- Excavator:
- 320D (S/N: A6F1-UP; A8F1-UP)
- 320D (S/N: A9F1-UP)
- 320D (S/N: BZF1-UP)
- 320D (S/N: KGF1-UP)
- 320D (S/N: MCH1-UP; TDH1-UP; FAL1-UP; KLM1-UP; SPN1-UP; GDP1-UP; EAX1-UP; PHX1-UP)
- 323D (S/N: LFL1-UP)
- 320D (S/N: A9F1-UP)
- Work Tool:
- HYDRAULIC KIT (S/N: HKD1-UP)
Introduction
This Special Instruction provides the information that is necessary to install the 275-7203 Auxiliary Control Wiring Gp on certain excavators. This wiring group can be used with either System 3 auxiliary hydraulics or with System 5 auxiliary hydraulics.
Safety Section
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| Illustration 1 | g00104545 |
Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or to the controls before you service the equipment. These warning tags (Special Instruction, SEHS7332) are available from your AVSpare dealer.
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Check valves in the hydraulic system may allow pressure to exist in the hydraulic lines after the engine has been stopped. Pressure must be relieved prior to servicing the components of the hydraulic system. Failure to relieve pressure prior to servicing may result in personal injury. |
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Required Parts
| Required Parts 275-7203 Auxiliary Control Wiring Gp |
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| Item | Qty | Part Number | Description |
| (1) | 22 | 3S-2093 | Cable Strap |
| (2) | 5 | 7K-1181 | Cable Strap |
| (3) | 1 | 275-7197 | Auxiliary Harness As |
| (4) | 1 | 132-5789 | Clip |
| (5) | 1 | 156-6175 | Clip |
| (6) | 1 | 8T-4121 | Hard Washer |
| (7) | 1 | 8T-4171 | Bolt |
| (8) | 1 | 8T-4191 | Bolt |
| (9) | 1 | 9X-8256 | Washer |
| (10) | 1 | 7K-1181 | Cable Strap |
Installation Procedure
- Locate the 12-pin connector in the engine room. Locate the 8-pin connector in the engine room.
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| Illustration 2 | g02159662 |
Excavator frame and auxiliary wiring. | |
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| Illustration 3 | g02160637 |
12-Pin and 8-Pin connectors to chassis harness. (A) Frame access hole (B) Chassis harness (2) 7K-1181 Cable Strap (3) 275-7197 Auxiliary Harness As | |
- Route twelve-pin connector and eight-pin connector through frame access hole (A) from the pump compartment. Follow the existing machine harness.
- Connect the twelve-pin connector to the machine chassis harness. Connect the eight-pin connector to the machine chassis harness.
- Secure this portion of harness to existing machine harness using cable straps (2). Refer to illustration 3.
- Route the four, 2-wire connectors toward the control solenoids.
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| Illustration 4 | g02160789 |
Auxiliary harness in pump compartment. (A) Frame access hole (1) 3S-2093 Cable Strap (2) 7K-1181 Cable Strap | |
- Remove existing bolt from boss of machine frame where existing ground wires are attached.
- Secure wire 235-BK with this bolt and tighten to 23 to 37 N.m (17 to 27 ft-lb). Refer to illustration 4.
- Route the remaining connectors alongside the frame and through frame access hole (C) of the main frame.
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| Illustration 5 | g02161126 |
Auxiliary harness frame routing. (C) Frame access hole (1) 3S-2093 Cable Strap (3) 275-7197 Auxiliary Harness As | |
- Secure the harness (3) to the machine harness using cable straps (1). Refer to illustration 5.
- Secure the loose connectors of the Auxiliary harness (3) to the existing machine harness below the boom foot using cable ties (1). These connectors are not used for installation of system 3 auxiliary hydraulics. These connectors are not used for installation of system 5 auxiliary hydraulics. Refer to illustration 6 and illustration 7.
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| Illustration 6 | g02161195 |
Harness at RH side of boom foot (not used with System 3 or 5) (C) Frame access hole (1) 3S-2093 Cable Strap (3) 275-7197 Auxiliary Harness As | |
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| Illustration 7 | g02161981 |
Harness at LH side of boom foot (not used with System 3 or 5) (1) 3S-2093 Cable Strap (3) 275-7197 Auxiliary Harness As | |
System 5 Connections
- Locate connector containing wires K860-BU and K868-BR and plug into the "Stem 1 Retract" (upper) solenoid.
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| Illustration 8 | g02162049 |
System 5 control solenoid connections (E) Unused connections for system 5 (1) 3S-2093 Cable Strap (2) 7K-1181 Cable Strap (4) 132-5789 Clip (6) 8T-4121 Hard Washer (8) 8T-4191 Bolt | |
- Locate connector containing wires K856-PU and K868-BR and plug into the "Stem 1 Extend" (lower) solenoid.
- Cap remaining two connectors (E) and secure the connectors to the harness using cable tie (1) .
- Secure auxiliary harness to machine using clip (4), washer (6), bolt (8) and cable strap (2). Refer to illustration 8.
System 3 Connections
- Locate connector containing wires K860-BU and K857-WH and plug into the "Stem 2 Extend" (upper) solenoid.
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| Illustration 9 | g02162195 |
System 3 control solenoid connections (G) Unused connections for System 3 (1) 3S-2093 Cable Strap (2) 7K-1181 Cable Strap (4) 132-5789 Clip (6) 8T-4121 Hard Washer (8) 8T-4191 Bolt | |
- Locate connector containing wires K856-PU and K868-BR and plug into the "Stem 1 Extend" (lower) solenoid.
- Cap remaining two connectors (G) and secure the connectors to the harness using cable tie (1) .
- Secure auxiliary harness to machine using clip (4), washer (6), bolt (8) and cable strap (2). Refer to illustration 9.
- Locate the chassis harness inside the right frame rail of the machine. Cut the strap securing the chassis harness. Route the harness through the wall of the pump compartment to the flow control valve.
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| Illustration 10 | g02162253 |
System 3 flow limit solenoid connection (5) 156-6175 Clip (7) 8T-4171 Bolt (9) 9X-8256 Washer (10) 7K-1181 Cable Strap | |
- Connect the chassis harness with wires M737-WH and M739-YL to the flow control valve solenoid.
- Attach clip (5) on to the flow control valve. Use washer (9), and bolt (7). Secure the chassis harness to clip (5) with strap (10). Refer to illustration 10.
- Secure wire harness in place as needed using straps (1), straps (2) or straps (10).