Global Manpower Development

336E Hydraulic Excavator

Pilot Hydraulic System
Module 6 - INSTRUCTOR MATERIALS

SERV1881-01

336E Hydraulic Excavator

Module 6 - Pilot Hydraulic System
Instructor Materials

© 2011 Caterpillar Inc.

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SERV1881-01 - 12/11 -2- Module 6 - Table of Contents

TABLE OF CONTENTS
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MODULE DESCRIPTION�������������������������������������������������������������������������������������������������������������3
PREPARATION CHECKLIST�������������������������������������������������������������������������������������������������������4
MODULE PREREQUISITES��������������������������������������������������������������������������������������������������������6
LESSON PLAN�����������������������������������������������������������������������������������������������������������������������������7
MODULE OBJECTIVES���������������������������������������������������������������������������������������������������������������9
LABORATORY EXERCISES������������������������������������������������������������������������������������������������������10
POSTTEST���������������������������������������������������������������������������������������������������������������������������������16

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SERV1881-01 - 12/11 -3- Module 6 - Module Description

MODULE DESCRIPTION
• CONTENT This module is designed to prepare the service technician to explain the systems
operation and perform testing and adjusting procedures on the 336E Hydraulic
Excavator Pilot Hydraulic System.

• 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
Specifications - Machine Systems KENR7983
Systems Operation - Hydraulic System KENR7984
Testing and Adjusting - Hydraulic System KENR7985
Hydraulic Schematic KENR7986
Electrical Schematic KENR7987
Machine Systems - Disassembly and Assembly KENR8157

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 6 - 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 Pilot Hydraulic System”

______ Service Manual (KENR7980)

______ Operation and Maintenance Manual (English) (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)

______ Systems Operation, Troubleshooting, Testing and Adjusting (KENR9508)
______ E Series Machine Monitoring System - Systems Operation (KENR9509)
______ Service Manual Module “Operation and Maintenance Manual” (SEBU8559)
______ Systems Operation - Hydraulic System (KENR7984)
______ Testing and Adjusting - Hydraulic System (KENR7985)
______ Hydraulic Schematic (KENR7986)
______ Electrical Schematic (KENR7987)

• 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 Pilot Hydraulic System Text Reference
to become familiar with the topic.

______ Duplicate enough 336E Hydraulic Excavator Pilot Hydraulic System Text
Reference for each participant in the training session.

______ Duplicate enough 336E Hydraulic Excavator Pilot Hydraulic System 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 6 - 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.

______ Prepare the 336E Hydraulic Excavator machine(s) to be used in the lab
exercises (and ensure the swing brake solenoid is disconnected).

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

______ Gather the following tools and material:

1. Operation and Maintenance Manual (SEBU8559)

2. PDF: “336E Hydraulic Excavator Pilot Hydraulic System”

3. Testing and Adjusting - Hydraulic System (KENR7985)

4. Hydraulic Schematic (KENR7986)

5. 8T-0856 Pressure Gauge [0 to 6,000 kPa (0 to 870 psi)]

6. Basic hand tools

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SERV1881-01 - 12/11 -6- Module 6 - 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 6 - 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 introduction (as required) and
the pilot hydraulic system; students take notes on component location and
functionality using the Lab 1 Worksheet.

Time Estimate: 45 min

• Conduct Lab 1 Lab 1: 336E Hydraulic Excavator Pilot Hydraulic System Component
Identification and Function

Give safety briefing and describe objective of lab.

Use Lab 1 Worksheet: 336E Hydraulic Excavator Pilot Hydraulic System

Component Identification and Function checklist

 tudents locate and explain functionality of pilot hydraulic system

S
components on class machine.

Review completed Lab 1 Worksheet with class - answer questions.

Time Estimate: 30 min

• Conduct Lab 2 Lab 2: 336E Hydraulic Excavator Relief Valve (Pilot) - Test and Adjust

Give safety briefing and describe objective of lab.

Ensure students have access to: Testing and Adjusting - Hydraulic System
(KENR7985)

Ensure students have access to: All tools and materials listed in the
Preparation Checklist of this document

Students to test and adjust the pilot relief valve on class machine.

Review Lab 2 test and adjust results - answer questions.

Time Estimate: 60 min

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SERV1881-01 - 12/11 -8- Module 6 - Pilot Hydraulic System

• Administer Posttest Posttest

Administer Posttest - Time Estimate: 20 min

Review correct answers with class - Time Estimate: 10 min

Restore Machine

N/A

Total Estimated Time: 3 hrs

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SERV1881-01 - 12/11 -9- Module 6 - Module Objectives

MODULE OBJECTIVES
• Visual Presentation 1. Given the presentation of the 336E Hydraulic Excavator Pilot Hydraulic System,
the student will take notes in the classroom on the identification, location, and
functionality of the major components of the machine’s pilot hydraulic system
using the Lab 1 Worksheet.

• Lab 1 1. Given a 336E Hydraulic Excavator and the Lab 1 Worksheet, the student will
identify the location and explain the functionality of the major components in the
machine’s pilot hydraulic system.

• Lab 2 1. Given a 336E Hydraulic Excavator, the student will test and adjust the machine’s
pilot relief valve.

• Posttest 1. Given all reference material and class notes, the student will answer questions
regarding the major components of, and the flow of oil through, the 336E Hydraulic
Excavator pilot hydraulic system.

2. Given all reference material and class notes, the student will answer questions
regarding the basic operational strategies of the 336E Hydraulic Excavator pilot
hydraulic system.

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SERV1881-01 - 12/11 -10- Module 6 - 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 -11- Module 6 - Lab Exercises

LAB 1: 336E HYDRAULIC EXCAVATOR PILOT HYDRAULIC

SYSTEM 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. Ensure students understand
the safe number of people (2-4) that can be on top of the machine at the same
time.

• SAFETY Students will adhere to all applicable safety regulations.

• EXERCISE Students will form teams of two persons and will identify the location and explain the
functionality of the pilot hydraulic system controls and components 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 Pilot Hydraulic System

Component Identification and Function

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SERV1881-01 - 12/11 -12- Module 6 - Pilot Hydraulic System

LAB 1: 336E Hydraulic Excavator Pilot Hydraulic System 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.

_______ Hydraulic lockout (activation) lever and limit switch

Function: Enables or disables the movement of machine implements and travel by blocking the delivery of
pilot pressure oil to the control valves

Location: Outside the left console and beneath the front of the left armrest in the operator compartment

_______ Pilot oil pump

Function: Provides hydraulic oil flow to the pilot relief valve in the pilot manifold

Location: Small outer gear pump driven by the idler (forward) pump

_______ Hydraulic oil S•O•S port

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

Location: Installed in the pilot oil filter base - top front of pump compartment (right rear of machine)

_______ Pilot pressure test port

Function: Allows the technician to connect a pressure gauge and test the pilot system pressure

Location: Installed in the pilot oil filter base - top front of pump compartment (right rear of machine)

_______ Pilot oil filter

Function: Removes contaminants from the hydraulic oil before it is delivered to the pilot manifold

Location: Top front of pump compartment (right rear of machine)

_______ Pilot oil filter bypass valve

Function: Allows pilot oil to bypass the pilot oil filter when the oil is cold or the filter is plugged (clogged)

Location: Installed in the pilot oil filter base - top front of pump compartment (right rear of machine)

_______ Pilot relief valve

Function: Sets the pilot system pressure

Location: Installed in the pilot oil filter base - top front of pump compartment (right rear of machine)

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SERV1881-01 - 12/11 -13- Module 6 - Pilot Hydraulic System

_______ Pilot manifold

Function: Main distribution center for pilot pressure oil used to control most implement hydraulic functions

Location: Above the center access plate, behind the swing bearing - beneath the carbody (upper structure)

_______ Pilot oil accumulator

Function: Stores pilot pressure oil for use by the pilot control valves when pilot oil pressure drops

Location: Installed in the right side of the pilot manifold

_______ Two-speed travel solenoid valve

Function: Sends pilot pressure oil to the travel motors’ change displacement valves when conditions allow

Location: Leftmost solenoid valve installed in the pilot manifold

_______ Power Shift Pressure Reducing Valve (PSPRV)

Function: Sends pilot oil to destroke the main hydraulic pumps as the hydraulic load on the pumps causes
engine speed to decrease below optimum rpm

Location: Installed in the manifold at the top of the main hydraulic pumps

_______ Hydraulic lockout solenoid valve

Function: A
 ctuates the pilot operated hydraulic activation valve, which enables the delivery of pilot pressure
oil to control valves

Location: Rightmost solenoid valve installed in the pilot manifold

_______ Hydraulic activation valve

Function: A
 ctuated by the hydraulic lockout solenoid valve - enables or disables the delivery of pilot pressure
oil to control valves

Location: Valve installed in the pilot manifold, immediately left of the hydraulic lockout solenoid valve

_______ Swing brake solenoid valve

Function: Sends pilot pressure oil to release the swing parking brake when any implements are moved

Location: Center solenoid valve installed in the pilot manifold

_______ Pilot oil distribution manifold

Function: Receives pilot pressure oil from the pilot manifold and distributes it to the implement control pilot
valves and the travel control pilot valves - directs all pilot drain oil to the pilot manifold

Location: Above the forward access panel beneath the operator’s station

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SERV1881-01 - 12/11 -14- Module 6 - Pilot Hydraulic System

_______ Implement pilot control valves

Function: Send pilot oil to move main implement valve spools (boom, stick, bucket, swing) when a joystick is
moved

Location: One four-way valve installed beneath each joystick (left and right)

_______ Travel pilot control valves

Function: Send pilot oil to move left or right travel valve spools when a travel lever/pedal is moved

Location: One two-way valve installed beneath each travel pedal/lever (left and right)

_______ Straight travel pilot control valve (if equipped)

Function: Sends equal pilot pressure to both left or right travel valve spools when the travel pedal is moved

Location: One two-way valve installed beneath the optional straight travel pedal

_______ Pilot resolver block

Function: Junction between the pilot lines from the implement pilot control valves and the pilot lines to the
main control valve group - also senses when an implement or swing function is activated

Location: Installed beneath the operator’s seat - access from beneath the carbody

_______ Boom down control pressure sensor

Function: Senses when boom down pilot control pressure is present and signals the Machine ECM

Location: Installed in the pilot resolver block

_______ Swing control pressure sensor

Function: Senses when swing pilot control pressure is present and signals the Machine ECM

Location: Installed in the pilot resolver block

_______ Implement control pressure switch

Function: Senses when implement pilot control pressure for boom up, stick in and out, and bucket open and
close is present and signals the Machine ECM

Location: Installed in the pilot resolver block

_______ Left and right travel control pressure switches

Function: Sense when travel pilot control pressure is present and signals the Machine ECM

Location: One each installed in the travel pilot control valves and in the straight travel pilot valve

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SERV1881-01 - 12/11 -15- Module 6 - Pilot Hydraulic System

LAB 2: 336E Hydraulic Excavator Relief Valve

(Pilot) - Test and Adjust
• 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. Ensure students understand
the safe number of people (2-4) that can be on top of the machine at the same
time. Ensure that students stay outside the identified safety zones when
warming the hydraulic oil for the Test and Adjust lab exercise.

• SAFETY Students will adhere to all applicable safety regulations.

• EXERCISE Students will work as a class to perform the 336E Hydraulic Excavator Pilot Relief
Valve testing and adjusting procedure. Students are to follow the detailed step-by-
step instructions for this test and adjust procedure that is outlined in the testing and
adjusting service manual module (KENR7985). Afterward, the students and
instructor will discuss the outcomes to ensure that all students understand how the
test and adjust procedure produced the results observed.

Procedure: Explain the lab exercises. Inform students that they may refer to their
printed materials and notes while completing the exercise.

• MATERIALS NEEDED All hand tools and specific tooling listed in the testing and adjusting procedure and
listed in the Preparations Checklist found earlier in this document.

______ 336E Hydraulic Excavator

______ Operation and Maintenance Manual (SEBU8559)

______ PDF: “336E Hydraulic Excavator Main Hydraulic Pumps”

______ Testing and Adjusting - Hydraulic System (KENR7985)

______ Hydraulic Schematic (KENR7986)

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SERV1881-01 - 12/11 -16- Module 6 - Posttest

POSTTEST
• INSTRUCTOR NOTE The following posttest is a paper test designed to measure the student’s understanding
of the 336E Hydraulic Excavator Pilot Hydraulic System components and strategies.
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 -17- Module 6 - Posttest

336E Hydraulic Excavator Pilot Hydraulic System 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 Pilot Hydraulic System
Posttest.”

Explain the posttest.

• MATERIALS NEEDED ______ 336E Hydraulic Excavator Pilot Hydraulic System Posttest

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SERV1881-01 - 12/11 -18- Module 6 - Pilot Hydraulic System

336E PILOT MANIFOLD

UNLOCKED - IMPLEMENTS ENABLED
TWO-SPEED TRAVEL ENABLED
SWING BRAKE RELEASED

(11) (07)
(06)
(01)
(12)
(08) (04)

(13)
(03)

(10) (02) (05)

(09)
18_1
336E Hydraulic Excavator Pilot Hydraulic System Posttest

Given all reference material and class notes, the student will answer questions
regarding the major components and the flow of oil through the 336E Hydraulic
Excavator Pilot Hydraulic System.

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

• Test Directions: Fill in the blanks 1. Pilot oil pump (pilot supply) 2. Accumulator check valve
next to the numbers with the
correct term 3. Accumulator 4. Hydraulic lockout solenoid valve

5. Hydraulic activation valve 6. To pilot control valves

7. To heavy lift solenoid 8. Swing brake solenoid valve

9. To swing brake 10. Two-speed travel solenoid valve

11. To travel motors 12. To straight travel solenoid valve

13. To NFC flow limit manifold

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SERV1881-01 - 12/11
• Test Directions: Place an “X”
beside the one response that
best completes the statement
• Fill in the blanks with the correct
responses.
-19- Module 6 - Pilot Hydraulic System
336E Hydraulic Excavator Pilot Hydraulic System Posttest
Given all reference material and class notes, the student will answer questions
regarding the basic operational strategies of the 336E Hydraulic Excavator pilot
hydraulic system.
Test Directions: Place an “X” beside the one response that best answers each
multiple choice question.
1. When the hydraulic lockout lever is placed in the locked position:
X The engine can be started
The implements can be operated
Travel is enabled but implements are disabled
The engine cannot be started
2. When the hydraulic lockout lever is placed in the UNLOCKED position:
Travel and implement control levers or pedals are disabled
The hydraulic lockout solenoid valve is DE-ENERGIZED
X The hydraulic lockout solenoid valve is ENERGIZED
Travel is enabled but implements are disabled
3. The limit switch that is operated by the hydraulic lockout lever:
Is grounded when the hydraulic lockout lever is moved to the
UNLOCKED position
Is a normally closed switch that is opened when the implement
lockout lever is moved to the UNLOCKED position
X Is a normally open switch that is closed when the implement
lockout lever is moved to the UNLOCKED position
The ground is taken away when the hydraulic lockout lever is
moved to the UNLOCKED position
4. The implement control pressure switch in the pilot resolver block CLOSES:
when boom, stick, bucket, attachment, or swing movement is
sensed
X when boom up, stick in/out, or bucket open/close movement
is sensed
when boom, stick, bucket, or travel movement is sensed
when boom up/down, stick in/out, or bucket open/close
movement is sensed
Test Directions: Fill in the blanks with the correct responses.
5. L ist the six basic circuits that utilize pilot pressure oil, along with a brief
statement of the purpose of the pilot oil usage:
1. P
 ower Shift PRV - pressure and flow control of the main hydraulic
pumps through the power shift pressure system
2. Pilot valves - for implement and travel operation (operator controls)
3. NFC flow limit manifold - for pump control strategies
4. Straight travel solenoid valve - to ensure straight travel during
implement movement
5. Two-speed travel solenoid valve - for two-speed travel operation
6. S
 wing brake solenoid valve - for releasing the swing brake during
implement operation
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