Diagnostico Backup Switch 320D GKL

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Product: EXCAVATOR
Model: 320D RR EXCAVATOR GKL
Configuration: 320D RR & 320D LRR 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
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; GKL1-
UP; WBN1-UP; BZP1-UP; GKS1-UP; YDS1-UP; DFT1-UP; SRT1-UP; BWW1-UP; EAX1-
UP; 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; 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; T2D1-UP; JJG1-UP; JGK1-UP; SYM1-UP; DFP1-UP;
JKR1-UP; JZR1-UP; JLS1-UP; CJX1-UP)
Pgina 1 de 11 320D RR & 320D LRR Excavators GKL00001-UP (MACHINE) POWERED BY 3066...
22/07/2014 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb...
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; T2Y1-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; MCY1-
UP)
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 replace 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 Nm (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 intermittent 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
Contact Rating
Inductive Load 3A
Min Current 0.01A
Contact between the harness terminal and the toggle switch
(1) Central connections
(2) Harness terminal
(3) Switch terminal
(4) Contact
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
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
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
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
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.
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.
Ring terminal for the former 128-4182 Terminal As
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
G-M11 128-4182 BK-18 235-G37
BK-18 235-G38
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
Identification Part Number Wire Color and Size Circuit and Wire Name
G-M4 128-4163 YL-16 308-G16
YL-16 308-G17
G-M9 128-4182 BK-18 235-G33
BK-18 235-G34
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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