Introduction

NOTE: This manual is divided into the following three main sections:

1. Electronic System Testing And Adjusting

2. Checking Procedures

3. Hydraulic System Testing And Adjusting

NOTE: As a general rule, if there is a doubt as to the cause of a problem, the electronic system should be checked first.

Reference: For information on Systems Operation of the above, make reference to: "Systems Operation, Electronic And Electrical Systems", Form No. SENR5404 and/or "Systems Operation, Hydraulic System", Form No. SENR5495.

This manual contains information on the troubleshooting procedures of the electronic control and hydraulic systems in the 330, 330 L, and 330 LN Excavators. For troubleshooting the engine components, refer to the module Systems Operation, Testing And Adjusting, Basic Engine Components 3306 Engine, Form No. SENR2057.

Checking Procedures

In each checking procedure, it is assumed that the engine operation is normal unless otherwise specified.

Electronic Control System

The monitor and electronic controller are the main components of the electronic control system. The monitor and electronic controller have a self diagnostic function. Self diagnostic checks of the monitor, electronic controller, and the communication line between them are the first steps when troubleshooting the problem(s) in the electronic system.

Action alarm indicators on the monitor panel, alert an operator to a problem in the electronic system. The controller service program "Data Mode" can also be used to identify the problems (see the section of this module "Data Mode"). If the service program is activated during machine operation, problem(s) that are monitored by the monitoring system are indicated on the character display. If the service program is activated when the machine operation is stopped, all existing problems and past problems (problems that have not been corrected) are indicated on the character display. To activate the controller service program "Data Mode", refer to the "Data Mode" section in this module.

Operational Tests

If the electronic power unit control system display indicates it is operating correctly, then do operational tests. Operate the machine, following the procedures described in the section "Hydraulic System Testing And Adjusting". Compare the results of the operational tests with specifications to determine the extent of the trouble. In operational tests, it is important to determine whether or not enough hydraulic force or implement speed is a problem that extends over the entire machine or with only a specific operation.

If there are any faults in the circuits between the main or pilot pumps and the control valves, the overall performance of the machine will decrease. This type of problem in the hydraulic system is not detected by the self diagnostic functions of the electronic control system described above (no action alarm indication on character display.). To detect such a problem, it is necessary to check the flow characteristics of the pumps, the main relief pressure, pilot pressure, etc.

Service Program

Electronic Monitor Panel

(1) Engine coolant temperature gauge. (2) Fuel gauge. (3) Action lamp. (4) Character display. (5) Monitor panel. (6) Hydraulic oil temperature gauge. (7) Work mode selector switch. (9) Charge alarm indicator. (10) Engine coolant temperature alarm indicator. (11) Hydraulic oil temperature alarm indicator. (12) Engine oil pressure alarm indicator. (13) Controller alarm indicator. (14) Monitor alarm indicator. (15) Work mode boom priority indicator. (16) Work mode swing priority indicator. (17) Power mode selector switch. (18) Power mode III indicator. (19) Power mode II indicator. (20) Power mode I indicator. (21) Work mode fine control indicator. (22) Light switch. (23) Light 1 indicator. (24) Light 2 indicator. (25) Wiper 2 indicator. (26) Travel speed HIGH (rabbit) indicator. (27) Travel speed LOW (tortoise) indicator. (28) Travel speed control switch. (29) AEC indicator. (30) Switch panel. (31) AEC switch. (32) Wiper 1 indicator. (33) Washer indicator. (34) Washer switch. (35) Wiper switch. (36) Alarm cancel switch. (37) Service switch. (38) Alarm cancel indicator.

Introduction

The electronic Monitor Panel activates and displays the output received from the Electronic Controller. The Electronic Controller Service Program is divided into two program modes. Each program mode has a particular function as follows:

1. Data Mode;

This program mode contains eight function modes and provides the necessary information for the mechanic to determine the machine condition.

2. Calibration Mode;

This program mode contains ten function modes and provides information used to adjust and confirm system/component functions after replacement of electronic control system components. This program level is also used to help the mechanic troubleshoot machine problems.

To activate the service program mode functions, use the control switches provided on the electronic monitor panel.

NOTE: Unexpected character display readings due to random operation of switches should be disregarded.

To select a desired function mode, first start a proper service program mode (see the section "Data Mode Start-up" and/or "Calibration Mode Start-up"). Next, operate the control switch(es) as specified, until the desired information is indicated on the character display.

When the selected service program function is no longer needed, use the proper procedure (see the section "Data Mode Stop Procedure" and/or "Calibration Mode Stop Procedure") to cancel.

Data Mode

NOTE: Activation of service program "Data Mode" does not affect any machine controls and operations except for the following:

The LED indicators for power mode switch, travel speed control switch, light switch, and wiper switch come ON only in flashing mode during activation of service program "Data Mode".

The Data Mode contains the following function modes which provide eight categories of information.

1. Power shift pressure.

2. Engine speed.

3. Engine coolant temperature.

4. Hydraulic oil temperature.

5. A/D (Analog/Digital) conversion.

6. Real time error.

7. Digital input.

8. Output control display.

Data Mode Start-up

Electronic Monitor Panel (Data Mode Start-up)
(4) Character display. (17) Power mode selector switch. (18) Power mode III indicator. (36) Alarm cancel switch. (38) Alarm cancel indicator.

NOTE: To access and view the eight available functions in the "Data Mode", the engine can either be running or shut down. If the engine is running the eight Data Mode functions can be viewed as operating values. If the engine is not running the starter switch must be in the "ON" position.

1. Depress and hold alarm cancel switch (36) until alarm cancel indicator (38) starts flashing.

2. While alarm cancel switch (36) is depressed, push power mode selector switch (17) until power mode III indicator (18) begins to flash. Release alarm cancel switch (36) and power mode selector switch (17).

3. The service program "Data Mode" is now activated and character display (4) will display the first function mode (power shift pressure) value.

NOTE: If switch (17) is held too long, the character display will sequence through the eight available function modes in the "Data Mode" program.

Data Mode Function Selection

Electronic Monitor Panel (Data Mode Function Selection)
(4) Character display. (17) Power mode selector switch. (18) Power mode III indicator. (36) Alert cancel switch.

1. Repeatedly push first alarm cancel switch (36) and then power mode switch (17) until the desired function mode is displayed on character display (4).

2. Each time both switches are pushed, the function mode changes in an increasing number sequence of the eight function modes in a repetitious manner.

3. At the same time that the function mode character is displayed the corresponding switch indicator comes on. To determine the function mode selected, look for the switch indicator which is flashing.

NOTE: If alarm cancel switch (36) is depressed for more than 2 seconds the Data Mode stops and character display (4) displays the engine speed dial position.

NOTE: Accessing the "Data Mode Functions" must be performed in the sequence shown in the following chart.

Each of the eight Data Mode functions has a designated indicator light. The following chart shows the eight Data Mode functions and their designated indicator lights:

Power Shift Pressure

Electronic Monitor Panel (Power Shift Pressure)
(4) Character display. (17) Power mode selector switch. (18) Power mode III indicator. (36) Alarm cancel switch.

When this function mode is selected, power mode III indicator (18) flashes. The character display (4) displays "P" in the first position and actual power shift pressure in the second and third positions. The unit of power shift pressure is in kgf/cm². 1 kgf/cm² is approximately the same as 100 kPa (14 psi).

Engine Speed

Electronic Monitor Panel (Engine Speed)
(4) Character display. (19) Power mode II indicator.

When this function mode is selected, power mode II indicator (19) flashes. Character display (4) will display the engine speed in rpm, regardless of the machine load. Multiply the rpm values in character display (4) by 10 to determine actual rpm.

Engine Coolant Temperature

Electronic Monitor Panel (Engine Coolant Temperature)
(4) Character display. (20) Power mode I indicator.

When this function mode is selected, power mode I indicator (20) flashes. Character display (4) displays the engine coolant temperature within a range of -40°C to 127°C (-40°F to 260°F). The engine coolant temperature units are displayed in 1°C (1.8°F) increments. If the character display reading is below 0°C, the first position on the character display reads "-".

NOTE: Character display (4) displays the engine coolant temperature in degrees Celsius.

Hydraulic Oil Temperature

Electronic Monitor Panel (Hydraulic Oil Temperature)
(4) Character display. (23) Light 1 indicator.

When this function mode is selected, light 1 indicator (23) flashes. Character display (4) displays the hydraulic oil temperature within a range of -40°C to 127°C (-40°F to 260.6°F). The hydraulic oil temperature units are displayed in 1°C (1.8°F) increments.

NOTE: Character display (4) displays the hydraulic oil temperature in degrees Celsius.

A/D (Analog/Digital) Conversion

Electronic Monitor Panel (A/D Conversion)
(4) Character display. (24) Light 2 indicator.

When the analog/digital conversion function mode is selected, light 2 indicator (24) flashes. Character display (4) displays the analog information for eight machine functions. A conversion chart is needed to understand the digital information indicated. Description of the eight machine functions omitted since this information is not needed for service or diagnosis.

Real Time Error Codes

Electronic Monitor Panel (Real Time Error Codes)
(4) Character display. (26) Travel speed HIGH (rabbit) indicator.

When this mode is selected, travel speed HIGH (rabbit) indicator (26) flashes. Character display (4) displays the codes for problems that have occurred. They are displayed in an increasing number sequence according to "Problem List" shown below, in a repetitious manner. A character display code remains displayed for 2 seconds with an interval of 1 second between codes.

NOTE: A display code of [E00] indicates that there are no system errors.

NOTE: Go to the appropriate "Electronic Sequence Chart" to troubleshoot the problem of [E33] in accordance with the following:

Digital Input

Electronic Monitor Panel (Digital Input)
(4) Character display. (7) Work mode switch. (17) Power mode selector switch. (27) Travel speed LOW (tortoise) indicator. (36) Alarm cancel switch.

When this mode is selected, travel speed LOW (tortoise) indicator (27) flashes. This mode displays 21 types of information on character display (4).

1. Depress and hold alarm cancel switch (36) and then depress power mode switch (17) until travel speed LOW (tortoise) indicator (27) flashes. Release alarm cancel switch (36) and power mode switch (17).

2. Character display (4) will display [0 3] or [0 4]. The "0" indicates that this is the first of 21 "ports" or additional types of information. The " 3" or " 4" indicates the wiring harness code for the 330, 330 L, and 330 N Excavators with 3306 engine.

3. To sequence through the 21 "ports", first depress and hold alarm cancel switch (36) and then work mode switch (7) until the character display reads the desired "port".

NOTE: This mode is capable of providing a total of 21 types of information. Eight of the 21 "ports" (additional types of information) are spares.

The following chart gives a listing of the 21 "ports" and their components:

Typical Examples:

[0 3]: Indicates the machine model of "330" "330 L", or "330 N" excavator with 3066 engine. If a different code appears in the second and third positions, check the circuit for good grounding.

[1 1]: Engine speed dial is in position "1".

[110]: Engine speed dial is in position "10".

[1Er]: There is a problem in engine speed dial or circuit between speed dial and controller. (Er:error)

[2On]: Travel pressure switch is ON.

[2oF]: Travel pressure switch is OFF.

NOTE: To check the travel pressure switch, activate the travel control with the pressure switch is ON position. If the character display does not read [2On], it is an indication of a possible problem in the travel pressure switch and/or its circuit.

Output Control Display

Electronic Monitor Panel (Output Control Display)
(4) Character display. (32) Wiper 1 indicator.

When this function mode is selected, wiper 1 indicator (32) flashes. Character display (4) displays the code that represents current pump output. The initial code displayed will be [L00] for a normal pump output control. The character display code remains ON for 2 seconds with an interval of 0.5 seconds between codes.

Typical Examples:

[L00]: Output control is normal.

[LA]: Pump output control when governor actuator feedback sensor is abnormal.

[Lb]: Pump control under too low hydraulic oil temperature.

NOTE: [Lb] is displayed only when one of the controls is activated.

NOTE: During "Output Control Display" function, the AEC system and one touch low idle do not activate. The engine speed dial switch controls the engine speed only under a no load condition.

Reference: For more information on the pump output control, refer to module, "Systems Operation, Electronic System", Form No. SENR5404.

Data Mode Stop Procedure

Electronic Monitor Panel (Stop Procedure)
(4) Character display. (36) Alarm cancel switch.

Use either of the following two methods.

1. Turn the engine start switch to the OFF position.

2. Keep alarm cancel switch (36) depressed at least 2 seconds until character display (4) displays the engine speed dial position.

Calibration Mode

NOTE: The procedures for each function in "Calibration Mode" are independent of each other. The engine does not need to be running for all the functions listed in the following chart. The following chart lists the functions in "Calibration Mode" and whether the engine must be running for each of the functions:

Calibration Mode Start-up

Electronic Monitor Panel (Calibration Mode Start-up)
(1) Engine coolant temperature gauge. (2) Fuel gauge. (3) Action lamp. (4) Character display. (6) Hydraulic oil temperature gauge. (9) Charge alarm indicator. (10) Engine coolant temperature alarm indicator. (11) Hydraulic oil temperature alarm indicator. (12) Engine oil pressure alarm indicator. (13) Controller alarm indicator. (14) Monitor alarm indicator. (37) Service switch.

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NOTICE
Before to starting the Calibration Mode, the engine speed dial switch should be set at dial position "1" and the engine start switch must be in the OFF position.

1. Depress service switch (37) and start the engine. As shown in the chart above, the engine does not need to be started to obtain information for certain functions in the "Calibration Mode".

2. Continue to depress service switch (37) until action lamp (3) comes ON and character display (4) displays [30C]. All the alarm indicators except character display (4) will turn OFF.

3. The "Calibration Mode" is now accessed and character display (4) displays the first of the 10 functions (machine and engine model numbers) as shown in the chart above. Action lamp (3) remains ON during all calibration function modes.

NOTE: Activation of the "Calibration Mode" overrides the AEC function and keeps the power shift pressure constant at a pressure level equivalent to a no-load condition. The engine speed dial switch works normally.

NOTE: Activation of the "Calibration Mode" overrides the function of engine coolant temperature gauge (1), fuel gauge (2), action lamp (3), hydraulic oil temperature gauge (6), charge alarm indicator (9), engine coolant temperature alarm indicator (10), hydraulic oil temperature alarm indicator (11), engine oil pressure alarm indicator (12), controller alarm indicator (13), and monitor alarm indicator (14).

Calibration Mode Function Selection

Electronic Monitor Panel (Function Selection)
(3) Action lamp. (4) Character display. (17) Power mode selector switch. (22) Light switch. (28) Travel speed control switch. (31) AEC switch. (35) Wiper switch.

Power mode selector switch (17), light switch (22), AEC switch (31), wiper switch (35), and travel speed control switch (28) are pushed each time to obtain one of ten function modes.

Machine And Engine Model

Electronic Monitor Panel (Machine And Engine Model)
(4) Character display. (17) Power mode selector switch. (18) Power Mode III indicator.

1. Start "Calibration Mode". See the section, "Calibration Mode Start-up".

Upon accessing the "Calibration Mode", the machine and engine model is the first function accessed. To obtain this function again after viewing or accessing any of the other functions, depress power mode selector switch (17) until power Mode III indicator (18) comes ON.

2. Character display (4) displays [30C], [30A], or [30F] for a "330", "330 L", or "330 LN" excavator. The first and second positions of character display (4) shows the code for the model excavator. The third position of character display (4) represents the equipped engine or machine configuration.

3. Stop "Calibration Mode" (unless another function selection is desired). See the section, "Calibration Mode Stop Procedure".

Controller/Monitor Software Version

Electronic Monitor Panel (Controller/Monitor Software Version)
(4) Character display. (17) Power mode selector switch. (19) Power Mode II indicator. (31) AEC switch.

1. Start "Calibration Mode". See the section, "Calibration Mode Start-up".

2. Depress power mode selector switch (17) until power Mode II indicator (19) comes ON.

3. Character display (4) displays [00C] for example. The "00" in the character display represents a two digit numeral particular to the software for each machine mode. The "C" represents the controller.

4. To determine the software version for the monitor depress AEC switch (31). Character display (4) displays [20P] for example. The "20" in the character display represents a two digit numeral particular to the software for each machine mode. The "P" represents the software version.

NOTE: Each time AEC switch (31) is depressed, the character display will alternate between the two software codes [00C] and [20P] for example.

5. Stop "Calibration Mode" (unless another function selection is desired). See the section, "Calibration Mode Stop Procedure".

Error log

Electronic Monitor Panel (Error Log)
(4) Character display. (17) Power mode selector switch. (20) Power Mode I indicator. (28) Travel speed control switch. (31) AEC switch. (34) Washer switch.

1. Start "Calibration Mode". See the section, "Calibration Mode Start-up".

2. Depress power mode selector switch (17) until power Mode I indicator (20) comes ON.

3. Character display (4) displays [Hd ]. This display indicates that the list of stored error codes can be viewed. The controller has a continual self-diagnostic function during machine operation. The controller will store error codes if a fault is detected, even an intermittent fault. The list of error codes is stored in the error history on important systems until the memory is cleared.

4. The error codes are viewed on the character display either in ascending or descending order. Each time AEC switch (31) is depressed, the ascending sequential list of stored error codes are displayed as shown in the following example:

[Hd ]

[F6]

[F10]

[F40]

[F41]

[End]

5. Each time washer switch (34) is depressed, the descending sequential list of stored error codes are displayed as shown in the following example:

[End]

[F41]

[F40]

[F10]

[F6]

[Hd]

NOTE: A "F" in the first position of character display (4) represents a stored error code (error history). An "E" in the first position of character display (4) represents a real time error code.

6. To clear the error codes and error history, push and hold in sequence for approximately three seconds the following three buttons:

* AEC switch (31)

* Power mode selector switch (17)

* Travel speed control switch (28)

7. The error codes are cleared from the error history memory when character display (4) displays [CLr] and then returns to display [Hd].

Reference: For a listing of error codes, see the section in this module "Data Mode, Real Time Errors Codes"

NOTE: Information about a problem is stored by this function mode until the correct clearing procedure is completed. Always clear the error history after the problem has been corrected.

NOTE: Activation of the error log mode overrides the function of the AEC system and keeps the power shift pressure constant at the no load pressure level. The engine speed dial works normally.

8. Stop "Calibration Mode" (unless another function selection is desired). See the section, "Calibration Mode Stop Procedure".

NOTE: The following error log codes are not displayed on the character display during activation of this calibration mode.

F1 to F5, F7, F9, F12, F15, F32, F34, F37, F38, F39, and F48.

Digital Output Test

Electronic Monitor Panel (Digital Output Test)
(4) Character display. (22) Light switch. (23) Light 1 indicator. (29) AEC indicator. (31) AEC switch. (33) Washer indicator. (34) Washer switch. (36) Alarm cancel switch.

1. Start "Calibration Mode". See the section, "Calibration Mode Start-up".

2. Depress light switch (22) until light 1 indicator (23) comes ON.

3. Character display (4) displays [0oF] which represents the first of 10 components that can be tested. There are 16 "ports" available of the electrical connections for various controller output components (similar to the "Digital Input" information accessed in "Data Mode"). Six of the "ports" are spares. The code in the first position of the character display represents the particular "port" of each component.

The "ports" and their components are shown in the following chart:

4. Each time AEC switch (31) is pushed, a different port code appears in character display (4) in an ascending order. Press washer switch (34) to view the ports in descending order.

5. Press alarm cancel switch (36) to turn the component for each port, either ON or OFF. Character display (4) displays as shown in the chart above as each port is turned ON or OFF. If an over current occurs at a component, the character display (4) displays [0Er].

6. Stop "Calibration Mode" (unless another function selection is desired). See the section, "Calibration Mode Stop Procedure".

Proportional Reducing Valve Sweep Test

Pilot Oil Manifold Compartment
(39) Connector.

1. Stop the engine and disconnect connector (39) from the proportional reducing valve.

2. Connect the test harness to connector (39).

Main Pump Compartment
(40) Power shift pressure tap.

3. Install a 4900 kPa (700 psi) pressure gauge at power shift pressure tap (40).

4. The pump backup switch must be in the "AUT" position.

5. Start "Calibration Mode". See the section, "Calibration Mode Start-up".

NOTE: The engine must be running to obtain accurate information for this test.

6. Warm the hydraulic oil to normal operating temperature.

7. Run the engine at maximum no-load rpm.

8. All controls must be in the NEUTRAL position.

Electronic Monitor Panel (Proportional Reducing Valve Sweep Test)
(4) Character display. (22) Light switch. (24) Light 2 indicator.

9. Start the "Proportional Reducing Valve Sweep Test" as follows:

a. Depress light switch (22) until light 2 indicator (24) comes ON.

b. The left column of character display (4) displays the letter "P". The "P" in the first column indicates that the proportional reducing valve is being tested.

NOTE: The purpose of this function is to check whether the proportional reducing valve is activating with a current signal from the controller. When this function is selected, the second and third column in character display (4) changes in an ascending number sequence from of 0 to 32. One cycle range from 0 to 32 takes about five seconds. The character display (4) sequences form [P 0] to [P32].

10. As the "PRV Sweep Test" is being performed, monitor the multimeter and the 4900 kPa (700 psi) pressure gauge.

The multimeter reading changes within a range of 0.16 to 0.63 amps in approximately five seconds. The pressure gauge at power shift pressure tap (40) simultaneously ranges from 0 to 3150 kPa (0 to 455 psi).

NOTE: During the "PRV Sweep Test" the multimeter and pressure gauge readings should cycle at a uniform rate of increase or decrease (no "spike" or quick changes). Also, during activation of this function mode, AEC functions do not activate, but speed dial activates as normal.

11. Stop "Calibration Mode" (unless another function selection is desired). See the section, "Calibration Mode Stop Procedure".

Engine Speed Change

NOTE: This test is useful to measure no load engine speeds in increments of 20 to 30 rpm, from the factory preset LOW IDLE to HIGH IDLE positions of the governor speed dial switch. This test is suitable for noise level measurement tests.

Electronic Monitor Panel (Engine Speed Change)
(4) Character display. (29) AEC indicator. (31) AEC switch. (32) Wiper 1 indicator. (33) Washer indicator. (34) Washer switch. (35) Wiper switch.

1. Start "Calibration Mode". See the section, "Calibration Mode Start-up".

2. Depress wiper switch (35) until wiper 1 indicator (32) comes ON.

3. Put the governor speed dial switch in the best position for the test requirement (the position that comes closest to the desired engine rpm setting).

4. Depress AEC switch (31) to increase the engine rpm, and depress washer switch (34) to decrease engine rpm. Each time AEC switch (31) is depressed, AEC indicator (29) comes ON. Each time washer switch (34) is depressed, washer indicator (33) comes ON.

5. Character display (4) will increment by 1 (10 rpm).

6. Stop "Calibration Mode" (unless another function selection is desired). See the section, "Calibration Mode Stop Procedure".

Fixed Power Shift Pressure

NOTE: This test allows the power shift pressure command signal to remain constant at a desired pressure level. The constant power shift pressure command signal is necessary to allow testing and adjusting procedures to be performed to line relief valves and also perform pump "P-Q" tests.

Electronic Monitor Panel (Fixed Power Shift Pressure)
(4) Character display. (25) Wiper 2 indicator. (31) AEC switch. (34) Washer switch. (35) Wiper switch. (36) Alarm cancel switch.

1. Start "Calibration Mode". See the section, "Calibration Mode Start-up".

2. Depress wiper switch (35) until wiper 2 indicator (25) comes ON.

3. Character display (4) will display "P" in the first position and the selected power shift pressure in the second and third positions. As a example the value shown in character display (4) of [P25] is in kgf/cm². To convert kgf/cm² to kPa, multiply the value shown in character display (4) by 100. The resultant power shift pressure is 2450 kPa (355 psi).

4. Depress AEC switch (31) to increase the power shift pressure command signal by 1 kgf/cm² within a range of 3 to 30 kgf/cm² [290 to 2950 kPa (42 to 430 psi)].

5. Depress washer switch (34) to decrease the power shift pressure command signal by 1 kgf/cm² within a range of 3 to 30 kgf/cm² [290 to 2950 kPa (42 to 430 psi)].

NOTE: Depressing alarm cancel switch (36) causes character display (4) to display alternately between the power shift pressure and the engine rpm.

NOTE: Refer to "Engine Speed Change" to determine the value of engine speed displayed on character display (4).

6. Stop "Calibration Mode" (unless another function selection is desired). See the section, "Calibration Mode Stop Procedure".

Engine Speed Dial Setting Check

NOTE: This test is used to verify that the selected engine speed dial switch position value is meeting the factory engine speed setting value.

Electronic Monitor Panel (Engine Speed Dial Setting Check)
(4) Character display. (26) Travel speed HIGH (Rabbit) indicator. (28) Travel speed control switch.

1. Start "Calibration Mode". See the section, "Calibration Mode Start-up".

2. Depress travel speed control switch (28) until travel speed HIGH (Rabbit) indicator (26) comes ON.

3. Character display (4) displays the engine rpm value characteristic to the setting of the engine speed dial switch position.

4. Stop "Calibration Mode" (unless another function selection is desired). See the section, "Calibration Mode Stop Procedure".

Automatic Governor Actuator (G/A) Calibration

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NOTICE
The hydraulic oil temperature must be at the normal operating temperature before this calibration procedure is performed.

NOTE: This procedure must be performed any time the governor actuator or controller has been replaced or reinstalled.

NOTE: Activation of this mode overrides the AEC system function, and keeps the power shift pressure constant at the no load pressure level. The engine speed dial can be placed at any position since it cannot activate until the governor actuator calibration has been completed. The governor backup switch must be in AUT (not backup) position.

Electronic Monitor Panel (Automatic Governor Actuator Calibration)
(4) Character display. (26) Travel speed HIGH (Rabbit) indicator. (28) Travel speed control switch. (31) AEC switch. (34) Washer switch. (36) Alarm cancel switch.

1. Start "Calibration Mode". See the section, "Calibration Mode Start-up".

2. Depress travel speed control switch (28) until travel speed HIGH (Rabbit) indicator (26) comes ON.

3. Depress and hold AEC switch (31) then depress and hold washer switch (34). Character display (4) displays [AC] in a flashing mode.

4. While still depressing AEC switch (31) and washer switch (34), depress alarm cancel switch (36) until character display (4) stops flashing and changes to [ACP]. The automatic calibration mode is now started and the governor actuator motor has moved to the initial high idle stop position. The governor actuator is now calibrated to the factory engine rpm setting designated for position "10" of the engine speed dial switch.

5. Once character display (4) displays [ACt], the calibration procedure can be completed.

6. Depress AEC switch (31) and washer switch (34) in sequence until character display (4) displays [AC1]. The calibration procedure for the factory engine rpm setting designated for positions "1" through "10" of the engine speed dial switch is now started. The calibration procedure from this point takes approximately two minutes. Character display (4) will change as follows:

NOTE: After initial setting has been completed, check to be sure that the governor lever is correctly positioned (in contact with the high idle stopper) by rotating the pulley by hand.

When [AC0] appears in character display (4), the calibration procedure is complete.

NOTE: If the data is not correct or within specified limits, character display (4) will indicate an error code as shown in the following chart:

NOTE: If character display (4) displays [AC2] and [- *] (*: error code shown in the following chart) alternately during Automatic G/A Calibration procedure, it is an indication of the following possible problems. Have necessary repairs made. If character display (4) displays [AC0] after taking corrective action, it indicates that the automatic governor actuator calibration has been completed correctly.

NOTE: If the error code [- 1], [- 2], [- 3], [-15], or [-16] is indicated on character display (4), readjust the accelerator/decelerator cables. See the section "Adjustment After Replacement Of Major Components".

NOTE: If the error code [- 4] through [-12] or [-14] is indicated on character display (4), check the corresponding checking procedure in the section "Checking Procedures (Electronic Control System)".

NOTE: When character display (4) displays [-13], return all controls to the NEUTRAL position. If the problem code still exists, check the pressure switches and circuits.

7. Stop "Calibration Mode" (unless another function selection is desired). See the section, "Calibration Mode Stop Procedure".

Calibration Of Proportional Reducing Valve

NOTE: This calibration procedure must be performed when either the proportional reducing valve and/or the controller has been replaced. This procedure is made at two power shift pressure points of 5 kgf/cm² [490 kPa (72 psi)] and 25 kgf/cm² [2450 kPa (355 psi).

Main Pump Compartment
(40) Power shift pressure tap.

1. Stop the engine and install a 4900 kPa (700 psi) pressure gauge to power shift pressure tap (40).

2. Make sure that the pump control backup switch is in the "AUT" position.

3. Start the "Calibration Mode". Refer to the section "Calibration Mode Start-up".

NOTE: The engine must be running and have a hydraulic oil temperature of approximately 50°C (122°F) to perform this calibration procedure.

4. Run the engine with engine speed dial switch at position "10".

NOTE: Activation of this calibration mode overrides the AEC function. If the engine speed dial switch is not at position "10" character display (4) will show an "E" in the first column. The engine speed must be corrected within specifications to continue the calibration procedure.

Electronic Monitor Panel (Calibration Of Proportional Reducing Valve)
(4) Character display. (27) Travel speed LOW (tortoise) indicator. (28) Travel speed control switch. (31) AEC switch. (34) Washer switch. (36) Alarm cancel switch.

5. Depress travel speed control switch (28) until travel speed LOW (tortoise) indicator (27) comes ON.

6. Character display (4) now displays [1 0]. The "1" indicates that the first calibration point has been accessed and the "0" indicates that the middle step of the 19 individual calibration steps has been accessed. Each step will change the power shift pressure by approximately 50 kPa (7.5 psi).

7. To change the power shift pressure:

a. To increase the power shift pressure, depress AEC switch (31) once. This will change character display (4) to [1 2]. Each time AEC switch (31) is depressed, character display (4) increases by one until character display (4) displays [1 9]. Also, the pressure reading at power shift pressure tap (40) increases by approximately 50 kPa (7.5 psi) for each increase. The following is an example of character display (4) readings in increasing order:

b. To decrease the power shift pressure, depress washer switch (34) once to lower the value displayed in character display (4). Each time washer switch (34) is depressed, character display (4) decreases by one in descending order until character display (4) displays [1-9]. Also, the pressure reading at power shift pressure tap (40) decreases by 50 kPa (7 psi) for each decrease. The following is an example of character display (4) readings in decreasing order:

8. To set "Calibration Point No. 1", perform the following steps:

a. Depress washer switch (34) until the pressure reading at tap (40) is less than 490 kPa (72 psi).

b. Depress AEC switch (31) until the pressure reading at tap (40) increases to approximately 490 kPa (72 psi).

NOTE: Pressure adjustments must always be made as the pressure is being increased.

c. Depress alarm cancel switch (36) to store the data in the controller.

d. Once the data is stored in the controller, display (4) changes to [2 0], which indicates that the first calibration point has been accepted and the second calibration point can be performed. At this time, the character display flashing light mode will change to a continuous lighting mode.

9. To set "Calibration Point No. 2", perform the following steps:

a. Depress washer switch (34) until the pressure reading at tap (40) is less than 2450 kPa (355 psi).

b. Depress AEC switch (31) until the pressure reading at tap (40) increases to approximately 2450 kPa (355 psi).

NOTE: Pressure adjustments must always be made as the pressure is being increased.

c. Depress alarm cancel switch (36) to store the data in the controller.

d. Once the data is stored in the controller, display (4) will change to [1 0], which indicates that the second calibration point has been accepted and the controller has reset to the first calibration point.

10. Stop "Calibration Mode" (unless another function selection is desired). See the section, "Calibration Mode Stop Procedure".

Calibration Mode Stop Procedure

Electronic Monitor Panel (Stopping Calibration Mode)
(4) Character display. (37) Service switch.

Use either of the following two methods:

1. Place engine in low idle position and turn the engine start switch to the OFF position.

2. Depress service switch (37) for a minimum of two seconds until character display (4) changes from "Calibration Mode" to engine speed dial position.

Adjustment After Replacement Of Major Components

When major components of the electronic control system have been replaced, adjustment is required.

The major components include:

* Governor actuator

* Proportional reducing valve

* Engine speed sensor

* Controller

Governor Actuator

Pump Compartment
(1) Accelerator cable. (2) Connector. (3) Governor actuator. (4) Decelerator cable.

Engine Compartment
(5) Pulley. (6) Inner cable wire (accelerator). (7) Outer cable wire (decelerator).

Installation Of Accelerator And Decelerator Cables
(1) Accelerator cable. (4) Decelerator cable. (5) Pulley. (6) Inner cable wire (accelerator). (7) Outer cable wire (decelerator). (8) Locknut. (9) Nut. (10) Support. (11) Nut. (12) Slot. (13) Locknut.

Initial Setting Of Governor Actuator

NOTE: This procedure is not necessary for a new governor actuator that is correctly calibrated for the initial (factory) dial setting position "10".

1. Connect the harness of governor actuator (3) to connector (2).

2. Determine the high idle position "10" (initial setting) by activating the automatic actuator calibration mode. See the section in this module "Calibration Mode", Automatic Governor Actuator (G/A) Calibration"

Adjustment Of Accelerator Cable

1. Accelerator cable (1) is identified by its seal. Turn nut (11) and locknut (13) of accelerator cable (1) counterclockwise until they are as far apart as possible.

NOTE: If the identification seal is missing, accelerator cable (1) is the upper cable when viewed from the governor actuator (3).

2. Place inner cable wire (6) into the inner groove (groove closest to the engine) of pulley (5).

3. Wrap inner cable wire (6) around (counterclockwise as viewed from the top of the machine) pulley (5).

4. Put the "T" end of inner cable wire (6) into slot (12). Make sure the "T" end of inner cable wire (6) is in line with the inner groove (groove closest to the engine) after installation.

5. Put the threaded portion of accelerator cable (1) in the upper notch of support (10).

6. Turn pulley (5) clockwise (as viewed from the top of the machine) to the high idle stop position (full rotation position).

7. Hold pulley (5) against the high idle stop position and turn nut (11) clockwise until the slack is removed from inner wire (6). Tighten nut (11) approximately an additional two turns by hand.

8. Torque (standard torque) locknut (13) against support (10).

Adjustment Of Decelerator Cable

1. Turn nut (8) and locknut (9) of decelerator cable (4) counterclockwise until they are as far apart as possible.

2. Place outer cable wire (7) into the outer groove (groove farthest from the engine) of pulley (5).

3. Wrap outer cable wire (7) around (clockwise as viewed from the top of the machine) pulley (5).

4. Put the "T" end of outer cable wire (7) into slot (12). Make certain the "T" end of outer cable wire (7) is in line with outer groove (groove farthest from the engine) after installation.

5. Put the threaded portion of decelerator cable (4) in the upper notch of support (10). Make certain outer cable wire (7) remains in outer groove of pulley (5).

6. Finger tighten nut (9) against support (10).

7. Loosen nut (9) approximately two turns to provide slack in outer cable wire (7).

8. Torque (standard torque) locknut (8) against support (10). Make certain nut (9) remains in position of threaded portion of decelerator cable (4) while tightening locknut (8) against support (10).

9. Reinstall clamps to decelerator cable (4) and accelerator cable (1). Do not allow the cables to twist.

NOTE: Check to be sure that the governor lever is in contact with the high idle stop lever. Also make sure nuts (11) and (9) are correctly tightened so that accelerator cable (1) is under tension and decelerator cable (4) has a small amount of slack. Failure to do so could result in incorrect engine speed setting, or overload the governor actuator. Governor actuator (3) must not be operated until the calibration procedure is complete. If actuator (3) is operated before the calibration procedure is complete, recalibrate.

Calibration Of Governor Actuator

Reference: Make reference to the section in this module, "Calibration Mode", "Automatic Governor Actuator Calibration".

1. Start the engine and perform the "Automatic Governor Actuator Calibration" by activating "Calibration Mode Start-up".

2. After correctly calibrated, clear the error log information.

Reference: Make reference to the section in this module, "Calibration Mode", "Error Log".

Proportional Reducing Valve

1. Calibrate the proportional reducing valve.

Reference: See the section of this module, "Calibration Of Proportional Reducing Valve" in "Calibration Mode".

2. After the proportional reducing valve is correctly calibrated, clear the error log information.

Reference: See the section of this module, "Error Log" in "Calibration Mode".

Engine Speed Sensor (Magnetic Pickup)

Installation Of Engine Speed Sensor
(1) Speed sensor. (2) Locknut. (3) Magnetic core. (4) Gear. (5) Flywheel housing.

Show/hide table

NOTICE
The engine must not be running prior to adjustment of the engine speed sensor.

1. With the engine stopped, slowly tighten speed sensor (1) into flywheel housing (5) until magnetic core (3) is in contact with gear (4).

2. Back out speed sensor 1/2 turn and temporarily tighten locknut (2).

3. With the engine speed dial switch set at position "1" (LOW IDLE position) start the engine.

4. Start service program "Data Mode" and select the engine speed display function.

Reference: Make reference to the section in this module, "Data Mode", "Engine Speed".

5. The character display should read a speed of approximately 800 rpm.

6. If the character display does not read correct rpm, gradually tighten speed sensor (1). Do not turn more than 120°.

7. If satisfactory, stop the engine and tighten locknut (2) to a torque of 44 N·m (32 lb ft).

8. After the speed sensor calibration is correct, clear the error log information.

Reference: See the section in this module, "Error Log" in "Calibration Mode".

Controller

1. Before removal/installation of the controller, be sure to turn the disconnect switch to the OFF position.

2. Perform the automatic governor calibration procedure.

Reference: See the section in this module, "Automatic Governor Actuator Calibration" in "Calibration Mode".

3. Perform the proportional reducing valve calibration procedure.

Reference: See the section in this module, "Calibration Of Proportional Reducing Valve" in "Calibration Mode".

Controller Input And Output Schematic (Voltage Signals In Normal Operating Condition)

Terminal (Pin) Numbers Of Controller Connection And Voltage Specifications

Voltage Specifications