Diagnostico Backup Switch 320D GKL

320D RR & 320D LRR Excavators GKL00001-UP (MACHINE) POWERED BY 3066...Página 1 de 11

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Product: EXCAVATOR Model: 320D RR EXCAVATOR GKL Configuration: 320D RR & 320D LRR Excavators Excavators GKL00001- UP (MACHI NE) POWERED BY 3066 Engine

Special Instruction Inspection Procedure for the Backup Switch{1408} Media Number -REHS4924-00

Publication Date -15/05/2009

Date Updated -15/05/2009

i03579040

Inspection Procedure for the Backup Switch{1408} SMCS - 1408 - 1408 Excavator: 319C (S/N: KGL1-UP) W345C (S/N: R5K1-UP) 311C (S/N: PAD1-UP; CKE1-UP) 311D (S/N: CLA1-UP; DDW1-UP) 312C (S/N: CBA1-UP; BWH1-UP; BNN1-UP; DBN1-UP; FDS1-UP; CBT1-UP) 312D (S/N: JBC1-UP; KCD1-UP; DLP1-UP; HCW1-UP; HJX1-UP; TGY1-UP) 314C (S/N: KJA1-UP; PCA1-UP; SNY1-UP) 314D (S/N: BYJ1-UP; PDP1-UP; SBP1-UP) 315C (S/N: CFB1-UP; CJC1-UP; AKE1-UP; ANF1-UP; CFT1-UP) 315D (S/N: KBD1-UP; NCM1-UP; CJN1-UP) 318C (S/N: FAA1-UP; GPA1-UP; BTG1-UP; DAH1-UP; MDY1-UP) 319D (S/N: BZH1-UP; FMH1-UP; EAW1-UP; DAY1-UP) 320C (S/N: BEA1-UP; EGA1-UP; GLA1-UP; ANB1-UP; BGB1-UP; MAB1-UP; PAB1-UP; AMC1-UP; BDC1-UP; HBC1-UP; MAC1-UP; PAC1-UP; CCD1-UP; GAD1-UP; BDE1-UP; NAE1-UP; DBG1-UP; EAG1-UP; GNG1-UP; JTG1-UP; SAH1-UP; AXK1-UP; BBL1-UP; EGL1-UP; JPL1-UP; CLM1-UP; BCN1-UP; SBN1-UP; BER1-UP; BPR1-UP; HKT1-UP; RAW1-UP; BRX1-UP; BMZ1-UP; CLZ1-UP) 320D (S/N: ZGB1-UP; MDE1-UP; TAE1-UP; A6F1-UP; A8F1-UP; A9F1-UP; BZF1-UP; KGF1-UP; MGG1-UP; MCH1-UP; DHK1-UP; FXK1-UP; XCK1-UP; FAL1-UP; G KL1UP; WBN1-UP; BZP1-UP; GKS1-UP; YDS1-UP; DFT1-UP; SRT1-UP; BWW1-UP; EAX1UP; PHX1-UP; CXY1-UP; EBY1-UP; CYZ1-UP; JFZ1-UP; JGZ1-UP) 321C (S/N: MCF1-UP; KCR1-UP) 321D (S/N: PBD1-UP; NAS1-UP; N AS1-UP; MDT1-UP) 322C (S/N: DAA1-UP; FED1-UP; BPH1-UP; M2H1-UP; BKJ1-UP; BFK1-UP; HEK1-UP; BYL1-UP; BKM1-UP; CAM1-UP; BLP1-UP; BGR1-UP; C3R1-UP; EMR1-UP; LAR1-UP; MAR1-UP; SLX1-UP; CBY1-UP) 323D (S/N: RAC1-UP; SDC1-UP; CYD1-UP; SED1-UP; YSD1-UP; NDE1-UP; PBE1-UP; JLG1-UP; BYM1-UP; PBM1-UP; DKW1-UP) 324D (S/N: LAB1-UP; EJC1-UP; E JC1-UP; T2D1-UP; JJG1-UP; JGK1-UP; SYM1-UP; DFP1-UP; JKR1-UP; JZR1-UP; JLS1-UP; CJX1-UP)


325C (S/N: CRB1-UP; JLC1-UP; S2C1-UP; BTD1-UP; JLD1-UP; BFE1-UP; DTF1-UP; AMH1-UP; CSJ1-UP; M2K1-UP; G1L1-UP; BMM1-UP; S3M1-UP; Y4P1-UP; BKW1-UP) 325D (S/N: GPB1-UP; NAC1-UP; KBE1-UP; PKE1-UP; KDG1-UP; C4H1-UP; DBH1-UP; PEH1-UP; C7K1-UP; ERK1-UP; RJK1-UP; C8L1-UP; LAL1-UP; MCL1-UP; PAL1-UP; C9M1-UP; AZP1-UP; A3R1-UP; GBR1-UP; SCR1-UP; T2S1-UP; CYW1-UP) 328D (S/N: GTN1-UP; MKR1-UP) 329D (S/N: MNB1-UP; BFC1-UP; DJF1-UP; JHJ1-UP; RSK1-UP; WDK1-UP; TPM1-UP; BYS1-UP; SCY1-UP) 330C (S/N: CYA1-UP; MCA1-UP; JAB1-UP; D3C1-UP; JCD1-UP; KDD1-UP; B1K1-UP; JNK1-UP; B2L1-UP; B3M1-UP; MKM1-UP; B4N1-UP; CAP1-UP; GKX1-UP; DKY1-UP; CGZ1-UP) 330D (S/N: NBD1-UP; R2D1-UP; GGE1-UP; B6H1-UP; EAH1-UP; THJ1-UP; C5K1-UP; E4K1-UP; FFK1-UP; H3K1-UP; L2K1-UP; PEL1-UP; JJM1-UP; LEM1-UP; LRM1-UP; ERN1-UP; JLP1-UP; MWP1-UP; HAS1-UP; RAS1-UP; MEY1-UP; T2 Y1-UP) 336D (S/N: JBF1-UP; J2F1-UP; PRF1-UP; KDJ1-UP; W3K1-UP; MPL1-UP; D3P1-UP; MYP1-UP; DTS1-UP; JBT1-UP; KKT1-UP; M4T1-UP; WET1-UP) 345C (S/N: TBA1-UP; FPC1-UP; SPC1-UP; ESD1-UP; MTE1-UP; WDE1-UP; TDG1-UP; GPH1-UP; TAJ1-UP; A3L1-UP; GCL1-UP; S5M1-UP; SCN1-UP; DHP1-UP; M2R1-UP; D3S1-UP; ELS1-UP; LYS1-UP; PJW1-UP; BWY1-UP) 345D (S/N: RGD1-UP; RAE1-UP; YEE1-UP; NEG1-UP; RGG1-UP; EEH1-UP; RAJ1-UP; MLK1-UP; JKN1-UP; PBT1-UP) 365C (S/N: ELC1-UP; GWC1-UP; MEM1-UP; FEN1-UP; PAR1-UP; MCS1-UP; MCY1UP) 374D (S/N: PAP1-UP; PAS1-UP; PAX1-UP) 385C (S/N: EDA1-UP; MMA1-UP; KGB1-UP; KBC1-UP; SBE1-UP; T2E1-UP; T2F1-UP; KKK1-UP; EAM1-UP; JCM1-UP; WAW1-UP; MNZ1-UP) Mobile Hydraulic Power Unit: 312D MHPU (S/N: DXH1-UP) 319D MHPU (S/N: KTJ1-UP) 320C MHPU (S/N: MSN1-UP) 324D MHPU (S/N: KJR1-UP) 325C MHPU (S/N: MSG1-UP) 336D MHPU (S/N: J6D1-UP) 345D MHPU (S/N: P5D1-UP) 365C MHPU (S/N: GSZ1-UP) 385C MHPU (S/N: MSF1-UP) 330C MHPU (S/N: MSL1-UP) 320D MHPU (S/N: GPX1-UP) 323D MHPU (S/N: DCJ1-UP; GRL1-UP; GRN1-UP; DCY1-UP) 325D MHPU (S/N: SRC1-UP; C3N1-UP; H3N1-UP) 330D MHPU (S/N: D3D1-UP; H3D1-UP; GMN1-UP) 345C MHPU (S/N: NRF1-UP; B6N1-UP)

Introduction This special instruction contains general information and procedures in order to perform the inspection of the backup switch. Even if there are symptoms of a short circuit or intermittent contact on the toggle switch, in most cases the function of the toggle switch is normal. Refer to the inspection procedure below. This will help to identify the root cause of the problem before you repl ace the toggle switch.


Refer to the Service Manual Module of Systems Operation, Troubleshooting, Testing and Adjusting, "Machine Electronic Control System" for the adaptable model.

Inspection Procedure 1. Check if the machine moves when the toggle switch malfunctions. Refer to the explanations on Backup System of Service Manual Module of Systems Operation, Troubleshooting, Testing and Adjusting, "Machine Electronic Control System" for the adaptable model. 2. Check if there are any loose screws on the terminal connection of the toggle switch. If there are any loose screws, tighten to a torque of 0.6 ± 0.1 N·m (0.44 ± 0.07 lb ft). Refer to Illustration 1. 3. Conduct the electrical continuity test between each terminal before replacing the toggle switch. Refer to Illustration 1. If a short circuit or intermittent contact between the toggle switch connection and the harness terminal is found, identify which harness terminal contacts the switch terminal. Refer to Illustration 2 through Illustration 9. 4. Cut the peripheral of the ring terminal with a nipper in order to avoid the terminal contact with the body of the switch. Refer to Illustration 10 and 11. The short circuit or intermitten t contact is most likely to happen when the harness terminal is connected with central connections of number 5 and number 8 switch terminals. Refer to Illustration 2 and 3. If the problem will never be resolved, replace the former harness assembly with the new harness assembly of the latest version for Series D excavators and 365C L and 385C excavators that are listed. A yellow tape was placed on the number 8 terminal of the toggle switch in order to prevent the wrong harness connection for the machines with the 259-4877 Console Harness As or the 251-0601 Console Harness As of the latest version that was implemented. It is possible to identify if the machine has the new harness assembly or not based on the existence of the yellow tape on the toggle switch of the machine. Refer to Illustration 4 and 5.


Illustration 1

g01908795

Schematic and tightening torque of the connection screw for the backup switch

Table 1 Number of Poles

4

Number of Throws

2

Circuit

Position

Contacts

A = On

1 and 2, 4 and 5, 7 and 8, 10 and 11

B = None C = On

2 and 3, 5 and 6, 8 and 9, 11 and 12 Inductive Load

3A

Min Current

0.01A

Contact Rating


Illustration 2

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Contact between the harness terminal and the toggle switch (1) Central connections

Illustration 3 (2) Harness terminal (3) Switch terminal (4) Contact

g01908939


Illustration 4

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Terminal number and arrangement of toggle switch for the 311D RR to 345D (5) Yellow tape on number 8 terminal for machine identification with new harness assembly

Illustration 5

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Terminal number and arrangement of toggle switch for the 365C L and 385C (5) Yellow tape on number 8 terminal for machine identification with new harness assembly


Illustration 6

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Location of toggle switch and harness in the right hand console for the 311D RR to 345D (6) Toggle switch (7) 259-4877 Console Harness As connected with toggle switch


Illustration 7

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Location of toggle switch and harness in the right hand console for the 365C L and 385C (6) Toggle switch (8) 251-0601 Console Harness As connected with toggle switch

Illustration 8

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Detail of harness terminal connection with toggle switch for the 311D RR to 345D


The harness terminal assembly from number 1 to number 12 is connected with the corresponding terminal of 283-3074 Toggle Switch . The 128-4189 Terminal As was adopted for the terminals from number 1 to number 12 except number 7 and number 10. Refer to Table 2.

Illustration 9

g01910618

Detail of harness terminal connection with toggle switch for the 365C L and 385C

The harness terminal assembly from number 1 to number 11 is connected with the corresponding terminal of 283-3074 Toggle Switch . The 128-4189 Terminal As was adopted for the number 5, number 8 and number 11 terminals. Refer to Table 3.

Illustration 10

g01910713

Ring terminal for the former 128-4182 Terminal As

320D RR & 320D LRR Excavators GKL00001-UP (MACHINE) POWERED BY 30... Página 10 de 11

Illustration 11

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Ring terminal for the new 128-4189 Terminal As

Table 2 Terminal for Wire Connected with Toggle Switch for the 311D RR to 345D Identification

Part Number

Wire Color and Size

Circuit and Wire Name

G-M9

128-4182

WH-18

F889-G16

BU-18

M736-G11

BK-18

235-G37

BK-18

235-G38

G-M11

128-4182

G-T1

128-4189

GN-18

K906-G5

G-T2

128-4189

BU-18

A768-G6

G-T3

128-4189

BK-18

235-G38

G-T4

128-4189

GY-18

A769-G7

G-T5

128-4189

BU-18

K907-G10

G-T6

128-4189

PK-18

169-G31

G-T7

128-4189

WH-18

L969-G12

G-T8

128-4189

PK-18

A770-G15

G-T10

128-4189

OR-18

L968-G13

G-T12

128-4189

BR-18

998-G14

G-T13

128-4189

OR-18

F773-G29

G-T14

128-4189

WH-18

F774-G28

Table 3 Terminal for Wire Connected with Toggle Switch for the 365C L and 385C

320D RR & 320D LRR Excavators GKL00001-UP (MACHINE) POWERED BY 30... Página 11 de 11

Identification

Part Number

Wire Color and Size

Circuit and Wire Name

G-M4

128-4163

YL-16

308-G16

YL-16

308-G17

BK-18

235-G33

BK-18

235-G34

G-M9

128-4182

G-T1

128-4189

BR-18

998-G24

G-T2

128-4189

YL-18

F717-G5

G-T3

128-4189

BU-18

F718-G6

G-T5

128-4189

BR-18

K952-G20

G-T6

128-4189

YL-18

H807-G19

G-T7

128-4182

BU-16

A768-G25

G-T8

128-4182

BU-16

K909-G39

G-T10

128-4189

BK-18

235-G34

G-T11

128-4189

GY-18

K948-G42

G-T12

128-4189

YL-18

K947-G41

G-T13

128-4189

OR-18

K946-G40

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Diagnostico Backup Switch 320D GKL

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