350-375.Monitor

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Service TrainingMALAGA

ELECTRONIC CONTROL SYSTEM

FrancisNOV 97

350/375/5080 Hydraulic Excavators

8/8/2019 350-375.Monitor

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CHAPTER : Electronic Control System

350/375/5080Hydraulic Excavators

CONTROLLER

Relay Box

LED's

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OPERATOR'S CONSOLE

1

2

1. Monitor Panel2. Engine Speed Dial

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BACKUP SYSTEMS

ENGINE SPEED CONTROL

MANAUT

AUT

PUMP CONTROL

Engine Speed Control

Pump Control

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350/375 HYDRAULIC EXCAVATOR MONITOR

1

2

1

2

POWER TRAVEL SPEED AEC

ALARM CANCEL

WASHERWIPERLIGHT

TEST SERVICE

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MONITOR PANEL

(Upper Section)

8/8/2019 350-375.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...

- show s engine speed dial position- displays fault codes for controller/monitor

problems- indicates when either or both backupsystems are activated

THE MONITOR. . .

MONITOR FEATURES

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PULSE WIDTH MODULATED (PWM) SIGNALS

ONECYCLE

VOLTAGEON

MEAN VOLTAGE

VOLTAGEOFF

ONECYCLE

VOLTAGEON

VOLTAGELEVEL

MEAN VOLTAGE

VOLTAGEOFF

VOLTAGELEVEL

ONE

CYCLE

VOLTAGE

ON

VOLTAGELEVEL MEAN

VOLTAGE

VOLTAGEOFF

ONECYCLE

VOLTAGEON

VOLTAGELEVEL

MEANVOLTAGE

VOLTAGEOFF

DIFFERENT FREQUENCY

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INPUTS TO CONTROLLER

PUMP

CONTROLLER

1

2

3 4

5

6

7 8

910

1112

13

14

15

16

17

18

1. Monitor2. Eng Speed Dial3. Low Idle Switch4. Alternator5. Harness Code6. Battery7. Gov. Actuat.

Feedback Sensor

15. Swing Press. Switch16. Eng. Coolant

Temp. Sensor17. Hyd. Oil Temp. Sensor18. Fuel Level Sensor

19. Fuse Box

19

8. Speed Sensor9. Engine10. Start Switch11. Attch Press Sw itch12. Eng. Press . Sw ich13. Travel Press. Sw itch

14. Impl. Press. Switch

8/8/2019 350-375.Monitor




PUMP

CONTROLLER

1

2 34 5

6 7

8

9

10

11

12

13

1415

161718

OUTPUTS FROM CONTROLLER

7. Bypass Sld8. Spd Chg Sw9. Gov Act Motor10. Spd Dial

Backup Sw11. Pwshf Press

Backup Sw

1. Monitor2. Travel Alarm3. Fault Alarm4. Two Speed

Travel Sld5. Swing Pump

Power Sld6. Bypass Sld

12. Proport Red. Valve13. Relay Box14. Washer15. Wiper16. Boom Light17. Boom Light18. Chassis Light

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POWER MODE SELECTION

1

2

1

2


ALARM CANCEL

WASHERWIPERLIGHT

TESTSERVICE

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1 2

P age:

PUMP CONTROLSPOWER MODE SELECTION

PUMP

ECU

1

2

3

4

5

6

7

a

98

b

a. PS Press From PRVb. Swing Pump Outputc. Power Shif t Press Signal

1. Monitor2. Eng. Speed Dial3. Travel Press Sw itch4. Impl Press Switch5. Swi ng Press Switch6. Attch Press Sw itch7. Propor Reduc Valve8. Engine9. Speed Sensor

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III

II

I

1

2

1

2

PUMP

ECU(CONTROLLER)

POWER

l l l

l

l l

SPEED DIAL LIMITS

1

2

34

56

7

8

1. Monitor2. Eng Speed Dial3. Proport Reduc Valve4. Gov Actuator5. Engine

6. Feedback Sensor7. Speed Sensor8. Power Mode Switch

DialPosition

RPM

1 8002 9503 11104 12605 14106 15707 1720

8 18709 203010 2200

350

70085010001150130014501600

175018601960

375

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AUTOMATIC ENGINE SPEED CONTROL (AEC)

ECU

IIIII

I

1

2

1

2

ON1

2

3

4

5

6

7

10

8

9

1. Monitor2. AEC Switch3. Impl Press Sw itch4. Travel Press Sw itch5. Swing Press Switch6. Attch Press Sw itch7. Gov Actuator8. Engine9. Speed Sensor10. Feedback Sensor

8/8/2019 350-375.Monitor




ECU

ON E-TOUCH LOW IDLE CON TROL CIRCUIT

1

2

3

4

5

6

8

9

10

7

1. Low Idle Switch

2. Engine Speed Switch3. Impl Press Switch4. Travel Press Sw itch5. Swing Press Switch6. Attch Press Switch7. Gov Actuator8. Engine9. Speed Sensor10. Feedback Sensor

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BACKUP SYSTEM CIRCUITS

24V

24V

ECU

PRVDRIVER

PRV

M

AUT MAN

AUT TOR

RAB TOR

(Normal Operation)

1

2

34

5

6

PRV7

8

9

1. Governor ActDrive Circuit

2. Backup Signal3. Backup Detection4. Backup Resistor5. Pump Control

Backup Switch6. PRV7. Engine Speed

Change Swi tch8. Governor Actuator9. Eng Speed Dial

Backup Switch

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24V

24V

ECU

PRVDRIVER

PRV

M

AUT MAN

AUT TOR

RAB TOR

(Engine Speed Dial Backup System "ON ")

1

2

34

5

6

PRV7

8

9


2. Backup Signal

3. Backup Detection4. Backup Resistor5. Pump Control


Change Switch8. Governor Actuator9. Eng Speed Dial

Backup Switch

8/8/2019 350-375.Monitor





24V

24V

ECU

PRVDRIVER

PRV

M

AUT MAN

AUT TOR

RAB TOR

(Pump Control Backup System 'ON")

1

2

3

4

5

6

7

8

9


2. Backup Signal

3. Backup Detection4. Backup Resistor5. Pump Control


Change Switch8. Governor Actuator9. Eng Speed Dial

Backup Switch

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PERFORMANCE MONITOR

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SERVICE FUNCTIONS

POWER

LIGHT WIPER WASHER

AECTRAVEL SPEED

ALARM CANCEL

12

1

2

INFORMATION PROVIDED

1. Power Shift Pressure

2. Engine Speed

3. Engine Coolant Temperature

4. Hydraulic Oil Temperature

5. Analog / Digital Conversion

6. Real Time Error

7. Digital input

8. Pump Output Control

DATA MODE

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CALIBRATION MODE

POWER

LIGHT WIPER WASHER

AECTRAVEL SPEED

ALARM CANCEL

1

2

1

2

CALIBRATION MODE

INFORMATION PROVIDED

1. Machine Model and Configuration

2. Controller / Monitor Software Version

3. Error Log

4. Digital Output Test

5. PRV Sweep Test

6. Engine Speed Change

7. Fixed Power shift Pressure Setting

8. Engine RPM Display

9. Automatic Governor Actuator Calibration

10. PRV Calibration

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(Condensed Supplement)

DATA MODE

12

12

POWER TRAVELSPEED AEC

ALARM CANCEL

WASHERWIPERLIGHT

1

2

1

2


ALARM CANCEL

WASHERWIPERLIGHT

1A

4

7

2

5

8

3

6

9

B

C

A

B

A

B

A

B

A

A

A

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 displaye d.To read each function below press buttons "7" & "1" once.

FUNCTIONLED "ON "

(See fig)READING

Power Shift Pressure

Engine RPM :Engine Off

Engine Running

Eng. Coolant temp.

Hydraulic oil temp.

Real Time Error

1 A

1 B

1 B

1 C

4 A

4 B

2 A

2 B

P 14

0

Multiply reading by 10

Centigrade

Centigrade

Not needed

If a number appears,check the error code list

Digital Input See reverse

Output Ctrl D isplay 5 A L O O = Output Normal

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(Condensed Supplement Cont.)

DATA MODE

12

12


ALARM CANCEL

WASHERWIPERLIGHT

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

DIGITAL INPUT TESTS

0123456789ABCDEFHJL

np

Harness codeEngine Speed Dial positionTravel pressure switchAttach. pump pressure switch (Optional)Engine oil pressure switchOpenOpenOpenLow idle switchImplement pressure switchEngine RPM back-up switchPRV Back-up switchOpenEngine start key SwitchSwing pressure switchAlternator condition (Eng. running)OpenOpenOpen

OpenOpen

010 (350) 012 (375)1 to 10

ON / OFFOFF

ON / OFFOFFOFFOFF

ON / OFFON / OFFON / OFFON / OFF

OFFON

ON / OFFONOFFOFFOFF

OFFOFF

Port Component Indication

1

2

1

2


ALARM CANCEL

WASHERWIPERLIGHT

1A

4

7

2

5

8

3

6

9

B

C

A

B

A

B

A

B

A

A

A

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(Condensed Supplement)

CALIBRATION MODE

1

2

1

2


ALARM CANCEL

WASHERWIPERLIGHT

FUNCTIONLED

"ON"READING

1 A

1 B

1 C

PREESSBUTTON

9

1

1

4

5 5A

5 5B

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

Computer software00C (for examp) C = Contr. P = Monit.

Error Log Hd is displayed,Press button "3" for ascending order,"6" for descending order. End at theend. 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 ReducingValve "Sweep Test"

4B Pressure changes from 0 to 32 Bar(in 5 sec.) and back.

Engine Speed Change(change for testpurposes)

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

Fixed Power shift

pressure(change for testpurposes)

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 shiftpressure to RPM and back

( F01 - F48. CheckError code list )

START : With the engine s tart-key in the off pos ition , press "9" on pane l.Maintain "9" pressed and turn start-key to on position. Continue pressing"9" til l "45b" (350) "75b" (375) displayed , then start the engine.

Press button "3" to change "C" and "P"

1

2

1

2


ALARM CANCEL

WASHERWIPERLIGHT

1

A

4

7

2

5

8

3

6

9

BC

A

B

A

B

A

B

A

A

A

8/8/2019 350-375.Monitor




(Condensed Supplement Cont.)CALIBRATION MODE

1

2 12


ALARM CANCEL

WASHERWIPERLIGHT

FUNCTIONLED"ON"

READINGPRESS

BUTTON

2 2B

Engine Speed DialSetting Check

2 2A

Governor calibration(Move throttle controlto 10)

2A

Power shift calibration

NOTA : To end, press button "9" till monitor changes to normal or : Turn-off eng ine

start-key.

Character displays the engine rpmvalue characteristic to the setting of the engine speed dial sw itch pos ition

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

"E" Displayed - Move throttle controlto position 10

"1" Displayed - First calibr. - 5 kg/cm2"2" Displayed - Sec. Calibr. - 25 kg/cm2

Press "3" to increase and "6" to decrease.Press button "7" to store the new settingsin memory. Each time "7" is pressed, thedisplay changes from first to secondcalibration.

1

2

1

2


ALARM CANCEL

WASHERWIPERLIGHT

1A

4

7

2

5

8

3

6

9

B

C

A

B

A

B

A

B

A

A

A

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REAL TIME ERROR CODES

* CODE No DESCRIPTION OF PROBLEMS

E00E01E02E03E04

E05E06E07E09E10E11E12E13E14E15E16

E17E18E19E20E21E25E26E27E28E29E30E31E32E33E34E36E37E38E39E40E41E48

No problem.Engine oil pressure: Low.Engine coolant temperature: High.Hydraulic oil temperature: High.Battery vol tage: (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.vol t.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 d ial backup sw i s "on" or gover. actuat. mtr. crct.: Open.Proportional Reduction Valve (PRV) crct.: Shorted to body gnd.

PRV circuit: Shorted to battery vol tage.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 .Digi tal output circuit: Shorted to batt. voltage.Gover. actuat.: N o 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: ErrorController program indicates not-existing machine model.Engine Stalls.

NOTE : E 33 Shows w henever a short occurs on the two-speed solenoid.

* E: In Data ModeF: In Calibration Mode

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Left Hand Display Test Items

0 Action alarm buzzer1 Washer Relay

Wiper Relay

Boom Light Relay

Chassis Light RelayTwo Speed Travel So lenoid *

Open

Open

5

6

78

9

A

DIGITAL OUTPUT TEST

b Travel Alarm Buzzer

F

Swing Control PowerSolenoidBypass Solenoid (Bm / Travel)OpenPRV Solenoid

2 Relay (Attachment)

3 Relay (Attachment)

4 Bypass soleno id valve (Bkt/Stk)

C

dE

* Only Short = Err

A C 1

A C 2

Check dial pos 2-9

Check hi RPM

A C 3 Check dial pos 9-2

A C 4 Check li RPM

A C 5 Comp. prosse s of inputs

A C 6 Confirm dial pos 2-10

A C 7

A C 8

A C 0

Store in memory

Samp data rpm ctr

End

*

*

GOVERNOR AUTOMATIC CALIBRATION ERROR TABLE

ErrorCode

- 1 Governor actuator (G / A) cable does not move freely .- 2 The difference of the inward and outward movements of G / A are too large.- 3 G / A needs too much response time- 4 Battery voltage is to high. - Same as Real Time Error (RTE) : E04.- 5 Vol tage of G / A feedback sensor is to low . - Same as RTE : E09.- 6 Circuit of G / A feedback sensor is shorted to batt.vol t. or open. - Same as RTE : E10.- 7 Circuit of G / A feedback sensor is shorted to body ground. - Same as RTE : E11.- 8 Vol tage of G / A feedback sensor is not stable . - Same as RTE : E12.- 9 Circuit of G / A motor is shorted to body ground. - Same as RTE : E13.- 10 G / A motor does not rotates or mtr. crct. is shorted to body gnd. - Same as RTE : E14.- 11 Speed dial backup is "ON " or G / A motor circuit is open. - Same as RTE : E15.- 12 Speed sensor circuit is ope n. - Same as RTE E06.- 13 Pressure sw itch for implement / sw ing or travel is "ON ." Any of controls are in act. pos .- 14 Controll er program indicates non-existing machine model . - Same as RTE : E41.- 15 G / A does not move freely near LOW or HIGH idle position- 16 G / A does not move freely near LOW IDLE position

- 51 The specified high idle speed is not obtained- 52 The accelerator cable has to much tension (one cable system only)- 53 The accelerator cable is to loose (one cable system only)

Description of problem

* Steps AC5/7 are completedsimultaneously.

GOVERNOR CALIBRATIONSEQUENCE

CALIBRATIONDATA

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