Global Manpower Development

336E Hydraulic Excavator

Machine Walkaround
Module 1 - INSTRUCTOR MATERIALS

SERV1881-01

336E Hydraulic Excavator

Module 1 - Machine Walkaround
Instructor Materials

© 2011 Caterpillar Inc.

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SERV1881-01 - 12/11 -2- Module 1 - Table of Contents

TABLE OF CONTENTS
MODULE DESCRIPTION�������������������������������������������������������������������������������������������������������������3
PREPARATION CHECKLIST�������������������������������������������������������������������������������������������������������4
MODULE PREREQUISITES��������������������������������������������������������������������������������������������������������6
LESSON PLAN�����������������������������������������������������������������������������������������������������������������������������7
MODULE OBJECTIVES���������������������������������������������������������������������������������������������������������������8
LABORATORY EXERCISES��������������������������������������������������������������������������������������������������������9
POSTTEST���������������������������������������������������������������������������������������������������������������������������������20

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SERV1881-01 - 12/11 -3- Module 1 - Module Description

MODULE DESCRIPTION
• CONTENT This module is designed to introduce the 336E Hydraulic Excavator major machine
systems and major component locations. Lab exercises and a written posttest will be
used for skills development and a knowledge check. Students will be expected to
demonstrate understanding and proficiency in each major area of instruction.

• AUDIENCE Level II--Field service personnel, resident mechanics, Technical Communicators, and
shop technicians. All students should have a working knowledge of basic electrical,
electronic, and hydraulic control systems on Cat machines.

Service Manual Modules Form No.

Safety SENR7733
Operation and Maintenance Manual SEBU8559

Reference Materials

300D Series Hydraulic Excavators SERV1852

Specalog

336E Hydraulic Excavator (ADSD North and South) AEHQ6153

336E Hydraulic Excavator (EAME) AEHQ6155
336E Hydraulic Excavator (APD) AEHQ6157

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SERV1881-01 - 12/11 -4- Module 1 - Preparation Checklist

PREPARATION CHECKLIST
• MODULE PREPARATION Prior to conducting the training session, gather the following materials:

______ PDF: “336E Hydraulic Excavator Introduction”

______ PDF: “336E Hydraulic Excavator Machine Walkaround”

______ Service Manual (KENR7980)

______ Operation and Maintenance Manual (SEBU8559)

A printed copy of the following for the classroom training session and lab exercises
and access to SIS Web or SIS DVD:

______ Service Manual “Safety” (SENR7733)

______ Service Manual Module “Operation and Maintenance Manual” (SEBU8559)

• CLASSROOM PREPARATION Prior to delivering the classroom training session, perform the following steps:

______ Prepare a safety briefing containing the following information:

-- emergency phone numbers

-- first aid responders
-- location of exits and fire extinguisher
-- room alerts or hazards
-- designated location for evacuation
-- storm shelter

______ Review the 336E Hydraulic Excavator Introduction Text Reference and the
Operation and Maintenance Manual (SEBU8559).

______ Review the 336E Hydraulic Excavator Machine Walkaround Text Reference
to become familiar with the topic.

______ Duplicate enough 336E Hydraulic Excavator Machine Walkaround Text

Reference for each participant in the training session.

______ Duplicate enough 336E Hydraulic Excavator Machine Walkaround Student

Materials for each participant in the training session.

­______ Check for applicable Service Magazine articles, Service Letters, and
Technical Information Bulletins related to the topic.

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SERV1881-01 - 12/11 -5- Module 1 - Preparation Checklist

PREPARATION CHECKLIST (continued)

• LABORATORY PREPARATION Prior to conducting the lab exercises, perform the following steps:

______ Prepare a safety briefing for each of the labs to be conducted.

______ Select the 336E Hydraulic Excavator to be used in the lab exercises.

______ Review the lab exercises to ensure that students can demonstrate their
ability to access the different modes needed to accomplish the objectives.

______ Gather the following tools and material:

1 - Operation and Maintenance Manual (SEBU8559)

2 - PDF: “336E Hydraulic Excavator Machine Walkaround”

3 - Basic hand tools for removing access panels

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SERV1881-01 - 12/11 -6- Module 1 - Module Prerequisites

MODULE PREREQUISITES
• PREREQUISITE COURSES There are no prerequisite courses for this module.

• PREREQUISITE TESTS There are no prerequisite tests for this module.

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SERV1881-01 - 12/11 -7- Module 1 - Lesson Plan

LESSON PLAN
• Provide each student with a copy Student Introduction and Module Objectives
of the course description and
objectives Instructor and students introductions

Safety briefing, objectives, class agenda, and hand out student materials

Time Estimate: 15 min

• Visual Presentation Visual Presentation:

• Distribute Lab 1 Worksheet Classroom visual presentation of machine walkaround; students take
notes on component location and functionality using the Lab 1 and Lab
Worksheets.

Time Estimate: 60 min

• Conduct Lab 1 Lab 1: Machine Service Points Location and Identification

Give safety briefing and describe objective of lab.

Distribute Lab 1 Worksheet, Machine Service Points Location and

Identification checklist.

 tudents locate and explain functionality of machine major service points

S
on class machine.

Review completed Lab 1 Worksheet with class and answer questions.

Time Estimate: 30 min

• Conduct Lab 2 Lab 2: Machine Systems Major Component Location and Identification
Give safety briefing and describe objective of lab.

Distribute Lab 2 Worksheet, Machine Systems Component Location and

Identification checklist.

 tudents locate and explain functionality of machine major service points

S
on class machine.

Review completed Lab 2 Worksheet with class and answer questions.

Time Estimate: 30 min

• Administer Posttest Posttest

Administer Posttest - Time Estimate: 25 min

Review correct answers with class - Time Estimate: 20 min

Total Estimated Time: 3 hrs

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SERV1881-01 - 12/11 -8- Module 1 - Module Objectives

MODULE OBJECTIVES
• Visual Presentation 1. Given the presentation of the 336E Hydraulic Excavator Machine Walkaround
module, the student will take notes in the classroom on the identification,
location, and functionality of major service points and major machine systems
components.

• Lab 1 1. Given a 336E Hydraulic Excavator and Lab 1 Worksheet, locate each service
compartment and identify the filters, fluid level indicators, fill tubes, and other
major service points located on the 336E Hydraulic Excavator.

• Lab 2 1. Given a 336E Hydraulic Excavator and Lab 2 Worksheet, locate and identify the
major system components for the engine and cooling system, the hydraulic
systems, and the mechanical systems on the 336E Hydraulic Excavator.

• POSTTEST 1. Given the posttest for Machine Walkaround module, name the major components
of the 336E Hydraulic Excavator electronic control system.

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SERV1881-01 - 12/11 -9- Module 1 - Lab Exercises

LABORATORY EXERCISES
• INSTRUCTOR NOTE The following section provides directions to set up, facilitate, and assist during the
student lab exercises.

Some lab exercises are the written type with worksheets, while other labs are the
traditional “on the iron” labs. Answers are provided for the worksheet exercises.

The actual student lab sheets, along with accompanying materials, are located in the
Student Materials section.

At the beginning of each lab, review the lab description.

NOTE: Discuss safety procedures with the students for each shop lab (i.e.
safety glasses, clothing). Safely Home. Everyone. Every Day.™

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SERV1881-01 - 12/11 -10- Module 1 - Lab Exercises

LAB 1: 336E HYDRAULIC EXCAVATOR MACHINE SERVICE

POINTS COMPONENT IDENTIFICATION AND FUNCTION
• INSTRUCTOR NOTE This is a shop exercise. Instructor should have had the swing brake solenoid
disconnected during the machine walkaround exercise. Ensure students
understand the safety zones around the machine. Basic hand tools should be
accessible for students to remove access panels in order to complete this
exercise.

• SAFETY Students will adhere to all applicable safety regulations.

• EXERCISE Students will form teams of two persons and will identify the location and explain
basic functionality of the machine service points using the Lab 1 Worksheet.

NOTE: Do not start the engine or set the key start switch to ON during this lab
exercise.

Procedure: Explain the lab exercise. Inform students that they may refer to their
printed materials and notes while completing the exercise. Students will use Lab 1
Worksheet to document completion of task.

• MATERIALS NEEDED ______ 336E Hydraulic Excavator

______ Lab 1 Worksheet: 336E Hydraulic Excavator Machine Service Points

Component Identification and Function

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SERV1881-01 - 12/11 -11- Module 1 - Machine Walkaround

LAB 1: 336E Hydraulic Excavator Machine Service Points Component Identification and Function

Directions: Use this checklist to take notes during the presentation regarding component function and location. During the lab
exercise, use this sheet as a checklist when identifying components.

_______ Ground level engine shutdown switch

Function: Stops the engine under any conditions

Location: Base of the operator’s seat, left side, just inside the operator station door

_______ Batteries

Function: Provide 24V DC power to all machine electrical systems

Location: Bottom of the battery and air filter compartment, left side, behind the operator station

_______ Secondary and tertiary fuel filters

Function: Filter impurities from the fuel before delivered to the fuel injectors

Location: Rear wall of the battery and air filter compartment, left side, behind the operator station

_______ Engine intake air filter

Function: Filters dust and dirt from the engine intake air

Location: Top of the battery and air filter compartment, left side, behind the operator station

_______ Air conditioning dryer bottle and condenser

Function: Part of the A/C system that provides dehumidified and cooled air inside the operator station

Location: Rear wall of the battery and air filter compartment, left side, behind the operator station

_______ Circuit breakers

Function: Disconnect electrical power from machine systems when electrical load exceeds safe limits

Location: Front wall of the battery and air filter compartment, left side, behind the operator station

_______ Windshield washer bottle

Function: Reservoir for windshield washer fluid

Location: Inside the cooler compartment door at the left rear of the machine

_______ Engine coolant S•O•S test port

Function: Allows technician to draw a sample of the engine coolant for analysis

Location: Inside the cooler compartment door at the left rear of the machine
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SERV1881-01 - 12/11 -12- Module 1 - Machine Walkaround

_______ Engine radiator drain valve

Function: Drains engine coolant from the cooling system

Location: Inside the cooler compartment door at the left rear of the machine

_______ Main machine and engine electrical disconnect switch

Function: Disconnects the batteries and all electrical power from all machine systems

Location: Inside the cooler compartment door at the left rear of the machine - front of compartment

_______ Engine oil ecology drain valve

Function: Drains engine oil from the oil pan and the engine oil system

Location: Rearmost center access opening beneath the carbody

_______ Hydraulic oil tank ecology drain valve

Function: Drains hydraulic oil from the hydraulic oil tank

Location: Forward access opening beneath the right rear of the carbody

_______ Fuel tank drain valve

Function: Sounds the exterior horn when pressed

Location: Rear access opening beneath the right rear of the carbody

_______ Main hydraulic pump case drain pressure test port

Function: Pressure test port for testing main hydraulic pump case drain oil pressure

Location: Rear access opening beneath the right rear of the carbody

_______ NFC 1 and NFC 2 flow limit pressure test ports

Function: Pressure test ports for both NFC flow limit signal pressure to the main hydraulic pumps

Location: Bottom of the pump compartment along the rear wall - right rear of the machine

_______ Engine oil filter

Function: Filters impurities and contaminants from the engine oil

Location: Top of the pump compartment along the rear wall - right rear of the machine

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SERV1881-01 - 12/11 -13- Module 1 - Machine Walkaround

_______ Engine oil S•O•S port

Function: Allows technician to draw a sample of the engine oil for analysis

Location: Top of the pump compartment toward the rear wall - right rear of the machine

_______ Electric fuel priming pump

Function: Draw fuel from the fuel tank and prime the entire fuel system - provide fuel to the emissions
system

Location: Top of the main hydraulic pumps in the pump compartment - right rear of the machine

_______ Primary fuel filter and water separator

Function: Coarse filtration of fuel and removal/separation of water from the fuel

Location: Top of the pump compartment toward the rear wall - right rear of the machine

_______ Power Shift Pressure test port

Function: Pressure test port for testing power shift oil pressure

Location: Top left button on top of left joystick

_______ Case drain oil filter

Function: Filters impurities from hydraulic oil returning from all pump and motor cases

Location: Top of the pump compartment toward the front wall - right rear of the machine

_______ Pilot oil filter

Function: Filters impurities from pilot oil before being delivered to the pilot manifold

Location: Top of the pump compartment toward the front wall - right rear of the machine

_______ Pilot pressure test port

Function: Pressure test port for testing pilot oil pressure

Location: Pilot oil filter base, top of the pump compartment toward the front wall - right rear of the machine

_______ Hydraulic oil S•O•S port

Function: Allows technician to draw a sample of the hydraulic oil for analysis

Location: Pilot oil filter base, top of the pump compartment toward the front wall - right rear of the machine

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SERV1881-01 - 12/11 -14- Module 1 - Machine Walkaround

_______ Hydraulic oil sight gauge

Function: Allows technician and operator to view the level of oil in the hydraulic oil tank

Location: Front wall of the pump compartment - installed in the rear wall of the hydraulic oil tank

_______ Locking fuel filler tube and cap

Function: Fuel fill tube for the fuel tank - locking cap prevents vandalism

Location: Right front corner of the machine, on top of the fuel tank

_______ Locking hydraulic oil tank filler tube cap

Function: Hydraulic oil fill tube for the hydraulic oil tank - locking cap prevents vandalism

Location: Top of hydraulic oil tank - right center of machine

_______ Capsule-type return oil filter

Function: Filters all of the hydraulic oil returning from the main hydraulic control valve and its circuits

Location: Access at top of hydraulic oil tank - right center of machine (integrated into the hydraulic oil tank)

_______ Main hydraulic oil suction screen

Function: Coarse filtration of hydraulic oil before being drawn into the hydraulic oil pumps

Location: Access at top of hydraulic oil tank - right center of machine (integrated into the hydraulic oil tank)

_______ Clean Emissions Module - DPF

Function: Captures and contains particulates from the diesel engine exhaust

Location: Top of engine compartment - beneath left rear of engine compartment door (hood)

_______ Alternator

Function: Sliding lever that operates the secondary function of a (two-way flow) work tool

Location: Top of engine compartment - beneath right front of engine compartment door (hood)

_______ Engine oil level gauge (dip stick)

Function: Level gauge for engine oil

Location: Top of engine compartment - beneath center of engine compartment door (hood)

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SERV1881-01 - 12/11 -15- Module 1 - Machine Walkaround

_______ Crankcase breather

Function: Directs engine block fumes into a collection canister

Location: Top of engine compartment - beneath center of engine compartment door (hood)

_______ Radiator fill tube and cap

Function: Fill tube for adding engine coolant to the cooling system

Location: Top of engine compartment - beneath far right side of engine compartment door (hood) - on top of
expansion tank

_______ Swing drive lube level gauge (dipstick)

Function: Level gauge for determining the level of swing drive lube oil

Location: Top right of swing drive assembly - to the rear of the boom foot

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SERV1881-01 - 12/11 -16- Module 1 - Lab Exercises

LAB 2: Machine Systems Major Component Location

and Identification
• INSTRUCTOR NOTE This is a shop exercise. Instructor should have had the swing brake solenoid
disconnected during the machine walkaround exercise. Ensure students
understand the safety zones around the machine. Basic hand tools should be
accessible for students to remove access panels in order to complete this
exercise.

• SAFETY Students will adhere to all applicable safety regulations.

• EXERCISE Students will form teams of two persons and will identify the location and explain
basic functionality of the major machine components using Lab B Worksheet.

NOTE: Do not start the engine or set the key start switch to ON during this lab
exercise.

Procedure: Explain the lab exercise. Inform students that they may refer to their
printed materials and notes while completing the exercise. Students will use Lab 2
Worksheet to document completion of task.

• MATERIALS NEEDED ______ 336E Hydraulic Excavator

______ Lab 2 Worksheet: Machine Systems Major Component Location and

Identification

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SERV1881-01 - 12/11 -17- Module 1 - Machine Walkaround

LAB 2: 336E Hydraulic Excavator Machine Systems Major Component Location and Identification

Directions: Use this checklist to take notes during the presentation regarding component function and location. During the lab
exercise, use this sheet as a checklist when identifying components.

_______ Hydraulic oil cooler

Function: Cools and maintains proper operating temperature for the hydraulic oil

Location: Behind the cooler compartment door at the left rear of the machine - forward cooler core

_______ Radiator

Function: Cools and maintains proper operating temperature for the engine coolant

Location: Behind the cooler compartment door at the left rear of the machine - center cooler core

_______ Air-To-Air AfterCooler (ATAAC)

Function: Cools the engine intake air before entering the intake manifold

Location: Behind the cooler compartment door at the left rear of the machine - rearward cooler core

_______ Fuel cooler

Function: Cools the fuel returning from the engine fuel system before returning to the fuel tank

Location: Behind the cooler compartment door at the left rear of the machine - outer horizontal cooler core

_______ Starter (engine)

Function: Provides mechanical rotation of the engine flywheel when turning the key-start switch to START

Location: Rearmost center access opening beneath the carbody

_______ Engine ECM

Function: Monitors all engine inputs and shared machine data and controls all engine electrical functions

Location: Left side of engine (facing rear of machine) - rearmost center access opening beneath the carbody

_______ Pilot manifold

Function: Distribution point for pilot oil delivery to most all components using pilot oil

Location: Center service access opening beneath the carbody, just rearward of the swing bearing

_______ Pilot accumulator

Function: Stores a small amount of pilot pressure oil for use when pilot pressure is low or machine is off

Location: Center service access opening beneath the carbody, attached to pilot manifold
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SERV1881-01 - 12/11 -18- Module 1 - Machine Walkaround

_______ NFC flow limit manifold

Function: Provide NFC flow limit signal pressure to the main hydraulic pumps in certain conditions

Location: Bottom of the pump compartment along the rear wall - right rear of the machine

_______ Idler pump

Function: Supplies high pressure hydraulic oil to rear half of main hydraulic control valve

Location: Rearmost main hydraulic pump in the pump compartment - right rear of machine

_______ Drive pump

Function: Supplies high pressure hydraulic oil to front half of main hydraulic control valve

Location: Forward main hydraulic pump in the pump compartment - right rear of machine

_______ Medium pressure pump

Function: Supplies medium pressure hydraulic oil for operation of machine attachments

Location: Driven by the idler pump in the pump compartment - right rear of machine

_______ Pilot pump

Function: Supplies pilot oil to the pilot oil filter for use in the pilot oil system

Location: Driven by the drive pump in the pump compartment - right rear of machine

_______ Pressure Reducing Valve (PRV) manifold for attachment control

Function: Contains four solenoids and pressure test ports used for electronically controlling oil supply to
machine attachments

Location: Forward area of pump compartment - right rear of machine

_______ Hydraulic oil tank

Function: Reservoir for hydraulic oil and contains the return oil filter

Location: Large tank immediately forward of the pump compartment door - right side of machine

_______ Fuel tank

Function: Reservoir for diesel fuel

Location: Large tank at the right front corner of the machine

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SERV1881-01 - 12/11 -19- Module 1 - Machine Walkaround

_______ Clean Emissions Module and DPF

Function: Captures and contains particulates from the diesel engine exhaust

Location: Top of engine compartment - beneath left rear of engine compartment door (hood)

_______ Main hydraulic control valve

Function: Controls the flow of high pressure pump oil to all the high pressure hydraulic circuits on the
machine

Location: Center of upper structure - forward of the engine compartment (beneath upper walkway)

_______ Main hydraulic relief valve

Function: Limits the maximum hydraulic pressure in the high pressure hydraulic system

Location: Bottom front of the main hydraulic control valve

_______ Heavy lift solenoid valve (if equipped)

Function: Provides pilot pressure oil to main hydraulic relief valve to increase the maximum hydraulic system
pressure

Location: Upper solenoid valve in the lower manifold on the bracket to the left of the main hydraulic control
valve

_______ Boom regeneration PRV

Function: Provides pilot oil for the operation of the boom regeneration valve

Location: Lower solenoid valve in the lower manifold on the bracket to the left of the main hydraulic control
valve

_______ Boom priority pressure reducing valve

Function: Provides pilot oil to ensure oil priority for boom operation over stick operation

Location: Solenoid valve in the upper manifold on a bracket to the left of the main hydraulic control valve

_______ Swing drive assembly

Function: Provides the rotational power to move the upper structure (swing) about the undercarriage

Location: Center of upper structure - to the rear of the boom foot

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SERV1881-01 - 12/11 -20- Module 1 - Posttest

POSTTEST
• INSTRUCTOR NOTE The following posttest is a paper test designed to measure the student’s ability to
identify the major components of the 336E Hydraulic Excavator electronic control
system. The answers are provided on the following pages. The actual student
posttests are provided in the Student Materials section.

The module posttest may also be used as a pretest.

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SERV1881-01 - 12/11 -21- Module 1 - Posttest

336E Hydraulic Excavator: Electronic Control System

Overview Posttest
• INSTRUCTOR NOTE Classroom Posttest

Students may refer to their course materials and class notes when taking the
posttest.

Students may not consult with others during the posttest.

• INDIVIDUAL EXERCISE Procedure

Give students a copy of the “336E Hydraulic Excavator: Electronic Control System
Overview Posttest.”

Explain the posttest.

• MATERIALS NEEDED ______ 336E Hydraulic Excavator: Electronic Control System Overview Posttest

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SERV1881-01 - 12/11 -22- Module 1 - Machine Walkaround

336E ELECTRONIC CONTROL SYSTEM

(02) (03) (04)

(01)

(07)

(05)
(08)
(11)
(06)

(10) (09)

(17)

(12)

(14) (16)

(15)

(13) 22_1

336E Hydraulic Excavator: Electronic Control System Overview Posttest

Given all reference material and class notes, the student will answer questions
regarding the identification of the major components in the 336E Hydraulic Excavator
Electronic Control System.

Test Directions: Fill in the blanks next to the numbers with the correct term.

• Test Directions: Fill in the blanks 1. Operator controls 2. Machine ECM

next to the numbers with the
correct term 3. WAVS Camera 4. Monitor

5. Machine Status Inputs 6. Switch Panel ECM

7. Local CAN Data Link 8. Engine ECM

9. Cat Data Link 10. Engine Local CAN Data Link

11. CAN 2 (J1939) Data Link 12. Combustion Air Controller

13. Soot Sensors & RF Soot Monitor 14. Gateway Worldview ECM

15. Communications Adapter 16. Cat ET

17. Combustion Air Valve

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