration 147
117
Check Of Monitor Indicator Signal
Check Of Monitor indicator Signal.
Illustration 148
1.18
Schematic Of The Circuits For The

Monitor (312C)
101-RD
Illustration 149
119

Monitor (315C)
Illustration 150
120

Monitor For 320C Series
Illustration 151
121

Monitor (322C)
SWITCH PANNEL
MONITOR
Illustration 152
122

Monitor (325C and 330C)
lllustration 153
123
Warning "Fuel Leftover

Is Little" Is Displayed -
Troubleshoot
(CID 96)
SMCS Code: 7490-035
Illustration 154
124
"Fuel Gauge Indication Is

Abnormal"
Illustration 155
125
"Check For Open Circuit And +B

Short Of Fuel Gauge Sensor"
Illustration 156
126
Schematic Of The Fuel Level

Sensor (312C)
Illustration 157

Sensor (320C And 322C)
Illustration 158
127

Sensor (325C and 330C)
Illustration 159
128
"Check For Ground Short Of Fuel

Gauge Sensor"
Illustration 160
129
"Check Of The Fuel Gauge Sensor

Characteristics"
Illustration 161
130
Warning "Engine Coolant

Temperature Is High" Is
Displayed - Troubleshoot
(CID110)
SMCS Code: 7490-035
Illustration 162
131
"Engine Coolant Temperature

Gauge Indication Is Abnormal"
Illustration 163
132
Illustration 164
Illustration 165
133
"Check For Open Circuit And

+B Short Of Engine Coolant
Temperature Sensor" For 320C
Series And 322C
Illustration 166
Diagram for 320C series and 322C
134

+B Short Of Engine Coolant
Temperature Sensor" For 312C
And 315C
Illustration 167
135
Schematic Of Engine Coolant

Temperature Sensor For 312C and
315C
Illustration 168
Schematic Of Engine Coolant

Temperature Sensor For 320C
Series And 322C
Illustration 169
136
"Check For Ground Short Of Engine

Coolant Temperature Sensor"
Illustration 170
137
"Check Of Engine Coolant

Temperature Sensor
Characteristics"
Illustration 171
138
Warning "Hydraulic Oil

Temperature Is High" Is
Displayed - Troubleshoot
(CID 600)
SMCS Code: 7490-035
139
Illustration 172
140
"Hydraulic Oil Temperature Gauge

Indication Is Abnormal"
Illustration 173
141

Short Of Hydraulic Oil Temperature
Sensor"
Illustration 174
142
Schematic Of The Hydraulic Oil

Temperature Sensor For 312CAnd
315C
Illustration 175

Temperature Sensor For 320C
Series and 322C
Illustration 176
143

Temperature Sensor For 325C and
330C
Illustration 177
"Check Of GND Short Of Hydraulic

Oil Temperature Sensor"
Illustration 178
144
"Check Of Hydraulic
Oil Temperature Sensor
Characteristics"
Illustration 179
145
Illustration 180
146
Warning "Engine Oil Pressure

Is Low" Is Displayed -
Troubleshoot
(CID 286 (325C and 330C))
SMCS Code: 7490-035
S/N: BLA1-Up
S/N: CYA1-Up
S/N: HAA1-Up
S/N: MCA1-Up
S/N:CRB1-Up
S/N: JAB 1-Up
S/N: BTD1-Up
S/N: KDD1-Up
S/N: BFE1-Up
S/N: GAG 1-Up
S/N: AMH1-Up
S/N: BKH1-Up
S/N: RBH1-Up
S/N: CSJ1-Up
S/N: BFK1-Up
S/N: M2K1-Up
S/N:G1L1-Up
S/N: BMM1-Up
S/N: BTM1-Up
S/N: S3M1-Up
S/N: BNN1-Up
S/N: CAP1-Up
S/N: BGR1-Up
S/N: BKT1-Up
S/N: CBT1-Up
S/N: BKW1-Up
S/N: BLX1-Up
S/N: GKX1-Up
S/N: DKY1-Up
S/N: CGZ1-Up
147
Illustration 181
148
"Warning Engine Oil Pressure Is

Low"
Illustration 182
325C
149
"Warning Engine Oil Pressure Is

Low" for 330C
Illustration 183
330C
150
Check For Open Circuit And Check

for +Battery Short Of Engine Oil
Pressure Signal
Illustration 184
151
"Check For Ground Short Of

Engine Oil Pressure Signal"
Illustration 185
Schematic Of The Engine Oil

Pressure Switch For 325C and
330C
Illustration 186
152
Warning "Air Cleaner Filter

Is Clogged" Is Displayed -
Troubleshoot
SWICS Code: 7490-035
Illustration 187
153
"Warning (AIR CLEANER FILTER IS

CLOGGED) Is Abnormal"
Illustration 188
154

Short Of Clogged Air Filter Switch"
Illustration 189
155
Schematic Of The Air Filter Switch

(312C)
Illustration 190

(315C)
Illustration 191

(320C, 320CU, 322C, 325C, and
330C)
Illustration 192
156

Clogged Air Filter Switch"
Illustration 193
157
Warning "Engine Coolant

Level Is Low" Is Displayed -
Troubleshoot
SMCS Code: 7490-035
Illustration 194
Diagram for the 325C
158
"Warning "Engine Coolant Level Is

Low" Is Abnormal"
Illustration 195
159

Short Of Engine Coolant Level
Switch"
Illustration 196
160
Schematic Of The Coolant Level

Switch (312C and 315C)
Illustration 197
Schematic Of The Coolant Level

Switch (320C, 320CU, 322C, 325C,
and 330C)
Illustration 198
161
"Check For Groud Short Of Engine

Coolant Level Switch"
Illustration 199
162
Warning "Hydraulic Oil

Level Is Low" Is Displayed -
Troubleshoot
SMCS Code: 7490-035
Illustration 200
163
"Warning "Hydraulic Oil Level Is

Low" Is Abnormal"
164
Illustration 201
165

+B Short For Hydraulic Oil Level
Switch"
C0HMS4-{ Jl2C),C«Hf l--{31501»
Illustration 202
166

Level Switch (312C)
Illustration 203

Level Switch (315C)
Illustration 204

Level Switch (320C, 320CU and
322C)
Illustration 205
167

Level Switch (325C and 330C)
Illustration 206

Hydraulic Oil Level Switch"
Illustration 207
168
i01624236
Warning "Engine Oil Level
Is Low" Is Displayed -
Troubleshoot
SMCS Code: 7490-035
Illustration 208
169
"Warning "Engine Oil Level Is Low"

Is Abnormal"
Illustration 209
170

Short Of Engine Oil Level Switch"
(312C And315C)
Illustration 210
171

Short Of Engine Oil Level Switch'
(320C And 322C)
Illustration 211
172

Short Of Engine Oil Level Switch"
(325C and 330C)
Illustration 212
Diagram for 325C
173
Schematic Of The Engine Oil Level

Switch (312C)
Illustration 213

Switch (315C)
Illustration 214

Switch (320C, 320CU, 325C and
330C)
Illustration 215
174

Switch (322C)
Illustration 216

Engine Oil Level Switch"
Illustration 217
175
i01624315
Warning "Return Filter is
Clogged" Is Displayed -
Troubleshoot
SMCS Code: 7490-035
Illustration 218
176
"Warning "Return Filter Is Clogged"

Is Abnormal" (312C And 315C)
Illustration 219
"Warning "Return Filter Is Clogged"

Is Abnormal" (320C, 322C, 325C,
and 330C)
177
illustration 220
Diagram for 320C series, 322C and 325C
178

Short Of Return Filter Switch"
Illustration 221
179
Schematic Of The Return Filter

Switch (312C)
g00777111
Illustration 222

Switch (315C)
Illustration 223

Switch (320C, 320CU, and 322C)
Illustration 224
180

Switch (325C)
Illustration 225

Switch (330C)
Illustration 226
181
"Check For Open Ground Short Of

Return Filter Switch"
Illustration 227
182
101624448
Warning "Battery Charge

Is Abnormal" Is Displayed
While Engine Is Running -
Troubleshoot
(CID 167)
SMCS Code: 7490-035
183
Illustration 228
184
Schematic Of The Alternator Circuit

For 312C And 315C
Illustration 229

For 320C Series
Illustration 230

For 322C, 325C, and 330C
Illustration 231
185
Check of Speed Sensor -

Troubleshoot
(CID 190)
SMCSCode: 1907-035
186
Check Of Speed Sensor.

187
Schematic Of The Speed Sensor

For 312C
Illustration 233

For 315C
Illustration 234

For 320C, 320CU, 325C, and 330C
Illustration 235

For 322C
Illustration 236
188
Battery Voltage Is Abnormal -

Troubleshoot
(CID 168)
SMCSCode: 1406-035
1
189
Illustration 237
190
Illustration 238
191
Testing and Adjusting Secfion
Schematic Of The Battery Circuit

For 312C
Illustration 239
192

For 315C
Illustration 240
193
Testing and Adjusting Seption

For 320C Series
Illustration 241
194

For 322C
Illustration 242
195

For 325C and 330C
Illustration 243
196
Engine Speed Dial Does Not

Work - Troubleshoot
(CID 586)
SMCS Code: 5721-035-VF
Illustration 244
197
Check Of Engine Speed Dial
Illustration 245
198
Testing a n d A d j u s t i n g S e c t i o n
Illustration 246
199
The Engine Speed Dial Does Not

Work For 325C and 330C
Illustration 247
Diagram for 325C
200
Check Of Engine Speed Dial (325C

and 330C)
j
201
Illustration 248
202
203
Schematic For The Engine Speed

Dial (312C)
Illustration 250
Schematic Of The Engine Speed

Dial For 315C
Illustration 251
204

Dial For 320C
Illustration 252

Dial For 320CU, 325C, and 330C
Illustration 253
205

Dial For 322C
Illustration 254
206
Low Idle Switch Does Not Work

- Troubleshoot
SMCS Code: 7332-035
Illustration 255
207
"Check Of Low Idle Switch"
Illustration 256
208
Schematic Of Low Idle Switch For

312C
Illustration 257

315C
Illustration 258
209

320C
Illustration 259

320CU, 325C, and 330C
Illustration 260
210

322C
Illustration 261
211
"Engine Speed At Each Dial

Position Is Abnormal"
Illustration 262
212
Engine Speed At Each Dial Position

Is Abnormal 325C and 330C
Illustration 263
213
AEC Is Abnormal -
Troubleshoot
SMCSCode: 1931-035
Illustration 264
214
Illustration 265
215
"AEC Mode Indicator Is Abnormal"
Illustration 266
216
Illustration 267
217
Schematic Of The Panel For The

AEC Mode Switch (312C)
Illustration 268

Illustration 269
218

Illustration 270

AEC Mode Switch (320CU)
Illustration 271
219

Illustration 272

AEC Mode Switch (325C and 330C)
lustration 273
220
S/N: BKK1-Up
Check of Governor Actuator - S/N: M2K1-Up
Troubleshoot S/N:BBL1-Up
(CID 91 (325C)) S/N: CFL1-Up
SMCS Code: 1716-035 S/N:G1L1-Up
S/N: APA1-Up S/N: BKM1-Up
S/N: BEA1-Up S/N: BMM1-Up
S/N: BLA1-Up S/N: CAM1-Up
S/N: CBA1-Up S/N: CLM1-Up
S/N:CYA1-Up S/N: S3M1-Up
S/N: MCA1-Up S/N: BCN1-Up
S/N:ANB1-Up S/N: BFN1-Up
S/N: BCB1-Up S/N: BNN1-Up
S/N: BDB1-Up S/N: BLP1-Up
S/N: BGB1-Up S/N: CAP1-Up
S/N: CFB1-Up S/N: BE.R1-Up
S/N: CRB1-Up S/N: BGR1-Up
S/N:AMC1-Up S/N: BPR1-Up
S/N: BBC1-Up S/N: FDS1-Up
S/N: BDC1-Up S/N: BKT1-Up
S/N: BTD1-Up S/N:CBT1-Up
S/N:CCD1-l)p S/N: CFT1-Up
S/N: BDE1-Up S/N: BKW1-Up
S/N: BFE1-Up S/N: ALX1-Up
S/N: CAE1-Up S/N: BFX1-Up
S/N:ALF1-Up S/N: BLX1-Up
S/N: BEF1-Up S/N: BMX1-Up
S/N:GAG1-Up S/N: BRX1-Up .
S/N: AKH1-Up S/N: GKX1-Up
S/N: AMH1-Up S/N: BNY1-Up
S/N: BKH1-Up S/N: CBY1-Up
S/N: BPH1-Up S/N: DKY1-Up
S/N: BKJ1-Up S/N: CGZ1-Up
S/N: CSJ1-Up S/N: CLZ1-Up
S/N: BFK1-Up
221
Illustration 274
222
Illustration 275
Illustration 276
S/N: M2K1-Up
Check of Feedback Signal S/N: BBL1-Up
From Governor Actuator - S/N: CFL1-Up
Troubleshoot S/N:G1L1-Up
(CID 587) S/N:BKM1-Up
SMCSCode: 1716-035 S/N: BMM1-Up
S/N:APA1-Up S/N: GAM1-Up
S/N:BEA1-Up S/N:CLM1-Up
S/N:BLA1-Up S/N: S3M1-Up
S/N: CBA1-Up S/N: BCN1-Up
S/N: CYA1-Up S/N: BFN1-Up
S/N: MCA1-Up S/N: BNN1-Up
S/N: ANB1-Up S/N: BLP1-Up
S/N: BCB1-Up S/N: CAP1-Up
S/N: BDB1-Up S/N: BER1-Up
S/N: BGB1-Up S/N: BGR1-Up
S/N: CFB1-Up S/N: BPR1-Up
S/N:CRB1-Up S/N: FDS1-Up
S/N:AMC1-Up S/N: BKT1-Up
S/N: BBC1-Up S/N: CBT1-Up
S/N: BDC1-Up S/N: CFT1-Up
S/N: CCD1-Up S/N: ALX1-Up
S/N: BDE1-Up S/N: BFX1-Up
S/N:BFE1-Up S/N: BLX1-Up
S/N: CAE1-Up S/N:BMX1-Up
S/N: ALF1-Up S/N: BRX1-Up
S/N: GAG1-Up S/N: BNY1-Up
S/N:AKH1-Up S/N: CBY1-Up
S/N:AMH1-Up S/N: DKY1-Up
S/N: BKJ1-Up
S/N: CSJ1-Up
S/N: BFK1-Up
S/N: BKK1-Up
224
Check Of Feedback Signal From Governor Actuator.
Illustration 277
225

Short Of Feedback Signal From
Governor Actuator"
Illustration 278
226

Feedback Signal From Governor
Actuator"
Check For Ground Short Of Feedback Signal From Governor Actuator.
Illustration 279
227
Schematic Of The Circuit For The

Governor Actuator (312C)
Illustration 280
228

Illustration 281
229

Illustration 282
230

Governor Actuator (320CU)
Illustration 283
231

Illustration 284
232
i01624560
Check of Fault Alarm -

Troubleshoot
(CID 2002 for 320C and 322C or
CID 271 for 312C, 315C, 325C
and 330C)
SMCS Code: 7407-035
Check of Fault Alarm
Illustration 285
233
Check For Open Circuit, Ground Short And +B Short Of Fault Alarm.
Illustration 286
234
Illustration 287
235
Illustration 288
236
Schematic Of The Fault Alarm

(312C)
CONTROLLER
<| 23 4~ FAULT ALARM
g00778597
Illustration 289
Schematic Of The Fault Alarm 315C
Illustration 290
Schematic Of The Fault Alarm For

320C Series
Illustration 291
237

(322C)
Illustration 292

(325C and 330C)
Illustration 293
238
Travel Alarm Is Abnormal -

Troubleshoot
(CID 376)
SMCS Code: 7429-035
"Travel Alarm Is Abnormal" for

312C and 315C
18. Travel Alarm Is Abnormal.
Illustration 294
239
"Travel Alarm Is Abnormal" for

320C, 322C, 325C and 330C
Illustration 295
240
"Check Of (Left) Travel Pressure

Switch"
Illustration 296
241
Schematic Of The Travel Pressure

Switch For 312C
Illustration 297
Schematic Of The Travel Pressure

Switch For 315C
Illustration 298
f
242
Schematic Of The Left Travel

Pressure Switch For 320C Series
Illustration 299
Schematic Of The Left Travel

Pressure Switch For 322C, 325C,
and 330C
Illustration 300
243
Check Of The Right Travel Pressure

Switch (320C And 322C)
Illustration 301
244
Illustration 302
Schematic Of The Right Travel

Pressure Switch For 320C Series
Illustration 303
245
Schematic Of The Right Travel

Pressure Switch (322C, 325C, and
330C)
Illustration 304
246

Ground Short Of Travel Alarm"
Check For Open Circuit And Ground Short Of Travel Alarm.
Illustration 305
247
"Check For +B Short Of Travel

Alarm"
Illustration 306
Schematic Of The Travel Alarm
Illustration 307
248
Schematic Of The Travel Alarm For

325C and 330C
Illustration 308
249
Automatic Travel Speed

Change Is Abnormal -
Troubleshoot
(CID 0598, CID 1161, and CID
1162)
SMCSCode: 1931-035
Illustration 309
250
"Check Of Power Supply To Switch

Panel"
Illustration 310
251
Schematic Of The Switch Panel

(312C)
Illustration 311

(315C)
Illustration 312

(320C Series)
Illustration 313
252

(322C)
Illustration 314

(325C and 330C)
Illustration 315
253
"Travel Mode Indicator Is

Abnormal"
Travel Mode Indicator is Abnormal
Illustration 316
254
Illustration 317
Schematic Of The Switch Panel For

The Travel Mode (312C)
Illustration 318
255

Illustration 319

Illustration 320
256

The Travel Mode (320CU)
Illustration 321

The Travel Mode (322C, 325C and
330C)
Illustration 322
257
'Tortoise Mode Sets Speed High"
Illustration 323
258
Schematic Of The Travel Speed

Solenoid (312C)
Illustration 324

Solenoid (315C)
Illustration 325

Solenoid For 320C Series, 322C,
325C, and 330C
Illustration 326
259
"Rabbit Mode Does Not Set Speed

High"(312CAnd315C)
illustration 327
260
"Rabbit Mode Does Not Set Speed

High" (320C, 322C, 325C, and 330C)
Illustration 328
261
"Check For +B Short Of Automatic

Travel Speed Change Solenoid"
Illustration 329
262

Ground Short Of Automatic Travel
Speed Change Solenoid"
Illustration 330
263
"Check Of First Pump Delivery

Pressure Sensor"
Illustration 331
264
Schematic Of The Pressure

Sensor (1) For The Delivery Pump
Discharge (312C Series)
Illustration 332

Illustration 333
265

Illustration 334

•jstratton 335
266

Discharge (325C and 330CSeries)
Illustration 336
267
"Check For Power Supply To First

Pump Delivery Pressure Sensor"
fcsfcafion 337
268
"Check For Ground Short Of First

Illustration 338
269

+B Short Of First Pump Delivery
Pressure Sensor"
Illustration 339
270
Illustration 340
271
"Check Of Second Pump Delivery

Pressure Sensor"
Check of 2ND Pump Delivery Pressure Sensor.
Illustration 341
272

Discharge (312C)
Illustration 342

Discharge (315C)
Illustration 343
273

Illustration 344

Discharge (322C)
Illustration 345
274

Discharge (325C and 330C)
Illustration 346
275
"Check Of Power Supply To Second

Check Of Power Supply To 2ND Pump Delivery Pressure Sensor.
Illustration 347
276

Second Pump Delivery Pressure
Sensor"
Check For Ground Short Of 2nd Pump Delivery Pressure Sensor.
Illustration 348

Short Of Second Pump Delivery
Pressure Sensor"
277
Check For Open Circuit And +8 short of 2ND Pump Delivery Pressure Sensor.
Illustration 349
278
Illustration 350
Swing Is Inoperable -
Troubleshoot
(CID 374)
SMCSCode: 6501-035
Swing Is Inoperable
Troubleshooting (312C And
315C)
279
Illustration 351
Swing Is Inoperable
Troubleshooting For 320C Series
and 322C
280
Swing Is Inoperable.
Illustration 352
281
Swing Is Inoperable
Troubleshooting For 325C and
330C Series
i
282
Illustration 353
283
"Check Hydraulic Activation

Control And Associated
Components (When Engine Is
Operable)"
284
Illustration 354
285
286
Illustration 356
287
Schematic For Troubleshooting

"Swing Is Inoperable" (312C)
Illustration 357
288

Illustration 358
289

"Swing Is Inoperable" (320C Series)
Illustration 359
290

Illustration 360
291

"Swing Is Inoperable" (325C and
330C)
Illustration 361
292
Check Of Timer Relay ("325C" and

330C)
Cheek Of Timer Relay 325C
Illustration 362
293
"Check Of Joystick Pressure

Switch"
Illustration 363
294
"Check For Open Circuit and

Ground Short Of Swing Brake
Solenoid"
Check For Open Circuit And Ground Short Of Swing Brake Solenoid.
Illustration 364
295
Illustration 365
296
"Check For +B Short Of Swing

Brake Solenoid"
Check For 4B Short Of Swing Brake Solenoid.
Illustration 366
297

Swing Brake Solenoid (312C)
Illustration 367
298

Illustration 368
299

Illustration 369
300

Swing Brake Solenoid (320CU)
Illustration 370
301

Illustration 371
302

Swing Brake Solenoid (325C and
330C)
Illustration 372
303
Check of Straight Travel

Proportional Reducing Valve -
Troubleshoot
(CID 1525)
SMCS Code: 5059-035
304

+B Short Of Straignt Travel
Proportional Reducing Valve"
Illustration 373
305

+B Short Of Straignt Travel
(325C and 330C)
Illustration 3 7 4
306
"Check For +B Short Of Straight

Travel Proportional Reducing
Valve"
Check For +B Short Of Straight Travel Proportional Reducing Valve.
Illustration 375
307
"Check For +B Short Of Straight

Travel Proportional Reducing
Valve" (325C and 330C)
Check For +S Short Of Straight Travel Proportional Reducing Valve.
Illustration 376
308
Schematic Of The Straight Travel

Solenoid
Illustration 377
Schematic Of The Straight Travel

Solenoid (325C and 330C)
Illustration 378
Check of Proportional
Reducing Valve - Troubleshoot
(CID581)
SMCS Code: 5473-035-QY
309
Check For Open Circuit Of Proportional Reducing Valve .
Illustration 379
310
"Check For Over Circuit Of

Check For Over Circuit Of Proportional Reducing Valve MID CID FMl
89 581 08
Illustration 380
311
Illustration 381
312
"Check For +B Short Of

Check For +B Short Of Proportional Reducing Valve,
Illustration 382
313
Schematic For The Proportional

Reducing Valve (312C)
Illustration 383
314

Illustration 384
315

Illustration 385
316

Reducing Valve (320CU)
Illustration 386
317

Illustration 387
318

Reducing Valve (325C and 330C)
Illustration 388
319
i01310815
Warning "Water Separator
Has Water" is Displayed -
Troubleshoot
SMCS Code: 7490-035
Warning "Water Separator Has Water" Is Displayed.
Warning "Water Separator

Has Water" Is Abnormal -
Troubleshoot
SMCS Code: 7490-035
320
Illustration 390
321

Short Of Water Separator Level
Switch"
Check For Open Circuit And +B Short Of Water Separator Level Switch
Illustration 391
322
"Check For Ground Short Of Water

Separator Level Switch"
Check For Ground Short Of Water Separator Level Switch
Illustration 392
323
"Check Of Power Supply To Water

Separator Level Switch"
Illustration 393
324
Schematic Of The Level Switch For

The Water Separator (312C)
Illustration 394

Illustration 395
325

The Water Separator (320C Series)
Illustration 396
Schematic Of The Level Switch

For The Water Separator (322CAnd
325C)
Illustration 397
326
Schematic Of The Level Sensor For

Illustration 398
Initial Troubleshooting Procedure

Charging System - Test 1. CHECK THE RESISTANCE IN THE EXCITATION
SMCSCode: 1406-081 CIRCUIT. This step is only for alternators
with external excitation when the terminal for
Often when problems with the charging system are excitation is labelled: " 1 " , "REG", and "D+".
being investigated, the alternator is not the problem. See "Alternator Specifications" if the method
If a low battery condition is present, test the of excitation is unknown. Go to Step 3 if your
batteries first. See Special Instruction, SEHS7633, alternator is self-excited. Proceed to Step 2 if
"Battery Test Procedure" for more information. If the the excitation terminal of the alternator has the
engine cranks slowly, then test the starting system. label "IG".
See Service Magazine, SEPD0020, "Testing The
Starter On The Engine" for more information. If a a. Turn the key start switch to the ON position.
warning indicator for the charging system is ON, see
Service Magazine, SEBD1751, "Difference Between b. Verify voltage at the excitation terminal.
Alternator Indicator In Electronic Monitoring System Connect the red lead from a multimeter to the
(EMS) And Low Voltage Indicator In Operating excitation terminal. Connect the black lead to
Monitoring System (OMS)". When a problem with a ground source (alternator case ground).
the charging system is suspected, then complete
the testing that is outlined in this Special Instruction. c. Read the voltage that is shown on the
multimeter.
See "Initial Troubleshooting Procedure" in order
to begin troubleshooting. The procedures in this Expected Result: The voltage reads at least
Special Instruction are designed to guide you to .2 volts.
the problem with as little testing as possible. In
most cases, you will only use a few of the tests to Results:
diagnose a problem. The tests are labelled as T1
- T8 for easy reference. A descriptive title for each • YES - The voltage reads .2 volts or more.
test is included as well. The excitation circuit is correct. Proceed
to Step 3.
327
• NO - The voltage is less than .2 volts. • YES - The voltage reads battery voltage.
There is a failure in the wiring harness The excitation circuit is correct. Proceed
to the alternator or there is a poor to Step 3.
electrical connection. Correct the problem
and operate the machine. Watch for a • NO - The voltage is more than .5 volts less
recurrence of the problem. than battery voltage. There is a failure in
the wiring harness to the alternator or there
2. CHECK THE RESISTANCE IN THE EXCITATION is a poor electrical connection. Correct the
CIRCUIT (CONTINUED). This step is only for problem and operate the machine. Watch
alternators with external excitation when the for a recurrence of the problem.
terminal for excitation is labelled: "IG". See
"Alternator Specifications" if the method of 3. CHECK THE SYSTEM VOLTAGE.
excitation is unknown. Go to Step 3 if your
alternator is self-excited. a. Before starting the machine, connect a
voltmeter between the "B+" terminal and the
a. Turn the key start switch to the ON position. case of the alternator. Turn OFF all electrical
loads.
b. Verify voltage at the excitation terminal.
Connect the red lead from a multimeter to the b. Turn the key to the ON position but do not
excitation terminal. Connect the black lead to start the engine.
a ground source. The case of the alternator
can be used as a good source of ground. Expected Result: This voltage should be
system voltage.
Note: For Denso G3B, K3A, and L3A alternators,
Insert a 7X-1710 Multimeter Probe Group into the Results:
rear of the middle wire in the connector. See figure
399 below. Insert the probe (spoon lead) between • YES - The voltage is system voltage. Go
the black seal that surrounds the wire and the outer to Step 4
shell of the connector. Do not insert the probe
between the wire insulation and the black seal. This • NO - The voltage is less tharr system
terminal (IG) is the terminal for excitation. 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%. 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
Illustration 399 voltage is also lower than the maximum
voltage that is listed in the specifications
Special Technique Using A Wire Probe On The Denso Alternator
for the alternator. The alternator is partially
charging. See the following diagnostic flow
c. Read the voltage that is shown on the chart for reference in continued testing.
multimeter. Proceed to "T1 Alternator Output - Test"".
Expected Result: The voltage is within .5
volts of battery voltage.
Results:
328
• 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. This 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 very low at idle.
329
Illustration 400
T1 Alternator Output - Test 3. Set the digital multimeter to "peak hold" or "max
mode" on the "mV" scale.
1. Ensure that the batteries are NOT fully charged.
4. Turn on all electrical accessories: lights, air
a. Fully charged batteries have open circuit conditioning, and radio.
voltage above 12.5 volts on 12 volt systems
or 25 volts on 24 volt systems. 5. Start the machine, and immediately set the
throttle to at least 75%. The peak current will
b. If the batteries are fully charged then crank appear on the voltmeter in "peak hold" or "max"
the engine for 30 seconds. This action mode.
reduces the battery voltage. Operate the
lights for 10 minutes while the engine is off Expected Result: This current reading should
as an alternative. be at least 90% of the specified peak output.
2. Connect the 9U-5795 Current Probe or 8T-0900 Results:

Ammeter to a DMM (digital multimeter). 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" .
330
• OK - The current is at least 90% of the Results:

specified peak output. See "Alternator
Specifications" for exact numbers. Go to • YES - The current is below 0.050 amperes. The
""T2a - Undesired Electrical System Current charging system is currently good. The fault is
- Test (For Machines Equipped With A Main possibly an intermittent draw in the system.
Disconnect Switch"" OR ""T2b - Undesired The batteries may be faulty. Check that NO
Electrical System Current - Test (For Any accessories were ON during the test.
Machine)"".
• NO - The current is above 0.050 amperes.
• NOT OK - The current is less than 90% of the There is a draw in the system. Go to ""T5
specified peak output. Go to ""T4 Alternator Alternator Current - Test"".
Drive System - Check"".
T2b - Undesired Electrical System
T2a - Undesired Electrical System Current - Test (For Any Machine)
Current - Test (For Machines
1. Turn off all accessories. Turn the keyswitch to
Equipped With A Main Disconnect the OFF position.
Switch)
2. Clamp a 9U-5795 Current Probe or 8T-0900
1. Turn off all of the accessories. Turn the keyswitch Ammeter around the main ground cable. Clamp
to the OFF position. the tool with the positive side away from the
battery. Reset the probe (zero) before clamping
2. Clamp a 91)-5795 Current Probe or 8T-0900 around the wire. Read the current.
Ammeter around the main ground cable. Clamp
the tool with the positive side away from the Expected Result: The current is below 2
battery. Reset the probe (zero) before clamping amperes.
the probe around the wire. Read the current.
Results:
Expected Result: The current is below 2
amperes. • YES - The current is below 2 amperes.
Continue to Step 3.
Results:
• NO - The current is above 2 amperes. There
• YES - The current is below 2 amperes. is a current draw in the system. Go to ""T5
Continue to Step 3. Alternator-Current - Test"".
• NO - The current is above 2 amperes. There 3. Remove the ground cable from the battery
is a current draw in the system. Go to ""T5 terminal. For systems with 4 batteries, or 12 volt
Alternator Current - Test"". systems with 2 batteries, disconnect the ground
cables from both negative batteries.
3. Turn the disconnect switch to the ON position.
Connect an ammeter across the disconnect 4. Connect an ammeter between the disconnected
switch terminals. Connect the red lead to the battery ground cable and one of the negative
terminal on the frame side. Connect the black battery terminals. Connect the red positive lead
lead to the terminal on the battery side. If a of the ammeter to the cable. The negative lead
multimeter is being utilized for this test, use the should be connected to the battery terminal. If
10A connections in order to avoid damage. a multimeter is being utilized for this test, use
the 10 ampere connections in order to avoid
4. Turn off the disconnect switch and read the damage.
current.
Expected Result: The current is below .050
Expected Result: The current is below .050 amperes (50 milliamperes).
amperes (50 milliamperes).
Note: The standard acceptable current draw is 50
Note: The standard acceptable current draw is 50 milliamperes. A current draw above 50 milliamperes
milliamperes. A current draw above 50 milliamperes usually indicates a problem. However, some large
usually indicates a problem. However, some large machines with multiple electronic control modules
machines with multiple electronic control modules have a higher acceptable limit. Contact a Caterpillar
have a higher acceptable limit. Contact a Caterpillar dealer for more information.
dealer for more information.
331
Results: Expected Result: The voltage is less than the

voltage or the voltage is equal to the voltage that
• YES - The current is below 0.050 amperes. The was recorded in Step 4 for a 12 volt system.
charging system is currently good. The fault is However, the voltage is within one volt. On 24
possibly an intermittent draw in the system. volt systems, the voltage is within 2 volts.
The batteries may be faulty. Check that NO
accessories were ON during the test. Results:
• NO - The current is above 0.050 amperes. • YES - If the voltage in Step 4 is not more than
There is a draw in the system. Go to ""T5 1 volt for 12 volt systems (2 volts for 24 volt
Alternator Current - Test"". • systems) higher than the voltage in Step 5,
this test is complete and the related wiring is
Note: The following alternators have a connector for correct at this time. Replace the alternator or
a regulator: 6T-1193, 6T-1194, 6T-1195, 6T-1196, disassemble the alternator and repair.
9G-6079, and 9G-6081. Disconnect the regulator
connector from the alternator. Recheck the current • NO - If the voltage in Step 4 is more than 1
that was found in the previous Step. If the current volt for 12 volt systems (2 volts for 24 volt
is below 0.050 amperes (50 milliamperes) the systems) higher than the voltage in Step 5,
regulator is faulty. there is high circuit resistance: corrosion, loose
connections, and damaged wiring. Continue
to Step 6.
T3 Charging System - Test
1. Verify that the alternator B+ terminal nut is tight 6. Check the voltage between the machine frame
and verify that the wire has a good connection and the alternator B+ terminal. Record the
to the B+ terminal. voltage.
2. Many Caterpillar machines are equipped with 7. Check the voltage between the machine frame
a connector for the 6V-2150 Starting/Charging and the + battery post. Step 7 should be
Analyzer. Use of this tester replaces the testing completed as quickly as possible after Step 6.
below. See Systems Operation, SENR2947,
"Starting and Charging Systems". Expected Result: The voltage difference
between Step 6 and Step 7 does not exceed 1
volt on 24 volt systems or 0.5 volts on 12 volt
3. Start the engine and set the throttle to at least 75
systems.
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 Results:
following table will assist in making calculations
during this test. • YES - The voltage difference does not exceed
the tolerance. The charging circuit is good.
Table 16 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 volt on 24 volt systems or 0.5 volts on 12 volt
systems.
4. Measure the voltage between the alternator B+
Results:
terminal and the alternator case ground.
• YES - The voltage difference does not exceed
5. Measure the voltage across the battery. Put the
the tolerance. The ground circuit is good.
red lead on the + battery terminal, and put the
There is an internal problem with the alternator.
black lead on the negative battery terminal. Step
5 should be completed as quickly as possible Go to ""T6 Residual Magnetism Restoration"".
after Step 4.
332
• NO - The voltage difference exceeds the • YES - The current is under 0.015 amperes.
tolerance. There is high resistance in the The alternator is operating correctly. There is
ground circuit: loose cables, corroded cables, a current draw on the machine. Go to ""T7
loose alternator mounting, and poor engine Identifying Source Of Current Draw - Test"".
ground. Correct the problem and retest the
system. • NO - The current is greater than 0.015
amperes. There is an internal problem with
the alternator. Go to ""T6 Residual Magnetism
T4 Alternator Drive System - Check Restoration"".
1. Check the condition of the alternator drive belt. If
the drive belt is oily, clean the pulleys. Replace T6 Residual Magnetism Restoration
the drive belt, and retest the system. If the drive
belt is wet, dry the belt and retest the system. If This test is only for self-excited alternators.
the drive belt is worn, replace the belt and retest See Service Magazine, SEBD1672, July 1986,
the system. "Brushless Alternators May Not Charge In Certain
Conditions" for additional information.
2. Check the tension of the alternator drive belt. If
the tension is off, adjust the tension. 1. Start the engine and set the throttle to at least
75%.
3. Check the nut on the alternator pulley. If the nut
is loose, tighten the nut and retest the system. 2. Connect a voltmeter between the "B+" terminal
and the alternator case ground.
4. If all of the previous steps find no problems go
to ""T3 Charging System - Test"". 3. If a wire is connected, disconnect the wire from
the "R" terminal.
T5 Alternator Current - Test Expected Result: The voltage remains
1. Turn the keyswitch to the OFF position. unchanged.
2. Connect the 9U-5795 Current Probe or 8T-0900 Results:

Ammeter to a DMM (digital multimeter). Clamp
the probe around the .alternator output wire • YES - The voltage stays the same. Continue
("B+"). Before clamping the probe around the to Step 4.
wire, ensure that the probe is "zeroed" .
• NO - The voltage rises and the alternator
begins charging. The wire to the "R" terminal
3. Read the current.
is shorted. Repair the wiring or replace
the wiring. Go to "Initial Troubleshooting
Expected Result: The current is under 2
Procedure" and retest the system.
amperes.
4. Connect one end of a jumper wire to the "B+"
Results:
terminal of the alternator.
• YES - The current is under 2 amperes.
5. Connect the other end of the jumper wire to the
Continue to Step 4.
"R" terminal ("D+" terminal for Bosch) of the
alternator for two seconds.
• NO - The current is over 2 amperes. There is
an internal problem with the alternator. Go to
""T6 Residual Magnetism Restoration"". Expected Result: The voltage output rises on
the "B+" terminal.
4. Disconnect the B+ terminal wire from the
alternator. Connect the red lead of the multimeter Results:
to the wire that was just disconnected. Connect
• OK - The voltage output rises. The alternator
the black lead of the multimeter to the B+
is now charging. Go to "Initial Troubleshooting
terminalof the alternator. Set the multimeter on
Procedure" and retest the system.
the 10 amp scale. Read the current.
Expected Result: The current is under 0.015

amperes.
Results:
333
• NOT OK - The voltage output does not rise. c. After all of the components in that circuit have
Proceed to Step 6, if the alternator has a been disconnected, check the current. If the
wire that is connected to the " I " terminal. problem still exists then check the wiring for
Disassemble the alternator and repair the corrosion or shorts to ground.
alternator. Replace the alternator if the
alternator can not be repaired. Note: The standard acceptable current draw is 50
milliamperes. A current draw above 50 milliamperes
6. Remove the wire that is connected to the " I " usually indicates a problem. However, some large
terminal. Check for a rise in voltage on the "B+" machines with multiple electronic control modules
terminal. have a higher acceptable limit. Contact a Caterpillar
dealer for more information.
Expected Result: The voltage rises.
Results:
T8a - Alternator Overcharging - Test
This test should be used on alternators that have an
• YES - The voltage rises. There is a short "IG", a "S" or some other sensing terminal.
in the wiring to the terminal. Repair the
wiring or replace the wiring. Go to "Initial 1. Clean the connection and tighten the connection
Troubleshooting Procedure" and retest the to the wiring terminal on the alternator.
system.
2. Verify that the alternator B+ terminal nut is tight
• NOT OK - The voltage output does not
and verify that the wire has a good connection to
rise. Disassemble the alternator and repair
the "B+" terminal.
the alternator. Replace the alternator if the
alternator can not be repaired. 3. Many Caterpillar machines are equipped with
a connector for the 6V-2150 Starting/Charging
T7 Identifying Source Of Current Analyzer. See Systems Operation, SENR2947,
"Starting and Charging Systems". Use of this
Draw - Test analyzer replaces the testing below through Step
1. Make sure that every electrical component is 8. Therefore, if the testing is good, go to Step
turned OFF. Make sure that the keyswitch is 9. If the analyzer finds a problem, correct the
turned OFF. Make sure that the dome lights are problem and retest the system. Go to "Initial
OFF. Troubleshooting Procedure".

2. Clamp a 9U-5795 Current Probe or 8T-0900
percent. Turn ON all electrical accessories for all
Ammeter around the main ground cable. Clamp
test steps below. Allow the engine to run for at
the tool with the positive side away from the
least 3 minutes before continuing to Step 5. The
battery. Reset the probe (zero) before clamping
following table will assist in making calculations
the probe around the wire. Use the current
during this test.
probe if the draw is above approximately 2
amperes. Use the Ammeter if the draw is below
Table 17
approximately 2 amperes.
Test Step Voltage Voltage Voltage
3. Monitor the current and remove fuses and Reading should be should be
below this below this
breakers one at a time. Check the current after 5 for 12 volt for 24 volt
each fuse (breaker) is removed. After removing system system
a fuse (breaker) and observing the current, 6
reinstall the fuse (breaker). Start with the main 5 minus 6 = 1.0 volt 2.0 volts
fuses (circuit breakers) first, and proceed to
7
smaller circuits.
8
4. If a removal of a fuse causes the current to drop,
then the problem is in that circuit. 7 minus 8 = 0.5 volt 1.0 volt
a. Check if any components on the circuit are 5. Measure the voltage between the "B+" terminal
ON. of the alternator and the case of the alternator.
b. If everything is OFF, disconnect electrical 6. Measure the voltage across the battery. Put the
components on that circuit one at a time and red lead on the + battery terminal, and put the
monitor current. black lead on the negative battery terminal. Step
6 should be completed as quickly as possible
after Step 5.
334
Expected Result: The voltage is within one volt

of the voltage that is recorded in Step 5 for 12
volt systems. The voltage is within 2 volts for 24
volt systems.
Results:
• YES - If the voltage in Step 5 is not more than

1 volt for 12 volt systems (2 volts for 24 volt
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.
• NO - If the voltage in Step 5 is more than 1

volt for 12 volt systems (2 volts for 24 volt
there is high circuit resistance: corrosion, loose
connections, and damaged wiring. Go to Step
7.
7. Check the voltage between the machine frame

and the alternator B+ terminal. Record the Illustration 401
voltage. Special Technique Using A Wire Probe For The Denso Alternator
8. Check the voltage between the machine frame Note: The following information is used only for the
and the + battery post. Step 8 should be Denso G3B, K3A, and L3A alternators: Insert a
completed as quickly as possible after Step 7. 7X-1710 Multimeter Probe Group into the rear of
the middle wire in the connector. See figure 401.
Expected Result: The voltage difference Insert the probe (spoon lead) between the black
between Step 7 and Step 8 does not exceed 1 seal that surrounds the wire and the outer shell of
volt on 24 volt systems or 0.5 volts on 12 volt the connector. Do not insert the probe between the
systems. wire insulation and the black seal. This terminal
("IG") is the terminal for excitation.
Results:
10. Measure the voltage between the sense terminal
• YES - The voltage difference does not exceed and the case of the alternator.
the tolerance. The charging circuit is good.
Go to Step 9.
Expected Result: The voltage at the sense
terminal is above the specification.
• NO - The voltage difference exceeds the
tolerance. There is high resistance in the Results:
charging circuit: loose cables, corroded
cables, damaged cables, faulty circuit breaker,
• YES - The voltage is over specification. There
and faulty main relay. Correct the problem.
is an internal malfunction in the alternator.
Go to "Initial Troubleshooting Procedure" and
See the appropriate service manual for
retest the system.
the alternator in order to test the internal
components and connections.
percent. Turn OFF all of the accessories. • 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.
335
1. Clean the connection and tighten the connection • NO - If the voltage in Step 5 is more than 1
to the wiring terminal on the alternator. volt for 12 volt systems (2 volts for 24 volt
2. Verify that the nut on the "B+" terminal of the there is high circuit resistance: corrosion, loose
alternator is tight. Verify that the wire has a good connections, and damaged wiring. Go to Step
connection to the "B+" terminal. 7.
3. Many Caterpillar machines are equipped with 7. Check the voltage between the machine frame
a connector for the 6V-2150 Starting/Charging and the "B+" terminal of the alternator. Record
Analyzer. See Systems Operation, SENR2947, the voltage.
"Starting and Charging Systems". Use of
this analyzer replaces the testing below. If 8. Check the voltage between the machine frame
the analyzer finds a problem, correct the and the + battery post. Step 8 should be
problem and retest the system. Go to "Initial completed as quickly as possible after Step 7.
Troubleshooting Procedure".
Expected Result: The voltage difference
4. Run the engine at 75 percent. Turn ON all between Step 7 and Step 8 does not exceed 1
electrical accessories for all test steps below. volt on 24 volt systems or 0.5 volts on 12 volt
Allow the engine to run for at least 3 minutes systems.
before continuing to Step 5. The following table
describes the measurements that are taken Results:
during this test.
• YES - The voltage difference does not
Table 18 exceed the tolerance. The charging circuit is
Test Step Voltage Voltage Voltage good. There is an internal malfunction in the
Reading should be should be alternator. See the appropriate service manual
below this below this for the alternator in order to test the internal
5 for 12 volt for 24 volt components and connections.
6 system system
• NO - The difference in the voltage exceeds
5 minus 6 = 1.0 volt 2.0 volts the tolerance. There is high resistance in
7 the charging circuit: loose cables, corroded
cables, damaged cables, failed circuit breaker,
8 and failed main relay. Correct the problem.
7 minus 8 = 0.5 volt 1.0 volt Go to "Initial Troubleshooting Procedure" and
retest the system.
5. Measure the voltage between the "B+" terminal
of the alternator and the case of the alternator. Specifications For Alternators
6. Measure the voltage across the battery. Put the Table 19
red lead on the + battery terminal, and put the
black lead on the negative battery terminal. Step
6 should be completed as quickly as possible
after Step 5.
Expected Result: The voltage is within one volt

of the voltage that was recorded in Step 5 for 12
volt systems. The voltage is within 2 volts for 24
volt systems.
Results:
• YES - If the voltage in Step 5 is not more

than 1 volt for 12 volt systems (2 volts for
24 volt 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.
(continued)
336

Specifications For Alternators
Peak Minimum
Current Peak
Rating Current
(Amps) (Amps)
8N-2268 75 68
3E-7892, OR-3616 85 77
105-2813(IG), OR-9274(IG), 90 81
105-2814(IG), OR-4328(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, 115 104
121-4136, OR-3527
3E-8827, 121-4135, 117-1379(1) 130 117
152-8746 135 122
125-9597, OR-8332 145 131
24 Volt Alternators
2P-1204, 3Y-8200 19 17 Device Test
2Y-8310 21 19 SMCSCode: 1931-081
6T-1395, 7T-2095, OR-3653 33 30
S/N: APA1-Up
6N-9294, OR-5217, OR-3482 35 32
S/N: BEA1-Up
5N-5692, OR-2698 45 41
S/N: BLA1-Up
5S-9088, 100-5047, 112-5041, 50 45
3E-7578, OR-5206, OR-3667, S/N: CBA1-Up
OR-3668
S/N: CYA1-Up
109-2362, 9W-3043 55 50
, OR-3652(D+), 112-8032 S/N: MCA1-Up
3E-7772(IG), OR-9437(IG), 60 54
105-3132(IG), 4N-3986, S/N: ANB1-Up
OR-5203
S/N: BCB1-Up
155-7434, 132-2156(1), 70 63
107-7977(1), OR-8279(l) S/N: BDB1-Up
169-4319, 167-7812 75 67.5 S/N: BGB1-Up
107-7976, 114-2401, OR-8997, 75 68 S/N: CFB1-Up
3E-7577, OR-3615
S/N: CRB1-Up
165-5140 100 90
9X-7803, OR-3749 100 90 S/N: AMC1-Up
Parts-Service Only Discontinued 12 Volt Alternators S/N: BBC1-Up
6T-1193 18 16 S/N: BDC1-Up
7N-6118, 6N-5460, 4N-4540 40 36 S/N: BTD1-Up
6T-1195 42 38
S/N: CCD1-Up
7X-1340 45 41
S/N: BDE1-Up
(continued)
337
S/N:BFE1-Up S/N: BFX1-Up

S/N: CAE1-Up S/N:BLX1-Up
S/N: ALF1-Up S/N: BMX1-Up
S/N: BEF1-Up S/N: BRX1-Up
S/N: GAG 1-Up S/N:GKX1-Up
S/N: AKH1-Up S/N: BNY1-Up
S/N: AMH1-Up S/N: CBY1-Up
S/N: BKH1-Up S/N: DKY1-Up
S/N: BPHI-Up S/N: CGZ1-Up
S/N: RBH1-Up S/N: CLZ1-Up
S/N: BKJI-Up This function brings the governor actuator and
S/N: CSJ1-Up various proportional reducing valves to the
maximum sweep outputs and fixed outputs. The
S/N: BFK1-Up outputs of various proportional reducing valves
and lamps can be tested. This function allows the
S/N: BKK1-Up activation of each component in order to confirm
the operation of the component.
S/N: M2K1-Up
S/N: BBL1-Up
S/N: CFL1-Up
S/N:G1L1-Up
S/N: BKM1-Up
S/N: BMM1-Up
S/N: CAM1-Up
S/N: CLM1-Up
S/N: S3M1-Up
S/N: BCN1-Up Illustration 402
Typical display
S/N: BFN1-Up
S/N: BNN1-Up 1. Enter the service mode. Highlight the second
line by using the arrow key.
S/N: BLP1-Up
S/N: CAP1-Up
S/N: BER1-Up
S/N: BGR1-Up
S/N: BPR1-Up
S/N: FDS1-Up
S/N: BKT1-Up
S/N: CBT1-Up
S/N: CFT1-Up
Illustration 403
S/N: BKW1-Up
S/N: ALX1-Up
338
2. The arrow keys are used to scroll through the Table 20

display in order to show "DEVICE TEST".
List Of Items For The Device Test
Name Of Device Content
"ENG SPEED- Fixed output of the engine speed
FIXED"
"ENG SPEED- Sweep output of the engine
SWEEP" speed
"PS PRV-FIXED" Fixed output of the power shift
pressure
"PS PRV-SWEEP" Sweep output of the power shift
pressure
"NFC1 PRV-FIXED" Fixed output of the flow limit
pressure (AUX)
Illustration 404 "NFC1 PRV- Sweep output of the flow limit

SWEEP" pressure (AUX)
3. The third line shows the name of the component NFC1 FLOW-FIXED Flow fixed output of flow limit
that is being tested. The illustration above shows pressure
the screen that is accessing the mode for the
NFC1 FLOW-PRESS Setting of delivery pressure
fixed engine speed. The list of the items that can
be tested is shown in table 20. 2P FLOW-FIXED 2 pump flow fixed output for flow
control proportional reducing
valve
2P FLOW-PRESS Setting of delivery pressure for
calculation of flow when 2 pump
flow output is fixed
1PFLOW1-FIXED 1 pump flow (f2 valve)
fixed output for flow control
proportional reducing valve
1PFLOW1-PRESS Setting of delivery pressure for
(f2 valve) flow output is fixed
1PFLOW2-FIXED 1 pump flow (f2 valve)
fixed output for flow control
proportional reducing valve
1PFLOW2-PRESS Setting of delivery pressure for
(f2 valve) flow output is fixed
"AEC LAMP-ON/ Output of the display lamp for
OFF" the AEC mode
TRV LAMP-ON/ Output of the travel mode of the
OFF" display lamp
"A CANCEL-ON/ Output of the travel alarm release
OFF" display lamp
'TRV SPEED-ON/ Output of the travel speed
OFF" solenoid
TRV STR-ON/OFF" Output of the straight travel
NOT ON 312C/315C solenoid
"SWING BRK-ON/ Output of the swing parking
OFF" brake release solenoid
339
Note: Refer to the appropriate service manual for 6. The "cancel" key is pressed while the fourth line
the tool control of the machine that is being serviced is highlighted in order to exit this mode. The
for device tests that are not listed. above illustration will be shown when the mode
has been exited.
Illustration 405
Illustration 408
4. In order to change the output value, highlight the
fourth line of the display by using the arrow keys. 7. In order to change between the fixed output
and the sweep output, move the area that is
highlighted by using the "menu" key. See the
above illustration.
Illustration 406
5. Press the "OK" key while the fourth line is

highlighted. The display of the fourth line will Illustration 409 g00689650
change to a numerical value. The numerical
value can be increased and decreased by using 8. Highlight the fourth line and press the "OK" key.
the arrow keys.
Illustration 410
Illustration 407
9. The "setting" key is pressed in order to change
the status of the sweep output between ON and
OFF.
340
Table 21
Error Codes For The Device Test
Display Description Of Corrective Action
Error
Error 01 Being calibrated Stop the calibration
by another that is being
device performed by the
other device. Perform
this calibration again.
Error 02 Being calibrated Stop the calibration

by another that is being
module performed by the
other module.
Perform this
Illustration 411 calibration again.
10.The "cancel" key is pressed while the fourth line Error 03 Failure of the Troubleshoot
is highlighted in order to exit from the mode of interlock signal the signal for
constant output. The mode has been cancelled communication to
the monitor.
when the display is shown according to the
above illustration. Error 21 Abnormal Confirm the error
operation of a code that is active.
component Troubleshoot
according to the
error code that is
active.
Governor Actuator Sweep

Test
SMCSCode: 1716-081
S/N: APA1-Up
Illustration 412
S/N: BEA1-Up
11. If any of the following errors are displayed in the
fourth line of the display, an error has occurred S/N: BLA1-Up
during the device test. For details of the error S/N: CBA1-Up
code, refer to the following list.
S/N: CYA1-Up
S/N: MCA1-Up
S/N: ANB1-Up
S/N: BCB1-Up
S/N: BDB1-Up
S/N: BGB1-Up
S/N: CFB1-Up
S/N: CRB1-Up
S/N: AMC1-Up
S/N: BBC 1-Up
S/N: BDC1-Up
341

S/N: BFE1-Up S/N: BLX1-Up
S/N: CAE1-Up S/N: BMX1-Up
S/N: AKH1-Up S/N: CBY1-Up
S/N: AMH1-Up S/N: DKY1-Up
S/N: BKJ1-Up This mode is used to confirm the activation of the
S/N: CSJ1-Up governor actuator.
S/N: BFK1-Up Note: The 325C series does not have a governor
actuator.
S/N: BKK1-Up
Table 22
S/N: M2K1-Up
Required Tools
S/N: BBL1-Up
146 4080 Digital Multimeter
S/N: CFl1-Up 188 8589 Test Harness
S/N:G1L1-Up
S/N: BKM1-Up
S/N: BMM1-Up
S/N: CAM 1-Up
S/N: CLM1-Up
S/N: S3M1-Up
S/N: BCN1-Up
S/N: BFN1-Up
S/N: BNN1-Up
Illustration 413
S/N: BLP1-Up Governor Actuator For 312C
S/N: CAP1-Up (1) Governor actuator
(2) Governor cables
S/N: BER1-Up (3) Connector
342
Illustration 414
Governor Actuator For 315C
(2) Governor cables
(3) Connector
Illustration 416
5. Use a digital multimeter to measure the frequency

of the speed command signal while the system
is in operation. See the above illustration. The
duty cycle should be approximately 45% to 90%.
A low duty cycle means a low engine speed. A
Illustration 415
higher duty cycle means a high engine speed.
Governor Actuator For 320C series and 322C The pulse width is narrow at low speeds and the
(1) Governor actuator pulse width is wide at high speeds.
(2) Governor cables
(3) Connector 6. An abnormality is present when the pulse width
is not correct. A failure may exist in the harness,
1. Stop the engine and disconnect the connector the governor actuator or the controller.
(3) for the governor actuator. Connect the test
harness to the connector. 7. The speed of the engine will vary in
synchronization with the reciprocating drive. If
2. Place the backup switch in the AUT position. the controller is operating properly, the engine
speed will vary between the high idle and the
3. Turn the engine start switch to the ON position. low idle. The governor actuator may be installed
Do not start the engine. Select the sweep test for incorrectly or the governor actuator may not
the governor actuator. be operating correctly, if the engine speed is
not correct. Also, the engine may be operating
4. Enter the service mode. Perform the device test incorrectly.
according to "ENG SWEEP".
Governor Actuator - Replace

SMCS Code: 1716-510
S/N: APA1-Up
343
S/N: BEA1-Up S/N: CLM1-Up

S/N: BLA1-Up S/N: S3M1-Up
S/N: CBA1-Up S/N: BCN1-Up
S/N: CYA1-Up S/N: BFN1-Up
S/N: MCA1-Up S/N: BNN1-Up
S/N: ANB1-Up S/N: BLP1-Up
S/N: BCB1-Up S/N: CAP1-Up
S/N: BDB1-Up S/N: BER1-Up
S/N: BGB1-Up S/N:BGR1-Up
S/N: CFB1-Up S/N: BPR1-Up
S/N: CRB1-Up S/N: FDS1-Up
S/N: AMC1-Up S/N: BKT1-Up
S/N: BBC1-Up S/N: CBT1-Up
S/N: BDC1-Up S/N: CFT1-Up
S/N: BFE1-Up S/N: BLX1-Up
S/N: CAE1-Up S/N: BMX1-Up
S/N: BEF1-U.p S/N: GKX1-Up
S/N: AKH1-Up S/N: CBY1-Up
S/N: AMH1-Up S/N: DKY1-Up
S/N: BKJ1-Up
Replacement
S/N: CSJ1-Up
Note: The 325C series does not have a governor
S/N: BFK1-Up actuator.
S/N: BKK1-Up
S/N: M2K1-Up
S/N: BBL1-Up
S/N: CFL1-Up
S/N:G1L1-Up
S/N: BKM1-Up
S/N: BMM1-Up
S/N: CAM1-Up
344
Illustration 417 Illustration 420

Governor actuator for 312C 312C

Governor actuator for 315C 320C series

Governor actuator for 320C and 322C series 322C
(1) Governor actuator (4) Support
(2) Accelerator cable (5) Bellows
(3) Connector for governor actuator (6) Lever
(7) Decelerator cable
(8) Nut
(9) Nut
(10) Bellows
1. Turn the nut (9) and the locknut of the accelerator

cable (2) in the counterclockwise direction until
the nuts are separated.
345
2. Insert the threaded "L" end of the accelerator 5. Tighten the nut (9) until the sag in the bellows
cable (2) through the hole in the lever (6). Install (10) is no longer present. The nut (9) should be
the nut in order to hold the cable in position. tightened two additional turns.
3. Insert the other threaded portion of the 6. Secure the accelerator cable (2) to the support
accelerator cable (2) into the notch of the (4) by tightening the locknut (9).
support (4).
7. Insert the threaded section of the decelerator
4. Turn the lever (6) in the counterclockwise cable (6) into the notch of the support.
direction to the position of high idle.
8. Tighten the nut (8) until the sag in the bellows
5. Hold the lever (6) against the position of high (5) is no longer present. Loosen the nut (8) by
idle stop. Then, turn the nut (9) clockwise until two turns.
the slack is removed from the bellows (5). The
nut (9) should be tightened for approximately 9. Secure the decelerator cable (7) to the support
two turns more. with the locknut (8). Then, tighten the locknut(8)
against the nut (8). Ensure that the nut (8) does
6. Tighten the locknut against the support (4). not turn as the locknut (8) is tightened.
7. Ensure that the nut (9) remains in position while

the locknut is tightened against the support (4).
Calibration
Note: For more information, see the topic Testing
8. Reinstall the two clamps to the accelerator cable
And Adjusting, "Governor Actuator - Calibrate".
(2). Do not allow the cable (2) to twist.
1. Start the engine. Perform the calibration
Note: Ensure that the governor lever is in contact
procedure for the governor actuator.
with the high idle stop. Also, ensure that the nut
(9) is correctly tightened in order to ensure that
2. After the calibration procedure has been
the accelerator cable has the correct tension. The
performed correctly, the error log is cleared.
setting of the engine speed or an overload condition
of the governor actuator could result if the cable is
not tightened correctly. Note: For more information, see Testing And
Adjusting, "Logged Error Mode".
Note: When the current governor is being used, the
following conditions will be applicable:
101592579
a. When the accelerator cable (2) is Governor Actuator - Calibrate
disconnected from the governor lever and the
engine speed dial is in a position rather than SMCS Code: 1716-524
11, the initial calibration procedure is required.
S/N: APA1-Up
b. No initial setting is required, if the accelerator
cable (2) is disconnected from the governor S/N: BEA1-Up
lever and the engine speed dial is positioned S/N: BLA1-Up
at 11. However, the initial setting is required,
when electricity is sent to the governor S/N: CBA1-Up
actuator.
S/N:CYA1-Up
Adjustment S/N: MCA1-Up
1. Loosen the nut (9) and the locknut (9) of the S/N: ANB1-Up
accelerator cable (2). The nuts should be S/N: BCB1-Up
separated as far as possible.
S/N: BDB1-Up
2. Install the accelerator cable (2) and the
decelerator cable (7) to the lever (6). S/N: BGB1-Up
3. Insert the threaded section of the accelerator S/N: CFB1-Up

cable (2) into the support (4). S/N: CRB1-Up
4. Turn the lever (6) clockwise toward the engine S/N: AMC1-Up
until the lever hits the stop for the high idle.
S/N: BBC1-Up
346
S/N: BDC1-Up S/N: BKT1-Up

S/N: BTD1-Up S/N: CBT1-Up
S/N: CCD1-Up S/N:CFT1-Up
S/N: BDE1-Up S/N: BKW1-Up
S/N: BFE1-Up S/N: ALX1-Up
S/N: CAE1-Up S/N: BFX1-Up
S/N: ALF1-Up S/N: BLX1-Up
S/N: BEF1-Up S/N: BMX1-Up
S/N: GAG 1-Up S/N: BRX1-Up
S/N: AKH1-Up S/N: GKX1-Up
S/N: AMH1-Up S/N: BNY1-Up
S/N: BKH1-Up S/N: CBY1-Up
S/N: BPH1-Up S/N: DKY1-Up
S/N: BKJ1-Up S/N: CGZL-Up
S/N:CSJ1-Up S/N:CLZ1-Up
S/N: BFK1-Up Note: The 325C series does not have a governor
S/N: BKK1-Up actuator.
S/N: M2K1-Up This function can memorize the rotation angle of the
governor actuator and the no-load engine speed.
S/N: BBL1-Up This information is saved into the controller after the
accelerator cable of the governor actuator has been
S/N: CFL1-Up replaced, installed and/or adjusted. The controller
S/N:G1L1-Up will use the information that was saved in order to
determine the target position for the actuation of the
S/N: BKM1-Up governor actuator.
S/N: BMM1-Up Note: Ensure that the calibration procedure for the
governor actuator is performed when the governor
S/N: CAM1-Up
actuator, the accelerator cable or the controller has
S/N: CLM1-Up been replaced or installed. The temperature of the
hydraulic oil should be 50 °C (122 °F) prior to the
S/N: S3M1-Up calibration.
S/N: BCNI-Up
S/N: BFN1-Up
S/N: BNN1-Up
S/N: BLP1-Up
S/N: CAP1-Up
S/N: BER1-Up
S/N: BGR1-Up
S/N: BPR1-Up
S/N: FDS1-Up
347
3. Highlight the third line by using the keys for

direction. The name of the device will be
shown on the third line. Scroll downward until
"STANDBY" is highlighted. Press the "OK" key
in order to start the calibration procedure.
"GOVERNOR-EXE" is displayed on the third
line when the governor actuator is calibrated.
Press the "OK" key after confirming the display
of "GOVERNOR-EXE".
Illustration 423
The above illustration is an example of the display for the 312C.
All of the other displays are identical with the sales model on the
fourth line.
1. Enter the service mode.
Illustration 426
4. The above illustration shows a display that is

temporarily shown when the governor actuator
is moved to the initial position. Press the "OK"
key again when the display shows "SP". The
calibration procedure has started.
Illustration 424
2. Highlight the second line of the display and

use the direction for direction to scroll through
the display. Scroll through the display until the
display shows "CALIBRATION".
Illustration 427
5. The numerical number that is being displayed in

the fourth line will change during the calibration.
This number is related to the process of the
calibration. See the following table 23.
Illustration 425
348
Table 23 (Table 24, contd)
Content For The Process Wire Pitch Wire nut is Tighten the accelerator
X (X is a installed too cable by the displayed
Display Process number loose by X pitch. Perform the
from 0 to pitch. X can calibration again.
STANDBY Prior to calibration
9) be a positive
1 Transfer of the initial position of the or negative
governor actuator number. Turn
clockwise.
SP The initial transfer of the information
about the position has been completed. Wire Pitch Wire nut is Loosen the accelerator
X (X is installed too cable by the displayed
3 High idle search number tight by X pitch. Perform the
from -9 to pitch. X can calibration again.
4 Positioning of the high idle
0) be a positive
5 Data collection of the intermediate points or negative
(9-2) down number. Turn
clockwise.
6 Low idle search
WARNING Insufficient High idle is less than the
7 Data acquisition of intermediate points 01 high idle specified value due to
(2-9) up malfunction of the engine,
incorrect installation of
8 Confirmation of the high idle
the governor cable, poor
9 Confirmation of the setting for the speed fuel, etc. After the engine
dial (down) has been inspected for a
malfunction, reinstall the
10 Confirmation of the setting for the speed cable and perform the
dial (up) calibration again.
11 End processing WARNING Incorrect Reinstall the cable and
02 installation perform the calibration
of cable again.
WARNING Excessive Low idle is more than
03 low idle the value specified due
to a malfunction in the
engine, an incorrectly
installed governor cable,
etc. After the engine has
been inspected, reinstall
the cable and perform the
calibration again.
WARNING Excessive Ensure that the cable
04 hysteresis is adjusted correctly.
Reinstall the cable and
perform the calibration
Illustration 428 again.
(continued)
6. The above illustration is shown after the governor
actuator has completed the calibration.
Warnings
If the fourth line of the display shows any of the
following warnings a failure is present. See the
following table 24 for a detailed description of the
warning displays.
Table 24
Warning Codes
Display Warning Corrective Action
(continued)
349
(Table 24, contd) Table 25

WARNING Unstable high High idle is unstable Error Codes For The Governor Actuator
05 idle due to a malfunction in
the engine, an incorrect Error Code Description Of Corrective
installation of the governor The Error Action
cable, etc. After the engine
ERROR 01 Improper Stop the
has been inspected, calibration of calibration of the
reinstall the cable and another device other device.
perform the calibration Perform one
again. calibration at a
WARNING Unstable dial The speed for the dial time.
06 speed setting is unstable due Improper
ERROR 02 Stop the
to a malfunction in the
calibration of calibration of the
engine, an incorrectly
another module other device.
installed cable, etc. After
Perform one
the engine has been
calibration at a
inspected, reinstall the
time.
cable and perform the
calibration again. ERROR 03 Failure of the Perform the
interlock signal troubleshooting
procedure that
Errors will confirm
the signal that
If the fourth line of the display shows any of the communicates
with the monitor.
following errors a failure is present. See the following
table for a detailed description of the error displays. ERROR 11 Abnormal speed Troubleshoot
sensor the confirmation
of the speed
sensor.
ERROR 12 Engine stop Perform the
calibration again.
Try to prevent
the engine from
stopping.
ERROR 13 Load available Reset all
operational
levers to the
neutral position.
Perform the
calibration again.
ERROR 14 Overheating of You need to allow
the coolant or the complete
the hydraulic cooldown. Clear
oil during the the overheating
calibration condition.
Perform the
calibration
procedure again.
ERROR 15 Pressure Clear the
decrease in the abnormal
engine oil occurrence and
Check for perform the
clogged air calibration again.
cleaner
ERROR 16 Excessive Troubleshoot the
governor confirmation of
movement time the governor
actuator.
Perform the following procedure when the data for

the calibration of the governor actuator is cleared.
350
1. Highlight the third line by using the arrow keys. 4. Highlight the fourth line by using the directional
keys. Press the "OK" key when the fourth line
is highlighted.
Illustration 430
2. Press the "menu" key. The area that is highlighted Illustration 433
will scroll to the right.
5. Press the "OK" key when the display shows
"CLEAR?".
Illustration 431
3. Change the display of the third line in order to Illustration 434

show "CLEAR" by using the arrow keys. See the
above illustration. 6. The data for the calibration has been cleared
when the fourth line of the display shows
"CLEARED".
351
101625302
Proportional Reducing Valve
Sweep - Test
(Power Shift)
This function allows the current to the proportional

reducing valve to change at a-specific rate. This
function is used to confirm the activation of the
proportional reducing valve.
Table 26
Illustration 437
Required Tools
Illustration for 320C series, 322C, 325C, and 330C
146 -4080 Digital Multimeter
(1) Power shift pressure solenoid
6V- 2100 Multitach Group (2) Tap for the power shift pressure
188 - 8588 Test Harness 1. Stop the engine. Disconnect connector "39" of
the proportional reducing valve and connect the
test harness to connector "39".
2. Install the test leads of the multimeter.
3. Install a 4900 kPa (710 psi) pressure gauge to

the tap (2).
4. Place the backup switch to the "AUT" position.
5. Set the engine speed dial to the position of 10.
6. Allow the hydraulic oil to warm to a temperature

of 50 °C (122 °F).
Illustration 435 7. Ensure that all control levers are in the neutral
Illustration for 312C position.
8. Enter the service mode. Select the sweep test for

the power shift pressure. Perform the device test
for "PS PRV-SWEEP".
9. The display on the multimeter should show a

wave from 0.2 amperes to 0.75 amperes within
a period of 20 seconds. The pressure gauge
should show a cycle of pressure from 482 kPa
(70 psi) to 3447 kPa (500 psi) during the identical
time of the wave of the ampere.
10. Verify that the current and the pressure are

showing the correct parameters.
Illustration 436
Illustration for 315C
352
6. Highlight the third line by using the arrow keys.

i01548264 The name of the device for the calibration is
displayed on the third line. Scroll through the
Proportional Reducing Valve - display until the display shows "PS PRV" by
Calibrate using the arrow keys. The power shift pressure
is calibrated for the low pressure and the high
(Power Shift) pressure.
• Low pressure 500 kPa (72 psi)
This calibration is used to memorize the power shift
pressure for the proportional reducing valve. Be sure • High pressure 2500 kPa (362 psi)
to perform this calibration when the proportional
reducing valve or the controller has been replaced.
1. Install a pressure gauge of 4900 kPa (710 psi) to

the tap for the power shift pressure.
2. Set the backup switch to the AUTO position.
3. Raise the hydraulic oil temperature to 50 °C

(122 °F).
4. Enter the service mode.
Illustration 440
The area that is highlighted is moved to the right

side by using the "menu" key in order to change
between low pressure and high pressure. Then,
the arrow keys are used in order to change the
display from low pressure to high pressure.
Illustration 438
5. Highlight the second line by using the arrow

keys. Scroll through the display on the second
line until the display shows "CALIBRATION" by
using the arrow keys.
Illustration 441
8. Highlight the fourth line by using the arrow keys.

Then, change the value. Press the "OK" key.
Illustration 439
353
Table 27
List Of Error Codes
Display Description Of Corrective Action
The Error
ERROR Being calibrated by Stop the calibration
01 another device of the other
component. Perform
calibration again.
ERROR Being calibrated by Stop the calibration
02 another module of the other
component. Perform
calibration again.
ERROR Failure of the Troubleshoot the
Illustration 442 03 interlock signal confirmation of
the signals for
9. The fourth line will show a numerical value. The communication.
engine speed should be increased to a position ERROR Abnormal Confirm the
of 10 on the engine speed dial. The pressure 21 component active error code.
gauge will indicate the actual power shift operation Troubleshoot the
pressure. Note the actual value that is shown problem according
on the pressure gauge. Use the left arrow key to the component.
and the right arrow key to enter the value that
is shown on the pressure gauge into the fourth
line of the display on the monitor. The value
should be set as close to the actual pressure as
possible. The power shift pressure will change
by approximately 30 kPa (4.3 psi) per step. The
Speed Sensor - Replace
monitor can correct the pressure by ±30 kPa SMCSCode: 1907-510
(4.3 psi).
10. The "setting" key is pressed in order to save the

value of the power shift pressure. After the value
has been saved, the third line will be highlighted.
Illustration 444
Installation of the speed sensor
(1) Speed Sensor
(2) Locknut
(3) Magnetic Core
(4) Gear
Illustration 443 (5) Flywheel Housing
11. Refer to the following table 27 if an error is Prior to replacement of the sensor, ensure that the
present on the display. The error will be displayed sensor has failed. Always check that the power
on the fourth line of the message center. is available to the sensor. Measure the voltage
between the contacts of the sensor. Check for metal
12. Repeat the same procedure for the high shavings on the magnetic tip or the gear teeth.
pressure.
Perform the following procedure in order to replace
the speed sensor.
1. Turn the key start switch and the disconnect

switch to the OFF position.
354
2. Slowly tighten speed sensor (1) into flywheel S/N: CRB1-Up

housing (5) until magnetic core (3) contacts gear
(4). S/N: JAB 1-Up
S/N: BTD1-Up
3. Turn speed sensor (1) counterclockwise. The
turn should be approximately 3/4 of a rotation. S/N: CCD1-Up
4. Temporarily tighten locknut (2). S/N: KDD1-Up
5. Set the engine speed dial at position 1 (LOW S/N: BDE1-Up

IDLE position). S/N: BFE1-Up
6. Turn the disconnect switch to the ON position. S/N: CAE1-Up
7. Start the engine. S/N: GAG1-Up

S/N: AMH1-Up
8. Activate the service mode.
S/N: BKH1-Up
9. Enter service code 11 in order to display the
engine speed. S/N: BPH1-Up
10. Verify that 800 RPM is displayed. S/N: RBH1-Up

S/N: BKJ1-Up
11. If the correct rpm is not displayed, turn speed
sensor (1) clockwise. The turn should not be S/N: CSJ1-Up
greater than 1/3 of a rotation.
S/N: BFK1-Up
12. Stop the engine.
S/N: BKK1-Up
13. Tighten locknut (2) to a torque of 25 N-m S/N: M2K1-Up
(18.4 lb ft).
S/N: BBL1-Up
14. Verify that the sensor corrects the problem.
S/N: CFLI-Up
15. Clear the error log. Refer to Testing and
S/N:G1L1-Up
Adjusting, "Using Service Mode".
S/N: BMM1-Up
S/N: BTM1-Up
Controller - Replace S/N: CAM1-Up
SMCSCode: 1931-510; 7610-510-NP S/N: S3M1-Up
S/N: BEA1-Up S/N: BCN1-Up
S/N: BLA1-Up S/N: BFN1-Up
S/N: CBA1-Up S/N: BNN1-Up
S/N: CYA1-Up S/N: CAP 1-Up
S/N: HAA1-Up S/N: BGR1-Up
S/N: MCA1-Up S/N: BPR1-Up
S/N: BCB1-Up S/N: FDS1-Up
S/N: BDB1-Up S/N: BKT1-Up
S/N: BGB1-Up S/N: CBT1-Up
S/N: CFB1-Up S/N: CFT1-Up
355
S/N: BKW1-Up
S/N: BFX1-Up Controller Connector Contact
S/N: BLX1-Up Identification
S/N: BMX1-Up SMCSCode: 1931-CY; 7610-NP
S/N: BRX1-Up
S/N: GKX1-Up
S/N: BNY1-Up
S/N: CBY1-Up
S/N: DKY1-Up
S/N: CGZ1-Up
Prior to replacement of the controller, ensure

that replacement is absolutely necessary. The
controller is not normally the cause of a diagnostic
code. Always check that power is available to
the controller and the monitor. Battery voltage is
required at contact 1 of connector 1. Ground is
required at contact 2 of the harness connector for
the controller.
When the controller is replaced, adjustments or

calibrations are required. Refer to Testing and
Adjusting, "Proportional Reducing Valve - Calibrate"
and Testing and Adjusting, "Governor Actuator -
Calibrate".
1. Turn the disconnect switch and the keyswitch to

the OFF position.
2. Disconnect the machine harnesses from the

controller.
3. Remove the controller.
4. Verify that the replacement for the controller has

the correct part number.
5. Install the new controller.
6. Connect the machine harness to the controller.
7. Turn the disconnect switch and the keyswitch

to the ON position.
8. Verify proper operation of the controller.
9. Calibrate the electronic governor. Refer to Testing

and Adjusting, "Governor Actuator- Calibrate".
10. Calibrate the proportional reducing valve. Refer

to Testing and Adjusting, "Proportional Reducing
Valve - Calibrate".
356
Illustration 445
Diagram Of The Connectors And Contacts For The Controller
357
(Table 28, contd)

i01549587
Controller Input and Output
Values
SMCSCode: 1931; 7610-NP
Table 28
(continued)
(continued)
358
(continued)
(continued)
359
(Table 29, contd)

Engine and Hydraulic Pump Control (Connector 1) Engine and Hydraulic Pump Control (Connector 2)
Pin Function Normal Voltage Measure Pin Function Normal Voltage Measure
No. Point No. Point
47 Water When water separator Ground 4 Swing (Fine swing NOT Ground
separator is NORMAL: 14 DCV parking equipped) -
level switch to 17 DCV. brake cancel When the joystick is
When water separator solenoid being operated: 18
need draining: DCV to 32 DCV.
approx. 0 DCV. When joystick is NOT
being operated: 0
48 Air filter When air cleaner is Ground DCV.
switch NORMAL: 14 DCV to (However,
(clogged) 17 DCV. immediately after the
When air cleaner is joystick is returned to
clogged: approx. 0 the neutral condition,
DCV. 18 DCV to 32 DCV is
53 Straight Straight travel pedal- Ground held for approximately
travel During operation: 6.5 seconds)
pressure approx. 0 DCV. (Fine swing equipped)
switch When NOT being Fine swing switch
(320C operated: 14 DCV to OFF: approx. 0 DCV.
ONLY) 17 DCV. Fine swing switch ON:
18 DCV TO 32 DCV.
Table 29 6 Fine swing (Fine swing Ground

switch non-equipped)
Engine and Hydraulic Pump Control (Connector 2) Approx. 0 DCV.
(Fine swing equipped)
Pin Function Normal Voltage Measure
Fine swing switch =
No. Point
OFF: approx. 0 DCV.
1 Straight When any of the Ground Fine swing switch =
travel following components ON: 14 DCV to 17
solenoid are operated: DCV.
(320C, Right lever
Left Lever 7 Power shift When the control Ground
320CU,
Joy stick pressure lever is n the neutral
322C ONLY)
proportional position: 6 to 9 DCV.
Straight travel pedal
reducing When the lever is
The voltage is 18 DCV
valve being operated the
to 32 DCV.
voltage will drop.
When NOT being
operated: approx. 0 8 Flow limit When the flow limit Ground
DCV. pressure function is not used: 0
proportional DCV.
2 Travel speed Travel speed = Ground
reducing When the flow limit
solenoid "Rabbit" and travel
valve function is being used:
lever is being operated
The voltage varies
and the pump delivery
according to the limit
pressure is at the
flow.
value specified for the
travel speed or lower: 9 Priority When pressure Ground
18 DCV to 32 DCV negative compensation type
Other than specified control flow dividing valve is
above: approx. 0 DCV. pressure NOT being operated:
(continued) proportional approx. 0 DCV.
reducing
valve
13 Travel alarm When travel lever is Ground
being operated: 18 to
32 DCV.
When the travel lever
is NOT operated:
approx. 0 DCV.
(continued)
360

Engine and Hydraulic Pump Control (Connector 2) Engine and Hydraulic Pump Control (Connector 2)
Pin Function Normal Voltage Measure Pin Function Normal Voltage Measure
No. Point No. Point
14 AEC mode AEC = First stage: 18 Ground 29 Coolant Temperature sensor Ground
lamp to 32 DCV. temperature resistance/voltage
AEC = Second stage: sensor 0 °C (32 °F) approx.
approx. 0 DCV. 23.14k/approx. 9.7
DCV.
15 Travel mode Travel mode = Ground 25 °C (77 °F) approx.
lamp 'Tortoise": 18 DCV 6.82k / approx. 7.1
to 32 DCV. DCV.
Travel mode = "Rabbit" 50 °C (122 °F) approx.
: approx 0 DCV. 2.47k / approx. 4.2
16 Speed Approx. 0 DCV Ground DCV.
sensor (-) 75 °C (167 °F) approx.
1.08k / approx. 2.3
17 Neutral start Hydraulic activation Ground DCV.
relay control lever: LOCKED
322C ONLY Starter switch: engine 30 Fuel level Fuel remaining / Ground
Start postion: 18 to 32 sensor Sensor resistance
DCV / Voltage:
Other than above: 0 Full / approx. 8.0k /
DCV approx. 0.2 DCV
Half / approx. 33.8k /
19 Proportional Approx. 0 DCV Ground approx. 1.0 DCV
reducing Empty / approx. 83.5 /
valve return approx. 2.2 DCV
(1)
35 Alternator R When the engine is in Ground
20 Proportional Approx. 0 DCV Ground terminal high idle: approx. 14
reducing DCV.
valve return
36 Governor 0.7 DCV to 9.0 DCV Ground
(2)
feedback. voltage will vary in
21 Proportional Approx. 0 DCV Ground proportion to engine
reducing speed dial. (Dial 1:
valve return low, 10: high)
(3)
37 Pump 0.7 DCV to 9.0 DCV - Ground
22 Proportional Approx. 0 DCV Ground delivery The voltage will vary
reducing pressure in proportion to the
valve return sensor delivery pressure of
(4) the first pump.
When NOT operated:
23 Action alarm When engine oil Ground 0.7 to 2.5 DCV
pressure is NORMAL: During relief operation:
approx. 0 DCV. 7 to 9 DCV
When engine oil
pressure is too low: 18 39 Hydraulic oil Temperature sensor Ground
DCV to 32 DCV. temperature resistance / voltage:
sensor 0 °C (32 °F) approx.
24 Travel alarm When travel alarm Ground 23.14k/approx. 9.7
cancel lamp cancel switch is being DCV.
operated: 0 DCV. 25 °C (77 °F) approx.
When travel alarm 6.82k / approx. 7.1
cancel switch is NOT DCV.
operated: 18 DCV to 50 °C (122 °F) approx.
32 DCV. 2.47k / approx. 4.2
25 Speed When engine is in high Conn. DCV.
sensor (+) idle: approx. 0.7 to 5 2-16 75 °C (167 °F) approx.
ACV. 1.08k / approx. 2.3
Measured by using DCV.
ACV range. (continued)
(continued)
(Table 29, contd)
Engine and Hydraulic Pump Control (Connector 2)
Pin Function Normal Voltage Measure
No. Point
44 Governor 0.5 to 7.0 DCV Ground
command The voltage will vary
signal in proportion to the
engine speed dial.
(Dial 1: Low, Dial 10:
High)
45 Pump 0.7 to 9 DCV Ground
delivery The voltage will vary
in proportion to the
second delivery pump
pressure.
When not in operation:
0.7 DCV to 2.5 DCV.
When in relief
operation: 7 DCV
to 9 DCV.
46 Boom hold 0.7 to 9 DCV Ground
pressure The voltage will vary
sensor in proportion to the
boom hold pressure.
(In low pressure:
low voltage, In
high pressure: high
voltage.)
47 Backup (Backup switch = OFF) Ground
switch 0.7 DCV to 9 DCV
The voltage will vary
in proportion to the
engine speed dial
position. (Dial 1: low,
Dial 10: high)
(Backup switch = ON)
52 12 DCV Approx. 12 DCV. Ground
power supply
(320C,
320CU,
322C ONLY)
i01625343
System Schematic
SMCS Code: 7566
312C and 315C System Schematic

362
g00779086
Illustration 446
363
System Schematic For 320C Series
To delivery pressure
sensor switch panel
Travel spaed switching solenoid
Illustration 447
364
322C System Schematic

365
Illustration 448
366
325C and 330CSystem Schematic

*
W
367
Illustration 449
368
Index Section
Index
A Schematic Of The Pressure Sensor (1) For
The Delivery Pump Discharge (325C and
Active Error Mode 74 330CSeries) 266
Adjust Clock Mode 66 Schematic Of The Pressure Sensor (2) For The
Adjustment Of The Clock 66 Delivery Pump Discharge (312C) 272
AEC Is Abnormal - Troubleshoot 213 Schematic Of The Pressure Sensor (2) For The
"AEC Mode Indicator Is Abnormal" 215 Delivery Pump Discharge (315C) 272
Schematic Of The Panel For The AEC Mode Schematic Of The Pressure Sensor (2) For The
Switch (312C) 217 Delivery Pump Discharge (320C Series) 273
Switch (315C) 217 Delivery Pump Discharge (322C) 273
Switch (320C) 218 Delivery Pump Discharge (325C and 330C).. 274
Schematic Of The Panel For The AEC Mode Schematic Of The Switch Panel (312C) 251
Switch (320CU) 218 Schematic Of The Switch Panel (315C) 251
Schematic Of The Panel For The AEC Mode Schematic Of The Switch Panel (320C
Switch (322C) 219 Series) 251
Schematic Of The Panel For The AEC Mode Schematic Of The Switch Panel (322C) 252
Switch (325C and 330C) 219 Schematic Of The Switch Panel (325C and
Automatic Engine Control 36 330C) 252
First Setting Of The AEC 36 Schematic Of The Switch Panel For The Travel
Second Setting Of The AEC 37 Mode (312C) 254
Automatic Travel Speed Change Is Abnormal - Schematic Of The Switch Panel For The Travel
Troubleshoot (CID 0598, CID 1161, and CID Mode (315C) 255
1162) 249 Schematic Of The Switch Panel For The Travel
"Check For +B Short Of Automatic Travel Speed Mode (320C) 255
Change Solenoid" 261 Schematic Of The Switch Panel For The Travel
"Check For Ground Short Of First Pump Delivery Mode(320CU) 256
Pressure Sensor" 268 Schematic Of The Switch Panel For The Travel
"Check For Ground Short Of Second Pump Mode (322C, 325C and 330C) 256
Delivery Pressure Sensor" 276 Schematic Of The Travel Speed Solenoid
"Check For Open Circuit And +B Short Of First (312C) 258
Pump Delivery Pressure Sensor" 269 Schematic Of The Travel Speed Solenoid
"Check For Open Circuit And +B Short Of Second (315C) 258
Pump Delivery Pressure Sensor" 276 Schematic Of The Travel Speed Solenoid For 320C
"Check For Open Circuit And Ground Short Of Series, 322C, 325C, and 330C 258
Automatic Travel Speed Change Solenoid".... 262 'Tortoise Mode Sets Speed High".,. 257
"Check For Power Supply To First Pump Delivery 'Travel Mode Indicator Is Abnormal" 253
Pressure Sensor" 267
"Check Of First Pump Delivery Pressure
Sensor" 263 B
"Check Of Power Supply To Second Pump Delivery
Pressure Sensor" 275 Backup System 43
"Check Of Power Supply To Switch Panel" 250 Engine Speed Control 43
"Check Of Second Pump Delivery Pressure Pump Control 44
Sensor" 271 Swing Parking Brake 44
"Rabbit Mode Does Not Set Speed High" (312C Battery Voltage Is Abnormal - Troubleshoot (CID
And315C) 259 168) 188
"Rabbit Mode Does Not Set Speed High" (320C, Schematic Of The Battery Circuit For312C 191
322C, 325C, and 330C) 260 Schematic Of The Battery Circuit For315C 192
Schematic Of The Pressure Sensor (1) For The Schematic Of The Battery Circuit For 320C
Delivery Pump Discharge (312C Series) 264 Series 193
Schematic Of The Pressure Sensor (1) For The Schematic Of The Battery Circuit For322C 194
Delivery Pump Discharge (315C Series) 264 Schematic Of The Battery Circuit For 325C and
Schematic Of The Pressure Sensor (1) For The 330C 195
Delivery Pump Discharge (320C Series) 265
Schematic Of The Pressure Sensor (1) For The
Delivery Pump Discharge (322C Series) 265
369
Index Section
c Check of Proportional Reducing Valve - Troubleshoot

(CID 581) 308
Charging Circuit 22 "Check For +B Short Of Proportional Reducing
Charging System - Test 326 Valve" 312
Initial Troubleshooting Procedure 326 "Check For Over Circuit Of Proportional Reducing
Specifications For Alternators 335 Valve" 310
T1 Alternator Output - Test 329 Schematic For The Proportional Reducing Valve
T2a - Undesired Electrical System Current - Test (312C). 313
(For Machines Equipped With A Main Disconnect Schematic For The Proportional Reducing Valve
Switch) 330 (315C) 314
T2b - Undesired Electrical System Current - Test Schematic For The Proportional Reducing Valve
(For Any Machine) 330 (320C) 315
T3 Charging System - Test 331 Schematic For The Proportional Reducing Valve
T4 Alternator Drive System - Check 332 (320CU) 316
T5 Alternator Current - Test 332 Schematic For The Proportional Reducing Valve
T6 Residual Magnetism Restoration 332 (322C) 317
T7 Identifying Source Of Current Draw - Test.. 333 Schematic For The Proportional Reducing Valve
T8a - Alternator Overcharging - Test 333 (325C and 330C) 318
T8b - Alternator Overcharging - Test (Continued) Check of Speed Sensor - Troubleshoot (CID
334 190) 185
Check of Controller LED Indicator - Troubleshoot.. 86 Schematic Of The Speed Sensor For312C .... 187
Check of Fault Alarm - Troubleshoot (CID 2002 for Schematic Of The Speed Sensor For315C .... 187
320C and 322C or CID 271 for312C, 315C, 325C Schematic Of The Speed Sensor For 320C,
and330C) 232 320CU, 325C, and 330C 187
Schematic Of The Fault Alarm (312C) 236 Schematic Of The Speed Sensor For 322C .... 187
Schematic Of The Fault Alarm (322C) 237 Check of Straight Travel Proportional Reducing Valve
Schematic Of The Fault Alarm (325C and -Troubleshoot (CID 1525) 304
330C) 237 "Check For +B Short Of Straight Travel Proportional
Schematic Of The Fault Alarm 315C 236 Reducing Valve" 306
Schematic Of The Fault Alarm For 320C "Check For +B Short Of Straight Travel Proportional
Series 236 Reducing Valve" (325C and 330C) 307
Check of Feedback Signal From Governor Actuator - "Check For Open Circuit And +B Short Of Straignt
Troubleshoot (CID 587) 223 Travel Proportional Reducing Valve" 304
"Check For Ground Short Of Feedback Signal "Check For Open Circuit And +B Short Of Straignt
From Governor Actuator" 226 Travel Proportional Reducing Valve" (325C and
"Check For Open Circuit And +B Short Of 330C) 305
Feedback Signal From Governor Actuator".... 225 Schematic Of The Straight Travel Solenoid 308
Schematic Of The Circuit For The Governor Schematic Of The Straight Travel Solenoid (325C
Actuator (312C) 227 and 330C) 308
Schematic Of The Circuit For The Governor Communication Problem Between Controller and
Actuator (315C) 228 Monitor - Troubleshoot ("CID 248" and "CID 588")..
Schematic Of The Circuit For The Governor Check Of Monitor Indicator Signal 117
Actuator (320C) 229 Check Of Power Supply To Monitor 116
Schematic Of The Circuit For The Governor Communication Problem Between Controller And
Actuator (320CU) 230 Monitor (312C And 315C) 110
Schematic Of The Circuit For The Governor Communication Problem Between Controller And
Actuator (322C) 231 Monitor (320C Series) 111
Check of Governor Actuator - Troubleshoot (CID 91 Communication Problem Between Controller And
(325C)) 220 Monitor (322C) 112
Communication Problem Between Controller And
Monitor (325C and 330C) 113
"Monitor Is Abnormal" „ 114
"Monitor Is Abnormal" (325C and 330C) 115
Schematic Of The Circuits For The Monitor
(312C) 118
(315C) 119
(322C) 121
Schematic Of The Circuits For The Monitor (325C
and 330C) 122
Schematic Of The Circuits For The Monitor For
320C Series 120
370
Index Section
Communication Problem Between Controller and General Information (Electronic Control System).. 26
Monitor - Troubleshoot ("CID 248" and "CID Governor Actuator - Calibrate 346
588") 110 Errors 349
Configuration Mode 71 Warnings 348
Controller - Replace 355 Governor Actuator - Replace 343
Controller Connector Contact Identification 355 Adjustment 345
Controller Input and Output Values 357 Calibration 345
Replacement 343
Governor Actuator Control 59
D Governor Actuator Sweep - Test 341
Device Test... 337

H
E Harness and Wire Identification 62
ECM Summary Mode 67

Electrical Components And Connector Locations.. 62 I
Electrical System 5
Electronic Control System 26 Important Safety Information 2
Engine and Hydraulic Pump Controller 46 Initial Troubleshooting Procedure 77
Input 50 Electronic Control System 77
Input/Output 50
Output 51
Engine and Pump Regulation 33 L
Engine Controller Is Abnormal - Troubleshoot
(590) 105 Logged Error Mode 75
The Engine Controller Is Abnormal 106 Logged Event Mode 76
Engine Speed Control 35 Low Current Circuit 25
Engine Speed Dial Does Not Work - Troubleshoot Low Idle Switch Does Not Work - Troubleshoot... 206
(CID 586) 196 "Check Of Low Idle Switch" 207
Check Of Engine Speed Dial 197 "Engine Speed At Each Dial Position Is
Check Of Engine Speed Dial (325C and Abnormal" 211
330C) 200 Engine Speed At Each Dial Position Is Abnormal
Schematic For The Engine Speed Dial 325C and 330C 212
(312C) 203 Schematic Of Low Idle Switch For 312C 208
Schematic Of The Engine Speed Dial For Schematic Of Low Idle Switch For 315C 208
315C 203 Schematic Of Low Idle Switch For 320C 209
Schematic Of The Engine Speed Dial For Schematic Of Low Idle Switch For 320CU, 325C,
320C 204 and330C 209
Schematic Of The Engine Speed Dial For 320CU, Schematic Of Low Idle Switch For 322C 210
325C, and330C 204
Schematic Of The Engine Speed Dial For
322C 205 M
The Engine Speed Dial Does Not Work For 325C
and330C 199 Monitoring System 44
Engine Speed Protection 40 Machine Information 45
Control Of The Hydraulic Oil At Low Tools 46
Temperatures 41 Travel Alarm 46
Memory Function 40 Warning Operation... 44
Prevention Of Overspeed During Low Engine Oil Working Hour 45
Pressure..... 40
Prevention Of Overspeed During Overheating
Condition 41
General Information 61
Electronic Control System 61
General Information (Electrical System) 5
371
Index Section
N s
No Power Supply to Controller - Troubieshoot 87 Senders 57
Check Of Power Supply Line (101 -RD) 89 Fuel Level Sender 57
Check Of Power Supply Line (109-RD) For Temperature Sender 57
322C,325C,and 330C 96 Sensors 56
Check Of Power Supply Line (112-PU) For 312C Engine Speed Sensor 56
And315C 90 Feedback Sensor 56
Check Of Power Supply Line (112-PU) For 320C Pressure Sensor 57
Series 92 Service Tools 61
Check Of Power Supply Line (112-PU) For Solenoid Valves 58
322C 94 Pressure Solenoid For Power Shift 58
Check Of Power Supply Line (112-PU) For 325C Proportional Reducing Solenoid Valve (Power
and330C 95 Shift) 58
Check Of Starter Switch.. 102 Solenoid Valve 58
Schematic Of Power Supply For 312C 97 Straight Travel Solenoid 59
Schematic Of Power Supply For315C 98 Travel Speed Solenoid and Swing Parking Brake
Schematic Of Power Supply For 320C Series... 99 Solenoid Valve 59
Schematic Of Power Supply For322C 100 Speed Sensor - Replace 353
Schematic Of Power Supply For 325C and Start and Stop Circuit 14
330C 101 Starting Aid Circuit 19
Schematic Of Starter Switch For312C 103 Status Mode 70
Schematic Of Starter Switch For315C 103 Straight Travel Control 39
Schematic Of Starter Switch For 320C Series.. 104 Swing Is Inoperable - Troubieshoot (CID 374) 278
Schematic Of Starter Switch For322C 104 "Check For +B Short Of Swing Brake
Schematic Of Starter Switch For 325C and Solenoid" 296
330C 105 "Check For Open Circuit and Ground Short Of
Swing Brake Solenoid" 294
"Check Hydraulic Activation Control And
O Associated Components (When Engine Is
Operable)".. 283
One Touch Low Idle 37 "Check Of Joystick Pressure Switch" 293
Release Of The One-touch Low Idle 38 Check Of Timer Relay ("325C" and 330C) 292
Start-up Of The One-touch Low Idle : 37 Schematic For Troubleshooting "Swing Is
Operator Monitor 52 Inoperable" (312C) 287
Schematic For Troubleshooting "Swing Is
Inoperable'' (315C) 288
P Schematic For Troubleshooting "Swing Is
Inoperable" (320C Series) 289
Power Circuit 9 Schematic For Troubleshooting "Swing Is
Proportional Reducing Valve - Calibrate (Power Inoperable" (322C) 290
Shift) 352 Schematic For Troubleshooting "Swing Is
Proportional Reducing Valve Sweep - Test (Power Inoperable" (325C and 330C) 291
Shift) 351 Schematic Of The Circuit For The Swing Brake
Pump Regulation 34 Solenoid (312C) 297
Constant Control of Horsepower 34 Schematic Of The Circuit For The Swing Brake
Control Of An Underspeed Condition 34 Solenoid (315C) 298
Schematic Of The Circuit For The Swing Brake
Solenoid (320C) 299
R Schematic Of The Circuit For The Swing Brake
Solenoid (320CU) 300
Related Components 60 Schematic Of The Circuit For The Swing Brake
Action Alarm 60 Solenoid (322C) 301
Action Lamp 60 Schematic Of The Circuit For The Swing Brake
Alternator 60 Solenoid (325C and 330C) 302
Data Link 60 Swing Is Inoperable Troubleshooting (312C And
Input for Air Heater Indicator 60 315C) 278
Travel Alarm 60 Swing Is Inoperable Troubleshooting For 320C
Series and 322C 279
Swing Is Inoperable Troubleshooting For 325C and
330C Series 281
Swing Lock System 42
Switch Status Mode 68
372
Index Section
Switches 53 U
Air Filter Switch 54
Engine Coolant Level Switch 54 Using Caterpillar Electronic Technician 78
Engine Oil Pressure Switch 54 Calibrations By Using The Electronic
Engine Speed Dial Switch 53 Technician 80
Hydraulic Level Switch and Engine Oil Level Diagnostic Tests 81
Switch 55 Status Groups For Electronic Technician 79
Hydraulic Oil Filter Switch 54 Using Service Mode 63
Key Start Switch 54 Exiting The Service Mode 65
One Touch Low Idle Switch 53 Start-Up Of The Service Mode 64
Pressure Switch 53, 56
Switch Panel Assembly 55
Water Separator Level Switch (320C Series and W
322C Series) 55
System Schematic 361 Warning "Air Cleaner Filter Is Clogged" Is Displayed -
312C and 315C System Schematic 361 Troubleshoot
322C System Schematic 364 "Check For Ground Short Of Clogged Air Filter
325C and 330CSystem Schematic 366 Switch" 156
System Schematic For 320C Series 363 "Check For Open Circuit And +B Short Of Clogged
Systems Operation Section 5 Air Filter Switch" 154
Schematic Of The Air Filter Switch (312C) 155
Schematic Of The Air Filter Switch (315C)...... 155
T Schematic Of The Air Filter Switch (320C, 320CU,
322C, 325C, and 330C) 155
Table of Contents 3 "Warning (AIR CLEANER FILTER IS CLOGGED)
Testing and Adjusting 61 Is Abnormal" 153
Testing and Adjusting Section 61 Warning "Battery Charge Is Abnormal" Is Displayed
Tool Control 38 While Engine Is Running - Troubleshoot (CID 167)..
Engine Speed Control 38 Schematic Of The Alternator Circuit For 312C And
Main Pump Control During Use Of The Attachment 315C 184
Pump 38 Schematic Of The Alternator Circuit For 320C
Main Pump Flow Control 38 Series 184
Selection Of A Tool 38 Schematic Of The Alternator Circuit For 322C,
Travel Alarm Is Abnormal - Troubleshoot (CID 325C, and 330C 184
376) 238 Warning "Engine Coolant Level Is Low" Is Displayed -
"Check For +B Short Of Travel Alarm" 247 Troubleshoot
"Check For Open Circuit And Ground Short Of "Check For Groud Short Of Engine Coolant Level
Travel Alarm" 246 Switch" 161
"Check Of (Left) Travel Pressure Switch" 240 "Check For Open Circuit And +B Short Of Engine
Check Of The Right Travel Pressure Switch (320C Coolant Level Switch" 159
And322C) 243 Schematic Of The Coolant Level Switch (312C and
Schematic Of The Left Travel Pressure Switch For 315C) 160
320C Series 242 Schematic Of The Coolant Level Switch (320C,
Schematic Of The Left Travel Pressure Switch For 320CU, 322C, 325C, and 330C) 160
322C, 325C, and 330C 242 "Warning "Engine Coolant Level Is Low" Is
Schematic Of The Right Travel Pressure Switch Abnormal" 158
(322C, 325C, and 330C) 245
Schematic Of The Right Travel Pressure Switch
For 320C Series 244
Schematic Of The Travel Alarm 247
Schematic Of The Travel Alarm For 325C and
330C... 248
Schematic Of The Travel Pressure Switch For
312C 241
Schematic Of The Travel Pressure Switch For
315C 241
'Travel Alarm Is Abnormal" for 312C and
315C 238
Travel Alarm Is Abnormal" for 320C, 322C, 325C
and330C 239
Troubleshooting Diagnostic Codes 84
373
Index Section
Warning "Engine Coolant Temperature Is High" Is Warning "Hydraulic Oil Level Is Low" is Displayed -
Displayed - Troubleshoot (CID 110) Troubleshoot
"Check For Ground Short Of Engine Coolant "Check For Ground Short Of Hydraulic Oil Level
Temperature Sensor" 136 Switch" 167
"Check For Open Circuit And +B Short Of Engine "Check For Open Circuit And +B Short For
Coolant Temperature Sensor" For 312C And Hydraulic Oil Level Switch" 165
315C 134 Schematic Of The Hydraulic Oil Level Switch
"Check For Open Circuit And +B Short Of Engine (312C) 166
Coolant Temperature Sensor" For 320C Series Schematic Of The Hydraulic Oil Level Switch
And322C 133 (315C) 166
"Check Of Engine Coolant Temperature Sensor Schematic Of The Hydraulic Oil Level Switch
Characteristics" 137 (320C, 320CU and 322C) 166
"Engine Coolant Temperature Gauge Indication Is Schematic Of The Hydraulic Oil Level Switch
Abnormal" 131 (325C and 330C) 167
Schematic Of Engine Coolant Temperature Sensor "Warning "Hydraulic Oil Level Is Low" Is
For312Cand315C 135 Abnormal" 163
Schematic Of Engine Coolant Temperature Sensor Warning "Hydraulic Oil Temperature Is High" Is
For 320C Series And 322C 135 Displayed - Troubleshoot (CID 600)
Warning "Engine Oil Level Is Low" Is Displayed - "Check For Open Circuit And +B Short Of Hydraulic
Troubleshoot Oil Temperature Sensor" 141
"Check For Ground Short Of Engine Oil Level "Check Of GND Short Of Hydraulic Oil Temperature
Switch" 174 Sensor" 143
"Check For Open Circuit And +B Short Of Engine "Check Of Hydraulic Oil Temperature Sensor
Oil Level Switch" (312C And 315C) 170 Characteristics" 144
"Check For Open Circuit And +B Short Of Engine "Hydraulic Oil Temperature Gauge Indication Is
Oil Level Switch" (320C And 322C) 171 Abnormal" 140
"Check For Open Circuit And +B Short Of Engine Schematic Of The Hydraulic Oil Temperature
Oil Level Switch" (325C and 330C) 172 Sensor For 312CAnd 315C... 142
Schematic Of The Engine Oil Level Switch Schematic Of The Hydraulic Oil Temperature
(312C) 173 Sensor For 320C Series and 322G 142
Schematic Of The Engine Oil Level Switch Schematic Of The Hydraulic Oil Temperature
(315C) 173 Sensor For 325C and 330C 143
Schematic Of The Engine Oil Level Switch (320C, Warning "Return Filter Is Clogged" Is Displayed -
320CU, 325Cand330C) 173 Troubleshoot
Schematic Of The Engine Oil Level Switch "Check For Open Circuit And +B Short Of Return
(322C) 174 Filter Switch" 178
"Warning "Engine Oil Level Is Low" Is "Check For Open Ground Short Of Return Filter
Abnormal" 169 Switch" 181
Warning "Engine Oil Pressure Is Low" Is Displayed - Schematic Of The Return Filter Switch
Troubleshoot (CID 286 (325C and 330C)) (312C) 179
"Check For Ground Short Of Engine Oil Pressure Schematic Of The Return Filter Switch
Signal" 151 (315C) 179
Check For Open Circuit And Check for +Battery Schematic Of The Return Filter Switch (320C,
Short Of Engine Oil Pressure Signal 150 320CU, and322C) 179
Schematic Of The Engine Oil Pressure Switch For Schematic Of The Return Filter Switch
325C and 330C 151 (325C) 180
"Warning Engine Oil Pressure Is Low" 148 Schematic Of The Return Filter Switch
"Warning Engine Oil Pressure Is Low" for (330C) 180
330C 149 "Warning "Return Filter Is Clogged" Is Abnormal"
Warning "Fuel Leftover Is Little" Is Displayed - (312C And 315C) 176
Troubleshoot (CID 96) "Warning "Return Filter Is Clogged" Is Abnormal"
"Check For Ground Short Of Fuel Gauge (320C, 322C, 325C, and 330C). 176
Sensor" 128
"Check For Open Circuit And +B Short Of Fuel
Gauge Sensor" 125
"Check Of The Fuel Gauge Sensor
Characteristics" 129
"Fuel Gauge Indication Is Abnormal" 124
Schematic Of The Fuel Level Sensor (312C).. 126
Schematic Of The Fuel Level Sensor (320C And
322C) 126
Schematic Of The Fuel Level Sensor (325C and
330C) 127
374
Index Section
Warning "Water Separator Has Water" Is Abnormal -

Troubleshoot
"Check For Ground Short Of Water Separator
Level Switch" 322
"Check For Open Circuit And +B Short Of Water
Separator Level Switch" 321
"Check Of Power Supply To Water Separator Level
Switch" 323
Schematic Of The Level Sensor For The Water
Separator (330C) 326
Schematic Of The Level Switch For The Water
Separator (320C Series) 325
Separator (322CAnd 325C) 325
Warning "Air Cleaner Filter Is Clogged" Is Displayed -
Troubleshoot 152
Warning "Battery Charge Is Abnormal" Is Displayed
While Engine Is Running - Troubleshoot (CID
167) 182
Warning "Engine Coolant Level Is Low" Is Displayed -
Troubleshoot 157
Warning "Engine Coolant Temperature Is High" Is
Warning "Engine Oil Level Is Low" Is Displayed -
Troubleshoot 168
Warning "Engine Oil Pressure Is Low" Is Displayed -
Troubleshoot (CID 286 (325C and 330C)) 146
Warning "Fuel Leftover Is Little" Is Displayed -
Troubleshoot (CID 96) 123
Warning "Hydraulic Oil Level Is Low" Is Displayed -
Troubleshoot 162
Warning "Hydraulic Oil Temperature Is High" Is
Warning "Return Filter Is Clogged" Is Displayed -
Troubleshoot 175
Warning "Water Separator Has Water" Is Abnormal -
Troubleshoot 319
Warning "Water Separator Has Water" Is Displayed -
Troubleshoot 319

Engine and Pump Control - Systems Operation, Testing and Adjusting 320 C

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Engine and Pump Control - Systems Operation, Testing and Adjusting 320 C

Uploaded by

Copyright:

Available Formats

RENR3814-04

CATERPILLAR November 2001

312C, 315C, 320C, 322C,

The meaning of this safety alert symbol is as follows:

Failure to heed this warning can lead to prema-

Table of Contents Warning "Fuel Leftover Is Little" Is Displayed -

System Schematic 361

Systems Operation Section

General Information (Electrical

The electrical system consists of the following

Start and Stop Circuit

Current is allowed to flow through the timer relay

Current from the battery will flow through the starter

After the engine has started, the alternator will begin

The timer relay will supply power for a specific

Starting Aid Circuit

The circuit for the starting aid is an auxiliary circuit.

Low Current Circuit

The low current circuit consists of the following

• The circuit for the lights and windshield wiper

• The circuit for the air conditioner

• The circuit for the cab heater

• The circuit for the horn

Electronic Control System

The engine and pump controller will monitor the

The engine and pump controller communicates with

The controller changes the output of the hydraulic

Block Diagram Of The Engine And Pump Control System (322C)

Engine and Pump Regulation

The controller (2) will determine the power shift

Engine Speed Control

The controller converts the signal from the engine

Note: The 325C series uses the ADEM III controller

The engine speed dial (3) is divided into 10

"Pos" 312C 315C 320C 322C 325C/

Automatic Engine Control

The AEC will lower the engine speed if no load

Second Setting Of The AEC

One Touch Low Idle

When the one-touch low idle switch (4) is pressed

Note: The 312C has only one travel pressure switch

Release Of The One-touch Low Idle Selection Of A Tool

(01621594 S/N: BBL1-Up

SMCSCode: 1931 S/N: BKMT-Up

S/N: APA1-Up S/N: BMM1-Up

S/N: BEA1-Up S/N: BTM1-Up

S/N: BLA1-Up S/N: CAM 1-Up

S/N: CYA1-Up S/N: CLM1-Up

S/N: HAA1-Up S/N: S3M1-Up

S/N: MCA1-Up S/N: BCN1-Up

S/N: ANB1-Up S/N: BFN1-Up

S/N: BCB1-Up S/N: BNN1-Up

S/N: BDB1-Up S/N: BLP1-Up

S/N: BGB1-Up S/N: CAP1-Up

S7N:CRB1-Up S/N: BER1-Up

S/N: JAB1-Up S/N: BGR1-Up

S/N: AMC1-Up S/N: BPR1-Up

S/N: BBC1-Up S/N: BKT1-Up

S/N: BDC1-Up S/N: CBT1-Up

S/N: BTD1-Up S/N: BKW1-Up

S/N: CCD1-Up S/N:ALX1-Up

S/N: KDD1-Up S/N: BFX1-Up