lhph 320 330 electronic control unit

Service TrainingMeeting Guide 621 SESV1621 August 1992

TECHNICAL PRESENTATION

320/330 HYDRAULIC EXCAVATORS

ELECTRONIC CONTROL UNIT

320/330 HYDRAULIC EXCAVATORSELECTRONIC CONTROL UNITMEETING GUIDE 621 SLIDES AND SCRIPT

AUDIENCE

Level II - Service personnel who understand the principles of machine systems operation, diagnosticequipment, and procedures for testing and adjusting.

CONTENT

This presentation contains the information and visuals necessary to develop a Level II course ofinstruction on the Electronic Control Unit (ECU) for the 320, 320L, 320N, 330, and 330L HydraulicExcavators. Emphasis is placed on explaining how the ECU and Monitor Panel function. The Data andCalibration 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; and4. 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) SENR5450320, 320L and 320N Excavators Service Manual (3066 Engine with Swashplate Pump) SENR5465320, 320L and 320N Excavators Hydraulic and Electronic Systems Testing and Adjusting SENR5473320, 320L and 320N Excavators Parts Book SEBP2034330 and 330L Excavators Service Manual SENR5490330 and 330L Excavators Hydraulic and Electronic Systems Testing and Adjusting SENR5496330 and 330L Excavators Parts Book SEBP2171

PREREQUISITES

Cat Hydraulics Course (or equivalent) SEGV2519STMG 546 "Graphic Fluid Power Symbols" SESV1546STMG 584 "Electronic Power Unit Control for E-Series Hydraulic Excavators" SESV1584

SUPPLEMENTARY TRAINING MATERIAL

STMG 619 "320/330 Hydraulic Excavator--Pumps and Pump Controls" SESV1619STMG 620 "320/330 Hydraulic Excavator--Hydraulic Systems Operation" SESV1620

Estimated Time: 3 HoursVisuals: 58 (2 X 2) SlidesServiceman Handouts: 4 line drawingsForm: SESV1621Date: 8/92

© 1992 Caterpillar Inc.

STMG 621 - 3 -8/92

TABLE OF CONTENTS

INTRODUCTION ........................................................................................................................5Component Location and Function.........................................................................................6Pulse Width Modulated Signals ............................................................................................13Controller Changes ...............................................................................................................14Monitor Features...................................................................................................................16Controller Input Components ...............................................................................................17Controller Output Components.............................................................................................19Power Mode Selection ..........................................................................................................21P-Q Curves (320 with 3116 engine and Bent Axis Pump) ...................................................22P-Q Curves (320 with 3066 engine and Swashplate Pump)............................................ .....24P-Q Curves (330 with 3306 engine).................................................................................. ...26P-Q Curves (320 with 3116 engine and Bent Axis Pump) ...................................................28P-Q Curves (320 with 3066 engine and Swashplate Pump) .................................................30P-Q Curve (330 with 3306 engine).......................................................................................32Pump Regulation...................................................................................................................34Speed Dial Limits .................................................................................................................36

SYSTEMS OPERATION ...........................................................................................................37320 System Behavior ............................................................................................................38330 System Behavior ............................................................................................................40Power Mode Settings ............................................................................................................42Automatic Engine Control (AEC) ........................................................................................47One-touch Low Idle Control.................................................................................................49Backup Systems ....................................................................................................................50

SERVICE FUNCTIONS.............................................................................................................53Data Mode.............................................................................................................................54Calibration Mode ..................................................................................................................64

CONCLUSION...........................................................................................................................83

SLIDE LIST................................................................................................................................85

SERVICEMAN'S HANDOUTS.................................................................................................87

STMG 621 - 4 -8/92

INSTRUCTOR NOTES

STMG 621 - 5 -8/92

• Electronic ControlUnit (ECU) also called"controller"

• Matches hydraulichorsepower to enginehorsepower

• Receives, processes,and sends signals

• Warns of machineproblems

• Varies pump flowrates

• Provides diagnostics

1

INTRODUCTION

This presentation introduces the Electronic Control Unit (ECU) used onthe Caterpillar 320 and 330 Hydraulic Excavators. These ECU's arereferred to as "controllers" because they match hydraulic horsepower toengine horsepower by controlling engine rpm.

The controller receives input signals from the engine, the hydraulicsystem and the operator. As operating conditions change, the controllersends output signals to change engine speed, warn the operator ofpotential problems and to vary the hydraulic pump flow rate.

This presentation will explain the major differences between the 320/330controller and those used on the "E" series hydraulic excavators. Theways in which this controller simplifies machine operation anddiagnostics for both operators and servicemen will also be discussed.

333322220000////333333330000 HHHHYYYYDDDDRRRRAAAAUUUUIIIICCCC EEEEXXXXCCCCAAAAVVVVAAAATTTTOOOORRRREEEELLLLEEEECCCCTTTTRRRROOOONNNNIIIICCCC CCCCOOOONNNNTTTTRRRROOOOLLLL UUUUNNNNIIIITTTT

© 1992 Caterpillar Inc.

rbonilla

Nota

proporciona

STMG 621 - 6 -8/92

• Controller locatedoutside the cab

• Totally sealed unit

• 3 LED's (arrow) forsome diagnostics

2

Component Location and Function

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

STMG 621 - 7 -8/92

•If controller faultsymbol stays ON,check the LED's

• Yellow LED ON,communicationproblem with monitor

• Red LED ON steady orflashing, replace CPU

• Green LED ON,normal operation

3

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

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

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

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

rbonilla

Nota

dejando

STMG 621 - 8 -8/92

• Monitor panel:- Push buttons

activate manyfunctions

- Displays information

• Engine speed dial:- Ten positions

- Replaces governorcontrol lever

4

The operator's console has a monitor panel that permits several machinefunctions to be activated with push buttons. The monitor panel alsodisplays information about the machine operating status and diagnosticinformation.

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

rbonilla

Nota

varios

STMG 621 - 9 -8/92

• Two backup systems:- Engine speed dial

(two switches)- Pump control (one

switch)

• Speed dial rear switch:- Normally run in

"AUT" position- Dial disconnected in

"MAN" position

• Speed dial frontswitch:- "Rabbit" position

increases rpm- "Tortoise" position

decreases rpm

• Pump control switch:- Normally run in

"AUT" position- "Tortoise" position

connects PRV tobackup resistor

5

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

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

The pump control backup switch (not visible in this view) is the singletoggle 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 theProportional Reducing Valve (PRV) is supplied through a backup resistor.

phuonglh

Sticky Note

BACK-UP SYS??!! Two backup systems are provided to prevent machine down situations.

phuonglh

Sticky Note

HYDRAULIC BACKUP_SYS The pump control backup switch (not visible in this view) is the single toggle switch on the left console.

phuonglh

Sticky Note

NEGATIVE FLOW

STMG 621 - 10 -8/92

• Monitor panel:- Upper section has

readout devices- Lower section has

push buttons- LED's tell when

function is ON orOFF

• Four red LED's makeup warning systemmaster lamp

• Three digit display:- Operating

parameters- Error codes- Used in diagnostics

• LCD gauges:- Engine temperature- Fuel level- Hydraulic oil

temperature

6

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 thelower section contains push button switches which control many machinefunctions. The push buttons are labeled and have LED's which indicatewhen the function is ON or OFF.

At the top of the upper section are four red LED's. These LED's make upthe master lamp, which is part of the warning system. The warningsystem is activated when various machine system faults are detected bythe controller. In the top right corner of the upper section is a three digitLiquid Crystal Display (LCD) which indicates various machine operatingparameters and, during diagnostic procedures, displays information onmachine systems, components, and error codes. Below this display arethree rotary LCD's which indicate engine coolant temperature, fuelquantity and hydraulic oil temperature.

phuonglh

Sticky Note

Monitor panel: - Upper section has readout Devices - Lower section has push buttons - LED's tell when function is ON or OFF

phuonglh

Sticky Note

master lamp

phuonglh

Highlight

STMG 621 - 11 -8/92

• Seven LED faultsymbols

• Master lamp turns ONwhen a fault symbol isactivated

7

Across the bottom of the upper section (below the rotary displays) areseven LED fault symbols that illuminate when an out of tolerancecondition 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

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

phuonglh

Sticky Note

Seven LED fault symbols

phuonglh

Highlight

STMG 621 - 12 -8/92

• Ether aid switch

• Start switch

• Engine speed dial:

- Ten positions- Each position has a

specific no loadspeed

8

This view shows the ether aid switch, start switch and the engine speeddial with the "tortoise" and "rabbit" symbols and an ascending pictorialscale. As previously stated, the engine speed dial has ten positions.

The monitor panel indicates the engine speed dial position from 1 through10. Each dial position has a specific no load engine speed.

9

STMG 621 - 13 -8/92

• ECU sends PWMsignals 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

PULSE WIDTH MODULATED (PWM) SIGNALS

ONECYCLE

VOLTAGEON

VOLTAGELEVEL MEAN VOLTAGE

VOLTAGEOFF

Pulse Width Modulated Signals

The 320/330 uses a Pulse Width Modulated (PWM) signal from thecontroller to the Proportional Reducing Valve (PRV) which is identical tothe signal used on the "E" series hydraulic excavators. In addition, thehydraulic oil temperature sensor and governor actuator motor on the320/330 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 isrepresented 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 isrepresented by the horizontal length of the "pulse" in the slide. This timeis normally a percentage of the total ON time available for the "pulse."

A PWM signal cannot be measured accurately with a VOM because thelonger a "pulse" is ON, the "mean voltage value" that is measured willalso be higher. The "mean voltage value" will never be as high as thepulsed voltage level. This same condition, but in reverse, holds true forshorter "pulses." A lower "mean voltage value" will be measured.

phuonglh

Sticky Note

Pulse Width Modulated Signals

10

STMG 621 - 14 -8/92

• Now a sealed unit, located outside the cab

CONTROLLER CHANGES. . .

• Three diagnostic LED's in the cover

• It operates the electronic governor control

• Functions as an underspeed controller,but ONLY in Power Mode llI, and if theengine speed dial is at position “10”

• Has an “anti-stall” feature instead of the“self-learning” function

• Has more “inputs” and “outputs”

Controller Changes

This slide summarizes some of the changes which have been made to the320/330 controller from the "E" series hydraulic excavators.

11

STMG 621 - 15 -8/92

• The controller has continual interactivecommunication with the monitor panel

• Controls the work mode solenoids, the two-speedtravel solenoid and relays for the lights, wiper andwasher 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

CONTROLLER CHANGES. . .

• Has two backup systems, one for the pumpcontrol and another for the engine speed dial

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

12

STMG 621 - 16 -8/92

• Communicates with the controller

• Has LCD displays in place of gauges

• Has push buttons that control many machinefunctions 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

THE MONITOR. . .

Monitor Features

This slide summarizes the operational features of the 320/330 monitor.

phuonglh

Sticky Note

THE MONITOR. . .

13

STMG 621 - 17 -8/92

FAULTALARM

ENG. OILPRESS.SWITCH

MONITOR

SWINGPRIORITYSOLEN.VALVE

ENG.SPEEDDIAL

TRAV.PRESS.SWITCH

BM. UPPRESS.SWITCH

IMPL. /SW.PRESS.SWITCH

FUELLEVEL

SENSORHYD. OIL

TEMP.SENSOR

ENG.COOLANT

TEMP.SENSOR

TRAV.SPD.

SOLEN.VALVE

FINECONTROL

SOLEN.VALVE

LOWIDLE

SWITCH

TRAVELALARM

PRV

P/SPRESSURE

BACKUPSWITCH

SPEEDCHANGESWITCH

SPD. DIALBACKUP SW.

ENGINE

PUMP

G/A

FUSEBOX

STARTSWITCH

G/A FDBKSENSOR

INPUTS TO CONTROLLER

RELAYBOX

SPEEDSENSORCHASSIS

LIGHTBOOMLIGHT

WIPER WASHER

BATTERY

ALT.

ECU (CONTROLLER)

ATTACH.PRESS.SWITCH

Controller Input Components

On this diagram, all of the inputs to the controller have been color codedred.

Fuse box: Electrical power from the battery and start switch is sentthrough the fuse box to the controller.

Monitor: Sends a number of input signals to the controller which will beexplained in detail later in this presentation.

Speed sensor: A magnetic pickup which is mounted on the engineflywheel housing just below the muffler.

Feedback sensor: Indicates the governor position and is located on thegovernor actuator motor which is mounted under a square cover in thehydraulic pump compartment.

phuonglh

Sticky Note

ECU AND THE INPUTS & OUTPUTS SIGNALS

STMG 621 - 18 -8/92

Engine speed dial: A rotary switch which is located on the operator’sconsole in the cab.

Travel pressure switch: Tells the controller when a travel circuit isactivated and is mounted on the top front of the main implement controlvalve.

Implement/swing pressure switch: Tells the controller when animplement or the swing circuit is activated; also mounted on the top frontof the main control valve.

Boom up pressure switch: Tells the controller when the boom control isfully stroked for "boom up."

Engine coolant temperature sensor: Located on the water pumphousing.

Hydraulic oil temperature sensor: Located on the right rear lowercorner of the hydraulic tank.

Fuel level sensor: Located on the right rear lower corner of the fuel tankand 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 controlsystem; located on top of the right joystick.

Attachment pressure switch: Sends a signal to the controller when anauxiliary pump is in operation.

phuonglh

Sticky Note

Attachment: MEAN ANY OTHER AUXILIARY COMPONENT ATTACHES TO THE MACHINE

phuonglh

Sticky Note

Implement: MEANS HYD COMPONENTS FACTORY SUPPLY TO THE MACHINE

14

STMG 621 - 19 -8/92

FAULTALARM

ENG. OILPRESS.SWITCH

MONITOR

SWINGPRIORITYSOLEN.VALVE

ENG.SPEEDDIAL

TRAV.PRESS.SWITCH

BM. UPPRESS.SWITCH

IMPL. /SW.PRESS.SWITCH

FUELLEVEL

SENSOR

HYD. OILTEMP.

SENSOR

ENG.COOLANT

TEMP.SENSOR

TRAV.SPD.

SOLEN.VALVE

FINECONTROL

SOLEN.VALVE

LOWIDLE

SWITCH

TRAVELALARM

PRV

P/SPRESSURE

BACKUPSWITCH

SPEEDCHANGESWITCH

SPD. DIALBACKUP SW.

ENGINE

PUMP

G/A

FUSEBOX

STARTSWITCH

OUTPUTS FROM CONTROLLER

RELAYBOX

SPEEDSENSOR

CHASSISLIGHT

BOOMLIGHT

WIPER WASHER

BATTERY

ALT.

ECU (CONTROLLER)

G/A FDBKSENSOR

ATTACH.PRESS.SWITCH

Controller Output Components

Shown here is the same diagram but with all the controller outputs colorcoded red.

Monitor: In addition to serving as an input component, the monitor alsoreceives signals from the controller.

Governor actuator motor: Electrically controls engine rpm as indicatedby 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 aftera signal is received from the WORK push button switch on the monitorpanel.

phuonglh

Sticky Note

Proportional Reducing Valve (PRV): Controls the Power Shift (PS) pressure to the pump group and is also part of the PWM signal circuit.

STMG 621 - 20 -8/92

Swing priority (Crowding) solenoid valve: Also activated by thecontroller after a signal is received from the WORK push button switchon the monitor panel.

Two speed travel solenoid valve: Activated by the controller after asignal is received from the TRAVEL SPEED push button switch on themonitor panel.

Fault alarm: An audible horn or buzzer.

Travel alarm: Activated by the controller after a signal is received fromthe travel pressure switch.

Windshield wiper relay: Actuated by the controller after a signal isreceived from the WIPER push button switch on the monitor panel.

Windshield washer relay: Actuated by the controller after a signal isreceived from the WASHER push button switch.

Chassis light relay: Actuated by the controller after a signal is receivedfrom the LIGHT push button switch.

Boom light relay: Also actuated after a signal is received from theLIGHT push button switch.

phuonglh

Sticky Note

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.

15

STMG 621 - 21 -8/92

• Power mode selectorswitch sends signal tocontroller

• LED's indicate levels I,II, or III

• Power modes matchmachine power totask

• Available enginehorsepower

PERFORMANCEMONITOR

12

12

POWER

IIIIII

WORK

TRAVEL SPEED ALARM CANCEL

LIGHT WASHERWIPER

ONAECPOWER MODE

SELECTION

Power Mode Selection

The power mode selector switch, located on the monitor panel, signals thecontroller which power mode level has been chosen. Three symbols withcorresponding 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 differentlevel and illuminate an LED.

The three power modes permit the operator to match the machine powerto the task by providing a different amount of hydraulic horsepower forthe implement, swing and travel systems. The amount of available enginehorsepower 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 toPower Mode II.

phuonglh

Sticky Note

PERFORMANCE MONITOR POWER MODE SELECTION

16

STMG 621 - 22 -8/92

• Pump pressureplotted against flow

• Both pumps equallyloaded

• Implement/swingpressure switchclosed

• Travel pressureswitch open

• Top curve for PowerMode III

•Middle curve for PowerMode II

10

20

30

40

50

60

PUMP PRESSURE (PSI)1000 2000 3000 4000 5000

46 GPM2130 PSI

37 GPM1480 PSI

22 GPM2490 PSI

20 GPM

15 GPM

9 GPM

A

B

40 GPM1990 PSI

C

27 GPM2775 PSI

25 GPM3980 PSI

PU

MP

FL

OW

(G

PM

)

IMPL. R/VSETTING4550 PSI

00

DIAL "7~10"

DIAL "9~10"

DIAL "10"

III

II

I

320 P-Q CHARACTERISTICS3116 ENGINE WITH BENT AXIS PUMP

2 PUMPS EQUALLY LOADEDWITH IMPLEMENTS ONLY

NOTEVALUES SHOWN ARE EXAMPLES ONLY

THEY SHOULD NOT BE USEDFOR PUMP TESTS

POWER SHIFT PRESSUREPOINT A = approx 255 ps

POINT B = approx 290 psiPOINT C = approx 320 psi

P-Q Curves (320 with 3116 engine and Bent Axis Pump)

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

The top curve, for Power Mode III, shows that the pump begins todestroke at Point A, which is approximately 14700 kPa (2130 psi). Atthat time, the power shift pressure is approximately 1750 kPa (255 psi).

The middle curve, for Power Mode II, shows that the pump begins todestroke at Point B, which is approximately 13700 kPa (1990 psi). At thattime, the power shift pressure is approximately 2000 kPa (290 psi).

STMG 621 - 23 -8/92

• Bottom curve forPower Mode I

The bottom curve, for Power Mode I, shows that the pump begins todestroke at Point C, which is approximately 10200 kPa (1480 psi). Atthat time, the power shift pressure is approximately 2200 kPa (320 psi).

NOTE TO THE INSTRUCTOR: All values shown are forCLASSROOM REFERENCE ONLY and should not be used fordiagnostic purposes.

17

STMG 621 - 24 -8/92






• Middle curve forPower Mode II

10

20

30

40

50

60


48 GPM1900 PSI

40 GPM1450 PSI

21 GPM2550PSI

16 GPM

14 GPM

9 GPM

A

B

43 GPM1500 PSI

C

23 GPM3050 PSI

29 GPM3050 PSI

PU

MP

FL

OW

(G

PM

)

POWER SHIFT PRESSUREPOINT A = approx 230 psi

POINT B = approx 280 psi

POINT C = approx 310 psi


00

DIAL "7~10"

DIAL "9~10"

DIAL "10"

IIIII

I

320 P-Q CHARACTERISTICS3066 ENGINE WITH SWASHPLATE PUMP

2 PUMPS EQUALLY LOADEDWITH IMPLEMENTS ONLY



P-Q Curves (320 with 3066 engine and Swashplate Pump)




phuonglh

Sticky Note

320C THEPMIENNAM EXCAVATOR MACHINE

STMG 621 - 25 -8/92




phuonglh

Sticky Note

CLASSROOM REFERENCE ONLY!!!

18

STMG 621 - 26 -8/92






• Middle curve forPower Mode II

10

20

30

40

50

60


59 GPM3130 PSI

47 GPM2200PSI

34 GPM3050 PSI

38 GPM

28 GPM

20GPM

AB57 GPM

2485 PSI

C 39 GPM3335 PSI

42 GPM4130 PSI

PU

MP

FL

OW

(G

PM

)

POWER SHIFT PRESSUREPOINT A = approx 160 psi

POINT B = approx 185 psi

POINT C = approx 200 psi


00

DIAL "7~10"

DIAL "9~10"

DIAL "10"III

II

I

330 P-Q CHARACTERISTICS2 PUMPS EQUALLY LOADED

WITH IMPLEMENTS ONLYNOTE

VALUES SHOWN ARE EXAMPLES ONLYTHEY SHOULD NOT BE USED

FOR PUMP TESTS

P-Q Curves (330 with 3306 engine)




STMG 621 - 27 -8/92




19

STMG 621 - 28 -8/92

• Only one pump loaded

• Power Mode III withspeed dial at 10

• Only implementloaded:- Implement/swing

pressure switchclosed

- Travel pressureswitch open

1000 2000 3000 4000 5000

POWER SHIFTPRESSUREPt. A = 130 psi

Pt. B = 45 psi10

20

30

40

50

60

PUMP PRESSURE (PSI)

PU

MP

FlO

W (

GP

M)

A

B

31 GPM

23 GPM

49 GPM2490 PSI 47 GPM

3980 PSI

27 GPM3980 PSI

IMPLEMENTS

TRAVEL

4550 PSIIMPL.

R/V SETTING

5000 PSITRAVEL

R/V SETTING

00



320 PUMP P-Q CHARACTERISTICS3116 ENGINE WITH BENT AXIS PUMP

ONE PUMP LOADED WITH IMPLEMENTS OR TRAVELIN POWER MODE III

P-Q Curves (320 with 3116 engine and Bent Axis Pump)

These two curves show the pump pressure plotted against flow when onlyone pump is loaded for either an implement/swing circuit or for the travelcircuit. The values shown here are for Power Mode III with the enginespeed dial at position 10.

Again, the controller can detect when only an implement is loadedbecause the implement/swing pressure switch at the main control valve isclosed and the travel pressure switch at the main control valve is open (nopressure in the travel circuits). The pump begins to destroke at Point A,which is approximately 17100 kPa (2490 psi). Power shift pressure willbe approximately 900 kPa (130 psi) at that time.

STMG 621 - 29 -8/92

• Only travel loaded:- Travel pressure

switch closed- Implement/swing

pressure switchopen

• Constant signal toPRV as circuit isloaded

• Engine rpm decreasesto target speed

• Signal to PRV variesto maintain targetspeed

The controller can detect when only the travel circuit is loaded becausethe travel pressure switch at the main control valve is closed and theimplement/swing pressure switch at the main control valve is open (nopressure in the implement/swing circuits). When using one pump to loada 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 willbe approximately 300 kPa (45 psi) at that time.

Thus, the controller sends a constant level of electrical signal to the PRVwhen loading the implement/swing or travel circuit. After the enginespeed decreases to the target speed of approximately 1750 rpm, thecontroller varies the electrical signal to the PRV to maintain that targetspeed.

20

STMG 621 - 30 -8/92


• Power Mode III withspeed dial at 10




1000 2000 3000 4000 5000

POWER SHIFTPRESSUREPt. A = 185 psi

Pt. B = 28 psi10

20

30

40

50

60

PUMP PRESSURE (PSI)

PU

MP

FlO

W (

GP

M)

A B

27 GPM

17 GPM

43 GPM2670 PSI

42 GPM3980 PSI

20 GPM3980 PSI

IMPLEMENTS

TRAVEL

4550 PSIIMPL.R/V

SETTING

5000 PSITRAVEL

R/VSETTING

00



320 PUMP P-Q CHARACTERISTICS3066 ENGINE WITH SWASHPLATE PUMP

ONE PUMP LOADED WITH IMPLEMENTS OR TRAVELIN POWER MODE III

P-Q Curves (320 with 3066 engine and Swashplate Pump)

These two curves show the pump pressure plotted against flow when onlyone pump is loaded for either an implement/swing circuit or for the travelcircuit. The values shown here are for Power Mode III with the enginespeed dial at position 10.

Again, the controller can detect when only an implement is loadedbecause the implement/swing pressure switch at the main control valve isclosed and the travel pressure switch at the main control valve is open (nopressure in the travel circuits). The pump begins to destroke at Point A,which is approximately 18400 kPa (2670 psi). Power shift pressure willbe approximately 1275 kPa (185 psi) at that time.

STMG 621 - 31 -8/92

• Only travel loaded:- Travel pressure

switch closed- Implement/swing

pressure switchopen




The controller can detect when only the travel circuit is loaded becausethe travel pressure switch at the main control valve is closed and theimplement/swing pressure switch at the main control valve is open (nopressure in the implement/swing circuits). When using one pump to loada 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 willbe approximately 200 kPa (28 psi) at that time.

As in the preceding example, the controller sends a constant level ofelectrical signal to the PRV when loading the implement/swing or travelcircuit. After the engine speed decreases to the target speed ofapproximately 1750 rpm, the controller varies the electrical signal to thePRV to maintain that target speed.

21

STMG 621 - 32 -8/92


• Power Mode III with speed dial at 10




Pt. A=100 psi

POWER SHIFTPRESSURE

1000 2000 3000 4000 5000

10

20

30

40

50

1000

60

PUMP PRESSURE (PSI)

PU

MP

FlO

W (

GP

M)

A53 GPM

61 GPM4195 PSI

IMPLEMENTS

4550 PSIIMPL.

R/V SETTING5000 PSITRAVEL

R/VSETTING

00



34 GPM

330 PUMP P-Q CHARACTERISTICSONE PUMP LOADED WITH IMPLEMENTS OR TRAVEL

IN POWER MODE III

P-Q Curve (330 with 3306 engine)

This curve shows the pump pressure plotted against flow when only onepump is loaded for either an implement/swing circuit or for the travelcircuit. The values shown here are for Power Mode III with the enginespeed dial at position 10.

The controller can detect when only an implement is loaded because theimplement/swing pressure switch at the main control valve is closed andthe travel pressure switch at the main control valve is open (no pressure inthe travel circuits). The pump begins to destroke at Point A, which isapproximately 28920 kPa (4195 psi). Power shift pressure will beapproximately 685 kPa (100 psi) at that time.

STMG 621 - 33 -8/92




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

22

STMG 621 - 34 -8/92

• Pump flow regulatedby controller

• Controller sendselectrical signal toPRV

• PRV sends pressuresignal to pumps

• Pressure signalaffects both pumps

PUMP

REGULATOR

PROPORTIONALREDUCING VALVE

ENGINE SPEED SENSOR

PUMP CONTROLSPOWER MODE SELECTION

PILOTPUMP

RESOLVERVALVE

MONITORENGINESPEEDDIAL

TRAV.PRESS.SWITCH

IMP. SW.PRESS.SWITCH

PUMP

ECU

P/SPRESSFROMPRV

P/S PRESSUREFROM PRV

ATTACH.PRESS.SWITCH

(IF EQUIPPED)

Pump Regulation

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

phuonglh

Sticky Note

PUMP CONTROLS POWER MODE SELECTION

STMG 621 - 35 -8/92

• Signal from controllerto PRV is constantand high

• Pumps destroke atlow system pressure

• Both pump flows varywith pump pressures

• Signal from controllerto PRV is constant butless than Power ModeI

• Pumps destroke atslightly higher systempressure

• Power shift pressureremains constant

• Signal from controlleris constant but lessthan Power Mode II

• Pumps destroke athigher pressure thanPower Mode II

• Power shift pressureremains constant

• Controller functionsas underspeed control

• As engine speeddecreases, controllersignal increases

• Controller variessignal to maintainengine rpm near fullload

Power Mode I: Any engine speed dial position

In Power Mode I, the electrical signal from the controller to the PRV isconstant and high. The PRV sends a constant and high power shiftpressure to the pumps causing them to begin destroking at a relatively lowpump system pressure. As system pressure in each pump increases above10700 kPa (1550 psi), the power shift pressure does not change. Theincreased pump pressures, acting internally in the pump regulators, beginto destroke the pumps. Both pump flows will increase or decrease aspump pressures decrease or increase.

Power Mode II: Any engine speed dial position

In Power Mode II, the electrical signal from the controller to the PRV isstill constant but slightly lower than in Power Mode I, so the power shiftpressure to the pumps is also slightly lower. The pumps begin to destrokeat a slightly higher pump system pressure than in Power Mode I. Aspump pressure increases and flow decreases, the power shift pressure willremain relatively constant. Again, pump flow is regulated by theindividual 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 isstill constant but slightly lower than in Power Mode II, so the power shiftpressure to the pumps is also slightly lower. The pumps begin to destrokeat a slightly higher pump system pressure than in Power Mode II. Asstated previously, when pump pressure increases and flow decreases, thepower shift pressure will remain relatively constant. Pump flow is stillregulated by the individual pump system pressure acting internally in thepump 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 controllerfunctions as an underspeed control. The controller monitors engine speedfrom the speed sensor and, as engine speed decreases to near full load(1980 rpm for 320, 1950 rpm for 330), the controller begins to increasethe electrical signal to the PRV. The PRV increases the power shift signalto the pumps and the pumps begin to destroke. The controller continuallyvaries the electrical signal to the PRV to maintain engine speed as near tofull load rpm as possible.

NOTE TO THE INSTRUCTOR: For a detailed explanation of thefunction and operation of the hydraulic pump regulators, refer toSTMG 619 "320/330 Hydraulic Excavators--Pumps and PumpControls" (Form SESV1619).

23

STMG 621 - 36 -8/92

• Power Mode I: Enginerpm limited to speeddial position 7

• Power Mode II:Engine rpm limited tospeed dial position 9

• Power Mode III:Engine rpm limited tospeed dial position 10

IIIIII

12

12

GOVERNORACTUATOR

ENGINESPEED DIAL

PUMP

SPEED SENSOR

PROPORTIONALREDUCING VALVE

ENGINE

ELECTRONICCONTROL CIRCUITS

SPEED DIAL LIMITS

POWERMODE

SWITCH

MONITOR

ECU FEEDBACKSENSOR(CONTROLLER)

POWERlll

ll l

Speed Dial Limits

The engine speed is limited by the power mode setting chosen. WhenPower Mode I is selected, the maximum engine rpm is limited to that ofthe 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 thatof the selected dial position.

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

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

phuonglh

Sticky Note

Speed Dial Limits: POWER MODE I,II,&III AND THE SPEED LIMITED

STMG 621 - 37 -8/92

24

SYSTEMS OPERATION

The 320/330 controllers provide a number of operational benefits.Productivity is a function of all systems operating correctly and withindesign specifications. A thorough understanding of how the controllercan vary the machine operational parameters will enhance productivityand the ability to isolate performance related problems.

phuonglh

Sticky Note

SYSTEMS OPERATION: A thorough understanding of how the controller can vary the machine operational parameters will enhance productivity and the ability to isolate performance related problems.

phuonglh

Sticky Note

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.

25

STMG 621 - 38 -8/92

• Normal operation inPower Mode III

• Engine speed dial atposition 10

• Controls in HOLD,three seconds beforeAEC comes ON

• Engine rpm to belowered

• Controls in HOLD forthree seconds, AEC isOFF

• Pumps at low standbyflow

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320 System Behavior

Engine speed and power shift pressures will vary during differentoperating conditions. This chart provides examples of approximateengine rpm and power shift pressure during different machine operatingconditions. For all conditions, the machine is shown during normaloperation in Power Mode III with the engine speed dial at position 10.

High Idle: All controls are in NEUTRAL or HOLD during the threeseconds before the Automatic Engine Control (AEC) comes ON. Enginespeed 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 forthree seconds and the AEC switch is OFF. Engine speed is 1870 rpm andpower shift pressure is approximately 1910 kPa (275 psi). The hydraulicpumps are at low standby flow and pump pressures are below 3450 kPa(500 psi). Component wear will be reduced and fuel consumption is low.

phuonglh

Sticky Note

pump pressures are below 3450 kPa (500 psi):Component wear will be reduced and fuel consumption is low.

phuonglh

Sticky Note

320 System Behavior Engine speed and power shift pressures will vary during different operating conditions.

STMG 621 - 39 -8/92

• Pump pressures atrelief valve setting

• Controller monitoringengine speed

• Boom up and swing atsame time

• Controls in HOLD forthree seconds, AEC isON


• One-touch low idleswitch is ON


Normal Load, Below Full Load Speed: Both pumps are pressurized upto 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 pumpflows are approximately 76 l/min. (20 gpm). The controller is monitoringengine speed to either increase or decrease the electrical signal to thePRV.

Maximum Flow, Full Load Speed: Booming up and swinging at thesame time. Engine speed is approximately 1800 rpm and power shiftpressure is from 1275 to 1765 kPa (185 to 255 psi). Pump pressures areat 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 andthe AEC switch is ON. Engine speed is approximately 1300 rpm andpower shift pressure is approximately 1910 kPa (275 psi). Hydraulicpressures are below 3450 kPa (500 psi) and the pumps are at low standbyflow of approximately 34 l/min. (9 gpm).

One-Touch Low Idle: One-touch low idle switch is ON. Engine speedis 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 arefor example only and should not be used for testing and adjusting.

26

STMG 621 - 40 -8/92

• Normal operation inPower Mode III

• Engine speed dial atposition 10

• Controls in HOLD,three seconds beforeAEC comes ON

• Engine rpm to belowered

• Controls in HOLD forthree seconds, AEC isOFF


POWER SHIFTPRESSURE

205 psi

205 psi

205 psi

205 psi

140 psi170 psi115 psi185 psi

1960

1790

1790

ENGINERPM

1300

1860

850

1840

High Idle(3 sec. period before

AEC comes ON)

Both pumps pressurizedup to main relief pressure

Boom Up and Swing

AEC ON

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

AEC Level I

One-Touch Low IdleON

330 SYSTEM BEHAVIORNORMAL OPERATION

330 System Behavior

Engine speed and power shift pressures will vary during differentoperating conditions. This chart provides examples of approximateengine rpm and power shift pressure during different machine operatingconditions. For all conditions, the machine is shown during normaloperation in Power Mode III with the engine speed dial at position 10.

High Idle: All controls are in NEUTRAL or HOLD during the threeseconds before the Automatic Engine Control (AEC) comes ON. Enginespeed 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 forthree seconds and the AEC switch is OFF. Engine speed is 1870 rpm andpower shift pressure is approximately1420 kPa (205 psi). The hydraulicpumps 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 - 41 -8/92

• Pump pressures atrelief valve setting

• Controller monitoringengine speed

• Boom up and swing atsame time

• Controls in HOLD forthree seconds, AEC isON


• One-touch low idleswitch is ON


Normal Load, Below Full Load Speed: Both pumps are pressurized upto 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 pumpflows are approximately 145 l/min. (38 gpm). The controller ismonitoring engine speed to either increase or decrease the electrical signalto the PRV.

Maximum Flow, Full Load Speed: Booming up and swinging at thesame time. Engine speed is approximately 1790 rpm and power shiftpressure is from 785 to 1275 kPa (115 to 185 psi). Pump pressures are at24100 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 andthe AEC switch is ON. Engine speed is approximately 1300 rpm andpower shift pressure is approximately 1420 kPa (205 psi). Hydraulicpressures are below 3450 kPa (500 psi) and the pumps are at low standbyflow of approximately 34 l/min. (9 gpm).

One-Touch Low Idle: One-touch low idle switch is ON. Engine speedis 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 arefor example only and should not be used for testing and adjusting.

27

STMG 621 - 42 -8/92

• Hydraulic torque foreach speed dialposition

• Power Mode III, dialposition 10


• Controller variessignal to maintaintarget rpm

6 87 95431 10LOW IDLE HIGH IDLE

2ENGINE SPEED DIAL POSITION

HY

DR

AU

LIC

TO

RQ

UE

l

RATED = 1800 RPM

TARGET SPEED = 1790 RPM (330)

1750 RPM (320)

HYDRAULIC TORQUE

ll

ll l

320-330 POWER MODE SETTINGS

Power Mode Settings

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

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 beginsworking, the engine speed will decrease from high idle rpm toward thefull load speed of 1800 rpm. The full load speed is near the target speed

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

STMG 621 - 43 -8/92

• Power Mode III, dialposition 9 or below

• Engine rpmdecreases, pumpsdestroke

• Steady signal to PRV

• Power Modes I and IIare similar

• Engine rpmdecreases, pumpsdestroke

• Steady signal to PRV

• Pump flow controlledby system pressures

When the engine speed dial is in position 9 or below (but still in PowerMode III) and the machine begins working, the engine rpm will decreasefrom the no load speed for that dial position until the pump systempressure begins to destroke the pump. In this condition, the controllersends a steady signal to the PRV and pump flow is controlled only by thepump system pressures.

The Power Mode II curve (blue) and Power Mode I curve (yellow) showsimilar characteristics. Power Mode II engine speed begins at dialposition 9 and the controller sends a steady and slightly higher electricalsignal to the PRV than in Power Mode III and dial position 9. PowerMode I begins at dial position 7 and the controller sends a steady andslightly higher electrical signal to the PRV than in Power Mode II. As themachine begins working, the engine speed will decrease from the no loadspeed for a selected dial position until pump pressure begins to destrokethe pumps. Remember, the controller sends a steady signal to the PRVduring these conditions and pump flow is controlled only by pump systempressures.

28

STMG 621 - 44 -8/92

• Anti-stall function

• Engine 250 rpm belowno load speed forselected dial position

• Signal to PRVincreases

• Flow rates decrease tounload engine

6 8531 42 10

HY

D T

OR

QU

E

LOW IDLE HIGH IDLE7 9

l

ll

l l l

CONSTANT TORQUECONTROL LINE

ENGINE SPEED DIAL POSITION

ANTI-STALLCONTROL LINE

320-330 POWER MODE SETTINGSANTI-STALL FUNCTION

The anti-stall function of the 320/330 controller replaces the self-learningfunction which was used on the "E" series excavator controllers.

When the machine is operating in Power Mode I and II or in Power ModeIII with the engine speed dial in position 9 or below, the power shiftpressure is constant. (Remember, however, that the power shift pressuresare different for each of these conditions.) The controller monitors enginespeed and, if the engine speed decreases 250 rpm below the no load speedof the engine speed dial, the controller begins to increase the electricalsignal to the PRV. The PRV then increases the power shift pressure sentto the pumps and causes the pump flow rates to decrease, therebyunloading the engine. When the engine speed increases above the enginespeed dial less 250 rpm value, the controller again provides a constantelectrical signal to the PRV.

STMG 621 - 45 -8/92

• Power Mode II, dialposition 8

• Engine rpm decreasesto 1500

• Signal to PRVincreases, pumpsdestroke

In the example shown on the graph, a 320 excavator is operating in PowerMode II with the engine speed dial in position 8. The no load enginespeed is 1750 rpm. As the machine begins to operate, the engine speeddecreases to 1500 rpm. To this point, the controller was supplying aconstant electrical signal to the PRV. After the engine speed decreases to1500 rpm, however, the controller begins to increase the signal to the PRVcausing the pumps to destroke and unload the engine. When engine speedincreases above 1500 rpm, the controller again supplies a constantelectrical signal to the PRV.

NOTE: The anti-stall feature functions as described above for eachof the engine speed dial positions and power mode levels exceptPower Mode III and dial position 10.

29

STMG 621 - 46 -8/92

• Power mode setting vshydraulic horsepower

• Power reductioncurves for all threemodes

ENGINE RPM800 1000 1200 1400 1600 1800 2000

HY

DR

AU

LIC

HO

RS

EP

OW

ER

l

ll

lllRATED SPEED

POWER MODEVS.

HYDRAULICHORSEPOWER

1 2 3 4 5 6 7 8 9 10

ENGINEHORSEPOWER

SPEED DIALSETTINGS

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

This graph illustrates the reduction in power capabilities for all threepower 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.

30

STMG 621 - 47 -8/92

• Purpose of AEC:- Reduce fuel

consumption- Reduce noise- Decrease rpm when

demand is low

GOVERNORACTUATOR

ENGINE

SPEED SENSOR

AUTOMATIC ENGINESPEED CONTROL CIRCUIT

(AEC)MONITOR

TRAVELPRESSURE SWITCH

IMPLEMENT/SWINGPRESSURE SWITCH

IIIIII

12

12

AEC SWITCH

ECU

ON

Automatic Engine Control (AEC)

The purpose of the automatic engine speed control that is used on the "E"series excavators and 200 family of excavators is to reduce fuelconsumption and engine/machine noise by automatically reducing enginespeed when no hydraulic power is demanded. The 320/330 AEC hasthese same features, but also slightly decreases engine rpm when thehydraulic power demand is very low. This rpm decrease occurs regardlessof the power mode that has been selected. The three levels of AEC on the320/330 are defined as:

STMG 621 - 48 -8/92

• Three levels of AEC 1. No load: No hydraulic demand (control levers in NEUTRAL orHOLD) for 3 seconds.

2. Light load: Engine speed is 50 rpm or less below the no load settingfor 10 or more seconds while an implement or travel circuit is inoperation.

3. Normal load: Engine speed is 70 rpm or more below the no loadsetting while an implement or travel circuit is in operation.

NOTE: Specific engine speed settings for each condition areprovided in the Serviceman's Handouts in the back of thispresentation.

31

STMG 621 - 49 -8/92

• Switch operates onlywith no demand

• First depressiondecreases rpm

• Second depressionincreases rpm

• Applied load at lowrpm causes increaseto no load setting

• Two depressions afterload removal causesreturn to AEC setting

ECU

ONE-TOUCHLOW IDLE CONTROL CIRCUIT

LOWIDLE

SWITCH

ENGINESPEEDDIAL

TRAVELPRESSURE

SWITCH

IMPLEMENT/SWINGPRESSURE

SWITCH

ENGINE

SPEEDSENSOR

GOVERNORACTUATOR

One-touch Low Idle Control

The final speed variable in the system is the one-touch low idle switchwhich operates only when no demand is placed on the hydraulic system.

The first depression (ON) of the switch decreases the engine rpm from theno load speed setting (either 100 rpm or 1300 rpm below high idle) to asetting of approximately 950 rpm for the 320 Excavator or 850 rpm forthe 330. The second depression (OFF) of the switch returns the enginespeed setting to the previous no load value.

If a hydraulic load is applied while the engine speed setting is at 950 or850 rpm, the setting will increase to the engine speed dial setting.

If the one-touch low idle switch is depressed (ON) within three seconds ofload removal (before the no load speed setting can be obtained) and thendepressed (OFF) again three or more seconds after load removal, theengine speed setting will return to the selected AEC speed setting (either100 rpm below high idle or 1300 rpm).

32

STMG 621 - 50 -8/92

• Normal operation

• Speed dial backupswitch in "AUT"position

• Pump control backupswitch in "AUT"position

• Backup systemscontrolled individually

BACKUP SYSTEM CIRCUITSNORMAL OPERATION

ENGINE SPEED DIALBACKUP SWITCH

24V

GOVERNOR ACTUATORDRIVE CIRCUIT

24V

PUMP CONTROLBACKUP SWITCH

GOVERNORACTUATOR

ENGINE SPEEDCHANGE SWITCHECU

PRVDRIVER

PRV

BACKUPRESISTOR

BACKUPDETECTION

M

PRV

AUT MAN

AUT TOR

RAB TOR

Backup Systems

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

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

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

phuonglh

Sticky Note

Backup Systems

33

STMG 621 - 51 -8/92

• Speed dial backupswitch in "MAN"position

• Governor actuatormotor disconnectedfrom speed dial

• Speed change switchis activated

BACKUP SYSTEM CIRCUITSENGINE SPEED DIAL BACKUP SYSTEM ON


24V


24V


GOVERNORACTUATOR


PRVDRIVER

PRV

BACKUPRESISTOR

BACKUPDETECTION

M

PRV

AUT MAN

AUT TOR

RAB TOR

In this schematic, the engine speed dial backup switch has been moved tothe "MAN" position which disconnects the governor actuator motor fromthe engine speed dial. At the same time, the speed change switch isinserted into the circuit. Moving the speed change switch left or right willsend power to the motor to either increase or decrease engine speed.

NOTE: When only the engine speed dial backup system is ON, theoperator will see an "A" in the three digit display on the monitorpanel. (The "A" means the governor actuator motor circuit is open.)

34

STMG 621 - 52 -8/92

• Pump control backupswitch in "Tortoise"position

• Backup resistorconnected to PRV

• PRV sends constantpower shift pressureto pumps

BACKUP SYSTEM CIRCUITS


24V


24V


GOVERNORACTUATOR


PRVDRIVER

PRV

BACKUPRESISTOR

BACKUPDETECTION

M

PRV

AUT MAN

AUT TOR

RAB TOR

PUMP CONTROL BACKUP SYSTEM ON

In this schematic, the pump control backup switch has been moved to the"Tortoise" position which disconnects the pump control from thecontroller and connects the backup resistor circuit to the PRV. The PRVreceives a constant signal of approximately 0.5 amps and sends a constantpower shift pressure to the hydraulic pumps. At this time, pump output isapproximately that of Power Mode II.

NOTE: When only the pump control backup system is ON, theoperator will see an “H” in the three digit display on the monitorpanel. When both the speed dial and pump control backup systemsare ON, a "U" will be shown in the three digit display.

35

STMG 621 - 53 -8/92

• Two level diagnosticcapability

• Data Mode providesinformation on eightkey systems

• Information displayedin three digit LCD's

PERFORMANCEMONITOR

SERVICEFUNCTIONS

12

12

POWER

IIIIII

WORK


LIGHT WASHERWIPER

ONAEC

SERVICE FUNCTIONS

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

36

STMG 621 - 54 -8/92

• Accessing the DataMode

• Push and hold ALARMCANCEL button untilLED flashes

• Push POWER buttonuntil Power Mode IIILED flashes

• Data Mode isaccessed

• To exit, push ALARMCANCEL button orturn key start switchOFF

PERFORMANCEMONITOR

ACCESSING THEDATA MODE

12

12

POWER

IIIIII

WORK


LIGHT WASHERWIPER

ONAEC

Data Mode

To access and view the first channel of information, the engine can eitherbe running or shut down. If the engine is running, however, somemachine systems can be observed in operation. In this service mode, allof the LCD gauges and warning indicators will continue to functionnormally and all machine functions can be controlled.

First, push and hold the ALARM CANCEL button until its LED begins toflash. Next, while still pushing the ALARM CANCEL button, push thePOWER button until the LED for Power Mode III begins to flash. Do nothold the POWER button too long or another of the eight LED's will flash.If this condition occurs, continue to push the ALARM CANCEL andPOWER buttons simultaneously until the LED for Power Mode III againflashes. The Data Mode has now been accessed and the eight channels ofinformation can be viewed.

To exit this service mode at any time, either push the ALARM CANCELbutton for more than two seconds or turn the key start switch OFF.

37

STMG 621 - 55 -8/92

• Power shift commandsignal

• Indicates level ofsignal sent to PRV

• Display will changeduring operation

• To access additionalchannels, pushALARM CANCEL andPOWER buttonstogether

PERFORMANCEMONITOR

12

12

POWER

IIIIII

WORK


LIGHT WASHERWIPER

ONAEC

POWER SHIFT PRESSURECOMMAND VALUE

The first channel of information that will be accessed in the three digitdisplay of the monitor is "P21." This display is the "Power ShiftCommand" signal and means that the controller is sending a certain levelof the PWM electrical signal to the PRV. "P21" indicates the controllersignal being sent to the PRV causes the PRV to send a power shiftpressure of 21 kg/cm2 [2070 kPa (300 psi)] to the pumps. Whenoperating the machine in Power Mode III and with the engine speed dialat "10," the display will change as the controller varies the power shiftsignal to the pumps.

To access the second and succeeding channels of information, push theALARM CANCEL and POWER buttons simultaneously. Remember,however, do not hold the two buttons down together for too long or thenext channel of information may be missed.

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• Engine rpm display

• Last rpm digit omitted

• Display will change asrpm varies

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ENGINE RPM DISPLAY

To check the engine rpm, push the ALARM CANCEL and POWERbuttons simultaneously until the LED for Power Mode II flashes. Thethree digit display now shows the engine rpm, but the last digit has beenomitted. The display shown in this example is "196" which means thatthe engine speed is 1960 rpm. If the engine speed dial position is changedor if the machine is operated, the change in engine rpm will be shown onthe display.

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STMG 621 - 57 -8/92

• Engine coolanttemperature in °C

• Power Mode I LEDflashes

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ENGINE COOLANTTEMPERATURE

To check the engine coolant temperature, push the ALARM CANCELand POWER buttons simultaneously until the LED for Power Mode Iflashes. The three digit display now shows the engine coolanttemperature in degrees Celsius. The "85" shown on the display meansthat the engine coolant temperature is 85°C.

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STMG 621 - 58 -8/92

• Hydraulic oiltemperature in °C

• Light 1 LED flashes

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ONAECHYDRAULIC OIL

TEMPERATURE

To check the hydraulic oil temperature, push the ALARM CANCEL andPOWER buttons simultaneously until the LED for Light 1 flashes. Thethree digit display now shows the hydraulic oil temperature in degreesCelsius. The "65" shown on the display means that the hydraulic oiltemperature is 65°C.

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STMG 621 - 59 -8/92

• Analog to digitalinformation

• Light 2 LED flashes

• Not usable at this time

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ANALOG / DIGITALINFORMATION

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

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STMG 621 - 60 -8/92

• Real time error codes

• "Rabbit" LED flashes

• List scrolls inascending order

• "E00" reading meansno errors occurring

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ONAECREAL TIME

ERROR CODES

To access the error codes for any current problems, push the ALARMCANCEL and POWER buttons simultaneously until the LED by theTravel Speed--Rabbit symbol flashes. The error codes for any currentproblems will automatically appear sequentially at intervals of twoseconds ON and one half second OFF. The list will scroll in ascendingorder 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 thismode are referred to as “real time” which means that the problemsare being detected by the controller at this time and have not beenstored in the controller. The next diagnostic level, the CalibrationMode, will show how to view stored error codes for intermittentproblems the controller has detected. For a complete listing of theerror codes, check the Testing and Adjusting modules of the 320Service Manual (Form SENR5473) and the 330 Service Manual(Form SENR5496).

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• Digital input tests

• "Tortoise" LEDflashes

• Initial display is "0 3"

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ONAECDIGITAL INPUT TESTS

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

STMG 621 - 62 -8/92

• Ports and components

• To access remainingports, push ALARMCANCEL and WORKMODE buttonstogether

• Travel pressure switchport

• Some ports are spares

• Ports can be turnedON or OFF

The 21 ports and components are:

Port Component Port Component

0 Harness code b PRV backup switch1 Engine speed dial position C 320 with 3066 engine2 Travel pressure switch d Main switch3 Attachment pump pressure E Implement/swing pressure

switch switch4 Engine oil pressure switch F Alternator5 Reserved H Reserved6 Reserved J Reserved7 Reserved L Reserved8 Low idle switch n Reserved9 Boom raise pressure switch P ReservedA Governor actuator backupswitch

To access the remaining 20 "ports" of information push the ALARMCANCEL and WORK MODE buttons simultaneously. The next port willshow "1" and a number (1 through 10) where the "1" indicates the portselected and the number indicates a speed dial position. If the enginespeed dial is moved, the display will change to show the new dialposition. If a malfunction in the engine speed dial is detected, the displaywill show "1Er."

Push the ALARM CANCEL and WORK MODE buttons again and thenext port, Travel Pressure Switch, appears with "2oF" showing in thedisplay. The "2" indicates the port and "oF" indicates that the travelpressure switch is OFF (or open). If either travel control is moved and thetravel 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 thepressure switch has opened.

Again, each succeeding port is accessed by pushing the ALARMCANCEL and WORK MODE buttons simultaneously. Some of the portsare "spares" and are not currently associated with an electroniccomponent. Those ports which have associated components can beturned ON or OFF by actuating the particular circuit or system whichcontains the component (as explained with the travel pressure switch).

NOTE TO THE INSTRUCTOR: For additional information on theport numbers and the electronic component for each port, refer to theTesting and Adjusting modules (Forms SENR5473 and SENR5496) inthe 320 and 330 Service Manuals respectively.

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• Output controldisplays

• "Wiper 1" LED flashes

• Initial display is "L00"

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ONAECOUTPUT CONTROL

DISPLAY

The last channel of information allows access to the output control displaywhich reads a code representing the pump output control at that time.Push the ALARM CANCEL and POWER buttons simultaneously untilthe 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 theTesting and Adjusting modules of the 320 Service Manual (FormSENR5473) and the 330 Service Manual (Form SENR5496).

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STMG 621 - 64 -8/92

• Calibration Mode:- Provides trouble-

shooting information- Used to calibrate

components- Used to perform

tests

• Use service manualfor tests

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CALIBRATIONMODE

Calibration Mode

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

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

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• Accessing theCalibration Mode

• Press hidden SERVICEbutton and startengine

• Hold button untilmaster light turns ON

• Only three digit displayremains on

• Ten channels can beaccessed

PERFORMANCEMONITOR

ACCESSING THECALIBRATION MODE

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To access the Calibration Mode, first shut the machine down. Next, pushthe SERVICE button which is the hidden button at the lower right cornerof the monitor panel. While pressing the SERVICE button, turn the mainkey ON and start the engine. Continue to press the Service button for twoto three seconds until the master light turns ON. All LCD's on themonitor panel will turn off except for the three digit display. TheCalibration Mode has now been accessed.

By selectively moving the LED indicator down the left side of the monitorpanel, plus using the two LED's on the wiper switch, a total of tendifferent channels of information and test programs can be accessed.

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STMG 621 - 66 -8/92

• Harness code

• Push POWER buttonuntil Power Mode IIILED turns ON

• Three digit display willshow machine andengine code

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HARNESS CODE

To initiate the first channel of information, push the POWER MODEbutton until the Power Mode III LED turns ON. The character displaywill 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" ifthe machine is a 330 with a 3306 engine. The "20" or "30" indicates thatthe machine is a 320 or 330 and the "C" or "H" indicates that the machineis equipped with a Caterpillar or Mitsubishi sourced engine.

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• Software code forcontroller

• Push POWER buttonuntil Power Mode IILED turns ON

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SOFTWARE CODES

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

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STMG 621 - 68 -8/92

• Software code formonitor

• Push AEC button

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SOFTWARE CODES

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 AECbutton is pushed, the display will alternate between the two codes. Thesecodes may change if the software is upgraded for the controller or themonitor. The "**" represents a two digit numeral used particular to thesoftware for each machine model. A generic "11P" has been used as anexample.

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STMG 621 - 69 -8/92

• Error code log

• Push POWER buttonuntil Power Mode ILED turns ON

• Display will show"Hd"

• To check list inascending order, pushAEC button

• To check list indescending order,push WASHER button

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ERROR CODES LOG

Push the POWER MODE button again until the LED for Power Mode Iturns ON and the display "Hd" will appear. This display indicates that thelist of stored error codes can be viewed. The controller has a continualself-diagnostic function during the time that the machine is in operation.The controller will store error codes if a fault is detected, evenintermittently. This list is the error history on important systems since thelast time the memory was cleared.

Two ways to check these codes are in ascending order or descendingorder. Each time the AEC button is pushed, the sequentially stored codesare displayed. The "Hd" means that the top of the code list will bedisplayed, and the list will scroll in ascending order from "F1" through"F48." As the numbers are scrolled and a fault code is displayed, thescrolling stops. Push the AEC button again to continue the scrolling.

The list can be checked in descending order by pressing the WASHERbutton. If a fault code is displayed, the descending scroll will stop. Pushthe WASHER button again to continue.

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• To clear codes, pushAEC, POWER, andTRAVEL SPEEDbuttons together

• Display will show "CLr"

After all the codes displayed have been recorded, they can be clearedfrom the controller memory. To clear the codes, simultaneously pushthree buttons: AEC, POWER MODE, and TRAVEL SPEED. Within twoto three seconds, "CLr" will appear in the display indicating the codeshave been cleared.

NOTE TO THE INSTRUCTOR: Error log codes are preceded bythe letter"F" but use the same numbering as the "real time" errorcodes that are accessed in the Data Mode. For a complete listing ofthe error codes, check the Testing and Adjusting modules of the 320Service Manual (Form SENR5473) and the 330 Service Manual(Form SENR5496).

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• Digital output ports

• Push LIGHT buttonuntil Light 1 LED turnsON

• Display will show"0oF"

• Check for electricalconnections

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DIGITAL OUTPUT PORTS

The next test is accessed by pushing the LIGHT button to turn ON theLED for Light 1. The display will show "0oF" which is the first of 16"ports" that permit a check of the electrical connections for variouscontroller output components (similar to the digital input informationaccessed in the Data Mode). However, these ports are for differentcomponents. The ports and their components are:

Port Component Port Component

0 Monitor alarm buzzer 8 Two speed travel solenoid1 Washer relay 9 Fine control solenoid2 Extra relay A Swing priority solenoid3 Extra relay b Travel alarm buzzer4 Extra relay C Extra solenoid5 Wiper relay d Extra solenoid6 Boom light relay E Extra solenoid7 Chassis light relay F PRV solenoid

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• Push AEC button todisplay different ports

• Push ALARM CANCELbutton to turncomponents ON andOFF

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

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STMG 621 - 73 -8/92

• PRV sweep test

• Push LIGHT buttonuntil Light 2 LED turnsON

• Display showspressure sweep from 1to 32

• If pressure does notcycle, check PRV andelectrical connections

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PRV SWEEP TEST

The PRV sweep test is initiated by pressing the LIGHT button to turn ONthe 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 showthe continuous pressure sweep from 1 to 32 and back to 1 kg/cm2

pressure. To convert these metric units to psi, multiply the indicated valueby 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 cycleup and down, indicating that the PRV is cycling. If the pressure does notcycle, check the PRV and the related electrical connections.

NOTE: To obtain the most accurate readings, perform this test withthe engine speed dial at position 10. This test is very similar to Test 1for the "E" series controllers.

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• RPM adjustment

• Push WIPER buttonuntil Wiper 1 LEDturns ON

• Engine rpm displayed

•Push AEC button toincrease rpm

• Push WASHER buttonto decrease rpm

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ENGINE SPEED CHANGE

To access the next test, press the WIPER button until the LED for Wiper 1turns 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 rpmare shown in the three digit display.

Each time the AEC button is pressed, the engine speed will be increasedby 20 to 30 rpm. The AEC LED remains on while the governor actuatoris moving toward high idle. After high idle is reached (at dial position10), the rpm will not increase higher.

Pushing the WASHER button will decrease the engine speed by 20 to 30rpm. The WASHER LED remains on while the governor actuator ismoving toward low idle.

If the AEC and WASHER buttons are pushed simultaneously, the signalsare ignored by the controller.

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STMG 621 - 75 -8/92

• Power shift pressureadjustment

• Push WIPER buttonuntil Wiper 2 LEDturns ON

• Display shows "P21"

• Push ALARM CANCELbutton to alternatebetween pressure andrpm

• Push AEC button toincrease pressure

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POWER SHIFTPRESSURE ADJUSTMENT

The next test permits changes to the factory setting of the power shiftpressure command signal from the controller to the proportional reducingvalve. These changes are sometimes necessary while other tests andadjustments are being performed (such as testing and adjusting the linerelief valves and performing the pump P-Q tests). Access this test bypressing the WIPER button until the LED for Wiper 2 turns ON and "P21"appears in the display.

Each time that the ALARM CANCEL button is pressed, the display willalternate between the power shift pressure command signal and the enginerpm.

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

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• Push WASHER buttonto decrease pressure

Pressing the WASHER button decreases the power shift pressurecommand signal from the controller to the proportional reducing valve.Power shift pressure decreases approximately 95 kPa (14 psi) and thedisplay number decreases by "1" each time that the AEC button is pushed.When the display reads "P3," the power shift pressure will not decreaselower.

NOTE: This procedure is for power shift pressure adjustment and isnot a calibration procedure. If a 5500 kPa (800 psi) pressure gauge isconnected to the power shift pressure test port on the hydraulicpumps, the change in power shift pressure can be observed as theAEC or WASHER buttons are pushed.

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STMG 621 - 77 -8/92

• Engine speed dialposition

• Push TRAVEL SPEED button until "Rabbit"LED turns ON

• Set speed dial atdesired position

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ENGINE SPEED DIALCHECK

This test channel shows the engine speed dial position in the three digitdisplay (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 dialposition to verify that the rpm is within the factory specifications for thatparticular dial setting.

Push the TRAVEL SPEED button until the "Rabbit" LED is ON to startthis mode. Set the speed dial at the desired position. The characterdisplay shows the actual rpm at the present time. This value must bemultiplied by 10 to read actual rpm.

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STMG 621 - 78 -8/92

• Governor actuatorcalibration

• Engine running

• Push TRAVEL SPEEDbutton until "Rabbit"LED is ON

• Display flashes "AC"

• Push AEC, WASHER,and ALARM CANCELbuttons at same time

• "ACP" indicatescalibration started

• "ACt" indicates initialmovement completed

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GOVERNOR ACTUATORAUTOMATIC CALIBRATION

Calibration of the governor actuator is accomplished in this test. This testshould be performed any time that the controller or governor actuatormotor has been replaced. The engine must be running to perform thiscalibration.

To enter this mode, push the TRAVEL SPEED button until the "Rabbit"LED is ON. Then, push the AEC and WASHER buttons simultaneouslyuntil the letters "AC" are flashing in the three digit display.

Next, while still holding down the AEC and WASHER switches, alsopush the ALARM CANCEL button. The "AC" display will stop flashingand then change to "ACP." This code indicates that the automaticcalibration mode has started and the governor actuator motor has movedto an initial position. When this movement is completed, the display willread "ACt."

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• Push AEC andWASHER buttons

• Display shows "AC1"

• When "AC0" appears,procedure is complete

• If data is not correct,procedure will restartone time

When "ACt" appears in the display, the calibration procedure can becompleted. Push the AEC and WASHER buttons simultaneously. The"ACt" code will change to "AC1" which indicates that the calibration iscontinuing. Approximately two minutes are required for the calibration tofinish. During this time, the codes "AC2" through "AC0" will appear inthe display. When "AC0" appears, the calibration has been successfullycompleted.

If the calibration data sent to the controller is not correct and within limitsby the time "AC6" appears in the display, the controller will restart thecalibration procedure one time. If the data is not correct or within limitsthe second time, the display will alternately show "ACE" and "-**." The"-**" is an error code that has a defined problem. Consult the latestversion of the Testing and Adjusting modules in the 320 and 330 ServiceManuals for a complete description of the error codes and problems.

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• PRV calibration

• Perform procedureafter PRV or controlleris replaced

• Two calibration points

• Install pressure gauge

• Pump control backupswitch in "AUT"position

• Start engine, speeddial at position 10

• Push TRAVEL SPEEDbutton until "Tortoise"LED turns ON

•Display shows "1 0"

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POWER SHIFTPRESSURE CALIBRATION

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

First, install a 4000 kPa (600 psi) pressure gauge on the power shiftpressure test port at the pump. Next, make sure that the pump controlbackup switch is in the "AUT" position. Finally, start the engine and besure 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" indicatesthat the first calibration point has been accessed and the "0" indicates thatthe center step of 19 calibration steps has been accessed. Each step willchange the power shift pressure by approximately 50 kPa (7 psi).

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• Push AEC button toincrease pressure

• Push WASHER buttonto decrease pressure

• Push WASHER buttonto decrease pressurebelow 72 psi

• Push AEC button toset pressure at 72 psi

• Push ALARM CANCELbutton to store data

• Display will show "2 0"

Increasing power shift pressure

With the display showing "1 0," push the AEC button once to increase thepower shift pressure. The pressure reading on the gauge should increaseand the display should change to "1 1." Push the AEC button a secondtime and the power shift pressure will again increase and the display willread "1 2." The AEC button can be pushed seven additional times. Eachpush of the button will change the power shift pressure until the displayreads "1 9." Any additional pushes of the AEC switch will not increasethe power shift pressure.

Decreasing power shift pressure

With the display showing "1 0," push the WASHER button once todecrease the power shift pressure. The pressure reading on the gaugeshould decrease and the display should change to "1-1." Push theWASHER button a second time and the power shift pressure will againdecrease and the display will read "1-2." The AEC button can be pushedseven additional times. Each push of the button will change the powershift pressure and until the display reads "1-9." Any additional pushes ofthe WASHER button will not decrease the power shift pressure.

Setting Calibration Point 1

Push the WASHER button to decrease the power shift pressure until thepressure setting is less than 490 kPa (72 psi). Then, push the AEC buttonuntil the pressure gauge reading increases to approximately 490 kPa (72 psi). (An exact reading may be difficult to obtain, but adjust thepressure 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 willchange to show "2 0" which indicates that the first calibration point hasbeen accepted and the calibration procedure for the second point can beperformed.

As with the first calibration point, the "2" indicates that the secondcalibration point has been accessed and the "0" indicates that the centerstep of 19 calibration steps has been accessed. Again, each step willchange the power shift pressure by approximately 50 kPa (7 psi).

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• Push AEC button toincrease pressure to355 psi

• Push ALARM CANCELbutton to store data

• Display will show "1 0"

Setting Calibration Point 2

Push the AEC button to increase the power shift pressure toapproximately 2450 kPa (355 psi). (As with the first point, an exactreading may be difficult to obtain, but adjust the pressure as closely aspossible.) After the correct reading has been set, push the ALARMCANCEL button to store the data in the controller. When the data hasbeen accepted by the controller, the display will change to show "1 0"which indicates that the second calibration point has been accepted andthe controller has reset to the first calibration point.

NOTE: Activation of this calibration mode overrides the function ofAEC system. If the engine speed is not within 1980 ± 50 rpm for the320, and 1950 ± 50 rpm for the 330, the three digit display will show"E." The engine speed must be corrected within specifications toeliminate the "E" from the display before continuing with thisprocedure. Additionally, pressure adjustments must always be madeas the pressure is being increased.

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• Presentationsummary

• ECU matches enginehorsepower withhydraulic horsepower

• Input components

• Controller

• Output components

• Three power modes

58

CONCLUSION

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 inPower Mode III and with the engine speed dial at position 10. Thecontroller receives input signals from several components which include:the engine speed dial, the power mode selector, the AEC button, the AECpressure switch, and the engine speed pickup. The controller analyzes theinput signals and, during specific conditions, sends output signals toseveral components which include: the AEC relay/motor, the proportionalreducing valve, and the monitoring system.

When the controller is active, three power modes can be selected. PowerMode I utilizes approximately 65% of the available engine horsepowerand is used for light duty work. Power Mode II utilizes approximately85% of the available engine horsepower and is used for ordinary work.Power Mode III utilizes approximately 100% of the available enginehorsepower.

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• Two backup systems The machine is also equipped with two backup systems. The pumpcontrol backup system can be activated to bypass the pump controls if thecontroller malfunctions. When this system is activated, the pumpsoperate at approximately Power Mode II. The engine speed backupsystem can be activated when a speed dial malfunction occurs. The AECwill not function when this backup system is activated

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SLIDE LIST

1. Model view2. Controller location3. Controller LED's4. Monitor location5. Backup switches location6. Monitor panel7. Fault symbols8. Start switch, engine speed dial, and ether

aid switch9. Pulse width modulated signals

10. Controller changes11. Controller changes (cont.)12. Monitor features13. Controller inputs14. Controller outputs15. Power Mode selection16. 320 P-Q Curves (2 pumps loaded equally

with 3116 engine)17. 320 P-Q Curves (2 pumps loaded equally

with 3066 engine)18. 330 P-Q Curves (2 pumps loaded equally

with 3306 engine)19. 320 P-Q Curves (1 pump loaded with 3116

engine)20. 320 P-Q Curves (1 pump loaded with 3066

engine)21. 330 P-Q Curves (1 pump loaded with 3306

engine)22. Pump regulation23. Engine speed dial limits24. Controller compartment25. 320 System behavior chart26. 330 System behavior chart

27. Power modes vs. hydraulic torque28. Anti-stall function29. Power modes vs. hydraulic horsepower30. Automatic Engine Control (AEC)31. One-touch low idle control32. Backup switches (normal operation)33. Engine speed dial backup switch "On"34. Pump control backup switch "On"35. Service Functions36. Accessing Data Mode37. Power shift command signal38. Engine rpm39. Engine coolant temperature40. Hydraulic oil temperature41. Analog to digital codes42. Error codes (real time)43. Digital input to the controller44. Pump output control45. Calibration Mode46. Accessing Calibration Mode47. Machine configuration codes48. Controller software code49. Monitor software code50. Error codes (stored)51. Component checks52. PRV sweep test53. Engine speed change adjustment54. Power shift pressure adjustment55. Engine speed dial setting check56. Governor actuator calibration57. PRV pressure calibration58. Controller compartment

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INSTRUCTOR NOTES

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AUTOMATIC ENGINE SPEED CONTROL CIRCUIT(AEC)

1. NO LOAD SETTINGS WITH AEC "ON"

Dial Position Engine rpm Setting Change

10 From 2160 to 1300 9 From 2000 to 1300 8 From 1850 to 1300 7 From 1700 to 1300 6 From 1550 to 1300 5 From 1400 to 1300 4 No change 3 No change 2 No change 1 No change

2. NO LOAD SETTINGS WITH AEC "OFF"



Serviceman's Handout No. 1

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3. LIGHT LOAD APPLICATION--AEC "ON" OR "OFF"



AUTOMATIC ENGINE SPEED CONTROL CIRCUIT(AEC)

4. LIGHT LOAD TO HEAVY LOAD--AEC "ON" OR "OFF"




STMG 621 - 89 -8/92

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STMG 621 - 90 -8/92

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STMG 621 - 91 -8/92

INSTRUCTOR NOTES

STMG 621 - 92 -8/92

INSTRUCTOR NOTES

STMG 621 - 93 -8/92

INSTRUCTOR NOTES

SESV1621 Printed in U.S.A.8/92

lhph 320 330 electronic control unit

Documents