350-375 Monitor

Service Training
MALAGA
350/375/5080 Hydraulic Excavators
ELECTRONIC CONTROL SYSTEM
Francis
NOV 97
350/375/5080
Hydraulic Excavators
CHAPTER : Electronic Control System
CONTROLLER
LED's
Relay Box
Page: 2
350/375/5080
OPERATOR'S CONSOLE
1. Monitor Panel
2. Engine Speed Dial
Page: 3
350/375/5080
BACKUP SYSTEMS
Engine Speed Control
ENGINE SPEED CONTROL
AUT MAN
Pump Control
PUMP CONTROL
AUT
Page: 4
350/375/5080
350/375 HYDRAULIC EXCAVATOR MONITOR
POWER TRAVEL SPEED AEC
LIGHT WIPER WASHER

1 1
2 2
ALARM CANCEL TEST SERVICE
Page: 5
350/375/5080
MONITOR PANEL
(Upper Section)
Page: 6
350/375/5080
MONITOR FEATURES
THE MONITOR. . .
• Communicates with the controller
• Has LCD displays in place of gauges
• Has push buttons that control many machine

functions and access diagnostic procedures
• Has a three digit character readout that...
- shows engine speed dial position

- displays fault codes for controller/monitor
problems
- indicates when either or both backup
systems are activated
Page: 7
350/375/5080
PULSE WIDTH MODULATED (PWM) SIGNALS
VOLTAGE
LEVEL
MEAN VOLTAGE
VOLTAGE VOLTAGE
ON OFF
ONE
CYCLE
VOLTAGE
LEVEL
MEAN VOLTAGE
VOLTAGE
ON VOLTAGE
OFF
ONE
CYCLE
DIFFERENT FREQUENCY
VOLTAGE
LEVEL MEAN
VOLTAGE
VOLTAGE
ON VOLTAGE
OFF
ONE
CYCLE
VOLTAGE
LEVEL
MEAN
VOLTAGE
VOLTAGE
ON
VOLTAGE
OFF
ONE
CYCLE
Page: 8
350/375/5080
INPUTS TO CONTROLLER
18 16 14 12
11
17 15 13
CONTROLLER
19
5
2
3 4 10
1 9
7 8
PUMP
1. Monitor
2. Eng Speed Dial 8. Speed Sensor
3. Low Idle Switch 9. Engine 15. Swing Press. Switch
4. Alternator 10. Start Switch 16. Eng. Coolant
5. Harness Code 11. Attch Press Switch Temp. Sensor
6. Battery 12. Eng. Press. Swich 17. Hyd. Oil Temp. Sensor
7. Gov. Actuat. 13. Travel Press. Switch 18. Fuel Level Sensor
Feedback Sensor 14. Impl. Press. Switch 19. Fuse Box
Page: 9
350/375/5080
OUTPUTS FROM CONTROLLER
4 5
3 6 7
2
CONTROLLER
13 8
11
10
9
PUMP
18 17 16
15 14 12
1. Monitor
2. Travel Alarm 7. Bypass Sld 12. Proport Red. Valve
3. Fault Alarm 8. Spd Chg Sw 13. Relay Box
4. Two Speed 9. Gov Act Motor 14. Washer
Travel Sld 10. Spd Dial 15. Wiper
5. Swing Pump Backup Sw 16. Boom Light
Power Sld 11. Pwshf Press 17. Boom Light
6. Bypass Sld Backup Sw 18. Chassis Light
Page: 10
350/375/5080
POWER MODE SELECTION
LIGHT WIPER WASHER

1 1
2 2
ALARM CANCEL TEST SERVICE
Page: 11
PUMP CONTROLS
POWER MODE SELECTION
1
2
9 b
8
3
PUMP
c
4

ECU
7
350/375/5080
6
a
1. Monitor
2. Eng. Speed Dial
3. Travel Press Switch
4. Impl Press Switch
5. Swing Press Switch
Page:
6. Attch Press Switch

7. Propor Reduc Valve a. PS Press From PRV
8. Engine b. Swing Pump Output
9. Speed Sensor c. Power Shift Press Signal
12
350/375/5080
SPEED DIAL LIMITS
POWER
lll
ll 8
l
III
II
I
7
1 1
2 2
PUMP
1
ECU 6 5
(CONTROLLER)
2
4
3
Dial RPM
Position
350 375
1 800 700
2 950 850
3 1110 1000
4 1260 1150 1. Monitor
2. Eng Speed Dial
5 1410 1300 3. Proport Reduc Valve
6 1570 1450 4. Gov Actuator
7 1720 1600 5. Engine
8 1870 1750 6. Feedback Sensor
9 2030 1860 7. Speed Sensor
8. Power Mode Switch
10 2200 1960
Page: 13
350/375/5080
AUTOMATIC ENGINE SPEED CONTROL (AEC)
1
ON
2
III
8
II
I
1 1
2 2
3 9
10
4 ECU
7
5
6
1. Monitor
2. AEC Switch
7. Gov Actuator
8. Engine
9. Speed Sensor
10. Feedback Sensor
Page: 14
350/375/5080
ONE-TOUCH LOW IDLE CONTROL CIRCUIT
1
8
9
3
ECU
10
4
7
1. Low Idle Switch

6 2. Engine Speed Switch
7. Gov Actuator
8. Engine
9. Speed Sensor
10. Feedback Sensor
Page: 15
350/375/5080
BACKUP SYSTEM CIRCUITS
(Normal Operation)
1
9
AUT MAN
RAB TOR
8
24V
7
PRV
ECU
24V AUT TOR
PRV
DRIVER
PRV 6
1. Governor Act
Drive Circuit 5
2. Backup Signal
3. Backup Detection 3
4. Backup Resistor 4
5. Pump Control
Backup Switch
6. PRV
7. Engine Speed
Change Switch
8. Governor Actuator
9. Eng Speed Dial
Backup Switch
Page: 16
350/375/5080
(Engine Speed Dial Backup System "ON")
1
9
AUT MAN
8
RAB TOR 24V
7
PRV
ECU
24V AUT TOR
PRV
DRIVER
PRV 6
1. Governor Act
Drive Circuit 5
2. Backup Signal
3. Backup Detection
3
4. Backup Resistor 4
5. Pump Control
Backup Switch
6. PRV
7. Engine Speed
Change Switch
9. Eng Speed Dial
Backup Switch
Page: 17
350/375/5080

(Pump Control Backup System 'ON")
1
9
AUT MAN
8
RAB TOR 24V
7
ECU
24V AUT TOR
PRV
DRIVER
PRV
6
5
1. Governor Act 3
Drive Circuit 4
2. Backup Signal
3. Backup Detection
4. Backup Resistor
5. Pump Control
Backup Switch
6. PRV
7. Engine Speed
Change Switch
9. Eng Speed Dial
Backup Switch
Page: 18
350/375/5080
PERFORMANCE MONITOR
Page: 19
350/375/5080
SERVICE FUNCTIONS
LIGHT WIPER WASHER
1 1
2 2
ALARM CANCEL
DATA MODE
INFORMATION PROVIDED
1. Power Shift Pressure 5. Analog / Digital Conversion
2. Engine Speed 6. Real Time Error
3. Engine Coolant Temperature 7. Digital input
4. Hydraulic Oil Temperature 8. Pump Output Control
Page: 20
350/375/5080
CALIBRATION MODE
LIGHT WIPER WASHER
1 1
2 2
ALARM CANCEL
CALIBRATION MODE
INFORMATION PROVIDED
1. Machine Model and Configuration 6. Engine Speed Change
2. Controller / Monitor Software Version 7. Fixed Power shift Pressure Setting
3. Error Log 8. Engine RPM Display
4. Digital Output Test 9. Automatic Governor Actuator Calibration
5. PRV Sweep Test 10. PRV Calibration
Page: 21
350/375/5080
DATA MODE
(Condensed Supplement)

A
A A
B 1 B
2 3
C
LIGHT WIPER WASHER
A 1 A 1 A
B 2
4 B 2
5 6
LIGHT WIPER WASHER
1 1
2 2 ALARM CANCEL
ALARM CANCEL
A
7 8 9
START : Turn engine start-key on.

Press button "7" until the corresponding LED "A" starts to blink.
Maintain "7" pressed and press button "1" until "P14" (375) is displayed.
To read each function below press buttons "7" & "1" once.
LED "ON"
FUNCTION READING
(See fig)
Power Shift Pressure 1A P 14
Engine RPM :
Engine Off 1B 0
Engine Running 1B Multiply reading by 10
Eng. Coolant temp. 1C Centigrade
Hydraulic oil temp. 4A Centigrade
4B Not needed
Real Time Error If a number appears,

2A
check the error code list
Digital Input 2B See reverse
Output Ctrl Display 5A L O O = Output Normal
Page: 22
350/375/5080
DATA MODE
(Condensed Supplement Cont.)

A
A A
B 1 B
2 3
C
LIGHT WIPER WASHER
A 1 A 1 A
B 2
4 B 2
5 6
LIGHT WIPER WASHER
1 1
2 2 ALARM CANCEL
ALARM CANCEL
A
7 8 9
LED "2 B" blinking

To change readings from "0" to "p", press buttons "7" & "8" once.
DIGITAL INPUT TESTS
Port Component Indication

0 Harness code 010 (350) 012 (375)
1 Engine Speed Dial position 1 to 10
2 Travel pressure switch ON / OFF
3 Attach. pump pressure switch (Optional) OFF
4 Engine oil pressure switch ON / OFF
5 Open OFF
6 Open OFF
7 Open OFF
8 Low idle switch ON / OFF
9 Implement pressure switch ON / OFF
A Engine RPM back-up switch ON / OFF
B PRV Back-up switch ON / OFF
C Open OFF
D Engine start key Switch ON
E Swing pressure switch ON / OFF
F Alternator condition (Eng. running) ON
H Open OFF
J Open OFF
L Open OFF
n Open OFF
p Open OFF
Page: 23
350/375/5080
CALIBRATION MODE
(Condensed Supplement)
START : With the engine start-key in the off position, press "9" on panel.
Maintain "9" pressed and turn start-key to on position. Continue pressing
"9" till "45b" (350) "75b" (375) displayed, then start the engine.

A
A A
B 1 B
2 3
C
LIGHT WIPER WASHER
A
A 1 4
A 1 6
5
LIGHT WIPER WASHER
B 2 B 2
1 1
2 2 ALARM CANCEL
ALARM CANCEL
A
7 8 9
FUNCTION PREESS LED READING

BUTTON "ON"
Machine model 9 1A 75 (375) = 75 Tons. b = Backhoe Config.
00C (for examp) C = Contr. P = Monit.
Computer software 1 1B
Press button "3" to change "C" and "P"
Error Log 1 1C Hd is displayed,
( F01 - F48. Check Press button "3" for ascending order,
Error code list ) "6" for descending order. End at the
end. To clear press "3", "1" and "2"
simultaneously until CLr is diplayed.
Digital output Test 4 4A OoF is displayed,

press button "3" for ascending order,
"6" for descending order. Press "7"
to check "O n / o F"
Proportional Reducing 4 4B Pressure changes from 0 to 32 Bar

Valve "Sweep Test" (in 5 sec.) and back.
Engine Speed Change 5 5A Press button "3" to increase RPM and

(change for test "6" to decrease.
purposes) (Indication X 10 = RPM)
Fixed Power shift 5 5B P25 (for exemple) is displayed, press
pressure button "3" to increse the pressure, "6"
(change for test to decrease. Each touch changes 1 Bar.
purposes) Press "7" to change from power shift
pressure to RPM and back
Page: 24
350/375/5080
CALIBRATION MODE
(Condensed Supplement Cont.)

A A
A
B 1 B
2 3
C
LIGHT WIPER WASHER
A
A 1 A 1 6
4 5
LIGHT WIPER WASHER
B 2 B 2
1 1
2 2 ALARM CANCEL
ALARM CANCEL
A
7 8 9
PRESS LED
FUNCTION "ON" READING
BUTTON
Engine Speed Dial 2 2A Character displays the engine rpm
Setting Check value characteristic to the setting of
the engine speed dial switch position
Governor calibration 2A Press and hold "3" and "6". AC flashing

(Move throttle control appears. While depressing "3" and "6"
to 10) press "7" until display changes to ACP.
Release all buttons then ACt will
appear. Press "3" and "6" once more to
start the Auto. Calibration Program
(display will change from AC1 to AC0)
If Problem : check Auto. Calibration
Error Table.
Power shift calibration 2 2B "E" Displayed - Move throttle control

to 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 settings
in memory. Each time "7" is pressed, the
display changes from first to second
calibration.
NOTA : To end, press button "9" till monitor changes to normal or : Turn-off engine
start-key.
Page: 25
350/375/5080
REAL TIME ERROR CODES
* CODE No DESCRIPTION OF PROBLEMS
E00 No problem.
E01 Engine oil pressure: Low.
E02 Engine coolant temperature: High.
E03 Hydraulic oil temperature: High.
E04 Battery voltage: (Over 43 V).
E05 Alternator terminal "R": open.
E06 Engine speed sensor malfunction (no or low signal).
E07 Engine speed is not normal.
E09 Voltage of governor actuator feedback sensor: Low.
E10 Cir. of gover. actuat. feedback sensor: Shorted/open to batt.volt.
E11 Cir. of gover. actuat. feedback sensor: Shorted to body gnd.
E12 Voltage of governor actuator feedback sensor: Not stable.
E13 Circuit of governor actuator motor: Shorted to body ground.
E14 Gover. actuat. mtr does not rotate or mtr crct.: Shorted to gnd.
E15 Spd dial backup sw is "on" or gover. actuat. mtr. crct.: Open.
E16 Proportional Reduction Valve (PRV) crct.: Shorted to body gnd.
E17 PRV circuit: Shorted to battery voltage.
E18 PRV circuit: Open.
E19 Attach. Puls With Modulation (PWM) output: Gnd shorted.
E20 Attach. PWM output: + B shorted.
E21 Attach. PWM output: Open.
E25 Crct. of eng. coolant temperature sensor: Shorted to body gnd.
E26 Crct. of eng. coolant temp. sensor: Shorted to batt. vol. or open.
E27 Crct. of hydraulic oil temp. sensor: Shorted to body gnd.
E28 Crct. of hydraulic oil temp. sensor: Shoted to batt. volt or open.
E29 Attach. PWM Input: Shorted to gnd.
E30 Attach. PWM input: + B shorted or open.
E31 Throttle dial and eng. rpm signals to controller: Mismatched
E32 Dial set. and act. eng. rpm: More than 100 rpm diff.
E33 Digital output circuit: Shorted to batt. voltage.
E34 Gover. actuat.: No movement for 2.5 sec. after spd dial setting.
E36 Monitor takes at least 1 sec. to respond to controller 's signal.
E37 Monitor RAM (Random Access Memory): Not normal.
E38 Controller feels error signal from monitor.
E39 Monitor feels error from controller.
E40 Controller memory: Error
E41 Controller program indicates not-existing machine model.
E48 Engine Stalls.
NOTE : E 33 Shows whenever a short occurs on the two-speed solenoid.
* E: In Data Mode
F: In Calibration Mode
Page: 26
350/375/5080
DIGITAL OUTPUT TEST

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

Error
Description of problem
Code
- 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 Voltage of G / A feedback sensor is to low. - Same as RTE : E09.
- 6 Circuit of G / A feedback sensor is shorted to batt.volt. or open. - Same as RTE : E10.
- 7 Circuit of G / A feedback sensor is shorted to body ground. - Same as RTE : E11.
- 8 Voltage 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 open. - Same as RTE E06.
- 13 Pressure switch for implement / swing or travel is "ON." Any of controls are in act. pos.
- 14 Controller 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)
Page: 27

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Service Training

ELECTRONIC CONTROL SYSTEM

Engine Speed Control

ENGINE SPEED CONTROL

350/375 HYDRAULIC EXCAVATOR MONITOR

POWER TRAVEL SPEED AEC

LIGHT WIPER WASHER

• Communicates with the controller

• Has LCD displays in place of gauges

• Has push buttons that control many machine

• Has a three digit character readout that...

- shows engine speed dial position

PULSE WIDTH MODULATED (PWM) SIGNALS

OUTPUTS FROM CONTROLLER

POWER MODE SELECTION

POWER TRAVEL SPEED AEC

LIGHT WIPER WASHER

CHAPTER : Electronic Control System

6. Attch Press Switch

SPEED DIAL LIMITS

AUTOMATIC ENGINE SPEED CONTROL (AEC)

ONE-TOUCH LOW IDLE CONTROL CIRCUIT

1. Low Idle Switch

BACKUP SYSTEM CIRCUITS

BACKUP SYSTEM CIRCUITS

(Engine Speed Dial Backup System "ON")

BACKUP SYSTEM CIRCUITS

POWER TRAVEL SPEED AEC

LIGHT WIPER WASHER

1. Power Shift Pressure 5. Analog / Digital Conversion

2. Engine Speed 6. Real Time Error

3. Engine Coolant Temperature 7. Digital input

4. Hydraulic Oil Temperature 8. Pump Output Control

POWER TRAVEL SPEED AEC

LIGHT WIPER WASHER

1. Machine Model and Configuration 6. Engine Speed Change

2. Controller / Monitor Software Version 7. Fixed Power shift Pressure Setting

3. Error Log 8. Engine RPM Display

4. Digital Output Test 9. Automatic Governor Actuator Calibration

5. PRV Sweep Test 10. PRV Calibration

POWER TRAVEL SPEED AEC

START : Turn engine start-key on.

Power Shift Pressure 1A P 14

Engine Running 1B Multiply reading by 10

Eng. Coolant temp. 1C Centigrade

Hydraulic oil temp. 4A Centigrade

Real Time Error If a number appears,

Digital Input 2B See reverse

Output Ctrl Display 5A L O O = Output Normal

POWER TRAVEL SPEED AEC

LED "2 B" blinking

DIGITAL INPUT TESTS

Port Component Indication

POWER TRAVEL SPEED AEC

FUNCTION PREESS LED READING

Digital output Test 4 4A OoF is displayed,

Proportional Reducing 4 4B Pressure changes from 0 to 32 Bar

Engine Speed Change 5 5A Press button "3" to increase RPM and

POWER TRAVEL SPEED AEC

Governor calibration 2A Press and hold "3" and "6". AC flashing

Power shift calibration 2 2B "E" Displayed - Move throttle control

Press "3" to increase and "6" to decrease.

REAL TIME ERROR CODES