350-375.Monitor

Service Training MALAGA

350/375/5080 Hydraulic Excavators

ELECTRONIC CONTROL SYSTEM

Francis NOV 97

350/375/5080 Hydraulic Excavators CHAPTER : Electronic Control System

CONTROLLER

LED's

Relay Box

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350/375/5080 Hydraulic Excavators CHAPTER : Electronic Control System

OPERATOR'S CONSOLE

1

2

1. Monitor Panel 2. Engine Speed Dial

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350/375/5080 Hydraulic Excavators CHAPTER : Electronic Control System

BACKUP SYSTEMS

Engine Speed Control

ENGINE SPEED CONTROL

AUT

MAN

Pump Control

PUMP CONTROL

AUT

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350/375/5080 Hydraulic Excavators CHAPTER : Electronic Control System

350/375 HYDRAULIC EXCAVATOR MONITOR

POWER TRAVEL SPEED AEC

LIGHT

1 2

WIPER

WASHER

1 2

ALARM CANCEL TEST

SERVICE

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350/375/5080 Hydraulic Excavators CHAPTER : Electronic Control System

MONITOR PANEL (Upper Section)

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350/375/5080 Hydraulic Excavators CHAPTER : Electronic Control System

MONITOR FEATURES

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

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350/375/5080 Hydraulic Excavators CHAPTER : Electronic Control System

PULSE WIDTH MODULATED (PWM) SIGNALS

VOLTAGE LEVEL MEAN VOLTAGE

VOLTAGE OFF

VOLTAGE ON ONE CYCLE

VOLTAGE LEVEL MEAN VOLTAGE VOLTAGE ON

VOLTAGE OFF ONE CYCLE

DIFFERENT FREQUENCY

VOLTAGE LEVEL

MEAN VOLTAGE VOLTAGE ON

VOLTAGE OFF ONE CYCLE

VOLTAGE LEVEL VOLTAGE ON

MEAN VOLTAGE VOLTAGE OFF ONE CYCLE

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350/375/5080 Hydraulic Excavators CHAPTER : Electronic Control System

INPUTS TO CONTROLLER 18

16

14

12 11

15

17

13

CONTROLLER

19

6 5

2 3

10

4 9

1 7 PUMP

1. 2. 3. 4. 5. 6. 7.

Monitor Eng Speed Dial Low Idle Switch Alternator Harness Code Battery Gov. Actuat. Feedback Sensor

8. 9. 10. 11. 12. 13. 14.

Speed Sensor Engine Start Switch Attch Press Switch Eng. Press. Swich Travel Press. Switch Impl. Press. Switch

8

15. Swing Press. Switch 16. Eng. Coolant Temp. Sensor 17. Hyd. Oil Temp. Sensor 18. Fuel Level Sensor 19. Fuse Box

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350/375/5080 Hydraulic Excavators CHAPTER : Electronic Control System

OUTPUTS FROM CONTROLLER

1

2

5

4

3

6

7

CONTROLLER

13

8 11

10

9 18

17

15 1. 2. 3. 4.

Monitor Travel Alarm Fault Alarm Two Speed Travel Sld 5. Swing Pump Power Sld 6. Bypass Sld

PUMP

16

7. Bypass Sld 8. Spd Chg Sw 9. Gov Act Motor 10. Spd Dial Backup Sw 11. Pwshf Press Backup Sw

12

14 12. 13. 14. 15. 16. 17. 18.

Proport Red. Valve Relay Box Washer Wiper Boom Light Boom Light Chassis Light

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350/375/5080 Hydraulic Excavators CHAPTER : Electronic Control System

POWER MODE SELECTION

POWER TRAVEL SPEED AEC

LIGHT

1 2

WIPER

WASHER

1 2

ALARM CANCEL TEST

SERVICE

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PUMP CONTROLS POWER MODE SELECTION

1 2

8

b

9

3 PUMP

c ECU

7 6

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1. 2. 3. 4. 5. 6. 7. 8. 9.

Monitor Eng. Speed Dial Travel Press Switch Impl Press Switch Swing Press Switch Attch Press Switch Propor Reduc Valve Engine Speed Sensor

a

a. PS Press From PRV b. Swing Pump Output c. Power Shift Press Signal

350/375/5080 Hydraulic Excavators

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CHAPTER : Electronic Control System

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350/375/5080 Hydraulic Excavators CHAPTER : Electronic Control System

SPEED DIAL LIMITS

POWER lll ll l

8

7

III II I 1 2

1 2

PUMP 1

ECU 2

6

5

(CONTROLLER)

4

3

Dial Position

1 2 3 4 5 6 7 8 9 10

RPM 350 375 800 700 950 850 1110 1000 1260 1150 1410 1300 1570 1450 1720 1600 1870 1750 2030 1860 2200 1960

1. 2. 3. 4. 5. 6. 7. 8.

Monitor Eng Speed Dial Proport Reduc Valve Gov Actuator Engine Feedback Sensor Speed Sensor Power Mode Switch

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350/375/5080 Hydraulic Excavators CHAPTER : Electronic Control System

AUTOMATIC ENGINE SPEED CONTROL (AEC)

1

ON

2

8

III II I 1

1

2

2

9

3 4 5 6

10

ECU 7

1. Monitor 2. AEC Switch 3. Impl Press Switch 4. Travel Press Switch 5. Swing Press Switch 6. Attch Press Switch 7. Gov Actuator 8. Engine 9. Speed Sensor 10. Feedback Sensor

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350/375/5080 Hydraulic Excavators CHAPTER : Electronic Control System

ONE-TOUCH LOW IDLE CONTROL CIRCUIT

1

8

2

3

9

ECU 10

4 7 5

6

1. Low Idle Switch 2. Engine Speed Switch 3. Impl Press Switch 4. Travel Press Switch 5. Swing Press Switch 6. Attch Press Switch 7. Gov Actuator 8. Engine 9. Speed Sensor 10. Feedback Sensor

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350/375/5080 Hydraulic Excavators CHAPTER : Electronic Control System

BACKUP SYSTEM CIRCUITS (Normal Operation)

1

9 AUT

MAN

M

RAB

TOR

8 24V

2 PRV 7

ECU 24V

AUT

TOR

PRV DRIVER

6

PRV

1. Governor Act Drive Circuit 2. Backup Signal 3. Backup Detection 4. Backup Resistor 5. Pump Control Backup Switch 6. PRV 7. Engine Speed Change Switch 8. Governor Actuator 9. Eng Speed Dial Backup Switch

5 3 4

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350/375/5080 Hydraulic Excavators CHAPTER : Electronic Control System

BACKUP SYSTEM CIRCUITS (Engine Speed Dial Backup System "ON")

1

9 AUT

MAN

M

RAB

TOR

8 24V

2 PRV 7

ECU 24V

AUT

TOR

PRV DRIVER

6

PRV

1. Governor Act Drive Circuit 2. Backup Signal 3. Backup Detection 4. Backup Resistor 5. Pump Control Backup Switch 6. PRV 7. Engine Speed Change Switch 8. Governor Actuator 9. Eng Speed Dial Backup Switch

5 3 4

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350/375/5080 Hydraulic Excavators CHAPTER : Electronic Control System

BACKUP SYSTEM CIRCUITS (Pump Control Backup System 'ON")

1

9 AUT MAN

M

RAB

TOR

8 24V

2 7

ECU 24V

AUT

TOR

PRV DRIVER

6

PRV

5 1. Governor Act Drive Circuit 2. Backup Signal 3. Backup Detection 4. Backup Resistor 5. Pump Control Backup Switch 6. PRV 7. Engine Speed Change Switch 8. Governor Actuator 9. Eng Speed Dial Backup Switch

3 4

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350/375/5080 Hydraulic Excavators CHAPTER : Electronic Control System

PERFORMANCE MONITOR

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350/375/5080 Hydraulic Excavators CHAPTER : Electronic Control System

SERVICE FUNCTIONS

POWER

TRAVEL SPEED

WIPER

LIGHT

1 2

AEC

WASHER

1 2

ALARM CANCEL

DATA MODE INFORMATION PROVIDED 1. Power Shift Pressure

5. Analog / Digital Conversion

2. Engine Speed

6. Real Time Error

3. Engine Coolant Temperature

7. Digital input

4. Hydraulic Oil Temperature

8. Pump Output Control

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350/375/5080 Hydraulic Excavators CHAPTER : Electronic Control System

CALIBRATION MODE

POWER

TRAVEL SPEED

WIPER

LIGHT

1 2

AEC

WASHER

1 2

ALARM CANCEL

CALIBRATION MODE INFORMATION PROVIDED

1. Machine Model and Configuration

6. Engine Speed Change

2. Controller / Monitor Software Version

7. Fixed Power shift Pressure Setting

3. Error Log

8. Engine RPM Display

4. Digital Output Test

9. Automatic Governor Actuator Calibration

5. PRV Sweep Test

10. PRV Calibration

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350/375/5080 Hydraulic Excavators CHAPTER : Electronic Control System

DATA MODE (Condensed Supplement)

POWER

A

1

B C

TRAVEL SPEED

A B

LIGHT

1 2

WIPER

1 B 2

A

AEC

4

A

1 B 2

A

5

3 WASHER

WIPER

LIGHT

POWER TRAVEL SPEED

2

AEC

A

6

WASHER

1 2

ALARM CANCEL

ALARM CANCEL

A

7

8

9

START : Turn engine start-key on. Press button "7" until the corresponding LED "A" starts to blink. Maintain "7" pressed and press button "1" until "P14" (375) is displayed. To read each function below press buttons "7" & "1" once.

FUNCTION

LED "ON"

READING

(See fig)

Power Shift Pressure

1A

P 14

Engine RPM : Engine Off

1B

0

1B

Multiply reading by 10

Eng. Coolant temp.

1C

Centigrade

Hydraulic oil temp.

4A

Centigrade

4B

Not needed

Real Time Error

2A

If a number appears, check the error code list

Digital Input

2B

See reverse

Output Ctrl Display

5A

L O O = Output Normal

Engine Running

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350/375/5080 Hydraulic Excavators CHAPTER : Electronic Control System

DATA MODE (Condensed Supplement Cont.)

TRAVEL SPEED

POWER

A

1

B C

A B

LIGHT

1 2

WIPER

1 B 2

A

AEC

4

A

2

1 B 2

A

5

3 WASHER

WIPER

LIGHT

POWER TRAVEL SPEED

AEC

A

6

WASHER

1 2

ALARM CANCEL

ALARM CANCEL

A

7

8

9

LED "2 B" blinking To change readings from "0" to "p", press buttons "7" & "8" once.

DIGITAL INPUT TESTS

Port 0 1 2 3 4 5 6 7 8 9 A B C D E F H J L n p

Component

Indication

Harness code 010 (350) 012 (375) Engine Speed Dial position 1 to 10 Travel pressure switch ON / OFF Attach. pump pressure switch (Optional) OFF Engine oil pressure switch ON / OFF Open OFF Open OFF Open OFF Low idle switch ON / OFF Implement pressure switch ON / OFF Engine RPM back-up switch ON / OFF PRV Back-up switch ON / OFF Open OFF Engine start key Switch ON Swing pressure switch ON / OFF Alternator condition (Eng. running) ON Open OFF Open OFF Open OFF Open OFF Open OFF

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350/375/5080 Hydraulic Excavators CHAPTER : Electronic Control System

CALIBRATION MODE (Condensed Supplement) START : With the engine start-key in the off position, press "9" on panel. Maintain "9" pressed and turn start-key to on position. Continue pressing "9" till "45b" (350) "75b" (375) displayed, then start the engine.

POWER

A

1

B C

TRAVEL SPEED

A

WIPER

LIGHT

A

POWER TRAVEL SPEED AEC

B LIGHT

WIPER

1 2

WASHER

1 2

1 2

4

2

B

AEC

A

A B

1 2

5

3 WASHER

A

6

ALARM CANCEL

ALARM CANCEL

A

7

8

9

PREESS BUTTON

LED "ON"

Machine model

9

1A

75 (375) = 75 Tons. b = Backhoe Config.

Computer software

1

1B

00C (for examp) C = Contr. P = Monit. Press button "3" to change "C" and "P"

Error Log ( F01 - F48. Check Error code list )

1

1C

Hd is displayed, Press button "3" for ascending order, "6" for descending order. End at the end. To clear press "3", "1" and "2" simultaneously until CLr is diplayed.

Digital output Test

4

4A

OoF is displayed, press button "3" for ascending order, "6" for descending order. Press "7" to check "O n / o F"

Proportional Reducing Valve "Sweep Test"

4

4B

Pressure changes from 0 to 32 Bar (in 5 sec.) and back.

Engine Speed Change (change for test purposes)

5

5A

Press button "3" to increase RPM and "6" to decrease. (Indication X 10 = RPM)

Fixed Power shift pressure (change for test purposes)

5

5B

P25 (for exemple) is displayed, press button "3" to increse the pressure, "6" to decrease. Each touch changes 1 Bar. Press "7" to change from power shift pressure to RPM and back

FUNCTION

READING

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350/375/5080 Hydraulic Excavators CHAPTER : Electronic Control System

CALIBRATION MODE (Condensed Supplement Cont.)

POWER

A

1

B C

TRAVEL SPEED

A

WIPER

LIGHT

A

POWER TRAVEL SPEED AEC

B LIGHT

1 2

WIPER

WASHER

1 2

1 2

4

2

B

AEC

A

A B

1 2

5

3 WASHER

A

6

ALARM CANCEL

ALARM CANCEL

A

7

8

9

FUNCTION

PRESS BUTTON

LED "ON"

Engine Speed Dial Setting Check

2

2A

Character displays the engine rpm value characteristic to the setting of the engine speed dial switch position

2A

Press and hold "3" and "6". AC flashing appears. While depressing "3" and "6" press "7" until display changes to ACP. Release all buttons then ACt will appear. Press "3" and "6" once more to start the Auto. Calibration Program (display will change from AC1 to AC0) If Problem : check Auto. Calibration Error Table.

2B

"E" Displayed - Move throttle control to position 10 "1" Displayed - First calibr. - 5 kg/cm2 "2" Displayed - Sec. Calibr. - 25 kg/cm2

Governor calibration (Move throttle control to 10)

Power shift calibration

2

READING

Press "3" to increase and "6" to decrease. Press button "7" to store the new settings in memory. Each time "7" is pressed, the display changes from first to second calibration.

NOTA : To end, press button "9" till monitor changes to normal or : Turn-off engine start-key.

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350/375/5080 Hydraulic Excavators CHAPTER : Electronic Control System

REAL TIME ERROR CODES

DESCRIPTION OF PROBLEMS

* CODE No E00 E01 E02 E03 E04 E05 E06 E07 E09 E10 E11 E12 E13 E14 E15 E16 E17 E18 E19 E20 E21 E25 E26 E27 E28 E29 E30 E31 E32 E33 E34 E36 E37 E38 E39 E40 E41 E48

No problem. Engine oil pressure: Low. Engine coolant temperature: High. Hydraulic oil temperature: High. Battery voltage: (Over 43 V). Alternator terminal "R": open. Engine speed sensor malfunction (no or low signal). Engine speed is not normal. Voltage of governor actuator feedback sensor: Low. Cir. of gover. actuat. feedback sensor: Shorted/open to batt.volt. Cir. of gover. actuat. feedback sensor: Shorted to body gnd. Voltage of governor actuator feedback sensor: Not stable. Circuit of governor actuator motor: Shorted to body ground. Gover. actuat. mtr does not rotate or mtr crct.: Shorted to gnd. Spd dial backup sw is "on" or gover. actuat. mtr. crct.: Open. Proportional Reduction Valve (PRV) crct.: Shorted to body gnd. PRV circuit: Shorted to battery voltage. PRV circuit: Open. Attach. Puls With Modulation (PWM) output: Gnd shorted. Attach. PWM output: + B shorted. Attach. PWM output: Open. Crct. of eng. coolant temperature sensor: Shorted to body gnd. Crct. of eng. coolant temp. sensor: Shorted to batt. vol. or open. Crct. of hydraulic oil temp. sensor: Shorted to body gnd. Crct. of hydraulic oil temp. sensor: Shoted to batt. volt or open. Attach. PWM Input: Shorted to gnd. Attach. PWM input: + B shorted or open. Throttle dial and eng. rpm signals to controller: Mismatched Dial set. and act. eng. rpm: More than 100 rpm diff. Digital output circuit: Shorted to batt. voltage. Gover. actuat.: No movement for 2.5 sec. after spd dial setting. Monitor takes at least 1 sec. to respond to controller 's signal. Monitor RAM (Random Access Memory): Not normal. Controller feels error signal from monitor. Monitor feels error from controller. Controller memory: Error Controller program indicates not-existing machine model. Engine Stalls.

NOTE : E 33 Shows whenever a short occurs on the two-speed solenoid. * E: In Data Mode F: In Calibration Mode Page:

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350/375/5080 Hydraulic Excavators CHAPTER : Electronic Control System

DIGITAL OUTPUT TEST Left Hand Display 0 1 2 3 4 5 6 7 8 9 A b C d E F *

Only Short = Err

Test Items

CALIBRATION DATA

Action alarm buzzer Washer Relay Relay (Attachment) Relay (Attachment) Bypass solenoid valve (Bkt/Stk) GOVERNOR CALIBRATION Wiper Relay SEQUENCE Boom Light Relay Chassis Light Relay A C 1 Check dial pos 2-9 Two Speed Travel Solenoid * Open A C 2 Check hi RPM Open A C 3 Check dial pos 9-2 Travel Alarm Buzzer A C 4 Check li RPM Swing Control Power * A C 5 Comp. prosses of inputs Solenoid A C 6 Confirm dial pos 2-10 Bypass Solenoid (Bm / Travel) Open * A C 7 Store in memory PRV Solenoid A C 8 Samp data rpm ctr A C 0 End * Steps AC5/7 are completed simultaneously.

GOVERNOR AUTOMATIC CALIBRATION ERROR TABLE Error Code -

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 51 52 53

Description of problem Governor actuator (G / A) cable does not move freely. The difference of the inward and outward movements of G / A are too large. G / A needs too much response time Battery voltage is to high. - Same as Real Time Error (RTE) : E04. Voltage of G / A feedback sensor is to low. - Same as RTE : E09. Circuit of G / A feedback sensor is shorted to batt.volt. or open. - Same as RTE : E10. Circuit of G / A feedback sensor is shorted to body ground. - Same as RTE : E11. Voltage of G / A feedback sensor is not stable. - Same as RTE : E12. Circuit of G / A motor is shorted to body ground. - Same as RTE : E13. G / A motor does not rotates or mtr. crct. is shorted to body gnd. - Same as RTE : E14. Speed dial backup is "ON" or G / A motor circuit is open. - Same as RTE : E15. Speed sensor circuit is open. - Same as RTE E06. Pressure switch for implement / swing or travel is "ON." Any of controls are in act. pos. Controller program indicates non-existing machine model. - Same as RTE : E41. G / A does not move freely near LOW or HIGH idle position G / A does not move freely near LOW IDLE position The specified high idle speed is not obtained The accelerator cable has to much tension (one cable system only) The accelerator cable is to loose (one cable system only)

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