Cat 312C 315C 320C 322C 325C & 330C Hex Technician Skill Training Systems Operation Manual

HEX TECHNICIAN SKILL TRAINING

312C, 315C, 320C, 322C, 325C and 330C Excavators Engine and Pump Control

Asia Pacific Learning (China)

300C Engine and Pump Control S&O

Contents System operation Section Electrical System General information (Electrical System) Power Circuit Start And Stop Circuit Charging Circuit Low Current Circuit Electronic Control System General Information (Eletronic Control System) Engine And Pump Regulation Pump Regulation Constant Control of Horsepower Control Of An Underspeed Condition Engine Speed Control Automatic Engine Control First Setting Of The AEC Second Setting Of The AEC One Touch Low Idel Start-up Of The One-touch Low Idle Release Of The One-touch Low Idle Tool Control Selection Of A Tool Engine Speed Control Main Pump Flow Control Main Pump Control During Use Of The Attachment Pump Straight Travel Control Engine Speed Protection Memory Function Prevention Of Overspeed During Low Engine Oil Pressure Prevention Of Overspeed During Overheating Condition Control Of The Hydraulic Oil At Low Temperatures Swing Lock System Backup System Engine Speed Control Pump Control Swing Parking Brake Page 2 of 59

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Monitoring System Warning Operation Machine Information Working Hour Tools Travel Alarm Engine And Hydraulic Pump Controller Input/Output Input Output Operator Monitor Switches Engine Speed Dial Switch One Touch Low Idle Switch Pressure Switch Engine Oil Pressure Switch Key Start Switch Air Filter Switch Hydraulic Oil Filter Switch Engine Coolant Level Switch Hydraulic Level Switch and Engine Oil Level Switch Water Separator Level Switch ( 320C Series and 322C Series) Switch Panel Assembly Pressure Switch Sensors Engine Speed Sensor Feedback Sensor Pressure Sensor Senders Fuel Level Sender Temperature Sender Solenoid Valves Proportional Reducing Solenoid Valve (Power Shift) Solenoid Valve Pressure Solenoid For Power Shift Travel Speed Solenoid and Swing Parking Brake Solenoid Valve Straight Travel Solenoid Governor Actuator Control Related Components Alternator Data Link Action Lamp Action Alarm Travel Alarm Input for Air Heater Indicator

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General Information (Electrical System) SMCS Code: 1406; 1450

Illustration 1

Schematic Of The Electrical Circuit For The 312C And The 315C (1) Disconnect switch (2) Battery (3) Power circuit (4) Breaker for the alternator (5) Main relay (6) Fuse panel (7) Low current circuit (9) Cigar lighter (10) Starter control relay (11) Starter switch (12) Neutral start switch (13) Cab heater (14) Air conditioner (15) Lights (16) Windshield wiper (17) Windshield washer (18) Start/stop circuit (19) Starter motor (20) Starter relay (21) Alternator (22) Horn (23) Controller (24) Switch panel (25) Governor actuator (26) Heater control unit (27) Air heater (28) Charging circuit (29) Timer relay (30) Neutral start relay (31) Heater relay

Illustration 2

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Schematic Of The Electrical Circuit For The 320C Series (1) Disconnect switch (2) Battery (3) Power circuit (4) Breaker for the alternator (5) Main relay (6) Fuse panel (7) Low current circuit (9) Cigar lighter (10) Starter control relay (11) Starter switch (12) Neutral start switch (13) Cab heater (14) Air conditioner (15) Lights (16) Windshield wiper (17) Windshield washer (18) Start/stop circuit (19) Starter motor (20) Starter relay (21) Alternator (22) Horn (23) Controller (24) Switch panel(25) Engine shutdown timer (26) Heater control unit (27) Air heater (28) harging circuit (29) Timer relay (30) Neutral start relay (31) Heater relay (32) Engine shutdown solenoid

Illustration 3

Schematic Of The Electrical Circuit For The 322C (1) Disconnect switch (2) Battery (3) Power circuit (4) Breaker for the alternator (5) Main relay (6) Fuse panel (7) Low current circuit (9) Cigar lighter (10) Starter control relay (11) Starter switch (12) Neutral start switch (13) Cab heater (14) Air conditioner (15) Lights (16) Windshield wiper (17) Windshield washer (18) Start/stop circuit (19) Starter motor (20) Starter relay (21) Alternator (22) Horn (23) Controller (24) Switch panel (25) Engine coolant temperature switch (26) Start aid solenoid (27) Start aid switch (28) Charging circuit (29) Timer relay (30) Neutral start relay (31) Governor actuator (32) Heater control unit (36) Heater relay (37) Air heater

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Illustration 4

Schematic Of The Electrical Circuit For The 325C (1) Disconnect switch (2) Battery (3) Alternator Circuit Breaker (4) Power Circuit (5) Main relay (6) Fuse panel (7) Low current circuit (8) Switch Panel (9) Radio (10) Wiper (11) Washer (12) Light (13) Cigar Lighter (14) Cab Heater (15) Air Conditioner (16) Controller (17) Horn (18) Timer Relay (19) Starter Switch (20) Neutral Start Relay (21) Starter Relay (22) Starter Motor (23) Neutral Start Switch (24) Start/stop Circuit (25) Engine Controller (26) Heater Relay (27) Air heater (28) Fuel Pump Relay (29) Fuel Pump (30) Charge Circuit (31) Alternator

Illustration 5

Schematic Of The Electrical Circuit For The 330C (1) Disconnect switch (2) Battery (3) Alternator Circuit Breaker (4) Power Circuit (5) Main relay (6) Fuse panel (7) Low current circuit (8) Switch Panel (9) Radio (10) Page 6 of 59

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Wiper (11) Washer (12) Light (13) Cigar Lighter (14) Cab Heater (15) Air Conditioner (16) Controller (17) Horn (18) Timer Relay (19) Starter Switch (20) Neutral Start Relay (21) Starter Relay (22) Starter Motor (23) Neutral Start Switch (24) Start/stop Circuit (25) Engine Controller (26) Heater Relay (27) Air heater (28) Fuel Pump Relay (29) Fuel Pump (30) Charge Circuit (31) Alternator (32) Emergency Stop Switch The electrical system consists of the following circuits: · Power circuit · Stop/start circuit · Charging circuit · Low current circuit

Power Circuit SMCS Code: 1401; 1408 The power circuit supplies electrical power to the electrical components of the machine. The components that are included are listed: the battery, the disconnect switch, breaker for the alternator and main relay.

Illustration 6

Schematic Of The Power Circuit For The 312C And 315C (1) Batteries (2) Circuit breaker for alternator (3) Alternator (4) Fuse panel (5) Timer relay (6) Start switch (7) Fuse panel (8) Main relay

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Illustration 7

Schematic Of The Power Circuit For The 320C Series (1) Batteries (2) Circuit breaker for alternator (3) Alternator (4) Fuse panel (5) Timer relay (6) Start switch (7) Fuse panel (8) Main relay

Illustration 8

Schematic Of The Power Circuit For The 322C (1) Batteries (2) Circuit breaker for alternator (3) Alternator (4) Fuse panel (5) Timer relay (6) Start switch (7) Fuse panel (8) Main relay

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Illustration 9

Schematic Of The Power Circuit For The 325C And 330C (2) Batteries (3) Circuit breaker for alternator (5) Main Relay (19) Starter Switch (31) Alternator (32) Fuse (33) Fuse

Start and Stop Circuit SMCS Code: 1450

Illustration 10

Schematic Of The Start/Stop Circuit For The 315C

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(1) Batteries (2) Alternator (3) Starter relay (4) Starter control relay (5) Engine shutdown solenoid (6) Timer relay (7) Starter switch (8) Neutral start relay (9) Neutral start switch (10) Starter solenoid (11) Starter motor (12) Engine shutdown timer

Illustration 11

Schematic Of The Start/Stop Circuit For The 312C and 320C Series (1) Batteries (2) Alternator (3) Starter relay (4) Starter control relay (5) Governor actuator (6) Timer relay (7) Starter switch (8) Neutral start relay (9) Neutral start switch (10) Starter solenoid (11) Starter motor

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300C Engine and Pump Control S&O Illustration 12

Schematic Of The Start/Stop Circuit For The 322C (1) Batteries (2) Alternator (3) Starter relay (6) Timer relay (7) Starter switch (8) Neutral start relay (9) Neutral start switch (10) Starter solenoid (11) Starter motor

Illustration 13

Schematic Of The Start/Stop Circuit For The 325C and 330C (18) Timer Relay (19) Starter Switch (20) Neutral Start Relay (21) Starter Relay(22) Starter Motor (23) Neutral Start Switch (25) Engine Controller (28) Fuel Pump Relay (29) Fuel Pump The start/stop circuit is used to start the engine and the start/stop circuit is used to stop the engine. The following items are included in the start/stop circuit: ∙ Starter control relay ∙ Starter relay ∙ Starter motor ∙ Timer relay ∙ Start switch ∙ Governor actuator ∙ Neutral start relay ∙ Neutral start switch The start/stop circuit also includes a circuit for an air heater in order to help the engine start in cold weather. The circuit for the air heater includes the following items: an air heater, an air heater control unit and heater relay.

Current is allowed to flow through the timer relay and the neutral start switch to the neutral start relay when the starter switch is placed in the ON position and the control lever is in the LOCKED position. The coil of the neutral start relay is energized.

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Current flows through the neutral start relay to the starter relay when the starter switch is placed in the START position. The contacts of the starter relay close and current flows to terminal "S" of the starter solenoid from the starter relay.

Note: Current will not pass through the starter relay if the starter switch is placed in the ON position and the control lever is NOT in the LOCKED position.

Current from the battery will flow through the starter solenoid to the starter motor when the contacts of the starter solenoid are closed.

After the engine has started, the alternator will begin to produce electricity. A current signal is sent from the "P" terminal of the alternator to the "P" terminal of the starter relay. Terminal "S" of the starter control relay will open and the coil of the starter relay will be deactivated. Then, the starter motor will stop operating. This action is designed to prevent the starter motor from rotating too fast.

The timer relay will supply power for a specific amount of time after the start switch is placed in the OFF position. The cable of the governor actuator will move in order to prevent fuel from entering the engine for a period of 10 seconds. The engine should stop. After a period of 10 seconds has elapsed, the cable of the governor actuator will move allowing fuel to flow to the engine. This action will allow restarting of the engine. Before the period of 10 seconds has elapsed and the start switch is moved to the ON position, the governor actuator will allow fuel to flow to the engine. The engine may remain running.

Charging Circuit SMCS Code: 1406 The charging circuit of the machine uses an alternator to charge the battery during normal operations. The charging circuit also supplies the low current circuit with power through the fuse panel.

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Illustration 18

Schematic Of The Charging Circuit 312C, 315C and 320C Series (1) Batteries (2) Alternator (3) Breaker for the alternator

Illustration 19

Schematic Of The Charging Circuit For The 322C (1) Batteries (2) Alternator (3) Breaker for the alternator Page 13 of 59

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Illustration 20

Schematic Of The Charging Circuit For The 325C and 330C (2) Batteries (3) Breaker for the alternator (31) Alternator The current from terminal +B of the alternator travels through the breaker for the alternator and to the batteries. The alternator supplies current to the electrical components of the electrical system through the fuse panel.

Low Current Circuit SMCS Code: 1400 The low current circuit consists of the following circuits: · The circuit for the lights and windshield wiper · The circuit for the air conditioner · The circuit for the cab heater · The circuit for the horn · The circuit for cigar lighter · The circuit for the washer fluidElectronic Control System

General Information (Electronic Control System) SMCS Code: 1931 The engine and pump controller will monitor the machine continuously. The controller will adjust the speed of the engine and the flow of the hydraulic pump according to the machine conditions and the selections of the operator. The control system consists of the following components: engine and pump control (controller), tool electronic control, monitor panel, various switches, relays, sensors, solenoids, lamps and alarms.

The engine and pump controller communicates with the monitor panel via the CAT data link. The monitor panel will provide the following information to the operator and/or service persons: the conditions of the machine systems, diagnostic Page 14 of 59

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information and adjustment information. The monitor panel is also used by the operator to select operational functions.

The controller changes the output of the hydraulic pump according to the load on the machine. This process is designed to improve the rate of fuel consumption. The controller will adjust the flow of hydraulic oil to a tool according to the rate of flow that is required by the specific tool.

Illustration 21

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Block Diagram Of The Engine And Pump Control System (312C)

Illustration 22

Block Diagram Of The Engine And Pump Control System (315C)

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Illustration 23

Block Diagram Of The Engine And Pump Control System (320C and 320CU)

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Illustration 24

Block Diagram Of The Engine And Pump Control System (322C)

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Illustration 25

Block Diagram Of The Engine And Pump Control System (325C and330C)

Engine and Pump Regulation SMCS Code: 1931

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Illustration 26

Diagram of Inputs and Outputs for Engine and Pump Regulation Models 312-322 (1) Engine speed dial (2) Engine and Pump Controller (3) Engine (4) Speed Sensor (5) Pump (6) Monitor (7) Governor lever (12) Shift valve (8) Hydraulic pump pressure sensor (right) (9) Governor actuator (10) Feedback sensor (11) Hydraulic pump pressure sensor (left)

Illustration 27

This diagram is of Inputs and Outputs for the 325C and 330C. (1) Engine speed dial (2) Engine and Pump Controller (3) Engine (4) Speed Sensor (5) Pump (6) Engine Controller (7) Shift valve (8) Monitor (9) Hydraulic pump pressure sensor (right) (10) Hydraulic pump pressure sensor (left)

Note: The Engine Controller and the Pump Controller Use Separate Speed Sensors.

The Engine ECM Uses a Separate Speed Sensor.

The controller (2) will determine the power shift pressure in order to control the pump. The controller determines the power shift pressure according to the position of the engine speed dial (1), the delivery pressure and the engine speed. When the power shift pressure is high, the output of the pump will decrease. When the power shift pressure is low, the output of the pump will increase. The power shift pressure will remain constant when the engine speed dial is set between 9 to 5. The power shift pressure will increase in increments as a setting of 4 or lower is selected. The power shift pressure will increase as the engine speed dial is set to a position lower than 5. The control of an underspeed condition is performed in the position of 10 of the engine speed dial.

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Pump Regulation SMCS Code: 1931

Constant Control of Horsepower Constant control of the horsepower is associated with the 1 to 9 setting of the engine speed dial. The flow of the pump is controlled by the power shift pressure when the engine speed dial is in the 9 through 1 position. The hydraulic output will be set according to the position of the engine speed dial. Control of the pump will be adjusted from one of the following set points: low pressure and middle pressure high pressure. Even though the pump is delivering the maximum flow, the controller will correct the power shift pressure in order to maintain the maximum amount of flow, when the delivery pressure of the pump is too low and the proper setting of horsepower can not be reached. During the delivery of middle pressure and high pressure, the horsepower of the main pump is controlled in order to prevent high horsepower of the pump with lower engine horsepower. The controller receives feedback from the engine speed sensor. The power shift pressure is proportional to the target flow. The target flow is calculated from the setting of the engine speed and the pressure of the delivery pump pressure sensor. Thus, the power shift pressure will vary according to the position of the engine speed dial and the pressure of the delivery pump. The antistall feature for the engine is used in order to prevent the engine from stalling. The antistall feature will be activated, if the speed of the engine decreases 250 rpm below the position of the dial in comparison to the setting of the engine speed dial.

The powershift pressure is fixed for the positions of 1 through 9 until the underspeed feature is activated. The positions of 1 through 4 of the engine speed dial have a different power shift pressure for each setting. The engine speed dial will set the desired RPM, which will produce the desired flows. The positions of 5 through 9 of the engine speed dial have a common power shift pressure that is fixed. The positions 1 through 9 use engine speed, the position of the engine speed dial, and the pump pressure to set a fixed output. The output is fixed until a decrease of 250 RPM below the target RPM. At a RPM of 250 below the target RPM, the engine controller will adjust the power shift pressure in order to maintain engine RPM within 250 RPM of the target RPM.

Control Of An Underspeed Condition Page 21 of 59

300C Engine and Pump Control S&O

The underspeed condition is associated with a position of 10 of the engine speed dial. The 10 position of the engine speed dial is used when a large amount of horsepower is required or a high travel speed is requested. In this case, it is necessary to utilize the underspeed feature when the engine is being operated at a maximum horsepower. The underspeed feature will maintain the speed of the engine at approximately maximum power. The controller reads the engine speed and the controller will adjust the power shift pressure in order to regulate the engine speed.

The controller controls the power shift pressure in the underspeed condition. The engine maintains a speed of approximately 1950 rpm for the 312C series, 2150 rpm for the 315C series,1800 rpm for the 320C and 322C series, and 1800 rpm for the 325C and 330C series in order to achieve the maximum horsepower. Therefore, when the engine speed is higher than the full load speed, the output of the pump will increase and the power shift pressure will decrease. Also, when the engine speed is lower than the target speed, the output of the pump will decrease and the power shift pressure will increase.

The horsepower of the engine may decrease under the following conditions: · The engine becomes worn. · The quality of the fuel is poor. · The engine is operating at a high altitude.

The controller will decrease the output of the pump and the controller will increase the power shift pressure in order to reduce the load on the engine without reducing the engine speed. This condition occurs if the speed of the engine decreases below full load speed.

Engine Speed Control SMCS Code: 1931

Illustration 28

Governor Actuator for 312C

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(1) Governor actuator (2) Governor cables (3) Control Connector

Illustration 29

Governor Actuator for 315C (1) Governor actuator (2) Governor cables (3) Control Connector

Illustration 30

Governor Actuator for 320C series and 322C (1) Governor actuator (2) Governor cables

Illustration 31

(4) Electronic Engine Control The controller converts the signal from the engine speed dial (3) into a pulse width modulated signal. Then, the controller will send a signal to the governor actuator(1).

The governor actuator will adjust the engine speed for the 10 positions of the engine speed dial switch. The governor actuator will use two cables (2) to increase the engine speed and the cables are used to decrease the engine speed.

Note: The 325C series uses the ADEM III controller for the HEUI system.

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Illustration 32

Engine Speed Dial Switch (3) Engine speed dial switch The engine speed dial (3) is divided into 10 positions. The governor lever position is determined in response to the position of the engine speed dial. The dial position is displayed on the character display of the monitor panel. The speed of the engine with no load for each dial position is shown in the following chart.

TABLE 1 RPM For The Engine Speed Dial Switch Pos

312C

315C

320C

322C

325C / 330C

1

800

930

900

800

800

2

1100

1100

1020

1020

1020

3

1250

1300

1160

1160

1160

4

1400

1500

1300

1300

1300

5

1550

1650

1470

1470

1470

6

1700

1800

1590

1590

1590

7

1850

1950

1700

1700

1700

8

1950

2100

1800

1800

1800

9

2050

2250

1900

1900

1900

10

2150

2380

1970

1970

1980

Automatic Engine Control SMCS Code: 1931

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Illustration 33

Diagram of Automatic Engine Control (AEC) (1) Engine and pump controller (2) Switch panel (3) Engine (4) Speed sensor (5) Monitor (6) Governor lever (7) Governor actuator (8) Feedback sensor

Illustration 34

This is a diagram of the 325C and 330C Automatic Engine Control.

(1) Engine and pump controller (2) Switch panel (3) Engine (4) Speed sensor (5) Monitor (6) Electronic control module The AEC will lower the engine speed if no load on the machine continues for approximately three seconds or a light load on the machine continues for ten seconds when the engine speed dial is set in a position of 5 to 10. This process is designed to reduce the noise and fuel consumption. The AEC has settings in two stages. The AEC can be set by the switch on the right console. The indicator of the switch will illuminate during the second setting of the AEC. The second setting of the AEC is available immediately after the engine start switch is turned to the ON position. The AEC can be set in the first stage and the second stage by alternately pressing the switch.

First Setting Of The AEC The first setting of the AEC will lower the speed of the setting of the engine speed dial by approximately 100 rpm in the "no load" or the "light load" condition.

Second Setting Of The AEC

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The second setting of the AEC will reduce the engine speed to approximately 1300 rpm in the "no load" condition. The AEC will lower the speed of the setting of the engine speed dial by approximately 100 rpm in the "light load" condition. The AEC will not function if the backup switch (MAN) is being operated.

One Touch Low Idle SMCS Code: 1931

Illustration 35

Diagram For The One Touch Low Idle Control (1) Engine speed dial (2) Engine and pump controller (3) Engine (4) One-touch low idle switch (5) Governor lever (6) Implement swing pressure switch (7) Travel pressure switch (right) (8) Governor actuator (9) Feedback sensor (10) Travel pressure switch (left)

Illustration 36

This Diagram Is For The 325C and 330C One Touch Low Idle Control.

(1) Engine speed dial (2) Engine and pump controller (3) Engine (4) One-touch low idle switch (5) Implement swing pressure switch (6) Travel pressure switch (right) (7) Travel pressure switch (left) (8) Electronic control module (10) Travel pressure switch (left) When the one-touch low idle switch (4) is pressed and the machine is not under a load, the engine speed can be lowered by more than the speed of the setting of the

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second stage of the AEC. When normal operations have resumed, the engine speed for the dial setting will return the corresponding RPM.

Start-up Of The One-touch Low Idle The one touch low idle feature will activate during all "stopped" conditions of the implement, swing, travel and tools. The following components are in the OFF position: implement swing pressure switch (6), the travel pressure switch (right) (10), the travel pressure switch (left) (7), the attachment pedal pressure switch and the straight travel pressure switch. However, when the one-touch low idle switch is pressed, the control will lower the engine speed to the speed of the "2" setting of the engine speed dial (approximately 1100 rpm for the 312C and 315C, 1020 rpm for the 320C, 322C, and 325C). This control overrides the AEC. Note: The 312C has only one travel pressure switch and the 315C has only one travel pressure switch.

Release Of The One-touch Low Idle The one-touch low idle will be released, if any of the following conditions occur: · The one-touch low idle switch (4) is pressed again. · The implement swing pressure switch is set to the ON position. · A travel pressure switch is set to the ON position. · A pressure switch that is related to a tool is set to the ON position.

The engine speed is different after the switch has been released. The different speed will depend on the conditions of the release.

1. The engine speed will be set to the setting of the engine speed dial, when the feature for one-touch low idle has been released by an operation of the implement, swing, etc..

2. The engine speed will be set by the AEC, when the feature of one-touch low idle has been released by using the one-touch low idle switch. The engine speed will be affected by the following conditions: a. When the first setting of the AEC is selected, the engine speed will be set to the speed of the first setting of the AEC. The speed is approximately 100 rpm lower than the setting of the engine speed dial. b. When the second AEC is selected, the engine speed will be set to the speed of the setting of the second AEC. c. The engine speed will be set to the speed of the engine speed dial if the engine speed is lower than the setting of the second AEC. The setting of this speed is not based on a setting of the AEC.

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Tool Control SMCS Code: 5700 When an attachment tool is being operated, the engine speed and the pump flow are controlled according to the type of tool. For more information, refer to the appropriate service manual for the tool control of the machine that is being serviced.

Selection Of A Tool There are five types of tools. The operator selects the type of tool by the monitor.

The following parameters are examples of some parameters that can be adjusted in order to accommodate a particular tool: · Setting of the engine speed dial · Pump flow in the single operation · Pump flow in the simultaneous operation · The setting of the horsepower for the attachment pump.

Engine Speed Control When the pedal is operated, the actual setting of the engine speed dial is compared to the position of the engine speed dial that was set by the parameter. The engine speed control will lower the engine speed to the selected engine speed that was set in the adjustable parameter. When the tool is deactivated, the speed of the engine will return to the actual speed of the setting of the engine speed dial. When the attachment tool is being operated, the AEC and the one-touch low idle are released.

Main Pump Flow Control If the pedal is operated for a tool that uses the flow of the main pump, the pressure switch detects the change. A flow control restricts the main pump flow. The shuttle valve selects the higher pressure between the pressure in the control valve and the pressure from the proportional reducing valve. This signal restricts the pump flow to a lower pressure. The main pump flow is then reduced.

This process results in better simultaneous operation of the tool and operation of the implement.

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Main Pump Control During Use Of The Attachment Pump The controller detects an attachment pump section. This offsets the load of the attachment pump. This process also prevents a decrease of the engine speed. If an attachment pump is operated with 30 percent of the rated load and the main pumps are operated at the same time, a reduction in engine speed is prevented.

Straight Travel Control SMCS Code: 1931 Note: The following models have straight travel control: 318C, 320C, 322C, 325C and 330C.

Illustration 37

This diagram is for the 320C and 322C series.

(1) Controller (2) Implement swing pressure switch (3) Travel pressure switch (right) (4) Travel pressure switch (left) (5) Pressure switch for the straight travel pedal (6)

Straight travel solenoid

Illustration 38

This diagram is for the 325C and 330C series.

(1) Controller (2) Swing pressure switch (3) Right travel pressure switch (4) Left travel pressure switch (5) Straight travel solenoid valve The straight travel solenoid (6) is energized and the hydraulic circuit for straight travel is open when one of the following conditions occur: · The travel pressure switch (right), the travel pressure switch (left) and the implement swing pressure switch are simultaneously activated. · The pressure switch for the straight travel pedal (5) and the implement swing pressure switch (2) are simultaneously activated.

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Engine Speed Protection SMCS Code: 1931

Memory Function After one of the following events has occurred, the engine will operate at the 10 position of the engine speed dial when the engine is restarted: · The engine was stopped with the AEC switch in the ON position (1300 rpm) and the engine speed dial was in the 10 position. · The engine was stopped at a low idle and the engine speed dial was in the 2 position.

Function The position of the governor actuator is stored in the memory when the starter switch is turned to the OFF position (engine OFF). After the key is turned to the OFF position, the governor actuator will move to the maximum position of the AEC side for 10 seconds in order to stop the engine. Then, the governor actuator will return to the stored position. Unless the governor actuator is moved by one of the following operations, the engine will start at the speed that was previously stored in the memory.

1. Release of AEC and one-touch low idle by operating the control levers and the pedals.

2. The engine speed dial is operated.

3. The AEC switch is operated.

4. The one-touch low idle switch is operated.

Note: The 325Cdoes this function with the ADEM.

Prevention Of Overspeed During Low Engine Oil Pressure This function is designed to prevent the engine from starting at a high speed during a condition of low oil pressure. After the engine oil filter is replaced, a long time may be required before the engine oil pressure will reach the specified level. The turbocharger may be damaged, if the engine runs at the speed dial position of 10.

The following information describes this function.

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The engine speed will be limited to the position of 5, if the engine oil pressure switch is open. The engine speed will also be limited to the position of 5, if the governor actuator was held in the high speed position before the stopping of the engine. The engine will start at the speed of the 5 position.

Prevention Of Overspeed During Overheating Condition This function is designed to prevent damage to the engine that is caused by overspeed during an overheating condition. Work that requires high pressure will be restricted during an overheating condition. The engine and other components are protected during this condition. The engine speed will be decreased to the second setting of the AEC (1300 rpm).

Control Of The Hydraulic Oil At Low Temperatures When the conditions of the climate are cold and the temperature of the hydraulic oil is low, the machine may not operate smoothly. The output of the pump will decrease by a small amount. This allows the operations to be smoother until the temperature of the oil rises. When the hydraulic oil temperature sensor has detected an oil temperature below 15 °C (59 °F) the system limits hydraulic pump output pressure to 80% of maximum hydraulic horsepower. When the hydraulic oil temperature sensor detects an oil temperature that has risen above 20 °C (68 °F), normal control of the hydraulic oil will begin again.

Swing Lock System SMCS Code: 1931

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Illustration 39

The swing parking brake is released immediately after any control lever of the boom, stick, bucket, swing or attachment is operated. The swing parking brake is engaged 6.5 seconds after all the control levers return to the neutral position. The swing parking brake is not released while the hydraulic activation control lever is placed to the locked position. The swing parking brake is released by turning the fine swing switch to the ON position, if the fine swing attachment is installed. The swing parking brake is released electrically when the backup switch is placed into the "MAN" side.

Backup System SMCS Code: 1931

Illustration 40

Schematic of the backup switch Page 32 of 59

300C Engine and Pump Control S&O

(1) Starter Switch (2) Engine and pump controller (3) Engine speed switch (4) Main relay (5) Timer relay (6) Circuit for the governor actuator (7) Governor actuator (8) Drive circuit for the proportional reducing valve (10) Proportional reducing valve for the power shift (13) Swing brake solenoid (11) Circuit of the swing brake (12) Backup switch for EPC (9) Backup resistor

Illustration 41

This diagram is for the 325C and 330C backup switch.

(1) Starter Switch (2) Engine and Pump Controller (3) Speed Change Switch (4) Main relay (5) Electronic Control Module (6) Backup Register (7) Proportional Reducing Solenoid Valve (8) Swing Brake Solenoid (9) Backup Switch (10) Engine Speed Control Circuit (11) Proportional reducing valve (12) Swing Brake Circuit The backup system is used when the controller is not able to control the machine properly. The backup system is provided so that the machine can be moved or an operation can be performed. The monitor will indicate when the backup system is

active.

Engine Speed Control The speed of the engine can also be controlled by using the engine speed change switch. When the switch is placed in the rabbit position, the engine speed will be increased. When the switch is placed in the tortoise position the engine speed will be decreased.

Pump Control The output of the pump will be reduced to 60% to 80% of the rated output. The power shift pressure is fixed. Care should be taken in order to prevent the engine from stalling. This condition could occur during machine operation while the engine

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speed dial is in a low position or the output of the engine has been decreased significantly.

Swing Parking Brake The swing parking brake can be released during a backup condition. However, the brake is under activation when the hydraulic oil supply is stopped. The hydraulic oil supply is stopped when the engine is stopped or the hydraulic lock lever is moved to the lock position.

Monitoring System SMCS Code: 7490

Illustration 42

Monitor panel The monitor panel has two functions: ∙ Displaying information by using gauges and indicators ∙ Allowing the operator and/or service person to input information to the controller The monitor panel is used to enter commands into the controller. Some examples of these operations are included: selecting operator modes, selecting service modes, changing parameters and many other operations

Warning Operation There are three types of warnings that will be displayed: Warning 1 - This warning is displayed on the liquid crystal display only. This is low level warning.

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300C Engine and Pump Control S&O

Warning 2 - This warning is displayed on the liquid crystal display and the action lamp will illuminate. This level of a warning will require the operation to be stopped and necessary actions should be taken.

Warning 3 - This warning will display the following indications: a warning on the liquid crystal display, illumination of the action lamp and sounding of the action alarm. This level of a warning will require all operations (engine OFF) to be immediately stopped and the necessary actions be taken.

Warnings The following list contains examples of these warnings.

Warning for decreasing engine oil pressure This warning warns the operator about an abnormal decrease in the engine oil pressure. During the abnormality, the action lamp will illuminate and the action alarm will sound.

Warning for high engine coolant temperature This warning warns the operator about an abnormally high temperature of coolant.

The temperature of the coolant is above 105 °C (221 °F).

Warning for high hydraulic oil temperature This warning warns the operator about an abnormally high temperature of hydraulic oil. The dangerous temperature is over 95 °C (203 °F).

Warning for backup switch This warning warns the operator when the backup switch is operated in the MAN position.

Warning for an abnormal battery charging This warning warns the operator about an abnormal battery charging while the engine is running.

Warning for abnormal condition in the controller This warning warns the operator about an abnormal condition in the monitor.

Warning for a return filter that is clogged This warning warns the operator about a return filter that is clogged. When this warning occurs, turn the key to the OFF position. Then, when the key is turned to the ON position again, verify that the warning is present. Verify that this warning is occurring during travel on level ground. The filter should be changed when the warning occurs during travel on level ground.

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Warning for a air filter that is clogged This warning warns the operator that the air filter is clogged. Clean the air filter or replace the air filter.

Warning for a fuel filter that is clogged This warning warns the operator that the fuel filter is clogged. Replace the fuel filter.

Warning for water separator ( 320C series, 322C series, 325C series, and 330C series) This warning warns the operator when the water in the water separator is over the specified level. Drain the water separator of water.

Warning for low fuel This warning warns the operator when the remaining fuel is low. Fill the tank with fuel.

Warning for air heater in operation This warning warns the operator that the air heater is operating. Start the engine after this warning goes off.

Warning for usage of oil and filter The usage and the recommended interval for exchanging the filter and oil is displayed on the monitor. The used time can be reset from the monitor. It is necessary to reset the used time after exchanging the filter. The following list contains examples of oil and filters: · Engine oil · Engine oil filter · Primary fuel filter · Secondary fuel filter · Water separator · Oil for the swing motor · Pilot filter · Drain filter · Return filter · Final drive oil · Hydraulic oil · Coolant Page 36 of 59

300C Engine and Pump Control S&O

Machine Information The monitor will display the following information about the status of the machine: · Engine RPM · Delivery pressure of the main pump (driver side) · Main pump delivery pressure (idle side) · Power shift pressure for the main pump Monitor Operation 1. The operation procedure for the monitor is listed below. a. Display the "MAIN MENU" screen from the normal display screen. b. Select "SPECIAL SETTINGS" from the "main menu" screen. c. The screen will change and the screen will display the "PASSWORD" screen. Input the password for the dealer (0001). d. The screen will change to the "SPECIAL SETTINGS" screen. Select "MACHINE INFO". e. The screen will change to the "MACHINE INFO" screen. You may choose the desired option.

Working Hour The monitor is capable of displaying the operating time of the following components: · Engine · Main pump · Travel motor · The tool for the "INSTALL TOOL #1" through the "INSTALL TOOL #5" display Monitor Operation 1. The operation procedure for the monitor is listed below. a. Display the "MAIN MENU" screen from the normal display. b. Select "SPECIAL SETTING" from the "MAIN MENU" screen. c. The screen will change to the "PASSWORD" screen. Input the password for the dealer (0001). d. The screen will change to the "SPECIAL SETTINGS" screen. Select "MACHINE INFO". e. The screen will change to the "MACHINE INFO" screen. Select the desired option.

2. The procedure that is used to reset the operating hours is listed below. a. The operating hours should be displayed. Press the "MENU" key in order to display the screen that will reset the total time. b. Press the "SET" key in order to reset the hours. c. Confirm the reset by pressing the "OK" key. d. The operating hours have been reset. The screen should return to the default display.

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Note: The screen will return to the default display unless the "cancel" key is pressed or no key is pressed within twenty seconds of confirming a reset of the operating hours.

Tools The monitor will display the currently selected tool and the pressure setting for hydraulics of the tool.

Travel Alarm When the travel pressure switch is in the ON position, the travel alarm will sound in order to call attention to the machine. When the travel alarm cancel switch is pressed during the activation of the travel alarm, the alarm will be silenced. This action is effective until the machine completely stops. After the machine has momentarily stopped and the machine begins to travel again, the alarm will sound.

Engine and Hydraulic Pump Controller SMCS Code: 1931; 7610-NP

Page 38 of 59

300C Engine and Pump Control S&O Illustration 43

Diagram Of Inputs And Outputs Of The 312C, 315C, 320C, and 322C Controller (1) Controller (2) Fuse Box (3) Engine (4) Governor lever (5) Hydraulic Pump (6) Battery (7) Start switch (8) Speed sensor (9) Backup switch (10) Governor actuator (11) Feedback sensor (12) Monitor (13) Action alarm (14) Engine speed dial (15) Switch panel (16) Engine coolant temperature sensor (17) Hydraulic oil temperature sensor (18) Fuel level sensor (19) Alternator (20) Engine oil pressure switch (21) One touch low idle switch (22) Engine oil level switch (23) Hydraulic oil level switch (24) Water separator level switch (25) Swing pressure switch for the implement (26) Travel pressure switch (27) Travel pressure switch (36) Air heater indicator (28) Pressure switch for the straight travel pedal (29) Pump pressure sensor (30) Pump pressure sensor (32) Solenoid valve for straight travel (31) Proportional reducing valve for the power shift pressure (35) Travel alarm (33) Solenoid valve for travel speed (37) Switch (Clogged air filter) (34) Solenoid valve for the swing parking brake (38) Switch (Clogged hydraulic oil filter) (39) Engine coolant level switch (40) Pressure switch for the attachment pump (41) Pressure switch for the attachment pedal (42) Pressure switch for the attachment pedal (2) (43) Proportional reducing valve for the auxiliary hydraulics (Attachment)

Illustration 44

Diagram Of Inputs And Outputs Of The 325C and 330C Controller

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(1) Engine and Pump Controller (2) Starter Switch (3) Fuse Box (4) Battery (5) Engine (7) Pump (8) Speed sensor (10) Electronic Control Module (11) Backup Switch (12) Action Alarm (13) Engine Speed Dial (14) Switch Panel (16) Hydraulic Oil Temperature Sensor (17) Fuel Level Sensor (18) Alternator (20) One-touch Low Idle (21) Engine Oil Level Switch (22) Hydraulic Oil Level Switch (23) Implement Swing Pressure Switch (24) Travel Pressure Switch (right) (25) Travel Pressure Switch (left) (26) Pump Pressure Sensor (27) Pump Pressure Sensor (28) Monitor (29) Proportional Reducing Valve (30) Straight Travel Solenoid Valve (31) Travel Speed Solenoid Valve (32) Swing Parking Brake Solenoid Valve (33) Travel Alarm (35) Clogged Air Filter Switch (40) Flow Control Valve (36) Clogged Hydraulic Oil Filter Switch (37) Engine Coolant Level Switch (38) Implement Pressure Switch (39) Attachment Pedal Pressure Switch (41) Water Separator Level Switch (42) Straight Travel Control (43) Attachment Pedal Pressure Switch Note: The 312C and 315C have only one travel pressure switch.

Note: The Engine Control Module is on the 325C. The controller is connected to the machine through two 54-pin connectors. The controller will monitor the system through the inputs and the controller will make adjustments to the system through the outputs. The controller will control the hydraulic output of the pump by adjusting the speed of the engine according to the load on the machine.

Illustration 45

Engine and Pump Controller (ECM) (44) Controller (45) Connector 2 (46) Connector 1 TABLE 2 Engine And Hydraulic Pump Control (Connector 1) No.1

Function

(1)

Type

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300C Engine and Pump Control S&O

1

+Unswitched Battery

Power

2

Ground

Ground

4

Air Heater Relay

Solenoid Output

7

Pressure Switch for 320C and 320CU

Switch Input

8

Hammer Switch for 320C and 320CU

Switch Input

9

Engine Speed Dial 1

10

Engine Speed Dial 2

11

One-touch Low Idle Switch

Switch Input

12

Mode Switch for the AEC

Switch Input

13

+Battery

Power

14

Ground

Ground

16

Overload protection

Switch Input

17

Operational Switch Input Operational Switch Input

Implement Pressure Switch for 312C and 315C

Switch Input

18

Implement Control Line 2

Output

19

Engine Speed Dial 3

20

Engine Speed Dial 4

21

Travel Mode Switch

Switch Input

22

Travel Alarm Switch

Switch Input

23

Key Start Switch

Switch Input

28

Implement Status 1

Output

Operational Switch Input Operational Switch Input

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300C Engine and Pump Control S&O

Control Lever Pressure Switch 320C and

29

Switch Input

322C

30

Left Travel Pressure Switch 312C and 315C

Switch Input

31

Coolant Level Switch

Switch Input

32

Hydraulic Oil Level Switch

Switch Input

33

Data Link +

Input/Output

39

Right Travel Pressure Switch

Switch Input

40

Engine Oil Level Switch

Switch Input

41

Engine Oil Pressure Switch

Switch Input

42

Clogged Air Filter Indicator

Switch Input

43

Data Link Negative

Input/Output

45

Implement Status 3

Output

46

Implement Status 4

Output

47

Water Separator Level Switch

Switch Input

48

Clogged Filter

Switch Input

53

Straight Travel Solenoid for 320C

Switch Input

(1)

The connector contacts that are not listed are not used. The connector has 54 contacts.

TABLE 3 Engine And Hydraulic Pump Control (Connector 2) No.1 1 2

Function

(1)

Type

Straight Travel Solenoid 320C, 320CU and 322C Travel Speed Solenoid

Solenoid Output Solenoid Output

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4

Swing Brake Solenoid

6

Fine Swing Switch

Solenoid Output Switch Input

7

Power Shift Solenoid

Solenoid Output

8

Pump Flow Limitation

Solenoid Output

Valve Solenoid

9

Priority Control Valve

13

Travel Alarm

14

Mode Indicator for the AEC

Output

15

Travel Mode Indicator

Output

16

Negative Speed Sensor

Sensor Return

17

Neutral Start Relay for 322C

Solenoid Output

19

Solenoid Return

Ground

20

Solenoid Return

Ground

21

Solenoid Return

Ground

22

Solenoid Return

Ground

23

Action Alarm

Output

24

Travel Alarm Indicator

Output

25

Engine Speed

Sensor Input

29

Coolant Temperature Sensor

Sensor Input

30

Fuel Level Sensor

Sensor Input (PWM)

35

Alternator Terminal R

Sensor Input (Voltage)

36

Feedback from the Governor

Sensor Input (PWM)

Solenoid Output Output

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300C Engine and Pump Control S&O

37

Main Pump Pressure Sensor

Sensor Input (PWM)

39

Hydraulic Oil Temperature Sensor

Sensor Input (PWM)

44

Governor Sensing

Sensor Input (Voltage)

45

Pump Delivery Pressure

Sensor Input (PWM)

46

Boom Hold

Sensor Input (PWM)

47

Backup Switch

Switch Input

52

+Battery for 320C, 320CU and 322C

Power

(1)

The connector contacts that are not listed are not used. The connector has 54 contacts.

When the controller determines that it is necessary to change the speed of the engine and the output of the hydraulic pump, the controller will actuate the governor actuator and the proportional reducing valve. Each input and output of the controller is connected to the machine harness through two 54-pin connectors.

Input/Output The data link is a bidirectional component. The data link allows the controller to receive information and the controller can send information. The data link is designed to allow communication between the controller and the monitor. The data link is not a visible component. The data link consists of internal control circuits and the connecting harness wiring. The controller sends information through the data link to the monitor panel. The following list contains some examples: fuel level and engine coolant temperature. The controller also receives requested information from the monitor panel.

Input Each input will describe the status of the machine system. Two types of inputs exist: switch type and sensor type. Switches and harnesses provide an open or ground to the controller. Sensors and harnesses provide a signal that changes to the controller.

Switch Input (Keyswitch) The input of the key start switch connects to the controller through connector 1 and contact 23. The key start switch will provide input information to the controller about

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the status of the key start switch. The input for the key start switch is +battery when the key start switch is placed in the ON position.

Switch Input (Operational Type) Each switch input will provide information about operator requests and machine systems. The condition of the system is sent to the controller through each input.

The status of each input will be grounded, open or +battery. Each input of the controller will receive information from the switches that are located in the machine systems (pressure and temperature).

Sensor Input (Frequency) An AC signal is present for the input of the frequency sensor. The AC signal is used to represent the speed of a machine system. For example, the engine speed sensor provides an AC signal to the controller. The controller measures the frequency (Hz) of the AC signals. The resulting speed is used by the controller to make decisions.

Sensor Input (Alternator) The sensor input for the alternator connects to connector contact 2-35. A square wave signal is present at this input. The signal is used to represent the speed of the alternator. The controller measures the frequency (Hz) of the square wave signal.

The controller uses this information to make determinations and the controller uses this information to monitor the output of the alternator. When an abnormal condition exists, the controller will alert the operator.

Sensor Input (PWM) The controller receives a PWM signal from the sensor. This signal will represent the condition of a machine system. For example, the controller can monitor pressure.

PWM sensors provide this information. The controller measures the duty cycle of the PWM signal. This signal will represent the information that is measured. The controller will use this information to perform decisions. When an abnormal condition exists, the controller will alert the operator.

Sensor Input (Voltage) For example, contact 2-35 is an input for voltage sensing. A voltage is present. This voltage will represent the condition of a machine system. For example, the level of voltage is a condition that is monitored by the controller. Analog sensors or senders provide this information. The controller measures the voltage, which represents the measured information. The controller uses this information to make decisions. The

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controller also uses this information to monitor machine systems. When an abnormal condition exists the controller alerts the operator.

Output The controller responds to decisions by sending electrical signals through the various outputs. The outputs will create an action or the outputs will provide information. Three status indicators inside the controller that are connected to the monitor panel are outputs of the controller. These outputs are additional to the outputs that are listed in the table for the descriptions of the connector contacts. The monitor panel shows the operating status of the engine and pump control system and diagnostic information. This action could be energizing a solenoid, sounding an alarm or activating a motor. The controller will send an output to the following components: · Governor actuator · Proportional reducing valve for the power shift pressure · Travel speed solenoid · Action alarm · Travel alarm · Swing parking brake solenoid · Proportional reducing valve for the tool mode · Straight travel solenoid

Operator Monitor SMCS Code: 7490

Illustration 46

Monitor Panel (1) Fuel gauge (2) Engine coolant temperature gauge (3) Action lamp (4) Engine speed dial indicator (5) Hydraulic oil temperature gauge (6) Message center The liquid crystal display panel will display various warnings and information. The monitor panel includes the following components: three gauges, an action lamp, the engine speed dial indicator, a message center and eight switches.

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Illustration 47

Monitor Panel (7)"Up" key (8)"Left" key (9)"Right" key (10)"Down" key (11)"Cancel" key (12)"Setting" key (13)"Menu" key (14)"OK" key The information about the condition of the machine from the controller is displayed on the monitor. The monitor has three gauges and a number of alert indicators. Each gauge is dedicated to a parameter within a machine system. Some of the possible parameters of the machine systems are listed: fuel level, engine coolant temperature and hydraulic oil temperature. The gauges receive information from sensors or senders that are connected to the controller. The controller uses the information from each sensor input to calculate the value that is shown on the gauges. The alert indicators will notify the operator of an abnormal condition in a machine system. The controller uses information from pressure switches, sensors and other inputs in order to determine when an abnormal condition is present. The controller will send a message to the monitor panel. Then, the monitor panel FLASHES the alert indicator for the machine system with the abnormal condition. The controller will process information from the switches of the monitor panel. The switches are used in order to select various functions. The controller will receive this information and the controller will perform the requested operation or mode of operation.

Switches SMCS Code: 1435; 7332

Engine Speed Dial Switch

Illustration 48

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Engine Speed Dial Switch The positions of the engine speed dial switch is designed to inform the controller about the speed that is desired by the operator. The engine speed dial switch has ten positions: 1 to 10. Each position of the switch has a unique combination of connector contacts that close to contact 1. A combination of contact 2 through contact 5 will close to contact 1. This switch will ground a unique combination of inputs for the engine speed dial switch to the controller.

One Touch Low Idle Switch The one touch low idle switch is incorporated into the top section of the lever on the right console. When the switch is in the ON position, the engine speed is decreased to 1020 rpm.

Pressure Switch

Illustration 49

Travel Pressure Switch And Implement/Swing Pressure Switch Left Travel Pressure Switch, Right Travel Pressure Switch, Straight Travel Pressure Switch and Implement/Swing Pressure Switch The travel pressure switch and the implement/swing pressure switch will monitor the hydraulic system. This switch is normally open. These switches will inform the controller about the status of the hydraulic demands. When there is no hydraulic demand these switches are open. The function of the automatic engine speed control (ECM) of the controller will use these switches to determine operation. These switches are in the normally open position, when the switches are not installed on the machine. The implement/swing pressure switch releases the swing brake. If the implement/swing pressure switch and the travel pressure switch are in the closed position the swing brake will be released.

Engine Oil Pressure Switch

Page 48 of 59

300C Engine and Pump Control S&O Illustration 50

Engine Oil Pressure Switch During normal operation, the engine oil pressure switch is closed to ground. This switch is normally open. The switch opens when engine oil pressure is less than the specified value for the switch. If the switch is in the open position, the controller will notify the operator that the engine oil pressure is insufficient. This switch is normally open, when the switch is not installed on the machine.

Key Start Switch

Illustration 51

Key Start Switch The key start switch is an input of the engine and pump controller. The key start switch informs the ECM of an attempt to start the engine. Then, the ECM initiates the start procedure.

During normal machine operation, the start terminal of the key start switch is open. If the key start switch is placed in the START position the start terminal will close. +Battery voltage is supplied to the start terminal. When all starting conditions are satisfied, the ECM sends a +battery signal to the start relay and engine cranking begins.

Note: After the key start switch is initially turned to the START position, the switch will not return to the START position from the ON position. The switch must be turned to the OFF position first. Then, the switch can be turned to the START position.

Air Filter Switch

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300C Engine and Pump Control S&O

Illustration 52

Air Filter Switch The air filter switch will open, if the air filter is blocked with debris. This switch is normally closed. A warning will be displayed on the monitor. However, when a warning of higher priority is occurring at the same time, the warning with the higher priority will be displayed.

Hydraulic Oil Filter Switch When the hydraulic oil filter is clogged, the hydraulic oil filter switch will be open. A warning will be displayed on the monitor.

Engine Coolant Level Switch The engine coolant level switch is an electronic switch that is activated by the coolant. The coolant level switch is closed to ground during normal operation. The switch opens when the coolant level is too low. The open switch informs the controller that the coolant level is too low in the cooling system.

Hydraulic Level Switch and Engine Oil Level Switch

Illustration 53

Hydraulic Oil Level Switch The hydraulic oil level switch monitors the hydraulic oil level after the starter key switch is held in the ON position for 2 seconds or more. The controller checks hydraulic oil level with the switch. The switch closes when the hydraulic oil level is below the normal operating level. This switch is in the normally open position, when the switch is not installed on the machine.

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Water Separator Level Switch ( 320C Series and 322C Series)

Illustration 54

Water Separator Level Switch When the volume of water that has been separated by the water separator reaches a specified volume, the switch is closed. The controller reads the input from the water separator switch. The controller will display a warning on the monitor. The water separator should be inspected. The water separator should be drained.

Switch Panel Assembly

Illustration 55

Switch Panel (1) Travel alarm cancel switch (2) Automatic engine control switch (AEC) (3) Travel Speed Switch Travel Alarm Cancel Switch

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When the travel alarm cancel switch (1) is activated and the machine is in motion, the travel alarm will temporarily stop until the machine has stopped. When the machine begins to travel again, the travel alarm will sound again. The indicator will illuminate while the switch is being pressed.

Automatic Engine Control Switch (AEC) Either "AEC 1" or "AEC 2" is set by pressing the Automatic Engine Control switch (2). The indicator will illuminate when "AEC 2" has been selected.

Travel Speed Switch When the travel speed switch (3) is pressed, the travel control is set in the position of automatic two-speed or the position of fixed low speed. The indicator will illuminate when the position of automatic two-speed has been selected.

Pressure Switch

Illustration 56

Attachment Pedal Pressure Switch (Hammer) Attachment Pedal Pressure Switch (Hammer) This pressure switch is in the closed position when the attachment pedal is being operated and the pedal is using the main pump. This switch is utilized for control of the engine speed and control of the pump. This switch is normally open.

Attachment Pump Pressure Switch This pressure switch is in the closed position when the attachment pedal is being operated and the pedal is using the attachment pump. This switch is utilized for the engine speed control and pump control. This switch is normally open.

Sensors SMCS Code: 1931-NS Sensors provide information to the controller about changing conditions. Some types of information are listed: speed, temperature and fluid level. The sensor signal changes in a proportional manner. This change will represent the changing condition. The controller will recognize the following types of sensor signals: Frequency - The sensor will produce an AC signal (sine wave or square wave) that varies in frequency (Hz) as the condition changes.

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Pulse Width Modulated - The sensor produces a digital signal (PWM) that varies the duty cycle as the condition changes. The frequency of the signal will remain constant.

Engine Speed Sensor

Illustration 57

Engine Speed Sensor The engine speed sensor is located on the flywheel housing. An AC voltage is produced as the gear teeth of the flywheel pass the tip of the sensor. The frequency of the voltage is proportional to the speed of the gear teeth as the teeth pass the tip of the sensor. The controller uses this signal to make decisions for the hydraulic pump and the engine.

Feedback Sensor

Illustration 58

Feedback Sensor Inside The Governor Actuator Note: The 325C Series does not have a governor actuator.

The feedback sensor is incorporated in the governor actuator. The sensor sends a PWM signal to the controller. The PWM signal informs the controller about the position of the governor lever. The controller will stop the activation of the governor actuator when the controller determines that the information from the feedback sensor matches the selected setting of the engine speed dial and the engine RPM.

Pressure Sensor

Illustration 59

Pump Discharge 1 (Drive) and Pump Discharge 2 (Idle)

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These sensors send a signal to the controller. The controller will use the signal to modify the following items: ∙ Adjusting the horsepower ∙ Changing the travel speed ∙ Determining light load and "AEC" level 1

Senders SMCS Code: 1931-UN

Fuel Level Sender

Illustration 60

Fuel Level Sender The fuel level sender is attached to a float in the fuel tank. As the fuel level changes, the float inside the tank moves. The movement of the float will change the resistance of the sender. The voltage at the input to the controller for the sender will change as the resistance of the sender changes. The controller will monitor this voltage and the controller will compare this voltage to values that are known. This comparison will determine the level of fuel in the tank.

Temperature Sender

Illustration 61

Engine Coolant The resistance of the sender will change as the temperature of the coolant changes.

The voltage at the input to the controller for the sender will change as the resistance Page 54 of 59

300C Engine and Pump Control S&O

of the sender changes. The controller will monitor this voltage and the controller will compare this voltage to values that are known. This comparison will determine the temperature of the coolant.

Hydraulic Oil The resistance of the sender will change as the temperature of the fluid changes.

The voltage at the input to the controller for the sender will change as the resistance of the sender changes. The controller will monitor this voltage and the controller will compare this voltage to values that are known. This comparison will determine the temperature of the hydraulic oil.

Solenoid Valves SMCS Code: 5479

Proportional Reducing Solenoid Valve (Power Shift) The proportional reducing solenoid valve changes the electrical signal from the controller into a hydraulic signal for the hydraulic pump. The hydraulic signal (power shift pressure) is used to regulate the output of the hydraulic pump. The controller varies the current (PWM signal) to the solenoid and the solenoid valve modulates the power shift pressure. The controller varies the current to the solenoid according to the engine speed.

Solenoid Valve

Illustration 62

Schematic Symbol The solenoid valve is designed to direct the flow of hydraulic oil through the hydraulic system. The controller will activate the proper solenoid valves according to the input from switches on the monitor panel and the pressure switches in the hydraulic system of the machine. When the solenoids are activated, a solenoid receives ground from the controller. The travel speed solenoid is activated when "HIGH" is selected in the travel speed mode. The "rabbit" travel speed indicator is illuminated when this mode is active.

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The solenoids have a connector with two contacts. One contact receives a ground signal from the corresponding connector contact of the controller. The other solenoid contacts are connected to a +battery source in the fuse panel.

Pressure Solenoid For Power Shift

Illustration 63

Pressure Solenoid For Power Shift for 312C and 315C (1)

Illustration 64

Power Shift Solenoid (1) Photo for 320C, 322C, 325C, and 330C The controller adjusts the current that drives the solenoid according to the following conditions: ∙ The position of the engine speed dial ∙ The actual engine speed ∙ The delivery pressure of the pump ∙ The pressure of the circuit for power shift

Travel Speed Solenoid and Swing Parking Brake Solenoid Valve

Illustration 65

Travel Speed Solenoid (2) and Swing Parking Brake Solenoid Valve (3) for 312C

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Illustration 66

Travel Speed Solenoid (2) for 315C

Illustration 67

Travel Speed Solenoid (2) and Swing Parking Brake Solenoid Valve (3) Photo for 320C, 322C, 325C, and 330C The travel speed solenoid changes the speed of the travel motor from high speed to low speed and vice versa. When the low speed mode has been selected, the solenoid is not energized. The displacement of the travel motor is controlled by the travel speed solenoid. If the travel motor is in the high speed mode and the controller detects a pressure that is too high, the travel speed solenoid will be de-energized and the travel motor will now be in the low speed mode.

The swing parking brake solenoid valve is energized in order to release the brakes, when the implement, the swing or the tool is operated. The swing parking brake solenoid valve will be de-energized and the brakes will be applied 6.5 seconds after a control lever has been operated.

Straight Travel Solenoid

Illustration 68

Straight Travel Solenoid (4) for 320C, 322C, 325C, and 330C

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The straight travel solenoid is energized, when the right travel pedal, the left travel pedal and other actuators are operated at an identical time.

Governor Actuator Control SMCS Code: 1716

Illustration 69

Governor Actuator Note: The 325C and 330C do not have governor actuators.

The operator selects an engine speed by placing the engine speed dial in one of the ten positions. The controller will determine if the engine is operating at the speed that was selected by comparing the engine speed with the engine speed sensor. If the engine is not operating at the selected speed the controller activates the governor actuator which moves the governor lever. The controller uses the governor feedback sensor to place the governor lever in a position that corresponds to the selected engine speed. The governor actuator uses a cable(s) to rotate the pulley. If the pulley is rotated counterclockwise, the governor lever that is connected to the pulley will move in the accelerate direction. If the pulley is rotated clockwise, the governor lever will move in the decelerate direction.

Related Components SMCS Code: 1931

Alternator The frequency output terminal of the alternator is connected to connector contact 235 of the controller. The controller will monitor the signal on this circuit. This signal informs the controller about the relative speed that the alternator is rotating. The frequency output terminal of the alternator is the "R" terminal.

Data Link The data link is an input and an output of the controller. The data link connects to the controller at connector contact 1-33 and 1-43. The data link is designed to carry communications between the controller and the monitor. The data link is not a visible Page 58 of 59

300C Engine and Pump Control S&O

component. The data link consists of internal control circuits and a harness wiring.

The data link is bidirectional. The controller can receive information and the controller can send information through the data link. The controller sends information about the fuel level, engine coolant temperature and many other signals to the monitor panel.

Action Lamp The FLASHING of the action lamp is designed to inform the operator about a condition that exists that requires a change in the operation of the machine. The controller will instruct the monitor panel to FLASH the action lamp when the controller determines that a warning category of 2 or 3 is present.

Action Alarm The action alarm connects to connector contact 2-23 of the controller. The SOUNDING of the action alarm will alert the operator when a high emergency condition is present. For example, the engine oil pressure decreases below a set value.

Travel Alarm The travel alarm connects to connector contact 2-13 of the controller. The SOUNDING of the travel alarm will alert the area that the machine is moving.

Input for Air Heater Indicator If the machine is equipped with an air heater, the air heater will be activated by the key start switch. The air heater will only activate if the temperature of the engine coolant is low. The controller will send a signal to the monitor. The monitor will show an indication that the air heater is active.

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