Case CX 210 Exc Trainnig Service

Construction Equipment Service Training

CX SERIES EXCAVATOR

Section 1 -GENERAL INTRODUCTION CNH Engine Diagnostic Class (2004)

CNH America LLC 700 STATE STREET RACINE, WI 53404 U.S.A.

 2004 All Rights Reserved Printed in U.S.A.

GENERAL INTRODUCTION

TABLE OF CONTENTS Section 1 - General Introduction PAGE NO.

Engines ...................................................................................................................... 2 Reservoir.................................................................................................................... 3 Filters ......................................................................................................................... 3 Pumps ........................................................................................................................ 4 Pilot System ............................................................................................................... 5 Hydraulic Systems ..................................................................................................6-7 Cushion Control ......................................................................................................... 7 Swing ......................................................................................................................... 7 Travel ......................................................................................................................... 8 Cylinders .................................................................................................................... 9 Electrical System.................................................................................................10-11

1-1

CX EXCAVATORS

GENERAL INTRODUCTION

EXPLANATION OF CX SERIES Engines MODEL

CX130

CX160

CX210

CX240

Make

CASE

CASE

CASE

CASE

Model

4TA390

4TA390

6TAA590

6TAA590

HP (net)

106

106

138

163

Cold Start

Ether

Ether

Electric

Electric

Rated rpm

2200

2200

1950

2150

When programming the excavators, the manufacture model number must be used. Detailed procedures are in section 3 of this training manual.

Manufacture model number

Case model number

SHO120

CX130

SHO150

CX160

SHO200

CX210

SHO220

CX240

When programming the excavators, the following codes will be used to change the language if necessary. Detailed procedures are in section 3 of this training manual. LANGUAGE

MODE NO.

LANGUAGE

MODE NO.

LANGUAGE

MODE NO.

Japanese

0

Italian

6

Swedish

12

English

1

Spanish

7

Finnish

13

Thai

2

Portuguese

8

Picture writing

14

Chinese

3

Dutch

9

German

4

Danish

10

French

5

Norwegian

11

1-2

CX EXCAVATORS

GENERAL INTRODUCTION

EXPLANATION OF CX SERIES Reservoir The reservoir is pressurized on all models. The air charge is provided by thermal expansion and the differential area of the cylinders as they are stroked the first time. There is a breather/pressure regulator/fill cap installed in the top cover of the excavators. A rubbercovered button on top of the breather is provided to release the air pressure in the reservoir. A sight gauge mounted to the side of the reservoir indicates the oil level. There is a 150-mesh screen at the outlet of the reservoir to the hydraulic pump.

Reservoir MODEL

CX130

CX160

CX210

CX240

Capacity Tank gal.

19

32

32

32

Capacity System gal.

32

38

54

59

Filters The oil returning from the main control valve flows through the oil cooler. There is a cooler bypass valve in the circuit to protect the system during cold start conditions. As the oil returns from the oil cooler, it passes through a full flow 10-micron filter. Some of the return oil is routed through a 1-micron ultra-fine filter. Drain oil from the pilot control circuits and the case drain oil from the swing and travel motors is returned through the main return filter. A cartridge type filter is installed in the outlet of the pilot pump to protect all pilot valves from contamination. All of these filters have filter bypass valves for cold start up protection.

Filters MODEL

CX130

CX160

CX210

CX240

Suction

150 mesh

150 mesh

150 mesh

150 mesh

Return

10 µ

10 µ

10 µ

10 µ

Ultra-fine

1µ

1µ

1µ

1µ

Pilot

10 µ

10 µ

10 µ

10 µ

1-3

CX EXCAVATORS

GENERAL INTRODUCTION

EXPLANATION OF CX SERIES Variable Pumps All of the CX Series Excavators use an open center hydraulic system, in that there is always an output flow from the hydraulic pump flowing through the system. The CX Series Excavators use a variable flow piston pump system to be able to fully use the engine horsepower. As the system operating pressure increases, the flow gradually reduces, to maintain a constant horsepower load on the engine. The theory is that when very high pressures are required, speed isn't so important. The CX Series Excavators use a twosection variable displacement piston pump, to provide the flow required to operate the functions. Variable pumps allow the delivery of higher flow rates at lower working pressures, and then allow the pumps to reduce the flow at higher pressures, to keep from stalling the engine. The increased flow at lower pressures makes the cycle times faster, and increases the overall efficiency of the excavator. The engine horsepower required to drive a hydraulic pump depends on the flow delivered by the pump, as well as the pressure at which system is operating. There is a mathematical formula to calculate the pump drive horsepower, but a rule of thumb to visualize this, is that it requires approximately 1 engine horsepower to deliver 1 gallon per minute of oil at 1500 psi. Therefore, it would require 25 HP to deliver 25 GPM at 1500 psi. If the pressure increases to 3000 psi, the requirement would be 50 HP. The CX Series Excavators have an automatic pump de-stroke feature that reduces the pump flow to a minimum, when all control levers are in the neutral position. This is accomplished with a hydraulic pilot signal from the control valve. This system saves fuel and eliminates wasted engine and hydraulic power. The minimum flow delivery of the pumps increases with excavator size and engine horsepower. Although the pump configuration and manufacturer varies, in principal, all of the pump control systems operate the same.

Pumps MODEL

CX130

CX160

CX210

CX240

Max. pump flow X2

32.4 gpm

36.2 gpm

53.1 gpm

56 gpm

Pilot pump flow

6 gpm

5.8 gpm

5.3 gpm

5.3 gpm

Manufacture

Uchida/ Kawasaki

Uchida/ Kawasaki

Kawasaki

Kawasaki

Configuration

Tandem

Tandem

Tandem

Tandem

1-4

CX EXCAVATORS

GENERAL INTRODUCTION

EXPLANATION OF CX SERIES Pilot Controls The attachment controls are pilot operated by hand actuated controllers on all models. The pilot hand controls are mounted to tilting armrests that can be positioned to provide for maximum operator comfort. The standard control pattern is the SAE pattern. The controls can be changed to other configurations by changing the pilot hose connections at the pilot manifold, located behind the cab (see Section 8001 of the Service Manual for instructions). There is a pattern change kit available as an option which allows pattern changes without moving hoses. When the left arm is tilted up or the gate lever is up, all pilot operated control functions are inactive. On all models, the travel system is actuated by foot pedals that also have hand control levers attached. The travel controls are pilot pressure operated on all models. The CX240 – CX800 have a single pedal feature. By actuating a single control pedal, both travel motors will travel at the same speed and direction. This feature gives the operator straight-line travel in either forward or reverse.

Pilot Controls MODEL Pilot operated hand and foot controls

CX130 yes

Single pedal no travel

CX160

CX210

CX240

yes

yes

yes

no

no

yes

1-5

CX EXCAVATORS

GENERAL INTRODUCTION

EXPLANATION OF CX SERIES Hydraulic System Overview All models use a triple hydraulic pump assembly that is located on the same side of the excavator as the reservoir. All of the excavators use two variable displacement piston pumps for the excavator functions. A fixed displacement gear pump used to supply pilot control oil for the system. The original CX130 and CX160 excavators used a tandem mounted pump supplied by Uchida. All later excavators use a tandem mounted pump supplied by Kawasaki. All of the pumps have a system to limit the horsepower load on the engine. This system allows the excavator to fully utilize the power available without overloading the engine. The CX Series Excavators have an electrically controlled feature that allows the hydraulic system to operate at less than full load to increase fuel economy or fine touch controllability. This feature allows for four digging modes: “Auto” -Variable- 90-85% engine speed- 93-90% hydraulic pump torque. "H" -Heavy Duty - 100% of engine speed - 100% hydraulic pump torque. "S" -Standard Duty - 95% of engine speed - 90% hydraulic pump torque. "L" -Light - 85% of engine speed - 70% hydraulic pump torque. The original excavators were in the “Auto” mode each time they were started, newer models default to the “H” mode. All models have Power Boost. CX130/CX160 excavators have One-Touch Power Boost. CX210/CX800 excavators have automatic Power Boost.

1-6

CX EXCAVATORS

GENERAL INTRODUCTION

EXPLANATION OF CX SERIES The CX Series Hydraulic System There is a single main relief with a second (power boost) setting. Boom and arm anti-drift valves are built into the main control valve. An auxiliary control valve is standard and a factory installed or field installed kit with plumbing to the end of the arm is available. Other features that are built into the main control valve are: Dual pump flow boom up Boom down regeneration Boom down anti-drift Dual pump flow arm in and out Arm in regeneration Arm in anti-drift Travel priority Swing priority Neutral pump de-stroke Two electrical pressure switches are installed on the main control valve, and one in the swing pilot shuttle valve. These switches are used to tell the controller what hydraulic functions are being operated.

Cushion Control System The CX Series excavators have an attachment control cushion system to allow the boom and arm cylinder control spools to gradually return to neutral, for shock-free operation. This feature allows a lesser skilled operator to work more smoothly. With the control cushion system active, the pilot oil from the hand control flows to the arm or boom control spool unrestricted. When the hand control is returned to neutral, the pilot oil is restricted as it leaves the control spool. This slow return of the spool accounts for the smooth operation. The system can be overridden with an electrical control switch on the monitor/switch panel.

Swing The CX Series Excavators do not have a mechanical house lock. The house lock is accomplished with the swing brake. The swing brake is applied when the switch on the left console is activated or the engine is shut off. The swing brake is also applied 5 seconds after the hand control is returned to neutral unless “Free-Swing” is turned on.

1-7

CX EXCAVATORS

GENERAL INTRODUCTION

EXPLANATION OF CX SERIES Travel CX130/CX160/CX210/CX240/CX290/CX330/CX460/CX800 The travel motors are located at the rear of each track assembly. The travel system is controlled by control spools in the main control valve located in the excavator upper section. The travel drive system has independent, compact, axial piston, two speed hydraulic motors. Each track is independently driven by a sprocket, which is driven by a planetary reduction gear. There is a spring applied, hydraulically released disc brake built into each motor. The travel brake is released by the travel pressure applied to the motor. Each travel motor is equipped with a counterbalance valve and a dual stage relief valves for smooth starts and stops. The counterbalance valve prevents over speeding of the motor while driving down an incline. The shockless relief valve allows for additional cushioning in the circuit by allowing a slight transfer of oil between travel directions as the excavator is started and stopped. The travel motors and planetary gears are mounted within the width of the side frame. Two-speed travel is controlled by the controller, which controls a solenoid valve. The travel speed solenoid supplies pilot system pressure to actuate the two-speed spool in each travel motor. Travel drive pressure is then ported through the two-speed control spool to the motor swash plates. The excavators are in “LOW SPEED” travel when the key is turned on. When the travel switch is depressed, the excavator will be in “HIGH SPEED” and if the drive load is too high, the motor will automatically shift to “LOW SPEED”, and back to “HIGH SPEED” when the load is reduced. The Dash still indicates “HI”, the change takes place in the motors. The travel system has a travel priority valve to insure straight travel, if the swing function, or any attachment function is activated, while traveling. When traveling without other functions activated, one pump supplies right travel with the other pump supplying left travel. When the travel priority spool shifts, because of multiple function application, one pump is used to supply both right and left travel, while the other pump is used for the attachment functions. With one pump supplying, both travel functions, the travel speed will naturally be reduced significantly.

Travel MODEL

CX130

CX160

CX210

L Speed

2.1

H Speed

3.4

1-8

CX240

CX EXCAVATORS

GENERAL INTRODUCTION

EXPLANATION OF CX SERIES Cylinders The attachment cylinders have a cushion feature to hydraulically reduce the speed of the cylinder rod at the extreme ends of travel to limit the shock on the excavator. Bucket open and boom down cylinder positions do not have cushions.

1-9

CX EXCAVATORS

GENERAL INTRODUCTION

EXPLANATION OF CX SERIES Electrical System All models have a 24-volt starting and charging system. The CX Series Excavators have two 12-volt batteries, wired in series to obtain the 24-volt capacity. These batteries are located in the compartment behind the cab. There is a battery relay connected between the positive battery cable and the excavator electrical system. The battery relay acts as the master disconnect for the system. The battery relay closes as the key switch is turned to the "on" position.

1 - 10

CX EXCAVATORS

GENERAL INTRODUCTION

EXPLANATION OF CX SERIES Electrical System To improve engine starting during cold temperatures, the CX130 and CX160 are equipped with an ether injection system as standard equipment. The ether injection system can only be activated when the key-switch is in the crank position. There is a rocker switch located on the left-hand control console for easy access to the operator. There is also a temperature switch located on the engine intake manifold to prevent engagement of the ether system when the engine is above 40°F (5°C). On the CX210, CX240, CX290 and CX330, there is an intake manifold heater for cold starting assistance, which is turned on with the key switch. The CX460 and CX800 engines use glow plugs in each cylinder to aid cold weather starting. The Alternator is rated at 24 volts. The electronic controller for the CX130/CX160 excavators require an engine speed signal from a magnetic sensor on the flywheel. This engine speed signal is extremely critical to excavator functions. The other CX excavators have electronic controlled engines. The excavator controller requires input from the engine controller. The engine, the hydraulic, and the electrical systems are all monitored by a controller. The controller for the CX130/CX160 is different than for the CX210/CX240. The controller receives signals from sending units. Very simply, the controller takes the information that it has received, and then sends the required outputs to cause the excavator to perform as selected. These outputs may be sent to the display panel to indicate a malfunction or to give a visual display of which performance features have been selected. The outputs may also be sent to the solenoid valves, which control the excavator functions. The controller has an automatic “limp home” feature to allow the excavator to be operated to complete the job in case of controller failure.

1 - 11

CX EXCAVATORS

GENERAL INTRODUCTION

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1 - 12

CX EXCAVATORS

CX130 Theoretical Pump Flow L, S & H Mode TSG - Technical Service Group 01 - 01 40

35

33.7

33.7

30.8

Flow = (GPM)

30

30.8

29.2

29.2

25.3

25

25.6

22.2

22.4 20

H Mode mA = 600 S Mode mA = 450

27.2 23.2 19.2

19

16.9

16.5 15

H Mode 2130 RPM S mode 1950 RPM L Mode 1850 RPM

20.5 17.9 16.3 14.9

14.1 12.4

11

10

13.5

13.7 11.2

9.9

8.3

12.1 9.9 7.9

5

0 0

1000

2000

3000

4000

5000

6000

7000

Pressure (PSI) = P1 + P2

8000

9000

10000

CX130 Theoretical Pump Flow L, S & H Mode TSG - Technical Service Group 01 - 01 40 35

35

Flow = (GPM)

30 H Mode mA = 600 S Mode mA = 450

25

H Mode 2130 RPM S mode 1950 RPM L Mode 1850 RPM

20

15

10

5

0 0

1000

2000

3000

4000

5000

6000

7000

Pressure (PSI) = P1 + P2

8000

9000

10000

CX160 Theoretical Pump Flow L, S, & H Mode TSG - Technical Service Group 01 - 01 40.0 37.7 35.0

37.7

34.7 33.0

34.7 33.0 31

Flow = (GPM)

30.0

29.1

29.6 25.6

25.6

25.0

H Mode mA = 600 S Mode mA = 490 L Mode mA = 280

26.7 23.2 21.8

21.7 20.0

19.2

18.9

18.8 17.2

16.1

15.0

H Mode 2230 RPM S Mode 2050 RPM L Mode 1950 RPM

20.6

15.3

14.0 12.4

10.0

15.3 12.7

11.2

13.7 11.2

9.5 8.1

5.0

0.0 0

1000

2000

3000

4000

5000

6000

7000

Pressure (PSI) = P1 + P2

8000

9000

10000

CX160 Theoretical Pump Flow L, S, & H Mode TSG - Technical Service Group 01 - 01 40.0

35.0

35.0

Flow = (GPM)

30.0 H Mode mA = 600 S Mode mA = 490 L Mode mA = 280

25.0

H Mode 2230 RPM S Mode 2050 RPM L Mode 1950 RPM

20.0

15.0

10.0

5.0

0.0 0

1000

2000

3000

4000

5000

6000

7000

Pressure (PSI) = P1 + P2

8000

9000

10000

CX210 Theoretical Pump Flow L, S & H Mode TSG - Technical Service Group 01 - 01 60 53.8

Flow = (GPM)

50

52.3

48.8 46.2

48 45.4 H Mode mA = 450 S Mode mA = 292 L Mode mA = 50

40

H Mode 1980 RPM S Mode 1800 RPM L Mode 1700 RPM

30 25.8 23

23.7

20 14.5 10

10 8.4

0 0

1000

2000

3000

4000

5000

6000

7000

Pressure = (PSI) P1 + P2

8000

9000

10000

11000

CX210 Theoretical Pump Flow L, S & H Mode TSG - Technical Service Group 01 - 01 60 55

Flow = (GPM)

50

H Mode mA = 450 S Mode mA = 292 L Mode mA = 50

40

H Mode 1980 RPM S Mode 1800 RPM L Mode 1700 RPM

30

20

10

0 0

1000

2000

3000

4000

5000

6000

7000

Pressure = (PSI) P1 + P2

8000

9000

10000

11000

CX240 Theoretical Pump Flow L, S, & H Mode TSG - Technical Service Group 60 56.803

54.9536

51.7832 49.4054

50

50.9906 48.877 H Mode mA = 466 S Mode mA = 307 L Mode mA = 50

Flow (GPM)

40

H Mode 2180 RPM S Mode 2000 RPM L Mode 1900 RPM

30.1188

30 26.9484

28.0052

20

18.7582 13.21

10

9.5112

0 0

1000

2000

3000

4000

5000

6000

7000

Pressure = (PSI) P1 + P2

8000

9000

10000

11000

CX240 Theoretical Pump Flow L, S, & H Mode TSG - Technical Service Group 60 55 50

H Mode mA = 466 S Mode mA = 307 L Mode mA = 50

Flow (GPM)

40

H Mode 2180 RPM S Mode 2000 RPM L Mode 1900 RPM

30

20

10

0 0

1000

2000

3000

4000

5000

6000

7000

Pressure = (PSI) P1 + P2

8000

9000

10000

11000

CX290 Theoretical Pump Flow L, S, & H Mode TSG - Technical Service Group 01 - 01 70

60

58.124

50

Flow = (GPM)

56.2746

53.3684 50.9906

49.9338

52.0474 H Mode mA = 466 S Mode mA = 305 L Mode mA = 50

40

30

30.1188

29.062

H Mode 2230 RPM S Mode 2050 RPM L Mode 1950 RPM

32.2324

20.8718

20

15.0594 11.3606

10

0 0

1000

2000

3000

4000

5000

6000

7000

Pressure = (PSI) P1 + P2

8000

9000

10000

11000

CX290 Theoretical Pump Flow L, S, & H Mode TSG - Technical Service Group 01 - 01 70

60

60

Flow = (GPM)

50

H Mode mA = 466 S Mode mA = 305 L Mode mA = 50

40

H Mode 2230 RPM S Mode 2050 RPM L Mode 1950 RPM

30

20

10

0 0

1000

2000

3000

4000

5000

6000

7000

Pressure = (PSI) P1 + P2

8000

9000

10000

11000

Construction Equipment Service Training

CX SERIES EXCAVATOR

Section 3 -Controller (2004)

CNH America LLC 700 STATE STREET RACINE, WI 53404 U.S.A. .

 2004 All Rights Reserved Printed in U.S.A.

CONTROLLER

Table of Contents Section 3 - CX Series Controller

CONTROLLER CALIBRATION.................................................................... 3 CHANGE THE DISPLAY LANGUAGE ONLY............................................ 11 CURRENT CONDITION DISPLAY ............................................................ 17 DIAGNOSTIC CONDITION DISPLAY ....................................................... 32 EXCAVATOR HISTORY DISPLAY............................................................ 38 OPTIONAL RESET DISPLAY.................................................................... 51

3- 1

CX EXCAVATORS

CONTROLLER

CONTROLLER CALIBRATION and DIAGNOSTIC SYSTEM SWITCHES

Work Mode Switch Travel Mode Switch

Buzzer Stop Switch

Auto Mode Switch

Cushion Switch

3- 2

CX EXCAVATORS

CONTROLLER

CONTROLLER CALIBRATION PROCEDURE CONTROLLER RESET

MACHINE: SH0200 –3 TERRITORY: 2 LANGUAGE: 1

CONT. P/N

KHR 3311

Machine confirmation In the normal display mode, when the Auto mode switch is pressed for 10 seconds, the machine selection screen will be displayed. Confirmation of the machine model, territory, language and computer part number can be done at this screen. If you do not need to make any changes, press the Auto mode switch again and the Display will return to the normal mode. If you only need to change the language, go to page 3-11. If you need to make changes, procede to the next page. 3- 3

CX EXCAVATORS

CONTROLLER

CONTROLLER CALIBRATION PROCEDURE CONTROLLER RESET Note: For CX130 & CX160 Excavators only, Warm up the Excavator before clearing the machine selection screen. Return to the normal mode screen by pressing and releasing the Auto Mode switch. Then press the Travel Mode and Work Mode Switches together longer than 3 seconds to go to the CHK1 screen (see page 3-15). Make sure that the coolant temperture (WT) is at least 160°F (70°C) and that the ENG section is indicating the engine speed. To warm up the engine, watch the CHK1 Screen while holding the arm-in function at Wide-Open-Throttle. When the temperature (WT) reaches 160°F, turn off the Engine. Turn the Key Switch on and press the Auto mode switch for 10 seconds to Return to the Controller Reset Screen. All Excavators: Press the Auto mode switch for 10 seconds to clear all data in this screen. All data will change to “?” and the buzzer will sound. MACHINE: SH ? –3 TERRITORY: ? LANGUAGE: ?

CONT. P/N

KHR XXXX

Turn off the key switch to finish clearing the data.

3- 4

CX EXCAVATORS

CONTROLLER

CONTROLLER CALIBRATION PROCEDURE 1. Turn the key switch “ON” A “?” is shown at MACHINE, TERRITORY and LANGUAGE areas. A “?” shown with dark background means that item is selected and ready to be changed. A “−3” means CX series

MACHINE: SH ? –3 TERRITORY: ? LANGUAGE: ?

CONT. P/N

KHR XXXX

2. The machine model code will change in the dark background area every time the Travel mode switch is pressed. MACHINE: SH0200 –3 TERRITORY: ? LANGUAGE: ?

CONT. P/N

KHR XXXX

Select the correct model code that corresponds with the machine.

Machine Code SH0120 SH0150 SH0200 SH0220 SH0250 SH0300 SH0400 SH0800

Case NA CX130 CX160 CX210 CX240 CX290 CX330 CX450 CX800 3- 5

CX EXCAVATORS

CONTROLLER

CONTROLLER CALIBRATION PROCEDURE 3. After selecting the model, it is necessary to select the correct pump code on some excavator models. Press the Buzzer Stop switch to select the correct Pump by changing the last digit in the model code from 0 to 1 or 2, see chart below.

SH0120 (UCHIDA PUMP) SH0121 (KAWASAKI PUMP) – DAC0713246 & After SH0150 (UCHIDA PUMP) SH0151 (KAWASAKI PUMP) – DAC0716270 & After SH0200 (KAWASAKI PUMP) SH0202 (LIFTING MAGNET M/C) SH0220 (KAWASAKI PUMP) SH0222 (LIFTING MAGNET M/C) SH0250 (KAWASAKI PUMP) SH0300 (UCHIDA PUMP) SH0301 (KAWASAKI PUMP) SH0302 (LIFTING MAGNET M/C) SH0400 (KAWASAKI PUMP) SH0800 (KAWASAKI PUMP)

CX130 CX160 CX210 CX240 CX290 CX330 CX460 CX800

The CX130 PIN Break for the change to the Kawasaki Pump is DAC0713246, code SH0121. The CX160 PIN Break for the change to the Kawasaki Pump is DAC0716270, code SH0151. All North American CX330 excavators have the Kawasaki Pump, therefore the code must be changed to SH0301.

3-6

CX EXCAVATORS

CONTROLLER

CONTROLLER CALIBRATION PROCEDURE 4. After selecting the model code, press the Work mode switch to select the Territory field. MACHINE: SH0200 –3 TERRITORY: ? LANGUAGE: ?

CONT. P/N

KHR XXXX

A “?” shown with a dark background means that item is selected. 5. The Territory will change everytime the Travel mode switch is pressed. Press the Travel mode switch until the number 2 appears in the Territory field for Case North America, pressure in psi and temperature in °F.

Other choices are: 0 for pressure in K(kg/cm² and temperture in °C. 1 for LBX North America 3 for pressure in MPa and temperature in °C. To switch between European and US units, press the Working Light Key MACHINE: SH0200 –3 TERRITORY: 2 LANGUAGE: ?

CONT. P/N

KHR XXXX

3-7

CX EXCAVATORS

CONTROLLER

CONTROLLER CALIBRATION PROCEDURE 6. Press the Work mode switch to select the language field. MACHINE: SH0200 –3 TERRITORY: 2 LANGUAGE: ?

CONT. P/N

KHR XXXX

A “?” shown with dark background means that item is selected. 7. Press the Travel mode switch to change the language. See language selection chart below. Language Code

Language

Language Code

Language

0

Japanese

8

Portuguese

1

English

9

Dutch

2

Thai

10

Danish

3

Chinese

11

Norwegian

4

German

12

Swedish

5

French

13

Finnish

6

Italian

14

Icons

7

Spanish

15

3-8

CX EXCAVATORS

CONTROLLER

CONTROLLER CALIBRATION PROCEDURE MACHINE: SH0200 –3 TERRITORY: 2 LANGUAGE: 1

CONT. P/N

KHR XXXX

Continue with step 8 for CX130 / CX160 ONLY (Go to the next page for CX210 / CX800 Continue with step 10) 8. After inputting all machine information, start the engine, turn the throttle to 50% and push the Cushion switch. The engine will go to full RPM and then slowly lower to idle. If the Auto Idle was turned off, the engine will then speed up to 50% to confirm that it is finished.

Note: Coolant temperature must be above 122°F (50°C) before the procedure will start. Cover the radiator if necessary to warm the engine. The process is finished when the engine RPM can be controlled by the throttle control again. 9. Press the Auto mode switch to finish, and return to the normal display.

3-9

CX EXCAVATORS

CONTROLLER

CONTROLLER CALIBRATION PROCEDURE

CX210 / CX800 10. After inputting all machine information, push the Auto mode switch. The CASE logo will be displayed, then automatically scroll to the normal display below.

3 - 10

CX EXCAVATORS

CONTROLLER

CONTROLLER CALIBRATION PROCEDURE MACHINE: SH0200 –3 TERRITORY: 2 LANGUAGE: 1

CONT. P/N

KHR XXXX

To change the language only, display the machine selection screen by pressing the Auto mode switch for 10 seconds.

The language is changed by pressing the Travel mode switch.

Press the Work mode switch to set the language, the buzzer will sound at this time. Turn the key switch off to complete the process.

3 - 11

CX EXCAVATORS

CONTROLLER

DIAGNOSTIC MODE FLOW CHART NORMAL DISPLAY MODE

DIAGNOSTIC MODE

1 CURRENT CONDITION CHK1 3 CHK2 3

EXCAVAT OR HISTORY

DIAG2

3 6

HR12 3 HR11 3

3

CHK4

DIAG4

3

HR10 3

3 DIAG5

4

CHK6

2

3

DIAG3

3

5

DIAGNOSTIC SYSTEM DIAG1

3

CHK3

CHK5

2

6

6

HR9

DIAG6

HR8 HR7

HR2

3 BRK 3

3 HR3

L/M 3

3 HR4 3 3 HR6

3

3

6

RESETTING RST1

3

HR5 3

3

2

3

AI 3 PA 3 AU 3 HLD 3 OUT 3

1 = (T + W) > 3 Seconds 5 = T > 10 Seconds, CHK6 displays 2 = Auto beeping occurs. 3 = Alarm Stop (Buzzer Stop) 6 = To erase see Page 3-14 description. 4 = T > 1 < 10 Seconds (Push and hold to read CHK5) To record faults, with the Key off, Hold down the One-Touch Idle & turn the Key on, release the Idle key and the computer will self check. 3 - 12 CX EXCAVATORS

CONTROLLER

DIAGNOSTIC MODE Current Condition (CHK1-CHK6) Displays the excavator’s current condition. Diagnostic System (DIAG1-DIAG6) Displays recorded fault codes of current and past conditions for the engine and the excavator. Records the computer hours of the detection of the fault. Excavator History (HR1-HR12) Displays recorded computer hours of each excavator operation. Resetting (RST1-RST2) Displays the excavator’s current settings and allows for the changing of the excavator setup. EXPLAINATION OF DIOGNOSTIC STEPS 1 To scroll between the Normal display and Diagnostic display screens press the Travel and Work mode switch simultaneously for 3 seconds. 2 To scroll across between the CHK, DIAG, HR and RST screens, press the Auto mode switch. 3 To scroll down through the CHK, DIAG, HR and RST screens, press the Buzzer stop switch. 4 A Self-Check of the protected transistor circuits can be checked automatically. While holding the One-Touch idle button down, turn the key switch on, then release the idle button. The controller will energize each of the transistor (TR) circuits automatically. If a short-circuit is detected, the display will indicate an “ELECTRICAL PROBLEM” and sound the buzzer. If no over-current is detected, the travel alarm will sound. To find the shorted circuit, go immediately to the CHK1 screen without turning off the Key Switch, then scroll to the CHK2 screen. While in the CHK2 screen, press and hold the Travel mode switch, you will scroll to the CHK5 screen. Recorded TR1, TR2 and TR3 faults will be displayed. 5 If you hold the Travel switch down longer than 10 seconds the CHK6 screen appears and the buzzer beeps intermittently. The same faults are displayed in the CHK6 screen. Turning off the Key switch erases the codes and silences the buzzer. 3 - 13

CX EXCAVATORS

CONTROLLER 6 To erase data in DIAG2, DIAG5, or HR1-HR12 screens, scroll to DIAG2, DIAG5 or HR1. At each of these fields, press the Work mode switch for 10 seconds, (the buzzer will sound), turn OFF the key switch. Erasing the data in the HR1 screen removes the history from all of the History screens, HR1 through HR12.

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CX EXCAVATORS

CONTROLLER

CURRENT CONDITION CHK1 CHK 1

MODE 2 H ENG

0 0

0 0

RPM

P1

0 0

0 0

PSI

I

0

0

0 0

mA

P2

0 0

0 0

PSI

WT

0

0

0 0

F

N

0 0

0 0

PSI

OT

0

0

0 0

F

• Mode: To reach this screen, Press and hold both the Travel and Work mode switches more than 3 seconds. Main Pump Pressure (P1) • P1: Main Pump Pressure (P2) • P2: Negative Control Pressure of pump supplying Arm 1 Spool. • N: Engine RPM • ENG: Current for Pump Proportional Solenoid • I: Water Temperature • WT: Hydraulic Oil Temperature • OT: Use this screen to check main relief and power boost settings. Verify negative control pressure from the arm/swing pump, engine RPM, controller signal to the proportional solenoid on the pump and hydraulic oil and coolant temperature. Use the Buzzer stop switch to scroll through CHK1 – CHK4 screens.

Use the Travel switch to scroll to the CHK5 screen from the CHK2 screen.

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CX EXCAVATORS

CONTROLLER

CURRENT CONDITION CHK2 CHK 2

• • • • • • •

R: FT: TV: TR1: TR2: TR3: TR4:

MODE 2 H TR1

0 0

0 0

R

0 0

0 0 %

TR2

0 0

0 0

FT

0 0

0 0 F

TR3

0 0

0 0

TV

0 0

0 0 %

TR4

0 0

0 0

Engine Load Ratio (CX210/CX240) Fuel Temperature (CX210/CX240) Throttle Volume Transistor Output Engine Load Ratio Transistor Output Transistor Output ((Q-Qn) / (Qf-Qn)) Not Used Fuel Flow: Q – Current Qn – No Load Qf – Maximum Flow

R: CX210/CX240 Information sent from the engine controller to the main controller. The main controller uses this information for recording purposes. The controller also uses this information plus pump pressure to determine when to activate Auto Power Boost. FT: CX210/CX240 Information sent from the engine controller to the main controller. The main controller uses this information for recording monitoring purposes. TV: Use this field to verify that the controller is receiving the signal from the throttle control knob. TR1, TR2, TR3: These fields can be used to verify that the controller is sending the signal to turn these various circuits on and off as they are selected by the operator.

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CX EXCAVATORS

CONTROLLER

CURRENT CONDITION CHK2 Continued

TR1

0

0

0

0 • Swing Park Brake • High Speed Travel • Travel Alarm • Power Boost

This screen can be used to verify that the controller is sending a signal to the circuits listed. TRANSISTOR OUTPUT (0=OFF, 1=ON) Start the engine and engage lever lock (pilot pressure). •

Swing Park Brake - Move the swing hand control just enough to close the swing pressure switch. Should see the 1 change to 0. Return the hand control to neutral. The 0 should change to 1 after 5 seconds. Slowly raise the boom until screen indicates swing brake is turned off. Return boom control to neutral. Swing brake should be turned on 5 seconds later.

•

High Speed Travel & Travel Alarm – Press the travel switch to select high-speed travel. The high speed travel field should change to a 1 and to 0 when the switch is pressed again. Move a travel foot control just enough to close the travel pressure switch. Should see the alarm field change to a 1 and change back to 0 when the foot control is released.

•

Power Boost – CX210/CX240 -Move one of the attachments to end of stroke. As the pressure increases the power boost field should change to a 1 as the Auto Power Boost is engaged. Power boost should be on for 8 seconds. Select L mode with the Work mode switch. Power boost should be turned on until another work mode is selected.

•

Power Boost – CX130/CX160 – Press the one-touch switch on the front of the right hand control. The power boost field should change to a 1 for 8 seconds. Select L mode with the Work mode switch. Power boost should be turned on until another work mode is selected.

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CX EXCAVATORS

CONTROLLER

CURRENT CONDITION CHK2 Continued

TR2

0 0

0 0 • Battery Relay • Cushion Valve (off/on) • Swing Shut Off • Swing Priority

TRANSISTOR OUTPUT (0=OFF, 1=ON) • Battery Relay – There should be a 1 here anytime the key switch is turned on. Can not observe off signal. • Cushion Valve (off/on) – While the engine is running, push the cushion switch, A 1 should appear in the cushion valve field. When the cushion switch is pressed again, the 1 should be changed to a 0. • Swing shut off – With the key switch on, push the swing lock switch, the swing shut off field should change to a 1. When the swing lock is pushed again the field should change to a 0. • Swing Priority – This feature is not used. The Swing Priority valve in the main control is shifted by hydraulic Pilot Pressure from the shuttle valve.

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CX EXCAVATORS

CONTROLLER

CURRENT CONDITION CHK2 Continued

TR3

0 0

0 0 • Free Swing • Thief Proof • Not Used • Not Used

TRANSISTOR OUTPUT (0=OFF, 1=ON) • Free Swing – With the engine running press the free swing switch the free swing field should change to a 1. When the switch is pressed again the 1 should be changed back to 0.

TR4

0 0

0 0 • Not Used • Not Used • Not Used • Not Used

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CX EXCAVATORS

CONTROLLER

CURRENT CONDITION CHK3 CHK 3

MODE 2 H SW4

0

0

0

0

SW1

0

0

0

0

SW5

0

0

0

0

SW2

0

0

0

0

SW6

0

0

0

0

SW3

0

0

0

0

SW7

0

0

0

0

This screen is used to verify that the controller is receiving the input from the listed switches and signals. • SW1: Upper pressure switch, travel pressure switch, swing pressure switch and hammer pressure switch. • SW2: Engine oil pressure switch, coolant level switch, and auxiliary pressure switch. • SW3: Battery charge. • SW4: Cushion switch (off/on), free swing switch, swing priority switch (Not used) and one touch idle switch. • SW5: Swing lock switch, emergency stop switch, work light and wiper switch. • SW6: Windshield washer switch, travel alarm and hammer mode switch, and Material Handling (L/M) mode. • SW7: Thief Proof, Key switch, and Overload (EU).

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CX EXCAVATORS

CONTROLLER

CURRENT CONDITION CHK3 Continued

SW1

0 0

0 0 • Upper pressure switch • Travel pressure switch • Swing pressure switch • Hammer pressure switch

SWITCH INPUT (0=OFF, 1=ON) Start the engine and engage the lever lock (pilot pressure). • Engage any upper function for the upper pressure switch. • Engage the swing for the swing and upper pressure switch. • Engage the travel function for the travel pressure switch. • Engage the hammer circuit, if equipped, for the hammer pressure switch. NOTE: The pressure switches should come on before the hydraulic circuit is active.

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CX EXCAVATORS

CONTROLLER

CURRENT CONDITION CHK3 Continued

SW2

0 0

0 0 • Engine oil pressure switch • Coolant level switch • Auxiliary Pressure Switch • Not used

SWITCH INPUT (0=OFF, 1=ON) • Engine oil pressure switch is “ON” with low pressure or when engine is off. CX130/CX160 ONLY. • Coolant level switch is “ON” when coolant level is low

SW3

0 0

0 0 • Alternator signal • Not used • Not used • Not used

• Observe with engine running. Should be “ON”.

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CX EXCAVATORS

CONTROLLER

CURRENT CONDITION CHK3 Continued

SW4

0 0

0 0 • Cushion switch (off/on) • Free Swing switch • Swing Priority-Not used • One touch idle switch

SWITCH INPUT (0=OFF, 1=ON) Key Switch “ON” • These are momentary switches. They are “ON” only while they are being pressed.

SW5

0 0

0 0 • Swing lock switch • Emergency Stop switch • Work light switch • Wiper switch

• These are momentary switches. They are “ON” only while they are being pressed.

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CONTROLLER

CURRENT CONDITION CHK3 Continued

SW6

0

0

0

0 • Windshield washer switch • Travel alarm off/on switch • Hammer. Mode switch • Material Handling (L/M)

SWITCH INPUT (0=OFF, 1=ON) Key Switch “ON” • Washer switch is a momentary switch. It is “ON” only while the switch is being pressed. • The travel alarm switch is a 2-position rocker switch on the left console and has a “0” in the third position when “OFF”, and a “1” when in the continuous position. • The auxiliary hydraulic mode switch is a 3-position rocker switch, there is a “1” when in the hammer position • The Material Handling is presently not used.

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CONTROLLER

CURRENT CONDITION CHK3 Continued

SW7

0

0

0

0 • Thief Proof • Key switch • Not used • Not used

SWITCH INPUT (0=OFF, 1=ON) Key Switch “ON” • “ON” when the key switch is.

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CX EXCAVATORS

CONTROLLER

CURRENT CONDITION CHK4 CHK 4

• • • • • • •

FS: AC: TR5: TG: BP: SP1: SP2:

MODE 2 H

OHMS

TG

0

0

0 0

BP

0

0

0

0

FS

0

0

0

0

AC

0

0

0

0

SP1

0

0

0

0

TR5

0

0

0

0

SP2

0

0

0

0

RPM MPa

Fuel Sensor Resistance Coolant Temperature for A/C Control Not Used Target Engine RPM Not Used Not Used Not Used

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CX EXCAVATORS

CONTROLLER

CURRENT CONDITION CHK4 Continued

AC

0

0

0

0

• 1: Water temperature: