LHPH 320 330 Electronic Control Unit

Service Training Meeting Guide 621 SESV1621 August 1992

TECHNICAL PRESENTATION

320/330 HYDRAULIC EXCAVATORS ELECTRONIC CONTROL UNIT

320/330 HYDRAULIC EXCAVATORS ELECTRONIC CONTROL UNIT MEETING GUIDE 621 SLIDES AND SCRIPT AUDIENCE Level II - Service personnel who understand the principles of machine systems operation, diagnostic equipment, and procedures for testing and adjusting.

CONTENT This presentation contains the information and visuals necessary to develop a Level II course of instruction on the Electronic Control Unit (ECU) for the 320, 320L, 320N, 330, and 330L Hydraulic Excavators. Emphasis is placed on explaining how the ECU and Monitor Panel function. The Data and Calibration Modes of the system are also explained in detail.

OBJECTIVES After learning the information in this presentation, the serviceman will be able to: 1. locate and identify the major components of the ECU and monitor panel system; 2. identify all input and output signals for the ECU and monitor panel; 3. explain the function and operation of each major component; and 4. explain and demonstrate how to access the built-in diagnostic procedures.

REFERENCES 320, 320L and 320N Excavators Service Manual (3116 Engine with Bent Axis Pump) 320, 320L and 320N Excavators Service Manual (3066 Engine with Swashplate Pump) 320, 320L and 320N Excavators Hydraulic and Electronic Systems Testing and Adjusting 320, 320L and 320N Excavators Parts Book 330 and 330L Excavators Service Manual 330 and 330L Excavators Hydraulic and Electronic Systems Testing and Adjusting 330 and 330L Excavators Parts Book

SENR5450 SENR5465 SENR5473 SEBP2034 SENR5490 SENR5496 SEBP2171

PREREQUISITES Cat Hydraulics Course (or equivalent) STMG 546 "Graphic Fluid Power Symbols" STMG 584 "Electronic Power Unit Control for E-Series Hydraulic Excavators"

SEGV2519 SESV1546 SESV1584

SUPPLEMENTARY TRAINING MATERIAL STMG 619 "320/330 Hydraulic Excavator--Pumps and Pump Controls" STMG 620 "320/330 Hydraulic Excavator--Hydraulic Systems Operation"

SESV1619 SESV1620

Estimated Time: 3 Hours Visuals: 58 (2 X 2) Slides Serviceman Handouts: 4 line drawings Form: SESV1621 Date: 8/92 © 1992 Caterpillar Inc.

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TABLE OF CONTENTS

INTRODUCTION ........................................................................................................................5 Component Location and Function.........................................................................................6 Pulse Width Modulated Signals............................................................................................13 Controller Changes ...............................................................................................................14 Monitor Features...................................................................................................................16 Controller Input Components ...............................................................................................17 Controller Output Components.............................................................................................19 Power Mode Selection ..........................................................................................................21 P-Q Curves (320 with 3116 engine and Bent Axis Pump) ...................................................22 P-Q Curves (320 with 3066 engine and Swashplate Pump)............................................ .....24 P-Q Curves (330 with 3306 engine).................................................................................. ...26 P-Q Curves (320 with 3116 engine and Bent Axis Pump) ...................................................28 P-Q Curves (320 with 3066 engine and Swashplate Pump) .................................................30 P-Q Curve (330 with 3306 engine).......................................................................................32 Pump Regulation...................................................................................................................34 Speed Dial Limits .................................................................................................................36 SYSTEMS OPERATION ...........................................................................................................37 320 System Behavior ............................................................................................................38 330 System Behavior ............................................................................................................40 Power Mode Settings ............................................................................................................42 Automatic Engine Control (AEC) ........................................................................................47 One-touch Low Idle Control.................................................................................................49 Backup Systems ....................................................................................................................50 SERVICE FUNCTIONS.............................................................................................................53 Data Mode.............................................................................................................................54 Calibration Mode ..................................................................................................................64 CONCLUSION...........................................................................................................................83 SLIDE LIST................................................................................................................................85 SERVICEMAN'S HANDOUTS.................................................................................................87

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INSTRUCTOR NOTES

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3 2 0 / 3 3 0 H Y D R A U I C E X C AVAT O R ELECTRONIC CONTROL UNIT

© 1992 Caterpillar Inc.

1

INTRODUCTION • Electronic Control Unit (ECU) also called "controller" • Matches hydraulic horsepower to engine horsepower • Receives, processes, and sends signals • Warns of machine problems • Varies pump flow rates • Provides diagnostics

This presentation introduces the Electronic Control Unit (ECU) used on the Caterpillar 320 and 330 Hydraulic Excavators. These ECU's are referred to as "controllers" because they match hydraulic horsepower to engine horsepower by controlling engine rpm. The controller receives input signals from the engine, the hydraulic system and the operator. As operating conditions change, the controller sends output signals to change engine speed, warn the operator of potential problems and to vary the hydraulic pump flow rate. This presentation will explain the major differences between the 320/330 controller and those used on the "E" series hydraulic excavators. The ways in which this controller simplifies machine operation and diagnostics for both operators and servicemen will also be discussed.

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2

Component Location and Function • Controller located outside the cab • Totally sealed unit

• 3 LED's (arrow) for some diagnostics

The controller is located in an outside compartment above and behind the battery box. A panel must be removed to access the controller. The controller is a totally sealed unit like the transmission controls for Caterpillar Off-highway Trucks and Wheel Tractor-Scrapers. The only time when removal of the compartment cover will be necessary is when the monitor panel on the operator's console in the cab shows the controller fault symbol or when the diagnostic error codes indicate that the three diagnostic Light Emitting Diodes (LED's - arrow) need to be checked. The fault symbols and error codes will be discussed in detail later in this presentation.

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3

•If controller fault symbol stays ON, check the LED's

As mentioned in the previous slide, if the controller fault symbol on the monitor panel comes ON and stays ON, a problem in the controller system is indicated. The three diagnostic LED's on the controller will provide an indication of the problem.

• Yellow LED ON, communication problem with monitor

When the yellow LED turns ON, a communication problem with the monitor is indicated.

• Red LED ON steady or flashing, replace CPU

If the red LED is ON (steady or flashing), the Central Processor Unit (CPU) is not functioning correctly and must be replaced.

• Green LED ON, normal operation

During engine start-up, the three LED's will briefly illuminate. The red and yellow LED's will quickly turn OFF leaving just the green LED ON, which indicates normal operation.

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4

• Monitor panel: - Push buttons activate many functions - Displays information

The operator's console has a monitor panel that permits several machine functions to be activated with push buttons. The monitor panel also displays information about the machine operating status and diagnostic information.

• Engine speed dial: - Ten positions

The machine is equipped with an engine speed dial that has ten different positions. This digital rotary switch replaces the governor control lever which was used in earlier hydraulic excavators. The engine speed dial will also be discussed in detail later in this presentation.

- Replaces governor control lever

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5

• Two backup systems: - Engine speed dial (two switches) - Pump control (one switch)

Two backup systems are provided to prevent machine down situations. One backup system is for the engine speed dial and the second is for the pump controls. Each system is activated by toggle switches at the rear of the operator's seat arm consoles.

• Speed dial rear switch: - Normally run in "AUT" position - Dial disconnected in "MAN" position

The engine speed dial circuit (shown) has two backup switches on the right console. The rear switch is normally run in the "AUT" position. When the switch is moved to the "MAN" position, the engine speed dial signal is disconnected from the controller. The front switch is then used to manually control the engine speed. Push the front switch toward the "Rabbit" to increase engine speed or toward the "Tortoise" to decrease engine speed.

• Speed dial front switch: - "Rabbit" position increases rpm - "Tortoise" position decreases rpm • Pump control switch: - Normally run in "AUT" position - "Tortoise" position connects PRV to backup resistor

The pump control backup switch (not visible in this view) is the single toggle switch on the left console. The backup switch has two positions-"AUT" and "Tortoise." This switch also is normally run in the "AUT" position. If a pump control problem occurs, move the switch to the "Tortoise" position. The pump control is bypassed and power to the Proportional Reducing Valve (PRV) is supplied through a backup resistor.

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6

• Monitor panel: - Upper section has readout devices - Lower section has push buttons - LED's tell when function is ON or OFF • Four red LED's make up warning system master lamp • Three digit display: - Operating parameters - Error codes - Used in diagnostics • LCD gauges: - Engine temperature - Fuel level - Hydraulic oil temperature

The monitor panel, located in front and to the right of the operator's seat, has two sections. The upper section contains readout devices and the lower section contains push button switches which control many machine functions. The push buttons are labeled and have LED's which indicate when the function is ON or OFF. At the top of the upper section are four red LED's. These LED's make up the master lamp, which is part of the warning system. The warning system is activated when various machine system faults are detected by the controller. In the top right corner of the upper section is a three digit Liquid Crystal Display (LCD) which indicates various machine operating parameters and, during diagnostic procedures, displays information on machine systems, components, and error codes. Below this display are three rotary LCD's which indicate engine coolant temperature, fuel quantity and hydraulic oil temperature.

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7

• Seven LED fault symbols

Across the bottom of the upper section (below the rotary displays) are seven LED fault symbols that illuminate when an out of tolerance condition occurs. These symbols (from left to right) are: - Air intake heater (for 320 Excavator with 3066 engine) - Charging system - Engine coolant temperature - Hydraulic oil temperature - Engine oil pressure - Controller system - Monitor system

• Master lamp turns ON when a fault symbol is activated

The master lamp (mentioned earlier) turns ON when the engine coolant temperature, hydraulic oil temperature, or engine oil pressure fault symbols are activated.

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8

• Ether aid switch • Start switch • Engine speed dial: - Ten positions - Each position has a specific no load speed

This view shows the ether aid switch, start switch and the engine speed dial with the "tortoise" and "rabbit" symbols and an ascending pictorial scale. As previously stated, the engine speed dial has ten positions. The monitor panel indicates the engine speed dial position from 1 through 10. Each dial position has a specific no load engine speed.

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PULSE WIDTH MODULATED (PWM) SIGNALS

VOLTAGE LEVEL

VOLTAGE ON

MEAN VOLTAGE

ONE CYCLE

VOLTAGE OFF

9 Pulse Width Modulated Signals • ECU sends PWM signals to: - PRV - Hydraulic oil temperature sensor - Governor actuator motor • PWM signals: - Specific voltage level - "Pulsed" on and off - ON time controlled by ECU - Cannot be measured accurately with VOM

The 320/330 uses a Pulse Width Modulated (PWM) signal from the controller to the Proportional Reducing Valve (PRV) which is identical to the signal used on the "E" series hydraulic excavators. In addition, the hydraulic oil temperature sensor and governor actuator motor on the 320/330 receive PWM signals. A PWM signal is a specific voltage level (for example, from 0 to 24 volts) that is "pulsed" (turned ON and OFF repeatedly). This voltage level is represented by the height of the vertical step in the slide. The time of the "pulse" (or ON time) will be varied by the controller. The time is represented by the horizontal length of the "pulse" in the slide. This time is normally a percentage of the total ON time available for the "pulse." A PWM signal cannot be measured accurately with a VOM because the longer a "pulse" is ON, the "mean voltage value" that is measured will also be higher. The "mean voltage value" will never be as high as the pulsed voltage level. This same condition, but in reverse, holds true for shorter "pulses." A lower "mean voltage value" will be measured.

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CONTROLLER CHANGES. . . • Now a sealed unit, located outside the cab • Three diagnostic LED's in the cover • Has more “inputs” and “outputs” • Functions as an underspeed controller, but ONLY in Power Mode llI, and if the engine speed dial is at position “10” • Has an “anti-stall” feature instead of the “self-learning” function • It operates the electronic governor control

10 Controller Changes This slide summarizes some of the changes which have been made to the 320/330 controller from the "E" series hydraulic excavators.

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CONTROLLER CHANGES. . . • The controller has continual interactive communication with the monitor panel • Controls the work mode solenoids, the two-speed travel solenoid and relays for the lights, wiper and washer solenoids • Stores fault codes for later retrieval • Provides three levels of Automatic Engine Control, or AEC • Has two built-in diagnostic service modes - Data mode and Calibration mode • Has two backup systems, one for the pump control and another for the engine speed dial

11 Shown in this slide are the remaining changes to the 320/330 controller.

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THE MONITOR. . . • Communicates with the controller • Has LCD displays in place of gauges • Has push buttons that control many machine functions and access diagnostic procedures • Has a three digit character readout that... - shows engine speed dial position - displays fault codes for controller/monitor problems - indicates when either or both backup systems are activated 12 Monitor Features This slide summarizes the operational features of the 320/330 monitor.

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INPUTS TO CONTROLLER

LOW IDLE SWITCH

ENG. COOLANT TEMP. SENSOR

FUEL LEVEL SENSOR

ENG. OIL PRESS. SWITCH

ALT.

IMPL. /SW. PRESS. SWITCH BM. UP PRESS. SWITCH

HYD. OIL TEMP. SENSOR

ENG. SPEED DIAL

MONITOR ATTACH. PRESS. SWITCH

TRAV. PRESS. SWITCH

ECU (CONTROLLER)

RELAY BOX

P/S PRESSURE BACKUP SWITCH

TRAVEL ALARM

CHASSIS LIGHT

BOOM WIPER LIGHT

WASHER

FAULT ALARM

TRAV. SPD. SOLEN. VALVE

FUSE BOX

BATTERY

SPD. DIAL BACKUP SW.

FINE CONTROL SOLEN. VALVE

SWING PRIORITY SOLEN. VALVE

SPEED CHANGE SWITCH

START ENGINE SWITCH G/A SPEED SENSOR

G/A FDBK SENSOR PRV

PUMP

13 Controller Input Components On this diagram, all of the inputs to the controller have been color coded red. Fuse box: Electrical power from the battery and start switch is sent through the fuse box to the controller. Monitor: Sends a number of input signals to the controller which will be explained in detail later in this presentation. Speed sensor: A magnetic pickup which is mounted on the engine flywheel housing just below the muffler. Feedback sensor: Indicates the governor position and is located on the governor actuator motor which is mounted under a square cover in the hydraulic pump compartment.

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Engine speed dial: A rotary switch which is located on the operator’s console in the cab. Travel pressure switch: Tells the controller when a travel circuit is activated and is mounted on the top front of the main implement control valve. Implement/swing pressure switch: Tells the controller when an implement or the swing circuit is activated; also mounted on the top front of the main control valve. Boom up pressure switch: Tells the controller when the boom control is fully stroked for "boom up." Engine coolant temperature sensor: Located on the water pump housing. Hydraulic oil temperature sensor: Located on the right rear lower corner of the hydraulic tank. Fuel level sensor: Located on the right rear lower corner of the fuel tank and is visible from the pump compartment. Alternator: Sends a signal to the controller indicating correct operation. Engine oil pressure switch: Located in the rear by the engine oil gallery. One-touch low idle switch: Part of the automatic engine speed control system; located on top of the right joystick. Attachment pressure switch: Sends a signal to the controller when an auxiliary pump is in operation.

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OUTPUTS FROM CONTROLLER

LOW IDLE SWITCH


FUEL LEVEL SENSOR


BM. UP PRESS. SWITCH


ALT.

ENG. SPEED DIAL

IMPL. /SW. PRESS. SWITCH


TRAV. PRESS. SWITCH

ECU (CONTROLLER)

RELAY BOX

SPEED CHANGE SWITCH


FUSE BOX

BATTERY


TRAVEL ALARM



ENGINE

START SWITCH

G/A

CHASSIS LIGHT

BOOM LIGHT

WIPER

WASHER FAULT ALARM


SPEED SENSOR

G/A FDBK SENSOR PUMP PRV

14 Controller Output Components Shown here is the same diagram but with all the controller outputs color coded red. Monitor: In addition to serving as an input component, the monitor also receives signals from the controller. Governor actuator motor: Electrically controls engine rpm as indicated by speed dial settings. Proportional Reducing Valve (PRV): Controls the Power Shift (PS) pressure to the pump group and is also part of the PWM signal circuit. Fine control (Leveling) solenoid valve: Activated by the controller after a signal is received from the WORK push button switch on the monitor panel.

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Swing priority (Crowding) solenoid valve: Also activated by the controller after a signal is received from the WORK push button switch on the monitor panel. Two speed travel solenoid valve: Activated by the controller after a signal is received from the TRAVEL SPEED push button switch on the monitor panel. Fault alarm: An audible horn or buzzer. Travel alarm: Activated by the controller after a signal is received from the travel pressure switch. Windshield wiper relay: Actuated by the controller after a signal is received from the WIPER push button switch on the monitor panel. Windshield washer relay: Actuated by the controller after a signal is received from the WASHER push button switch. Chassis light relay: Actuated by the controller after a signal is received from the LIGHT push button switch. Boom light relay: Also actuated after a signal is received from the LIGHT push button switch.

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PERFORMANCE MONITOR POWER MODE SELECTION

POWER

WORK

III II I

AEC ON

LIGHT

1 2

WIPER

WASHER

1 2

TRAVEL SPEED ALARM CANCEL

15 Power Mode Selection • Power mode selector switch sends signal to controller • LED's indicate levels I, II, or III • Power modes match machine power to task

• Available engine horsepower

The power mode selector switch, located on the monitor panel, signals the controller which power mode level has been chosen. Three symbols with corresponding LED's indicate which level (I, II or III) has been selected. Each time the switch is pushed, the power mode will cycle to a different level and illuminate an LED. The three power modes permit the operator to match the machine power to the task by providing a different amount of hydraulic horsepower for the implement, swing and travel systems. The amount of available engine horsepower that can be utilized in each of the three power modes is: Power Mode I - up to 65% Power Mode II - up to 85% Power Mode III - up to 100% NOTE: At engine start-up, the controller automatically defaults to Power Mode II.

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320 P-Q CHARACTERISTICS 3116 ENGINE WITH BENT AXIS PUMP 2 PUMPS EQUALLY LOADED WITH IMPLEMENTS ONLY DIA L "1 0" DIA L "9 ~10 "

PUMP FLOW (GPM)

60 50

40 GPM 1990 PSI

NOTE VALUES SHOWN ARE EXAMPLES ONLY THEY SHOULD NOT BE USED FOR PUMP TESTS

46 GPM 2130 PSI A

DIA L "7 ~10"

40

IMPL. R/V SETTING 4550 PSI III

37 GPM C 1480 PSI

30 20

B

II

25 GPM 3980 PSI

I

20 GPM

POWER SHIFT PRESSURE POINT A = approx 255 ps POINT B = approx 290 psi POINT C = approx 320 psi

10 0 0

1000

15 GPM 22 GPM 2490 PSI

9 GPM

27 GPM 2775 PSI

2000 3000 PUMP PRESSURE (PSI)

4000

5000

16 P-Q Curves (320 with 3116 engine and Bent Axis Pump) • Pump pressure plotted against flow • Both pumps equally loaded • Implement/swing pressure switch closed • Travel pressure switch open • Top curve for Power Mode III •Middle curve for Power Mode II

The three curves on this diagram show pump pressure plotted against pump flow for each of the three power modes when only an implement or swing circuit is loaded. Each curve shows the flow for one pump when both pumps are equally loaded. The controller detects when only an implement or swing circuit is loaded because the implement/swing pressure switch at the main control valve is closed and the travel pressure switch at the main control valve is open (no pressure in the travel circuits). The top curve, for Power Mode III, shows that the pump begins to destroke at Point A, which is approximately 14700 kPa (2130 psi). At that time, the power shift pressure is approximately 1750 kPa (255 psi). The middle curve, for Power Mode II, shows that the pump begins to destroke at Point B, which is approximately 13700 kPa (1990 psi). At that time, the power shift pressure is approximately 2000 kPa (290 psi).

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The bottom curve, for Power Mode I, shows that the pump begins to destroke at Point C, which is approximately 10200 kPa (1480 psi). At that time, the power shift pressure is approximately 2200 kPa (320 psi). NOTE TO THE INSTRUCTOR: All values shown are for CLASSROOM REFERENCE ONLY and should not be used for diagnostic purposes.

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320 P-Q CHARACTERISTICS 3066 ENGINE WITH SWASHPLATE PUMP 2 PUMPS EQUALLY LOADED WITH IMPLEMENTS ONLY DIAL "10" DIA L "9 ~10 " DIAL "7 ~10"

PUMP FLOW (GPM)

60 50

43 GPM 1500 PSI

A 48 GPM 1900 PSI B

40


IMPL. R/V SETTING 4550 PSI

III II

40 GPM C 1450 PSI

29 GPM 3050 PSI

I

30 POWER SHIFT PRESSURE

20

16 GPM

POINT A = approx 230 psi

14 GPM

POINT B = approx 280 psi

10

POINT C = approx 310 psi

0 0

1000

21 GPM 2550PSI

9 GPM

23 GPM 3050 PSI


4000

5000

17 P-Q Curves (320 with 3066 engine and Swashplate Pump) • Pump pressure plotted against flow • Both pumps equally loaded • Implement/swing pressure switch closed • Travel pressure switch open

The three curves on this diagram show pump pressure plotted against pump flow for each of the three power modes when only an implement or swing circuit is loaded. Each curve shows the flow for one pump when both pumps are equally loaded. The controller detects when only an implement or swing circuit is loaded because the implement/swing pressure switch at the main control valve is closed and the travel pressure switch at the main control valve is open (no pressure in the travel circuits).

• Top curve for Power Mode III

The top curve, for Power Mode III, shows that the pump begins to destroke at Point A, which is approximately 13100 kPa (1900 psi). At that time, the power shift pressure is approximately 1590 kPa (230 psi).

• Middle curve for Power Mode II

The middle curve, for Power Mode II, shows that the pump begins to destroke at Point B, which is approximately 10300 kPa (1500 psi). At that time, the power shift pressure is approximately 1950 kPa (280 psi).


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330 P-Q CHARACTERISTICS 2 PUMPS EQUALLY LOADED WITH IMPLEMENTS ONLY DIAL "10"

60 PUMP FLOW (GPM)


III

DIAL "9~10"

50

DIAL "7~10"

40

II

I

57 GPM B 2485 PSI

A 59 GPM 3130 PSI

42 GPM 4130 PSI

IMPL. R/V SETTING 4550 PSI

39 GPM 3335 PSI

47 GPM C 2200PSI

38 GPM

30

34 GPM 3050 PSI

28 GPM

POWER SHIFT PRESSURE

20

20GPM

POINT A = approx 160 psi POINT B = approx 185 psi

10

POINT C = approx 200 psi

0 0

1000


4000

5000

18 P-Q Curves (330 with 3306 engine) • Pump pressure plotted against flow • Both pumps equally loaded • Implement/swing pressure switch closed • Travel pressure switch open • Top curve for Power Mode III • Middle curve for Power Mode II

The three curves on this diagram show pump pressure plotted against pump flow for each of the three power modes when only an implement or swing circuit is loaded. Each curve shows the flow for one pump when both pumps are equally loaded. The controller detects when only an implement or swing circuit is loaded because the implement/swing pressure switch at the main control valve is closed and the travel pressure switch at the main control valve is open (no pressure in the travel circuits). The top curve, for Power Mode III, shows that the pump begins to destroke at Point A, which is approximately 21570 kPa (3130 psi). At that time, the power shift pressure is approximately 1100 kPa (160 psi). The middle curve, for Power Mode II, shows that the pump begins to destroke at Point B, which is approximately 17160 kPa (2485 psi). At that time, the power shift pressure is approximately 1275 kPa (185 psi).


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320 PUMP P-Q CHARACTERISTICS 3116 ENGINE WITH BENT AXIS PUMP ONE PUMP LOADED WITH IMPLEMENTS OR TRAVEL IN POWER MODE III 60 49 GPM 2490 PSI

PUMP FlOW (GPM)

50 40 30

A

47 GPM 3980 PSI

B


20


TRAVEL

31 GPM 5000 PSI TRAVEL R/V SETTING

IMPLEMENTS 27 GPM 3980 PSI

Pt. A = 130 psi

23 GPM

Pt. B = 45 psi

10

4550 PSI IMPL. R/V SETTING

0 0

1000

2000

3000

4000

5000

PUMP PRESSURE (PSI)

19 P-Q Curves (320 with 3116 engine and Bent Axis Pump) • Only one pump loaded • Power Mode III with speed dial at 10

• Only implement loaded: - Implement/swing pressure switch closed - Travel pressure switch open

These two curves show the pump pressure plotted against flow when only one pump is loaded for either an implement/swing circuit or for the travel circuit. The values shown here are for Power Mode III with the engine speed dial at position 10. Again, the controller can detect when only an implement is loaded because the implement/swing pressure switch at the main control valve is closed and the travel pressure switch at the main control valve is open (no pressure in the travel circuits). The pump begins to destroke at Point A, which is approximately 17100 kPa (2490 psi). Power shift pressure will be approximately 900 kPa (130 psi) at that time.

STMG 621 8/92 • Only travel loaded: - Travel pressure switch closed - Implement/swing pressure switch open

• Constant signal to PRV as circuit is loaded • Engine rpm decreases to target speed • Signal to PRV varies to maintain target speed

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The controller can detect when only the travel circuit is loaded because the travel pressure switch at the main control valve is closed and the implement/swing pressure switch at the main control valve is open (no pressure in the implement/swing circuits). When using one pump to load a travel circuit (as in a pivot turn), the pump begins to destroke at Point B, which is approximately 27400 kPa (3980 psi). Power shift pressure will be approximately 300 kPa (45 psi) at that time. Thus, the controller sends a constant level of electrical signal to the PRV when loading the implement/swing or travel circuit. After the engine speed decreases to the target speed of approximately 1750 rpm, the controller varies the electrical signal to the PRV to maintain that target speed.

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320 PUMP P-Q CHARACTERISTICS 3066 ENGINE WITH SWASHPLATE PUMP ONE PUMP LOADED WITH IMPLEMENTS OR TRAVEL IN POWER MODE III NOTE 60

PUMP FlOW (GPM)

50

VALUES SHOWN ARE EXAMPLES ONLY THEY SHOULD NOT BE USED FOR PUMP TESTS

40

43 GPM 2670 PSI



20 GPM 3980 PSI

Pt. B = 28 psi

17 GPM

0 0

1000

27 GPM

IMPLEMENTS

Pt. A = 185 psi

10

TRAVEL

B

A

30 20

42 GPM 3980 PSI

2000

3000

4000

5000 PSI TRAVEL R/V SETTING

5000

PUMP PRESSURE (PSI)

20 P-Q Curves (320 with 3066 engine and Swashplate Pump) • Only one pump loaded • Power Mode III with speed dial at 10


These two curves show the pump pressure plotted against flow when only one pump is loaded for either an implement/swing circuit or for the travel circuit. The values shown here are for Power Mode III with the engine speed dial at position 10. Again, the controller can detect when only an implement is loaded because the implement/swing pressure switch at the main control valve is closed and the travel pressure switch at the main control valve is open (no pressure in the travel circuits). The pump begins to destroke at Point A, which is approximately 18400 kPa (2670 psi). Power shift pressure will be approximately 1275 kPa (185 psi) at that time.

STMG 621 8/92 • Only travel loaded: - Travel pressure switch closed - Implement/swing pressure switch open

• Constant signal to PRV as circuit is loaded • Engine rpm decreases to target speed • Signal to PRV varies to maintain target speed

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The controller can detect when only the travel circuit is loaded because the travel pressure switch at the main control valve is closed and the implement/swing pressure switch at the main control valve is open (no pressure in the implement/swing circuits). When using one pump to load a travel circuit (as in a pivot turn), the pump begins to destroke at Point B, which is approximately 27400 kPa (3980 psi). Power shift pressure will be approximately 200 kPa (28 psi) at that time. As in the preceding example, the controller sends a constant level of electrical signal to the PRV when loading the implement/swing or travel circuit. After the engine speed decreases to the target speed of approximately 1750 rpm, the controller varies the electrical signal to the PRV to maintain that target speed.

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330 PUMP P-Q CHARACTERISTICS ONE PUMP LOADED WITH IMPLEMENTS OR TRAVEL IN POWER MODE III 60

61 GPM 4195 PSI


50 PUMP FlOW (GPM)

A

IMPLEMENTS

40

5000 PSI TRAVEL R/V SETTING


10

34 GPM


30 20

53 GPM

Pt. A=100 psi

0 0

1000

2000

3000

4000

5000

PUMP PRESSURE (PSI)

21 P-Q Curve (330 with 3306 engine) • Only one pump loaded • Power Mode III with speed dial at 10


This curve shows the pump pressure plotted against flow when only one pump is loaded for either an implement/swing circuit or for the travel circuit. The values shown here are for Power Mode III with the engine speed dial at position 10. The controller can detect when only an implement is loaded because the implement/swing pressure switch at the main control valve is closed and the travel pressure switch at the main control valve is open (no pressure in the travel circuits). The pump begins to destroke at Point A, which is approximately 28920 kPa (4195 psi). Power shift pressure will be approximately 685 kPa (100 psi) at that time.

STMG 621 8/92 • Constant signal to PRV as circuit is loaded • Engine rpm decreases to target speed • Signal to PRV varies to maintain target speed

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The controller sends a constant level of electrical signal to the PRV when loading the implement/swing or travel circuit. After the engine speed decreases to the target speed of approximately 1750 rpm, the controller varies the electrical signal to the PRV to maintain that target speed.

STMG 621 8/92

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PUMP CONTROLS

RESOLVER VALVE

POWER MODE SELECTION ENGINE SPEED DIAL

REGULATOR

MONITOR PILOT PUMP

TRAV. PRESS. SWITCH

ENGINE

IMP. SW. PRESS. SWITCH

SPEED SENSOR

PUMP

PUMP

P/S PRESS FROM PRV

ECU P/S PRESSURE FROM PRV ATTACH. PRESS. SWITCH (IF EQUIPPED)

PROPORTIONAL REDUCING VALVE

22 Pump Regulation • Pump flow regulated by controller • Controller sends electrical signal to PRV • PRV sends pressure signal to pumps • Pressure signal affects both pumps

Pump flow is regulated by the controller. As machine operation begins, the implement/swing pressure switch or the travel pressure switch closes because pressure in the main control valve logic circuit increases. The controller then processes the signals from the power mode switch, engine speed dial and the engine speed sensor to determine the level of electrical signal that is sent to the proportional reducing valve. The PRV then sends a variable reduced pilot system pressure signal (called power shift pressure) to the hydraulic pump regulators. Power shift pressure affects both pumps at the same time based on the power mode level selected by the operator.

STMG 621 8/92

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Power Mode I: Any engine speed dial position • Signal from controller to PRV is constant and high • Pumps destroke at low system pressure • Both pump flows vary with pump pressures

In Power Mode I, the electrical signal from the controller to the PRV is constant and high. The PRV sends a constant and high power shift pressure to the pumps causing them to begin destroking at a relatively low pump system pressure. As system pressure in each pump increases above 10700 kPa (1550 psi), the power shift pressure does not change. The increased pump pressures, acting internally in the pump regulators, begin to destroke the pumps. Both pump flows will increase or decrease as pump pressures decrease or increase. Power Mode II: Any engine speed dial position

• Signal from controller to PRV is constant but less than Power Mode I • Pumps destroke at slightly higher system pressure • Power shift pressure remains constant • Signal from controller is constant but less than Power Mode II • Pumps destroke at higher pressure than Power Mode II • Power shift pressure remains constant • Controller functions as underspeed control • As engine speed decreases, controller signal increases • Controller varies signal to maintain engine rpm near full load

In Power Mode II, the electrical signal from the controller to the PRV is still constant but slightly lower than in Power Mode I, so the power shift pressure to the pumps is also slightly lower. The pumps begin to destroke at a slightly higher pump system pressure than in Power Mode I. As pump pressure increases and flow decreases, the power shift pressure will remain relatively constant. Again, pump flow is regulated by the individual pump system pressure acting internally in the pump regulators (as described in Power Mode I). Power Mode III: Engine speed dial positions 1 through 9 In Power Mode III, the electrical signal from the controller to the PRV is still constant but slightly lower than in Power Mode II, so the power shift pressure to the pumps is also slightly lower. The pumps begin to destroke at a slightly higher pump system pressure than in Power Mode II. As stated previously, when pump pressure increases and flow decreases, the power shift pressure will remain relatively constant. Pump flow is still regulated by the individual pump system pressure acting internally in the pump regulators (as described in Power Modes I and II). Power Mode III: Engine speed dial position 10 If the engine speed dial is at 10 and the pumps are loaded, the controller functions as an underspeed control. The controller monitors engine speed from the speed sensor and, as engine speed decreases to near full load (1980 rpm for 320, 1950 rpm for 330), the controller begins to increase the electrical signal to the PRV. The PRV increases the power shift signal to the pumps and the pumps begin to destroke. The controller continually varies the electrical signal to the PRV to maintain engine speed as near to full load rpm as possible. NOTE TO THE INSTRUCTOR: For a detailed explanation of the function and operation of the hydraulic pump regulators, refer to STMG 619 "320/330 Hydraulic Excavators--Pumps and Pump Controls" (Form SESV1619).

STMG 621 8/92

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POWER lll ll l

POWER MODE SWITCH

ELECTRONIC CONTROL CIRCUITS

III II I 1 2

SPEED DIAL LIMITS SPEED SENSOR

1 2

PUMP MONITOR

ECU

FEEDBACK SENSOR

(CONTROLLER)

PROPORTIONAL REDUCING VALVE

ENGINE

GOVERNOR ACTUATOR

ENGINE SPEED DIAL

23 Speed Dial Limits • Power Mode I: Engine rpm limited to speed dial position 7

The engine speed is limited by the power mode setting chosen. When Power Mode I is selected, the maximum engine rpm is limited to that of the engine speed dial at position 7, even if the dial is at position 8, 9 or 10. If the dial is at position 6 or below, the maximum engine rpm will be that of the selected dial position.

• Power Mode II: Engine rpm limited to speed dial position 9

In Power Mode II, the maximum engine rpm is limited to that of dial position 9, even if the dial is at position 10. If the dial is at position 8 or below, the maximum engine rpm will be that of the selected dial position.

• Power Mode III: Engine rpm limited to speed dial position 10

In Power Mode III, the maximum engine rpm is limited to that of the engine speed dial at position 10. If the dial is at position 9 or below, the maximum engine rpm will be that of the selected dial position.

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24

SYSTEMS OPERATION The 320/330 controllers provide a number of operational benefits. Productivity is a function of all systems operating correctly and within design specifications. A thorough understanding of how the controller can vary the machine operational parameters will enhance productivity and the ability to isolate performance related problems.

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320 SYSTEM BEHAVIOR NORMAL OPERATION

1970

High Idle (3 sec. period before AEC comes ON)

275 psi

1870

AEC Level l

275 psi

1790

Both pumps pressurized up to main relief pressure

1750 1850

Boom Up and Swing

190 psi 260 psi 185 psi 255psi

1300

AEC ON

275 psi

One-Touch Low Idle ON

275 psi

940 ENGINE RPM

POWER SHIFT PRESSURE THE VALUES SHOWN ARE FOR THE 320, 320L. ACTUAL VALUES WILL VARY WITH MACHINE MODEL

25 320 System Behavior • Normal operation in Power Mode III • Engine speed dial at position 10 • Controls in HOLD, three seconds before AEC comes ON • Engine rpm to be lowered • Controls in HOLD for three seconds, AEC is OFF • Pumps at low standby flow

Engine speed and power shift pressures will vary during different operating conditions. This chart provides examples of approximate engine rpm and power shift pressure during different machine operating conditions. For all conditions, the machine is shown during normal operation in Power Mode III with the engine speed dial at position 10. High Idle: All controls are in NEUTRAL or HOLD during the three seconds before the Automatic Engine Control (AEC) comes ON. Engine speed is 1970 rpm and power shift pressure is approximately 1910 kPa (275 psi). Engine speed is about to be reduced to AEC level 1 or 2. No Load, Maximum RPM: All controls are in NEUTRAL or HOLD for three seconds and the AEC switch is OFF. Engine speed is 1870 rpm and power shift pressure is approximately 1910 kPa (275 psi). The hydraulic pumps are at low standby flow and pump pressures are below 3450 kPa (500 psi). Component wear will be reduced and fuel consumption is low.

STMG 621 8/92

• Pump pressures at relief valve setting • Controller monitoring engine speed

• Boom up and swing at same time

• Controls in HOLD for three seconds, AEC is ON • Pumps at low standby flow

• One-touch low idle switch is ON • Pumps at low standby flow

- 39 -

Normal Load, Below Full Load Speed: Both pumps are pressurized up to the implement relief valve setting. Engine speed is approximately 1790 rpm and power shift pressure is from 1325 to 1815 kPa (190 to 260 psi). Pump pressures are at 31350 kPa (4550 psi) and pump flows are approximately 76 l/min. (20 gpm). The controller is monitoring engine speed to either increase or decrease the electrical signal to the PRV. Maximum Flow, Full Load Speed: Booming up and swinging at the same time. Engine speed is approximately 1800 rpm and power shift pressure is from 1275 to 1765 kPa (185 to 255 psi). Pump pressures are at 24100 kPa (3500 psi) and pump flows are approximately 129 l/min. (34 gpm). AEC On: All controls are in NEUTRAL or HOLD for three seconds and the AEC switch is ON. Engine speed is approximately 1300 rpm and power shift pressure is approximately 1910 kPa (275 psi). Hydraulic pressures are below 3450 kPa (500 psi) and the pumps are at low standby flow of approximately 34 l/min. (9 gpm). One-Touch Low Idle: One-touch low idle switch is ON. Engine speed is approximately 950 rpm and power shift pressure is approximately 2050 kPa (295 psi). Hydraulic pump pressures are below 3450 kPa (500 psi) and the pumps are at low standby flow of approximately 34 l/min. (9 gpm). NOTE TO THE INSTRUCTOR: Power shift pressures shown are for example only and should not be used for testing and adjusting.

STMG 621 8/92

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330 SYSTEM BEHAVIOR NORMAL OPERATION

1960 1860

High Idle (3 sec. period before AEC comes ON) AEC Level I

205 psi 205 psi

1790

Both pumps pressurized up to main relief pressure

1790 1840

Boom Up and Swing

140 psi 170 psi 115 psi 185 psi

1300

AEC ON

205 psi

One-Touch Low Idle ON

205 psi

850 ENGINE RPM


THE VALUES SHOWN ARE FOR THE 330, 330L. ACTUAL VALUES WILL VARY WITH MACHINE MODEL

26 330 System Behavior • Normal operation in Power Mode III • Engine speed dial at position 10

• Controls in HOLD, three seconds before AEC comes ON • Engine rpm to be lowered • Controls in HOLD for three seconds, AEC is OFF • Pumps at low standby flow

Engine speed and power shift pressures will vary during different operating conditions. This chart provides examples of approximate engine rpm and power shift pressure during different machine operating conditions. For all conditions, the machine is shown during normal operation in Power Mode III with the engine speed dial at position 10. High Idle: All controls are in NEUTRAL or HOLD during the three seconds before the Automatic Engine Control (AEC) comes ON. Engine speed is 1960 rpm and power shift pressure is approximately 1420 kPa (205 psi). Engine speed is about to be reduced to AEC level 1 or 2. No Load, Maximum RPM: All controls are in NEUTRAL or HOLD for three seconds and the AEC switch is OFF. Engine speed is 1870 rpm and power shift pressure is approximately1420 kPa (205 psi). The hydraulic pumps are at low standby flow and pump pressures are below 3450 kPa (500 psi). Component wear will be reduced and fuel consumption is low.

STMG 621 8/92 • Pump pressures at relief valve setting • Controller monitoring engine speed

• Boom up and swing at same time

• Controls in HOLD for three seconds, AEC is ON • Pumps at low standby flow • One-touch low idle switch is ON • Pumps at low standby flow

- 41 -

Normal Load, Below Full Load Speed: Both pumps are pressurized up to the implement relief valve setting. Engine speed is approximately 1790 rpm and power shift pressure is from 980 to 1175 kPa (140 to 170 psi). Pump pressures are at 31350 kPa (4550 psi) and pump flows are approximately 145 l/min. (38 gpm). The controller is monitoring engine speed to either increase or decrease the electrical signal to the PRV. Maximum Flow, Full Load Speed: Booming up and swinging at the same time. Engine speed is approximately 1790 rpm and power shift pressure is from 785 to 1275 kPa (115 to 185 psi). Pump pressures are at 24100 kPa (3500 psi) and pump flows are approximately 190 l/min. (50 gpm). AEC On: All controls are in NEUTRAL or HOLD for three seconds and the AEC switch is ON. Engine speed is approximately 1300 rpm and power shift pressure is approximately 1420 kPa (205 psi). Hydraulic pressures are below 3450 kPa (500 psi) and the pumps are at low standby flow of approximately 34 l/min. (9 gpm). One-Touch Low Idle: One-touch low idle switch is ON. Engine speed is approximately 850 rpm and power shift pressure is approximately 1420 kPa (205 psi). Hydraulic pump pressures are below 3450 kPa (500 psi) and the pumps are at low standby flow of approximately 34 l/min. (9 gpm). NOTE TO THE INSTRUCTOR: Power shift pressures shown are for example only and should not be used for testing and adjusting.

STMG 621 8/92

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320-330 POWER MODE SETTINGS HYDRAULIC TORQUE RATED = 1800 RPM HYDRAULIC TORQUE

TARGET SPEED = 1790 RPM (330) 1750 RPM (320) lll ll l

1 LOW IDLE

2

3

4

5

6

7

ENGINE SPEED DIAL POSITION

8

9

10

HIGH IDLE

27 Power Mode Settings • Hydraulic torque for each speed dial position

This chart shows hydraulic torque in each of the three power modes for each of the ten engine speed dial positions. The normal engine torque curve (black) is at the top.

• Power Mode III, dial position 10

The Power Mode III torque curve (red) is the second curve from the top. When the engine speed dial is in position 10 and the machine begins working, the engine speed will decrease from high idle rpm toward the full load speed of 1800 rpm. The full load speed is near the target speed

• Engine rpm decreases to target speed • Controller varies signal to maintain target rpm

(1750 rpm for 320, 1790 rpm for 330) for Power Mode III and dial position 10. After the engine rpm decreases to the target speed, the controller varies the electrical signal to the PRV to maintain the engine rpm at or near the target speed.

STMG 621 8/92 • Power Mode III, dial position 9 or below • Engine rpm decreases, pumps destroke • Steady signal to PRV • Power Modes I and II are similar

• Engine rpm decreases, pumps destroke • Steady signal to PRV • Pump flow controlled by system pressures

- 43 -

When the engine speed dial is in position 9 or below (but still in Power Mode III) and the machine begins working, the engine rpm will decrease from the no load speed for that dial position until the pump system pressure begins to destroke the pump. In this condition, the controller sends a steady signal to the PRV and pump flow is controlled only by the pump system pressures. The Power Mode II curve (blue) and Power Mode I curve (yellow) show similar characteristics. Power Mode II engine speed begins at dial position 9 and the controller sends a steady and slightly higher electrical signal to the PRV than in Power Mode III and dial position 9. Power Mode I begins at dial position 7 and the controller sends a steady and slightly higher electrical signal to the PRV than in Power Mode II. As the machine begins working, the engine speed will decrease from the no load speed for a selected dial position until pump pressure begins to destroke the pumps. Remember, the controller sends a steady signal to the PRV during these conditions and pump flow is controlled only by pump system pressures.

STMG 621 8/92

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320-330 POWER MODE SETTINGS ANTI-STALL FUNCTION CONSTANT TORQUE CONTROL LINE HYD TORQUE

lll ll l ANTI-STALL CONTROL LINE

1

LOW IDLE

2

3

4

5

6

7

ENGINE SPEED DIAL POSITION

8

9

10

HIGH IDLE

28 • Anti-stall function

• Engine 250 rpm below no load speed for selected dial position • Signal to PRV increases • Flow rates decrease to unload engine

The anti-stall function of the 320/330 controller replaces the self-learning function which was used on the "E" series excavator controllers. When the machine is operating in Power Mode I and II or in Power Mode III with the engine speed dial in position 9 or below, the power shift pressure is constant. (Remember, however, that the power shift pressures are different for each of these conditions.) The controller monitors engine speed and, if the engine speed decreases 250 rpm below the no load speed of the engine speed dial, the controller begins to increase the electrical signal to the PRV. The PRV then increases the power shift pressure sent to the pumps and causes the pump flow rates to decrease, thereby unloading the engine. When the engine speed increases above the engine speed dial less 250 rpm value, the controller again provides a constant electrical signal to the PRV.

STMG 621 8/92 • Power Mode II, dial position 8 • Engine rpm decreases to 1500 • Signal to PRV increases, pumps destroke

- 45 -

In the example shown on the graph, a 320 excavator is operating in Power Mode II with the engine speed dial in position 8. The no load engine speed is 1750 rpm. As the machine begins to operate, the engine speed decreases to 1500 rpm. To this point, the controller was supplying a constant electrical signal to the PRV. After the engine speed decreases to 1500 rpm, however, the controller begins to increase the signal to the PRV causing the pumps to destroke and unload the engine. When engine speed increases above 1500 rpm, the controller again supplies a constant electrical signal to the PRV. NOTE: The anti-stall feature functions as described above for each of the engine speed dial positions and power mode levels except Power Mode III and dial position 10.

- 46 -

HYDRAULIC HORSEPOWER

STMG 621 8/92

POWER MODE VS. HYDRAULIC HORSEPOWER

lll RATED SPEED

ll

ENGINE HORSEPOWER

l

SPEED DIAL SETTINGS

1

2

800

3

1000

4

5

1200

6

1400

7

1600

8

9

1800

10

2000

ENGINE RPM

29 • Power mode setting vs hydraulic horsepower

This graph compares available engine horsepower to the hydraulic horsepower for each engine speed dial position in each power mode. The top curve (black) represents the available engine horsepower. Power Mode III is shown by the red curve, Power Mode II by the blue curve and Power Mode I by the yellow curve.

• Power reduction curves for all three modes

This graph illustrates the reduction in power capabilities for all three power modes. Notice how the power decreases from approximately 100% in Power Mode III, to 85% in Power Mode II, to 65% in Power Mode I.

STMG 621 8/92

- 47 -

MONITOR

ON

AUTOMATIC ENGINE SPEED CONTROL CIRCUIT (AEC) AEC SWITCH ENGINE

III II I 1 2

1 2

IMPLEMENT/SWING PRESSURE SWITCH

ECU

SPEED SENSOR

GOVERNOR ACTUATOR

TRAVEL PRESSURE SWITCH

30 Automatic Engine Control (AEC) • Purpose of AEC: - Reduce fuel consumption - Reduce noise - Decrease rpm when demand is low

The purpose of the automatic engine speed control that is used on the "E" series excavators and 200 family of excavators is to reduce fuel consumption and engine/machine noise by automatically reducing engine speed when no hydraulic power is demanded. The 320/330 AEC has these same features, but also slightly decreases engine rpm when the hydraulic power demand is very low. This rpm decrease occurs regardless of the power mode that has been selected. The three levels of AEC on the 320/330 are defined as:

STMG 621 8/92 • Three levels of AEC

- 48 -

1. No load: No hydraulic demand (control levers in NEUTRAL or HOLD) for 3 seconds. 2. Light load: Engine speed is 50 rpm or less below the no load setting for 10 or more seconds while an implement or travel circuit is in operation. 3. Normal load: Engine speed is 70 rpm or more below the no load setting while an implement or travel circuit is in operation. NOTE: Specific engine speed settings for each condition are provided in the Serviceman's Handouts in the back of this presentation.

STMG 621 8/92

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LOW IDLE SWITCH

ONE-TOUCH LOW IDLE CONTROL CIRCUIT ENGINE

ENGINE SPEED DIAL

TRAVEL PRESSURE SWITCH

ECU

SPEED SENSOR

GOVERNOR ACTUATOR

IMPLEMENT/SWING PRESSURE SWITCH

31 One-touch Low Idle Control • Switch operates only with no demand

• First depression decreases rpm • Second depression increases rpm • Applied load at low rpm causes increase to no load setting • Two depressions after load removal causes return to AEC setting

The final speed variable in the system is the one-touch low idle switch which operates only when no demand is placed on the hydraulic system. The first depression (ON) of the switch decreases the engine rpm from the no load speed setting (either 100 rpm or 1300 rpm below high idle) to a setting of approximately 950 rpm for the 320 Excavator or 850 rpm for the 330. The second depression (OFF) of the switch returns the engine speed setting to the previous no load value. If a hydraulic load is applied while the engine speed setting is at 950 or 850 rpm, the setting will increase to the engine speed dial setting. If the one-touch low idle switch is depressed (ON) within three seconds of load removal (before the no load speed setting can be obtained) and then depressed (OFF) again three or more seconds after load removal, the engine speed setting will return to the selected AEC speed setting (either 100 rpm below high idle or 1300 rpm).

STMG 621 8/92

- 50 -

BACKUP SYSTEM CIRCUITS GOVERNOR ACTUATOR DRIVE CIRCUIT

NORMAL OPERATION AUT

ENGINE SPEED DIAL BACKUP SWITCH

MAN

M GOVERNOR ACTUATOR

RAB

TOR

24V

ENGINE SPEED CHANGE SWITCH

ECU 24V

AUT

TOR

PRV DRIVER PRV PRV PUMP CONTROL BACKUP SWITCH BACKUP DETECTION

BACKUP RESISTOR

32 Backup Systems • Normal operation • Speed dial backup switch in "AUT" position

This schematic shows the two backup systems during normal machine operation. The controller sends electrical signals through the engine speed dial backup switch to the governor actuator motor. Notice that the engine speed dial backup switch is in the "AUT" position. The engine speed change switch is in the spring loaded center position.

• Pump control backup switch in "AUT" position

The controller also sends signals through the pump control backup switch to the PRV. Notice that the pump control backup switch is in the "AUT" position. Also, the backup resistor is connected to only the backup switch at this time.

• Backup systems controlled individually

The engine speed dial and pump control backup are separate systems and are controlled individually.

STMG 621 8/92

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BACKUP SYSTEM CIRCUITS ENGINE SPEED DIAL BACKUP SYSTEM ON GOVERNOR ACTUATOR DRIVE CIRCUIT

AUT


MAN

M

RAB

TOR

GOVERNOR ACTUATOR 24V


ECU 24V

AUT

TOR


BACKUP RESISTOR

33 • Speed dial backup switch in "MAN" position • Governor actuator motor disconnected from speed dial • Speed change switch is activated

In this schematic, the engine speed dial backup switch has been moved to the "MAN" position which disconnects the governor actuator motor from the engine speed dial. At the same time, the speed change switch is inserted into the circuit. Moving the speed change switch left or right will send power to the motor to either increase or decrease engine speed. NOTE: When only the engine speed dial backup system is ON, the operator will see an "A" in the three digit display on the monitor panel. (The "A" means the governor actuator motor circuit is open.)

STMG 621 8/92

- 52 -

BACKUP SYSTEM CIRCUITS PUMP CONTROL BACKUP SYSTEM ON GOVERNOR ACTUATOR DRIVE CIRCUIT


AUT

MAN

M GOVERNOR ACTUATOR

RAB

TOR

24V


ECU 24V

AUT

TOR


BACKUP RESISTOR

34 • Pump control backup switch in "Tortoise" position • Backup resistor connected to PRV • PRV sends constant power shift pressure to pumps

In this schematic, the pump control backup switch has been moved to the "Tortoise" position which disconnects the pump control from the controller and connects the backup resistor circuit to the PRV. The PRV receives a constant signal of approximately 0.5 amps and sends a constant power shift pressure to the hydraulic pumps. At this time, pump output is approximately that of Power Mode II. NOTE: When only the pump control backup system is ON, the operator will see an “H” in the three digit display on the monitor panel. When both the speed dial and pump control backup systems are ON, a "U" will be shown in the three digit display.

STMG 621 8/92

- 53 -

PERFORMANCE MONITOR POWER

SERVICE FUNCTIONS

WORK

III II I LIGHT

1 2

AEC ON

WIPER

WASHER

1 2


35 SERVICE FUNCTIONS • Two level diagnostic capability • Data Mode provides information on eight key systems • Information displayed in three digit LCD's

A comprehensive two level diagnostic capability is built into the 320/330 controller. The first level (called the "Data Mode") will be explained in detail since this level will be used most often. The Data Mode provides status information on the function of eight key systems within the machine. The POWER, LIGHT, TRAVEL SPEED and WIPER LED's are used as a guide to access the eight channels of information in the Data Mode. The information from these eight channels will be displayed in the three digit LCD's on the monitor panel.

STMG 621 8/92

- 54 -

PERFORMANCE MONITOR ACCESSING THE DATA MODE

POWER

WORK

III II I LIGHT

1 2

AEC ON

WIPER

WASHER

1 2


36 Data Mode • Accessing the Data Mode

• Push and hold ALARM CANCEL button until LED flashes • Push POWER button until Power Mode III LED flashes • Data Mode is accessed • To exit, push ALARM CANCEL button or turn key start switch OFF

To access and view the first channel of information, the engine can either be running or shut down. If the engine is running, however, some machine systems can be observed in operation. In this service mode, all of the LCD gauges and warning indicators will continue to function normally and all machine functions can be controlled. First, push and hold the ALARM CANCEL button until its LED begins to flash. Next, while still pushing the ALARM CANCEL button, push the POWER button until the LED for Power Mode III begins to flash. Do not hold the POWER button too long or another of the eight LED's will flash. If this condition occurs, continue to push the ALARM CANCEL and POWER buttons simultaneously until the LED for Power Mode III again flashes. The Data Mode has now been accessed and the eight channels of information can be viewed. To exit this service mode at any time, either push the ALARM CANCEL button for more than two seconds or turn the key start switch OFF.

STMG 621 8/92

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PERFORMANCE MONITOR POWER SHIFT PRESSURE COMMAND VALUE

POWER

WORK

III II I LIGHT

1 2

AEC ON

WIPER

WASHER

1 2


37 • Power shift command signal • Indicates level of signal sent to PRV

• Display will change during operation

• To access additional channels, push ALARM CANCEL and POWER buttons together

The first channel of information that will be accessed in the three digit display of the monitor is "P21." This display is the "Power Shift Command" signal and means that the controller is sending a certain level of the PWM electrical signal to the PRV. "P21" indicates the controller signal being sent to the PRV causes the PRV to send a power shift pressure of 21 kg/cm2 [2070 kPa (300 psi)] to the pumps. When operating the machine in Power Mode III and with the engine speed dial at "10," the display will change as the controller varies the power shift signal to the pumps. To access the second and succeeding channels of information, push the ALARM CANCEL and POWER buttons simultaneously. Remember, however, do not hold the two buttons down together for too long or the next channel of information may be missed.

STMG 621 8/92

- 56 -


ENGINE RPM DISPLAY

WORK

III II I LIGHT

1 2

AEC ON

WIPER

WASHER

1 2


38 • Engine rpm display • Last rpm digit omitted

• Display will change as rpm varies

To check the engine rpm, push the ALARM CANCEL and POWER buttons simultaneously until the LED for Power Mode II flashes. The three digit display now shows the engine rpm, but the last digit has been omitted. The display shown in this example is "196" which means that the engine speed is 1960 rpm. If the engine speed dial position is changed or if the machine is operated, the change in engine rpm will be shown on the display.

STMG 621 8/92

- 57 -


ENGINE COOLANT TEMPERATURE

WORK

III II I LIGHT

1 2

AEC ON

WIPER

WASHER

1 2


39 • Engine coolant temperature in °C • Power Mode I LED flashes

To check the engine coolant temperature, push the ALARM CANCEL and POWER buttons simultaneously until the LED for Power Mode I flashes. The three digit display now shows the engine coolant temperature in degrees Celsius. The "85" shown on the display means that the engine coolant temperature is 85°C.

STMG 621 8/92

- 58 -


HYDRAULIC OIL TEMPERATURE

WORK

III II I LIGHT

1 2

AEC ON

WIPER

WASHER

1 2


40 • Hydraulic oil temperature in °C • Light 1 LED flashes

To check the hydraulic oil temperature, push the ALARM CANCEL and POWER buttons simultaneously until the LED for Light 1 flashes. The three digit display now shows the hydraulic oil temperature in degrees Celsius. The "65" shown on the display means that the hydraulic oil temperature is 65°C.

STMG 621 8/92

- 59 -


ANALOG / DIGITAL INFORMATION

WORK

III II I LIGHT

1 2

AEC ON

WIPER

WASHER

1 2


41 • Analog to digital information • Light 2 LED flashes • Not usable at this time

Eight channels of Analog to Digital (A/D) conversion information can be accessed by pushing the ALARM CANCEL and POWER buttons simultaneously until the LED for Light 2 flashes. The three digit display now shows Analog to Digital conversion information. The information, however, is not usable at this time for service or diagnostics.

STMG 621 8/92

- 60 -

PERFORMANCE MONITOR REAL TIME ERROR CODES

POWER

WORK

III II I LIGHT

1 2

AEC ON

WIPER

WASHER

1 2


42 • Real time error codes • "Rabbit" LED flashes • List scrolls in ascending order

• "E00" reading means no errors occurring

To access the error codes for any current problems, push the ALARM CANCEL and POWER buttons simultaneously until the LED by the Travel Speed--Rabbit symbol flashes. The error codes for any current problems will automatically appear sequentially at intervals of two seconds ON and one half second OFF. The list will scroll in ascending order until stopped. A reading of "E00" means that no system errors are occurring at this time. NOTE TO THE INSTRUCTOR: The error codes displayed in this mode are referred to as “real time” which means that the problems are being detected by the controller at this time and have not been stored in the controller. The next diagnostic level, the Calibration Mode, will show how to view stored error codes for intermittent problems the controller has detected. For a complete listing of the error codes, check the Testing and Adjusting modules of the 320 Service Manual (Form SENR5473) and the 330 Service Manual (Form SENR5496).

STMG 621 8/92

- 61 -

PERFORMANCE MONITOR DIGITAL INPUT TESTS

POWER

WORK

III II I LIGHT

1 2

AEC ON

WIPER

WASHER

1 2


43 • Digital input tests

• "Tortoise" LED flashes • Initial display is "0 3"

The next channel of information allows access to the digital input information sent to the controller from the various electronic system components. Push the ALARM CANCEL and POWER buttons simultaneously until the LED by the Travel Speed--Tortoise symbol flashes. The initial display is "0 3." The "0" indicates that this display is the first of 21 "ports" or additional channels of information, and the "3" is the wiring harness code for the 320 and 330.

STMG 621 8/92 • Ports and components

- 62 -

The 21 ports and components are: Port 0 1 2 3 4 5 6 7 8 9 A

• To access remaining ports, push ALARM CANCEL and WORK MODE buttons together

• Travel pressure switch port

• Some ports are spares • Ports can be turned ON or OFF

Component

Port

Harness code Engine speed dial position Travel pressure switch Attachment pump pressure switch Engine oil pressure switch Reserved Reserved Reserved Low idle switch Boom raise pressure switch Governor actuator backupswitch

b C d E F H J L n P

Component PRV backup switch 320 with 3066 engine Main switch Implement/swing pressure switch Alternator Reserved Reserved Reserved Reserved Reserved

To access the remaining 20 "ports" of information push the ALARM CANCEL and WORK MODE buttons simultaneously. The next port will show "1" and a number (1 through 10) where the "1" indicates the port selected and the number indicates a speed dial position. If the engine speed dial is moved, the display will change to show the new dial position. If a malfunction in the engine speed dial is detected, the display will show "1Er." Push the ALARM CANCEL and WORK MODE buttons again and the next port, Travel Pressure Switch, appears with "2oF" showing in the display. The "2" indicates the port and "oF" indicates that the travel pressure switch is OFF (or open). If either travel control is moved and the travel pilot signal pressure begins to increase, the display will show "2On." This code indicates that the travel pressure switch has closed. Release the travel control and the "2oF" appears again indicating that the pressure switch has opened. Again, each succeeding port is accessed by pushing the ALARM CANCEL and WORK MODE buttons simultaneously. Some of the ports are "spares" and are not currently associated with an electronic component. Those ports which have associated components can be turned ON or OFF by actuating the particular circuit or system which contains the component (as explained with the travel pressure switch). NOTE TO THE INSTRUCTOR: For additional information on the port numbers and the electronic component for each port, refer to the Testing and Adjusting modules (Forms SENR5473 and SENR5496) in the 320 and 330 Service Manuals respectively.

STMG 621 8/92

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PERFORMANCE MONITOR OUTPUT CONTROL DISPLAY

POWER

WORK

III II I LIGHT

1 2

AEC ON

WIPER

WASHER

1 2


44 • Output control displays • "Wiper 1" LED flashes • Initial display is "L00"

The last channel of information allows access to the output control display which reads a code representing the pump output control at that time. Push the ALARM CANCEL and POWER buttons simultaneously until the LED by the Wiper 1 symbol flashes. The initial display will read "L00" when pump output control is normal. NOTE: For a complete listing of the output control modes, check the Testing and Adjusting modules of the 320 Service Manual (Form SENR5473) and the 330 Service Manual (Form SENR5496).

STMG 621 8/92

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PERFORMANCE MONITOR CALIBRATION MODE

POWER

WORK

III II I LIGHT

1 2

AEC ON

WIPER

WASHER

1 2


45 Calibration Mode • Calibration Mode: - Provides troubleshooting information - Used to calibrate components - Used to perform tests

The Data Mode service function provides an easy way to check the machine conditions. A second level of diagnostics, the Calibration Mode, provides additional troubleshooting information. The Calibration Mode is used to calibrate various components after replacement, or to perform functional tests on the systems after adjustments have been made.

• Use service manual for tests

The operation of the Calibration Mode is very similar to the Data Mode through the use of the monitor panel switches. However, some of the tests are longer, so the service manual must be used as a reference.

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PERFORMANCE MONITOR ACCESSING THE CALIBRATION MODE

POWER

WORK

III II I LIGHT

1 2

AEC ON

WIPER

WASHER

1 2


46 • Accessing the Calibration Mode • Press hidden SERVICE button and start engine • Hold button until master light turns ON • Only three digit display remains on • Ten channels can be accessed

To access the Calibration Mode, first shut the machine down. Next, push the SERVICE button which is the hidden button at the lower right corner of the monitor panel. While pressing the SERVICE button, turn the main key ON and start the engine. Continue to press the Service button for two to three seconds until the master light turns ON. All LCD's on the monitor panel will turn off except for the three digit display. The Calibration Mode has now been accessed. By selectively moving the LED indicator down the left side of the monitor panel, plus using the two LED's on the wiper switch, a total of ten different channels of information and test programs can be accessed.

STMG 621 8/92

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PERFORMANCE MONITOR HARNESS CODE

POWER

WORK

III II I LIGHT

1 2

AEC ON

WIPER

WASHER

1 2


47 • Harness code • Push POWER button until Power Mode III LED turns ON • Three digit display will show machine and engine code

To initiate the first channel of information, push the POWER MODE button until the Power Mode III LED turns ON. The character display will show "20C" if the machine is a 320 equipped with a 3116 engine, "20H" if the machine is a 320 equipped with a 3066 engine and "30C" if the machine is a 330 with a 3306 engine. The "20" or "30" indicates that the machine is a 320 or 330 and the "C" or "H" indicates that the machine is equipped with a Caterpillar or Mitsubishi sourced engine.

STMG 621 8/92

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PERFORMANCE MONITOR SOFTWARE CODES

POWER

WORK

III II I LIGHT

1 2

AEC ON

WIPER

WASHER

1 2


48 • Software code for controller • Push POWER button until Power Mode II LED turns ON

The second channel of information identifies the controller and monitor software codes. Access these codes by pushing the POWER MODE button until the Power Mode II LED turns ON. The display will show "**C" which is the software version for the controller. The "**" in the character display represents a two digit numeral particular to the software for each machine model. A generic "00C" has been used as an example.

STMG 621 8/92

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PERFORMANCE MONITOR SOFTWARE CODES

POWER

WORK

III II I LIGHT

1 2

AEC ON

WIPER

WASHER

1 2


49 • Software code for monitor • Push AEC button

Now, push the AEC button and the display will change to show "**P" which is the software version for the monitor. Each time that the AEC button is pushed, the display will alternate between the two codes. These codes may change if the software is upgraded for the controller or the monitor. The "**" represents a two digit numeral used particular to the software for each machine model. A generic "11P" has been used as an example.

STMG 621 8/92

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PERFORMANCE MONITOR ERROR CODES LOG

POWER

WORK

III II I LIGHT

1 2

AEC ON

WIPER

WASHER

1 2


50 • Error code log • Push POWER button until Power Mode I LED turns ON • Display will show "Hd"

• To check list in ascending order, push AEC button

• To check list in descending order, push WASHER button

Push the POWER MODE button again until the LED for Power Mode I turns ON and the display "Hd" will appear. This display indicates that the list of stored error codes can be viewed. The controller has a continual self-diagnostic function during the time that the machine is in operation. The controller will store error codes if a fault is detected, even intermittently. This list is the error history on important systems since the last time the memory was cleared. Two ways to check these codes are in ascending order or descending order. Each time the AEC button is pushed, the sequentially stored codes are displayed. The "Hd" means that the top of the code list will be displayed, and the list will scroll in ascending order from "F1" through "F48." As the numbers are scrolled and a fault code is displayed, the scrolling stops. Push the AEC button again to continue the scrolling. The list can be checked in descending order by pressing the WASHER button. If a fault code is displayed, the descending scroll will stop. Push the WASHER button again to continue.

STMG 621 8/92 • To clear codes, push AEC, POWER, and TRAVEL SPEED buttons together • Display will show "CLr"

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After all the codes displayed have been recorded, they can be cleared from the controller memory. To clear the codes, simultaneously push three buttons: AEC, POWER MODE, and TRAVEL SPEED. Within two to three seconds, "CLr" will appear in the display indicating the codes have been cleared. NOTE TO THE INSTRUCTOR: Error log codes are preceded by the letter"F" but use the same numbering as the "real time" error codes that are accessed in the Data Mode. For a complete listing of the error codes, check the Testing and Adjusting modules of the 320 Service Manual (Form SENR5473) and the 330 Service Manual (Form SENR5496).

STMG 621 8/92

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PERFORMANCE MONITOR DIGITAL OUTPUT PORTS POWER

WORK

III II I

AEC ON

LIGHT

WIPER

WASHER

1 2

1 2


51 • Digital output ports • Push LIGHT button until Light 1 LED turns ON • Display will show "0oF" • Check for electrical connections

The next test is accessed by pushing the LIGHT button to turn ON the LED for Light 1. The display will show "0oF" which is the first of 16 "ports" that permit a check of the electrical connections for various controller output components (similar to the digital input information accessed in the Data Mode). However, these ports are for different components. The ports and their components are: Port 0 1 2 3 4 5 6 7

Component Monitor alarm buzzer Washer relay Extra relay Extra relay Extra relay Wiper relay Boom light relay Chassis light relay

Port 8 9 A b C d E F

Component Two speed travel solenoid Fine control solenoid Swing priority solenoid Travel alarm buzzer Extra solenoid Extra solenoid Extra solenoid PRV solenoid

STMG 621 8/92 • Push AEC button to display different ports • Push ALARM CANCEL button to turn components ON and OFF

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Each time that the AEC button is pushed, a different port will appear in the display. Pressing the ALARM CANCEL button turns the component in each port ON. Pressing the ALARM CANCEL button again turns the component OFF.

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PERFORMANCE MONITOR PRV SWEEP TEST POWER

WORK

III II I LIGHT

1 2

AEC ON

WIPER

WASHER

1 2


52 • PRV sweep test • Push LIGHT button until Light 2 LED turns ON • Display shows pressure sweep from 1 to 32 • If pressure does not cycle, check PRV and electrical connections

The PRV sweep test is initiated by pressing the LIGHT button to turn ON the LED for Light 2. The left column of the display has the letter "P" which indicates that the PRV is being tested. The two right columns show the continuous pressure sweep from 1 to 32 and back to 1 kg/cm2 pressure. To convert these metric units to psi, multiply the indicated value by 14.22. Thus, the pressure sweep is from approximately 14 to 455 psi. If the power shift pressure is tested at the pumps, the pressure will cycle up and down, indicating that the PRV is cycling. If the pressure does not cycle, check the PRV and the related electrical connections. NOTE: To obtain the most accurate readings, perform this test with the engine speed dial at position 10. This test is very similar to Test 1 for the "E" series controllers.

STMG 621 8/92

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PERFORMANCE MONITOR ENGINE SPEED CHANGE POWER

WORK

III II I LIGHT

1 2

AEC ON

WIPER

WASHER

1 2


53 • RPM adjustment • Push WIPER button until Wiper 1 LED turns ON • Engine rpm displayed •Push AEC button to increase rpm

• Push WASHER button to decrease rpm

To access the next test, press the WIPER button until the LED for Wiper 1 turns ON. The engine rpm at each dial position can now be adjusted. This test is also useful to measure no load engine speeds. The engine rpm are shown in the three digit display. Each time the AEC button is pressed, the engine speed will be increased by 20 to 30 rpm. The AEC LED remains on while the governor actuator is moving toward high idle. After high idle is reached (at dial position 10), the rpm will not increase higher. Pushing the WASHER button will decrease the engine speed by 20 to 30 rpm. The WASHER LED remains on while the governor actuator is moving toward low idle. If the AEC and WASHER buttons are pushed simultaneously, the signals are ignored by the controller.

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PERFORMANCE MONITOR POWER SHIFT PRESSURE ADJUSTMENT

POWER

WORK

III II I LIGHT

1 2

AEC ON

WIPER

WASHER

1 2


54

• Display shows "P21"

The next test permits changes to the factory setting of the power shift pressure command signal from the controller to the proportional reducing valve. These changes are sometimes necessary while other tests and adjustments are being performed (such as testing and adjusting the line relief valves and performing the pump P-Q tests). Access this test by pressing the WIPER button until the LED for Wiper 2 turns ON and "P21" appears in the display.

• Push ALARM CANCEL button to alternate between pressure and rpm

Each time that the ALARM CANCEL button is pressed, the display will alternate between the power shift pressure command signal and the engine rpm.

• Power shift pressure adjustment • Push WIPER button until Wiper 2 LED turns ON

• Push AEC button to increase pressure

Pressing the AEC button increases the power shift pressure command signal from the controller to the proportional reducing valve. Power shift pressure increases approximately 95 kPa (14 psi) and the display number increases by "1" each time that the AEC button is pushed. When the display reads "P30," the power shift pressure will not increase higher.

STMG 621 8/92 • Push WASHER button to decrease pressure

- 76 -

Pressing the WASHER button decreases the power shift pressure command signal from the controller to the proportional reducing valve. Power shift pressure decreases approximately 95 kPa (14 psi) and the display number decreases by "1" each time that the AEC button is pushed. When the display reads "P3," the power shift pressure will not decrease lower. NOTE: This procedure is for power shift pressure adjustment and is not a calibration procedure. If a 5500 kPa (800 psi) pressure gauge is connected to the power shift pressure test port on the hydraulic pumps, the change in power shift pressure can be observed as the AEC or WASHER buttons are pushed.

STMG 621 8/92

- 77 -

PERFORMANCE MONITOR ENGINE SPEED DIAL CHECK

POWER

WORK

III II I LIGHT

1 2

AEC ON

WIPER

WASHER

1 2


55 • Engine speed dial position

This test channel shows the engine speed dial position in the three digit display (the same as when the Monitor is in the normal operation mode). This test is used to check the actual rpm of a selected engine speed dial position to verify that the rpm is within the factory specifications for that particular dial setting.

• Push TRAVEL SPEED button until "Rabbit" LED turns ON • Set speed dial at desired position

Push the TRAVEL SPEED button until the "Rabbit" LED is ON to start this mode. Set the speed dial at the desired position. The character display shows the actual rpm at the present time. This value must be multiplied by 10 to read actual rpm.

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PERFORMANCE MONITOR GOVERNOR ACTUATOR AUTOMATIC CALIBRATION

POWER

WORK

III II I LIGHT

1 2

AEC ON

WIPER

WASHER

1 2


56 • Governor actuator calibration • Engine running • Push TRAVEL SPEED button until "Rabbit" LED is ON • Display flashes "AC" • Push AEC, WASHER, and ALARM CANCEL buttons at same time • "ACP" indicates calibration started • "ACt" indicates initial movement completed

Calibration of the governor actuator is accomplished in this test. This test should be performed any time that the controller or governor actuator motor has been replaced. The engine must be running to perform this calibration. To enter this mode, push the TRAVEL SPEED button until the "Rabbit" LED is ON. Then, push the AEC and WASHER buttons simultaneously until the letters "AC" are flashing in the three digit display. Next, while still holding down the AEC and WASHER switches, also push the ALARM CANCEL button. The "AC" display will stop flashing and then change to "ACP." This code indicates that the automatic calibration mode has started and the governor actuator motor has moved to an initial position. When this movement is completed, the display will read "ACt."

STMG 621 8/92 • Push AEC and WASHER buttons • Display shows "AC1" • When "AC0" appears, procedure is complete

• If data is not correct, procedure will restart one time

- 79 -

When "ACt" appears in the display, the calibration procedure can be completed. Push the AEC and WASHER buttons simultaneously. The "ACt" code will change to "AC1" which indicates that the calibration is continuing. Approximately two minutes are required for the calibration to finish. During this time, the codes "AC2" through "AC0" will appear in the display. When "AC0" appears, the calibration has been successfully completed. If the calibration data sent to the controller is not correct and within limits by the time "AC6" appears in the display, the controller will restart the calibration procedure one time. If the data is not correct or within limits the second time, the display will alternately show "ACE" and "-**." The "-**" is an error code that has a defined problem. Consult the latest version of the Testing and Adjusting modules in the 320 and 330 Service Manuals for a complete description of the error codes and problems.

STMG 621 8/92

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PERFORMANCE MONITOR POWER SHIFT PRESSURE CALIBRATION

POWER

WORK

III II I LIGHT

1 2

AEC ON

WIPER

WASHER

1 2


57 • PRV calibration • Perform procedure after PRV or controller is replaced • Two calibration points

The final test procedure in the Calibration Mode is the calibration of the Proportional Reducing Valve (PRV). This procedure must be performed to eliminate any variation in the operation of the PRV or controller when either component has been replaced. The procedure is similar to the PRV and controller calibration on the "E" series excavators but, instead of one calibration point, this procedure has two calibration points at 490 kPa (72 psi) and 2450 kPa (355 psi).

• Install pressure gauge • Pump control backup switch in "AUT" position • Start engine, speed dial at position 10 • Push TRAVEL SPEED button until "Tortoise" LED turns ON •Display shows "1 0"

First, install a 4000 kPa (600 psi) pressure gauge on the power shift pressure test port at the pump. Next, make sure that the pump control backup switch is in the "AUT" position. Finally, start the engine and be sure the engine speed dial is at position 10. This test is accessed by pressing the TRAVEL SPEED button until the "Tortoise" LED is ON. The display then shows "1 0." The "1" indicates that the first calibration point has been accessed and the "0" indicates that the center step of 19 calibration steps has been accessed. Each step will change the power shift pressure by approximately 50 kPa (7 psi).

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Increasing power shift pressure • Push AEC button to increase pressure

With the display showing "1 0," push the AEC button once to increase the power shift pressure. The pressure reading on the gauge should increase and the display should change to "1 1." Push the AEC button a second time and the power shift pressure will again increase and the display will read "1 2." The AEC button can be pushed seven additional times. Each push of the button will change the power shift pressure until the display reads "1 9." Any additional pushes of the AEC switch will not increase the power shift pressure. Decreasing power shift pressure

• Push WASHER button to decrease pressure

With the display showing "1 0," push the WASHER button once to decrease the power shift pressure. The pressure reading on the gauge should decrease and the display should change to "1-1." Push the WASHER button a second time and the power shift pressure will again decrease and the display will read "1-2." The AEC button can be pushed seven additional times. Each push of the button will change the power shift pressure and until the display reads "1-9." Any additional pushes of the WASHER button will not decrease the power shift pressure. Setting Calibration Point 1

• Push WASHER button to decrease pressure below 72 psi • Push AEC button to set pressure at 72 psi • Push ALARM CANCEL button to store data • Display will show "2 0"

Push the WASHER button to decrease the power shift pressure until the pressure setting is less than 490 kPa (72 psi). Then, push the AEC button until the pressure gauge reading increases to approximately 490 kPa (72 psi). (An exact reading may be difficult to obtain, but adjust the pressure as closely as possible.) After the correct reading has been set, push the ALARM CANCEL button to store the data in the controller. When the data has been accepted by the controller, the display will change to show "2 0" which indicates that the first calibration point has been accepted and the calibration procedure for the second point can be performed. As with the first calibration point, the "2" indicates that the second calibration point has been accessed and the "0" indicates that the center step of 19 calibration steps has been accessed. Again, each step will change the power shift pressure by approximately 50 kPa (7 psi).

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Setting Calibration Point 2 • Push AEC button to increase pressure to 355 psi • Push ALARM CANCEL button to store data • Display will show "1 0"

Push the AEC button to increase the power shift pressure to approximately 2450 kPa (355 psi). (As with the first point, an exact reading may be difficult to obtain, but adjust the pressure as closely as possible.) After the correct reading has been set, push the ALARM CANCEL button to store the data in the controller. When the data has been accepted by the controller, the display will change to show "1 0" which indicates that the second calibration point has been accepted and the controller has reset to the first calibration point. NOTE: Activation of this calibration mode overrides the function of AEC system. If the engine speed is not within 1980 ± 50 rpm for the 320, and 1950 ± 50 rpm for the 330, the three digit display will show "E." The engine speed must be corrected within specifications to eliminate the "E" from the display before continuing with this procedure. Additionally, pressure adjustments must always be made as the pressure is being increased.

STMG 621 8/92

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58

CONCLUSION

• Presentation summary • ECU matches engine horsepower with hydraulic horsepower • Input components • Controller • Output components

• Three power modes

This presentation has discussed major components, systems operation, and service functions of the Electronic Control Unit (ECU). In summary, some of the key functions of this system are: The ECU matches hydraulic horsepower with engine horsepower in Power Mode III and with the engine speed dial at position 10. The controller receives input signals from several components which include: the engine speed dial, the power mode selector, the AEC button, the AEC pressure switch, and the engine speed pickup. The controller analyzes the input signals and, during specific conditions, sends output signals to several components which include: the AEC relay/motor, the proportional reducing valve, and the monitoring system. When the controller is active, three power modes can be selected. Power Mode I utilizes approximately 65% of the available engine horsepower and is used for light duty work. Power Mode II utilizes approximately 85% of the available engine horsepower and is used for ordinary work. Power Mode III utilizes approximately 100% of the available engine horsepower.

STMG 621 8/92 • Two backup systems

- 84 -

The machine is also equipped with two backup systems. The pump control backup system can be activated to bypass the pump controls if the controller malfunctions. When this system is activated, the pumps operate at approximately Power Mode II. The engine speed backup system can be activated when a speed dial malfunction occurs. The AEC will not function when this backup system is activated

STMG 621 8/92

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SLIDE LIST 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

Model view Controller location Controller LED's Monitor location Backup switches location Monitor panel Fault symbols Start switch, engine speed dial, and ether aid switch Pulse width modulated signals Controller changes Controller changes (cont.) Monitor features Controller inputs Controller outputs Power Mode selection 320 P-Q Curves (2 pumps loaded equally with 3116 engine) 320 P-Q Curves (2 pumps loaded equally with 3066 engine) 330 P-Q Curves (2 pumps loaded equally with 3306 engine) 320 P-Q Curves (1 pump loaded with 3116 engine) 320 P-Q Curves (1 pump loaded with 3066 engine) 330 P-Q Curves (1 pump loaded with 3306 engine) Pump regulation Engine speed dial limits Controller compartment 320 System behavior chart 330 System behavior chart

27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58.

Power modes vs. hydraulic torque Anti-stall function Power modes vs. hydraulic horsepower Automatic Engine Control (AEC) One-touch low idle control Backup switches (normal operation) Engine speed dial backup switch "On" Pump control backup switch "On" Service Functions Accessing Data Mode Power shift command signal Engine rpm Engine coolant temperature Hydraulic oil temperature Analog to digital codes Error codes (real time) Digital input to the controller Pump output control Calibration Mode Accessing Calibration Mode Machine configuration codes Controller software code Monitor software code Error codes (stored) Component checks PRV sweep test Engine speed change adjustment Power shift pressure adjustment Engine speed dial setting check Governor actuator calibration PRV pressure calibration Controller compartment

STMG 621 8/92

- 86 -

INSTRUCTOR NOTES

STMG 621 8/92

- 87 -

Serviceman's Handout No. 1

AUTOMATIC ENGINE SPEED CONTROL CIRCUIT (AEC)

1.

NO LOAD SETTINGS WITH AEC "ON" Dial Position 10 9 8 7 6 5 4 3 2 1

2.

Engine rpm Setting Change From 2160 to 1300 From 2000 to 1300 From 1850 to 1300 From 1700 to 1300 From 1550 to 1300 From 1400 to 1300 No change No change No change No change

NO LOAD SETTINGS WITH AEC "OFF" Dial Position 10 9 8 7 6 5 4 3 2 1


STMG 625 9/92

- 88 -

Serviceman's Handout No. 2

AUTOMATIC ENGINE SPEED CONTROL CIRCUIT (AEC)

3.

LIGHT LOAD APPLICATION--AEC "ON" OR "OFF" Dial Position 10 9 8 7 6 5 4 3 2 1

4.


LIGHT LOAD TO HEAVY LOAD--AEC "ON" OR "OFF" Dial Position 10 9 8 7 6 5 4 3 2 1


RELAY BOX

CHASSIS LIGHT

LOW IDLE SWITCH

ALT.


WASHER

FUEL LEVEL SENSOR

BOOM WIPER LIGHT

ENG. OIL PRESS. SWITCH BM. UP PRESS. SWITCH TRAV. PRESS. SWITCH

IMPL. /SW. PRESS. SWITCH



PRV


PUMP

BATTERY

SPEED CHANGE SWITCH

G/A FDBK SENSOR

G/A



ENG. SPEED DIAL

SPEED SENSOR

START ENGINE SWITCH

FUSE BOX

- 89 -

FAULT ALARM

TRAVEL ALARM


ECU (CONTROLLER)


INPUTS TO CONTROLLER

STMG 621 8/92 Serviceman's Handout No. 3

RELAY BOX

CHASSIS LIGHT

LOW IDLE SWITCH

ALT.

BOOM LIGHT


WIPER


WASHER

FUEL LEVEL SENSOR BM. UP PRESS. SWITCH

IMPL. /SW. PRESS. SWITCH TRAV. PRESS. SWITCH

TRAVEL ALARM

FAULT ALARM


PRV

MONITOR

PUMP

BATTERY

FUSE BOX

START SWITCH

SPEED SENSOR

ENGINE

ATTACH. PRESS. SWITCH

SPEED CHANGE SWITCH

G/A FDBK SENSOR

G/A



ENG. SPEED DIAL

- 90 -



ECU (CONTROLLER)


OUTPUTS FROM CONTROLLER

STMG 621 8/92 Serviceman's Handout No. 4

STMG 621 8/92

- 91 -

INSTRUCTOR NOTES

STMG 621 8/92

- 92 -

INSTRUCTOR NOTES

STMG 621 8/92

- 93 -

INSTRUCTOR NOTES

SESV1621 8/92

Printed in U.S.A.

LHPH 320 330 Electronic Control Unit

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