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SERV2110-01 - 11/17 -2- Course PARTICIPANT MATERIALS
Table Of Contents
Course Preparation
• Course Agenda............................................................................................................................. 5
• Course Description....................................................................................................................... 9
• Learning Outcomes.................................................................................................................... 10
• Course Pre-Work.........................................................................................................................11
INTRODUCTION
• Learning Outcomes.................................................................................................................... 13
• Lab 1: WALKAROUND COMPONENT IDENTIFICATION.......................................................... 14
Course Preparation
PARTICIPANT MATERIALS
Course Description
• Course purpose/reason This course is designed for participants to locate and identify components, test and
adjust components and systems, and gain knowledge of the operations and
strategies used in the 320/320GC/323 Next Generation Hydraulic Excavators. Lab
exercises will be used for skill development and knowledge check.
• Competency Statement At the completion of this course, you will be able to accurately locate and identify
machine and system components and demonstrate understanding of machine
functionality during classroom knowledge checks with at least 80% accuracy.
Learning Outcomes
• Course learning outcomes Upon completion of this 320/320GC/323 Next Generation Hydraulic Excavators
course, you will be able to:
• Locate and identify major machine components and service points
• Diagnose component and machine systems problems
• Use all machine operation controls in the operator’s station
• Test and adjust machine components and systems
• Describe systems and component operations and strategies
INTRODUCTION
PARTICIPANT MATERIALS
Learning Outcomes
• Module learning outcomes You will meet the following learning outcomes during this Introduction module of the
320/320GC/323 Next Generation Hydraulic Excavator course:
• Locate and identify the major components and service points during a machine
walkaround.
• Module Competency Statement At the completion of this module, you will be able to successfully complete the
following exercises:
• Lab 1 Component Identification
Instructions: Identify the following components and systems during your machine walkaround session. Check each item as it
is located.
_____ GNSS receiver and antenna _____ Hydraulic oil level gauge and cap
_____ Windshield wash fluid reservoir _____ Travel pedal position sensor
_____ Main control valve supply and return hoses _____ Clean emissions module
10
Learning Outcomes
• Module learning outcomes You will meet the following learning outcomes during this Electronic Control System
and Monitor module of the 320/320GC/323 Next Generation Hydraulic Excavators
course:
• Locate and identify the electronic control system components and monitor
screens.
• Identify the correct operation of the electronic control system circuits.
• Access and record machine data using the monitor, and make changes to
parameters.
• Module Competency Statement At the completion of this module, you will be able to successfully complete the
following exercises:
• Lab 1 Component Identification
• Lab 2 Electronic Control System Practical Usage Exercises
• Knowledge Check
Instructions: During the lab exercise, use this sheet as a checklist when identifying components and their functions.
1. LCD monitor
Function:
Function:
Function:
Function:
5. Engine ECM
Function:
Function:
Function:
Function:
Function:
1 0.0h
SMART
2 ISO/JIS 8:48 4
3
5 6
7 8 9 10
14
LAB 1: ELECTRONIC CONTROL SYSTEM AND MONITOR
Component Identification worksheet 2 Name: Date
Directions: Fill in the blanks next to the numbers with the correct component name.
1. 6.
2. 7.
3. 8.
4. 9.
5. 10.
Instructions: Follow the instructions below to access and gather information, make changes to settings, and adjust
parameters. During the lab exercise, use this sheet to record your findings.
Knowledge Check
2 1
0.0h ISO/JIS 8:48
SMART
6 5
7
3
8
2
8
10
19
3
7
1
Directions: Fill in the blanks next to the numbers with the correct component name.
1. 6.
2. 7.
3. 8.
4. 9.
5. 10.
Score:
1. The engine speed dial and AEC switches are inputs to the:
a. Engine ECM
b. Primary Machine ECM
c. Secondary Machine ECM
d. body control module
2. All of the following are input components to the Primary ECM except:
a. bucket angle sensor
b. fan speed sensor
c. operator seat switch
d. hydraulic lock switch
3. The monitor can receive direct video signals from up to ________ work area video cameras.
a. 2
b. 3
c. 4
d. 5
5. To determine when to employ the Delayed Engine Shutdown (DES) strategy, the Engine ECM considers what two things?
21
Learning Outcomes
• Module learning outcomes You will meet the following learning outcomes during this Main Hydraulic Pumps
module of the 320/320GC/323 Next Generation Hydraulic Excavators course:
• Locate and identify the components, service points, and adjustment points of
the main hydraulic pumps.
• Test, adjust, and calibrate the hydraulic pumps during a lab exercise.
• Identify the correct operation of the hydraulic pumps.
• Module Competency Statement At the completion of this module, you will be able to successfully complete the
following exercises:
• Lab 1 Component Identification
• Lab 2 Main Hydraulic Pumps Test and Adjust
• Knowledge Check
Instructions: During the lab exercise, use this sheet as a checklist when identifying components and their functions.
Function:
Function:
3. Pump regulator
Function:
4. Small actuators
Function:
5. Large actuators
Function:
Function:
Function:
6 5
4
7
1
3
1 2
24_1
Instructions: Fill in the blanks next to the numbers with the correct component name.
1. 5.
2. 6.
3. 7.
4.
Knowledge Check
3
5
4
2 6
1 7
15
14 13 12 10
11
9 8
26_1
Directions: Fill in the blanks next to the numbers with the correct component name.
1. 9.
2. 10.
3. 11.
4. 12.
5. 13.
6. 14.
7. 15.
8.
Score:
1. The main hydraulic pumps in the Next Gen HEX are electronically controlled by the:
a. Engine ECM
b. Primary Machine ECM
c. Implement ECM
d. Monitoring system
3. List the electronic inputs which control the pump flow rate and pump delivery pressure in the P-Q curve:
4. The small actuators ___________ the pump swashplate toward the _______________ angle stop.
a. destroke, maximum
b. destroke, minimum
c. upstroke, maximum
d. upstroke, minimum
5. The large actuators ___________ the pump swashplate toward the _______________ angle stop.
a. destroke, maximum
b. destroke, minimum
c. upstroke, maximum
d. upstroke, minimum
28
Learning Outcomes
• Module learning outcomes You will meet the following learning outcomes during this Main Control Valve and
Return Oil System module of the 320/320GC/323 Next Generation Hydraulic
Excavators course:
• Locate and identify the components, service points, and adjustment points of
the main control valve and return oil system.
• Test, adjust, and calibrate the main control valve and return oil system during a
lab exercise.
• Identify the correct operation of the main control valve and return oil system.
• Module Competency Statement At the completion of this module, you will be able to successfully complete the
following exercises:
• Lab 1 Component Identification
• Lab 2 Main Control Valve and Return Oil System Test and Adjust
• Knowledge Check
Instructions: During the lab exercise, use this sheet as a checklist when identifying components and their functions.
Function:
2. Auxiliary valve
Function:
Function:
Function:
Function:
Function:
Function:
Function:
Function:
Function:
Function:
Function:
Function:
3 6
9 5
7 8
4
2 1
32
LAB 1: MAIN CONTROL VALVE AND RETURN OIL SYSTEM
COMPONENT IDENTIFICATION WORKSHEET 2 Name: Date
Instructions: Fill in the blanks next to the numbers with the correct component name.
1. 6.
2. 7.
3. 8.
4. 9.
5.
Knowledge Check
3 4 5 6 7 8 9
1 2
24
20 22 10
21 34 11
19
12
18 17 16 15 14 13
34
Module 3 Knowledge Check WORKSHEET 1 Name: Date
Directions: Fill in the blanks next to the numbers with the correct component name.
1. 9.
2. 10.
3. 11.
4. 12.
5. 13.
6. 14.
7. 15.
8. 16.
17. 21.
18. 22.
19. 23.
20. 24.
Score:
1. There are how many primary valve spools in the main control valve?
a. 2
b. 5
c. 9
d. 12
4. In addition to the hydraulic tank, the major components of the return oil system are:
5. There are how many electronically controlled fans (e-fans) behind the coolers?
a. 2
b. 3
c. 4
d. 5
37
Learning Outcomes
• Module learning outcomes You will meet the following learning outcomes during this Boom, Stick, and Bucket
Circuits module of the 320/320GC/323 Next Generation Hydraulic Excavators
course:
• Locate and identify the components, service points, and adjustment points of
the boom, stick, and bucket circuits.
• Test, adjust, and calibrate the boom, stick, and bucket circuits during a lab
exercise.
• Identify the correct operation of the boom, stick, and bucket circuits.
• Module Competency Statement At the completion of this module, you will be able to successfully complete the
following exercises:
• Lab 1 Component Identification
• Lab 2 Boom, Stick, and Bucket Circuits Test and Adjust
• Knowledge Check
Instructions: During the lab exercise, use this sheet as a checklist when identifying components and their functions.
1. Operator controls
Function:
Function:
3. Boom cylinders
Function:
4. Stick cylinder
Function:
5. Bucket cylinder
Function:
Function:
Function:
Function:
Function:
Function:
Function:
Function:
4 2
3
2
1
1
4
5
10
9
8
3
2
1 4
7
3
6 8
6
7
41
LAB 1: BOOM, STICK, AND BUCKET CIRCUITS
COMPONENT IDENTIFICATION WORKSHEET 2 Name: Date
Instructions: Fill in the blanks next to the numbers with the correct component name.
1. 6.
2. 7.
3. 8.
4. 9.
5. 10.
1
2
3
6
18 20 9
3 6
14
19
5
25
8
23 22 9
21
4
19
15
8
24
7
20
12
5 18 11 10
17 16
13
42
LAB 1: BOOM, STICK, AND BUCKET CIRCUITS
COMPONENT IDENTIFICATION WORKSHEET 3 Name: Date
Instructions: Fill in the blanks next to the numbers with the correct component name.
1. 8.
2. 9.
3. 10.
4. 11.
5. 12.
6. 13.
7. 14.
15. 21.
16. 22.
17. 23.
18. 24.
19. 25.
20.
Knowledge Check
7
6
9
4
1
3 2
10
8
5
45
Module 4 Knowledge Check WORKSHEET 1 Name: Date
Directions: Fill in the blanks next to the numbers with the correct component name.
1. 6.
2. 7.
3. 8.
4. 9.
5. 10.
Score:
2. What prevents unexpected movement of the stick cylinders when the joystick is initially activated at a low pump delivery
pressure?
a. Stick unload valve
b. Stick 1 spool
c. Stick drift reduction valve
d. Load check valves
4. The ______________ prevents oil leakage from the head end of the stick cylinder, and prevents the stick from drifting
when the control lever is in neutral and the implements are suspended above the ground.
a. stick drift reduction valve
b. stick unload valve
c. stick line relief and makeup valve
d. main control valve
47
Learning Outcomes
• Module learning outcomes You will meet the following learning outcomes during this Swing Hydraulic System
module of the 320/320GC/323 Next Generation Hydraulic Excavators course:
• Locate and identify the components, service points, and adjustment points of
the swing hydraulic system.
• Test, adjust, and calibrate the swing hydraulic system during a lab exercise.
• Identify the correct operation of the swing hydraulic system.
• Module Competency Statement At the completion of this module, you will be able to successfully complete the
following exercises:
• Lab 1 Component Identification
• Lab 2 Swing Hydraulic System Test and Adjust
• Knowledge Check
Instructions: During the lab exercise, use this sheet as a checklist when identifying components and their functions.
1. Swing spool
Function:
Function:
Function:
Function:
5. Swing motor
Function:
6. Breather
Function:
Function:
8. Anti-reaction valves
Function:
9. Brake piston
Function:
Function:
Function:
1 2
4
3
6 7
9
8
51
LAB 1: SWING HYDRAULIC SYSTEM
COMPONENT IDENTIFICATION WORKSHEET 2 Name: Date
Instructions: Fill in the blanks next to the numbers with the correct component name.
1. 6.
2. 7.
3. 8.
4. 9.
5.
Knowledge Check
5
3
4
8
1
7
6
53
Module 5 Knowledge Check WORKSHEET 1 Name: Date
Directions: Fill in the blanks next to the numbers with the correct component name.
1. 5.
2. 6.
3. 7.
4. 8.
Score:
55
Learning Outcomes
• Module learning outcomes You will meet the following learning outcomes during this Travel Hydraulic System
module of the 320/320GC/323 Next Generation Hydraulic Excavators course:
• Locate and identify the components, service points, and adjustment points of
the travel hydraulic system.
• Test, adjust, and calibrate the travel hydraulic system during a lab exercise.
• Identify the correct operation of the travel hydraulic system.
• Module Competency Statement At the completion of this module, you will be able to successfully complete the
following exercises:
• Lab 1 Component Identification
• Lab 2 Travel Hydraulic System Test and Adjust
• Knowledge Check
Instructions: During the lab exercise, use this sheet as a checklist when identifying components and their functions.
Function:
2. Final drives
Function:
3. Swivel
Function:
Function:
5. Counterbalance valves
Function:
Function:
Function:
1 2 3
4
5
7
6
2
9
8
10
58
LAB 1: TRAVEL HYDRAULIC SYSTEM
COMPONENT IDENTIFICATION WORKSHEET 2 Name: Date
Instructions: Fill in the blanks next to the numbers with the correct component name.
1. 6.
2. 7.
3. 8.
4. 9.
5. 10.
Knowledge Check
12
13 13 TRAVEL MOTOR 5
12 6
14 5
7 3
14
2 8
11
7 9
2
10 1 9
10 1
60
Module 6 Knowledge Check WORKSHEET 1 Name: Date
Directions: Fill in the blanks next to the numbers with the correct component name.
1. 8.
2. 9.
3. 10.
4. 11.
5. 12.
6. 13.
7. 14.
Score:
1. The final drives _____________ and _____________ through a gear reduction system.
a. reduce travel motor speed, increase torque
b. increase travel motor speed, reduce torque
2. During low speed operation, the ______________ directs the high pressure oil to the pressure chamber at the left of the
maximum angle servo piston.
a. travel control valve
b. swashplate
c. brake pilot valve
d. displacement change valve
3. The travel counterbalance valves and crossover relief valves work together to perform what four functions?