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
EXPLANATION OF CX SERIES
Engines
MODEL Make Model HP (net) Cold Start Rated rpm CX130 CASE 4TA390 106 Ether 2200 CX160 CASE 4TA390 106 Ether 2200 CX210 CASE 6TAA590 138 Electric 1950 CX240 CASE 6TAA590 163 Electric 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 SHO120 SHO150 SHO200 SHO220
Case model number CX130 CX160 CX210 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 Japanese English Thai Chinese German French MODE NO. 0 1 2 3 4 5 LANGUAGE Italian Spanish Portuguese Dutch Danish Norwegian MODE NO. 6 7 8 9 10 11 LANGUAGE Swedish Finnish Picture writing MODE NO. 12 13 14
1-2
CX EXCAVATORS
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 Capacity Tank gal. Capacity System gal. CX130 19 32 CX160 32 38 CX210 32 54 CX240 32 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 Suction Return Ultra-fine Pilot CX130 150 mesh 10 1 10 CX160 150 mesh 10 1 10 CX210 150 mesh 10 1 10 CX240 150 mesh 10 1 10
1-3
CX EXCAVATORS
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 Max. pump flow X2 Pilot pump flow Manufacture Configuration CX130 32.4 gpm 6 gpm Uchida/ Kawasaki Tandem CX160 36.2 gpm 5.8 gpm Uchida/ Kawasaki Tandem CX210 53.1 gpm 5.3 gpm Kawasaki Tandem CX240 56 gpm 5.3 gpm Kawasaki Tandem
1-4
CX EXCAVATORS
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 yes CX130 yes CX160 yes CX210 yes CX240
Single pedal no travel
no
no
yes
1-5
CX EXCAVATORS
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
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
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 L Speed H Speed CX130 CX160 2.1 3.4 CX210 CX240
1-8
CX EXCAVATORS
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
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
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 40F (5C). 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
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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 30.8
33.7 29.2 30.8 27.2 23.2 19.2 16.5 20.5 16.9 14.1 12.4 17.9 16.3 14.9 11 13.5 9.9 13.7 11.2 8.3 12.1 9.9 7.9 H Mode 2130 RPM S mode 1950 RPM L Mode 1850 RPM H Mode mA = 600 S Mode mA = 450
30
29.2
Flow = (GPM)
25
25.3 22.4
25.6
22.2 19
20
15
10
0 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000
Pressure (PSI) = P1 + P2

TSG - Technical Service Group 01 - 01 40 35
35
30
Flow = (GPM)
25
H Mode mA = 600 S Mode mA = 450
20
H Mode 2130 RPM S mode 1950 RPM L Mode 1850 RPM
15
10
0 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000
CX160 Theoretical Pump Flow L, S, & H Mode

TSG - Technical Service Group 01 - 01 40.0 37.7 35.0 34.7 33.0 37.7 34.7 33.0 31 29.1 25.6 21.7 20.0 18.9 16.1 14.0 12.4 10.0 29.6 25.6 26.7 23.2 21.8 19.2 17.2 15.3 11.2 9.5 8.1 5.0 15.3 12.7 13.7 11.2 20.6 18.8 H Mode mA = 600 S Mode mA = 490 L Mode mA = 280 H Mode 2230 RPM S Mode 2050 RPM L Mode 1950 RPM
30.0
Flow = (GPM)
25.0
15.0
0.0 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000

TSG - Technical Service Group 01 - 01 40.0
35.0
35.0
30.0 H Mode mA = 600 S Mode mA = 490 L Mode mA = 280 H Mode 2230 RPM S Mode 2050 RPM L Mode 1950 RPM
Flow = (GPM)
25.0
20.0
15.0
10.0
5.0
0.0 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000

TSG - Technical Service Group 01 - 01 60 53.8 50 48.8 46.2 48 45.4 H Mode mA = 450 S Mode mA = 292 L Mode mA = 50 H Mode 1980 RPM S Mode 1800 RPM L Mode 1700 RPM
52.3
Flow = (GPM)
40
30 25.8 23 20 14.5 10 10 8.4 23.7
0 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000
Pressure = (PSI) P1 + P2

TSG - Technical Service Group 01 - 01 60 55 50
Flow = (GPM)
40
H Mode mA = 450 S Mode mA = 292 L Mode mA = 50 H Mode 1980 RPM S Mode 1800 RPM L Mode 1700 RPM
30
20
10
0 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000

TSG - Technical Service Group 60 56.803 51.7832 49.4054 50.9906 48.877 H Mode mA = 466 S Mode mA = 307 L Mode mA = 50 H Mode 2180 RPM S Mode 2000 RPM L Mode 1900 RPM 54.9536
50
40
Flow (GPM)
30 26.9484
30.1188 28.0052
20
18.7582 13.21
10
9.5112
0 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000

TSG - Technical Service Group 60 55 50
40
Flow (GPM)
30
20
10
0 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000

60
58.124 53.3684 50.9906 56.2746 49.9338 52.0474 H Mode mA = 466 S Mode mA = 305 L Mode mA = 50 H Mode 2230 RPM S Mode 2050 RPM L Mode 1950 RPM
50
Flow = (GPM)
40
30
29.062
30.1188
32.2324
20
20.8718 15.0594
10
11.3606
0 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000

60
60
50
Flow = (GPM)
40
30
20
10
0 0 1000 2000 3000 4000 5000 6000 7000 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 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 160F (70C) 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 160F, 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

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

CX EXCAVATORS
CONTROLLER

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

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/cm 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

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 0 1 2 3 4 5 6 7 Language Japanese English Thai Chinese German French Italian Spanish Language Code 8 9 10 11 12 13 14 15 Language Portuguese Dutch Danish Norwegian Swedish Finnish Icons
3-8
CX EXCAVATORS
CONTROLLER

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 122F (50C) 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
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

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 1 CURRENT CONDITION CHK1 3 CHK2 3 CHK3 3 CHK4 3 4 CHK5 5 CHK6 6 2 DIAGNOSTIC SYSTEM DIAG1 3 DIAG2 3 DIAG3 3 DIAG4 3 DIAG5 3 DIAG6 3 HR7 HR8 3 6 HR9 3 6 2 EXCAVAT OR HISTORY 3 HR12 3 HR11 3 HR10 3 3 HR2 3 HR3 3 HR4 3 HR5 3 HR6 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 2 6 RESETTING RST1 3 BRK 3 L/M 3
DIAGNOSTIC MODE
CONTROLLER
DIAGNOSTIC MODE
Current Condition (CHK1-CHK6) Displays the excavators 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 excavators 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.
3 - 14
CX EXCAVATORS
CONTROLLER
CURRENT CONDITION CHK1

CHK 1 P1 P2 N MODE 2 H ENG 0 0 0 0 0 0 0 0 0 0 0 0 PSI PSI PSI I WT OT 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 RPM mA F 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.
3 - 15
CX EXCAVATORS
CONTROLLER

CHK 2 R FT TV MODE 2 H TR1 0 0 0 0 0 0 0 0 % 0 0 F 0 0 % TR2 TR3 TR4 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
R: FT: TV: TR1: TR2: TR3: TR4:
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.
3 - 16
CX EXCAVATORS
CONTROLLER

Continued
TR1
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.
3 - 17
CX EXCAVATORS
CONTROLLER

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.
3 - 18
CX EXCAVATORS
CONTROLLER

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

CHK 3 SW1 SW2 SW3 MODE 2 H SW4 0 0 0 0 0 0 0 0 0 0 0 0 SW5 SW6 SW7 0 0 0 0 0 0 0 0 0 0 0 0 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

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

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

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.
3 - 23
CX EXCAVATORS
CONTROLLER

Continued
SW6
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.
3 - 24
CX EXCAVATORS
CONTROLLER

Continued
SW7
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

CHK 4 FS AC TR5 MODE 2 H TG 0 0 0 0 0 0 0 0 0 0 0 0 OHMS BP SP1 SP2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 RPM MPa
FS: AC: TR5: TG: BP: SP1: SP2:
Fuel Sensor Resistance Coolant Temperature for A/C Control Not Used Target Engine RPM Not Used Not Used Not Used
3 - 26
CX EXCAVATORS
CONTROLLER

Continued
AC
1: Water temperature: <86F 2: Water temperature is between: 86F & 113F 3: Water temperature is between: 113F & 149F 4: Water temperature is between: 149F & 176F
Press the Buzzer stop switch to return to CHK1.
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CX EXCAVATORS
CONTROLLER
PRESENT OVER LOAD CONDITION CHK5

CHK 5 R FT TV MODE 2 H TR1 0 0 0 0 0 0 0 0 0 0 0 0 % F % TR2 TR3 TR4 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Engine Load Ratio (CX210/CX240) Fuel Temperature (CX210/CX240) Throttle Volume Transistor output has detected an over current Transistor output has detected an over current Transistor output has detected an over current Not Used
A Self-Check of the protected transistor circuits can be done 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 shorted-circuit is detected, the display will indicate an ELECTRICAL PROBLEM and sound the buzzer. If no overcurrent is detected, the travel alarm will sound. If a short is indicated, do not turn off the key switch. Press the Travel and Work mode buttons together to go to the CHK1 screen. Press the buzzer stop switch to scroll to the CHK2 screen. While in the CHK2 screen, press and hold the Travel mode switch, this will allow you to view the CHK5 screen. The CHK5 screen displays a 1 in the TR section if an over current was detected. If you hold the switch down longer than 10 seconds the buzzer will sound and the CHK6 screen will be displayed. The key must be turned off to silence the buzzer, which also erases the fault codes. Note: To erase the fault codes in the CHK5 screen, just switch the key switch off.
3 - 28
CX EXCAVATORS
CONTROLLER
PAST OVER LOAD CONDITION CHK5

Continued
TR1
0
Swing Park Brake High Speed Travel Travel Alarm Power Boost
TRANSISTOR OUTPUT (0 = No Overload, 1 = Overload)
TR2
0 0
0 0
Battery Relay Cushion Valve Swing Shut Off Swing Priority
3 - 29
CX EXCAVATORS
CONTROLLER
PAST OVER LOAD CONDITION CHK5

Continued
TR3
0 0
0 0
Free Swing Thief Proof Not Used Not Used
TRANSISTOR OUTPUT (0 = No Overload, 1 = Overload)
TR4
0 0
0 0
Not Used Not Used Not Used Not Used
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CX EXCAVATORS
CONTROLLER
SELF - CHECK CHK6

CHK 6 R FT TV MODE 2 H TR1 0 0 0 0 0 0 0 0 0 0 0 0 % F % TR2 TR3 TR4 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Engine Load Ratio (CX210/CX240) Fuel Temperature (CX210/CX240) Throttle Volume Transistor output has detected an over current Transistor output has detected an over current Transistor output has detected an over current Not Used
NOTE: While viewing the CHK5 screen, if the Travel mode switch is held longer than 10 seconds, the CHK6 screen will appear. The buzzer will sound until the key switch is turned off, the fault codes will be erased. Transistor output can be checked for over current (short to ground) automatically. To do this hold down the one-touch idle switch while you turn on the key, then release the one-touch switch. You will hear the system check itself. If there is no short circuit detected, the travel alarm will sound. If a short circuit is detected, the buzzer will sound intermittently and ELECTRICAL PROBLEM will be displayed on the screen. The CHK5 screen will indicate which circuit the fault is in. See pages 3-29 and 3-30 for identification of the fault location.
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CX EXCAVATORS
CONTROLLER
DIAGNOSTIC SYSTEM CX210/CX240

DIAG1 Current Engine Failure Condition
DIAG 1 E E E MODE 2 H E 0 0 0 0 0 0 0 0 0 0 0 0 E E E 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
E 0000 No Failures E 0111 ECM internal Hardware Error E 0115 No engine speed detected at engine speed sensor. E 0122 High voltage detected at Boost pressure sensor. E 0123 Low voltage detected at Boost pressure sensor. E 0131 Throttle position sensor E 0132 Throttle position sensor E 0135 Oil pressure high E 0141 Oil pressure sensor low E 0143 Oil pressure sensor / EPF E 0144 Coolant temp sensor high E 0145 Coolant temp sensor low E 0146 Coolant temp sensor / EPF E 0151 Coolant temp sensor / EPF E 0153 Intake air temp sensor high E 0154 Intake air temp sensor low E 0155 Intake air temp sensor / EPF E 0234 ESS, crankshaft position sensor E 0235 Coolant level sensor / EPF E 0261 Fuel temp sensor pump over-heat E 0264 VP44 fuel temp sensor E 0278 Lift pump relay E 0283 ESS/Crankshaft position sensor high E 0284 ESS/Crankshaft position sensor low E 0319 EECM E 0352 Sensor voltage supply E 0361 VP44 fuel system high current E 0362 VP44 fuel system value open E 0363 VP44 fuel system feed back error E 0364 VP44 fuel system com error
E E E E E E E E E E E E E E E E E E E E E E E E E E E
0365 0366 0367 0368 0369 0372 0373 0374 0376 0377 0381 0386 0391 0415 0418 0422 0429 0431 0433 0434 0441 0442 0443 0488 0517 0524 0611
VP44 fuel system low VP44 fuel system measurement error VP44 fuel system IAT error VP44 fuel system timing error VP44 fuel system sync error VP44 fuel system idle validation error VP44 fuel system FSO high VP44 fuel system shutoff error VP44 fuel system mismatch error Fuel pump power shutoff relay Intake air heater control error, relay 2 Engine sensor voltage supply high Fuel pump power shutoff relay Oil pressure sensor / EPF Water in fuel sensor Coolant level sensor Water in fuel sensor Throttle position sensor low Boost pressure high ECM Battery voltage low Battery voltage high Throttle position sensor Intake air temp sensor / EPF Fuel pump has a stuck control valve High speed governor droop switch Hot shutdown error
Note: Go to Section 8, Page 19~24 for the fault description in more detail.
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CX EXCAVATORS
CONTROLLER

DIAG2 Past Engine Failure Condition
DIAG 2 E E E MODE 2 H E 0 0 0 0 0 0 0 0 0 0 0 0 E E E 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
E 0000 No Failures E 0111 ECM internal Hardware Error E 0115 No engine speed detected at engine speed sensor. E 0122 High voltage detected at Boost pressure sensor. E 0123 Low voltage detected at Boost pressure sensor. E 0131 Throttle position sensor E 0132 Throttle position sensor E 0135 Oil pressure high E 0141 Oil pressure sensor low E 0143 Oil pressure sensor / EPF E 0144 Coolant temp sensor high E 0145 Coolant temp sensor low E 0146 Coolant temp sensor / EPF E 0151 Coolant temp sensor / EPF E 0153 Intake air temp sensor high E 0154 Intake air temp sensor low E 0155 Intake air temp sensor / EPF E 0234 ESS, crankshaft position sensor E 0235 Coolant level sensor / EPF E 0261 Fuel temp sensor pump over-heat E 0264 VP44 fuel temp sensor E 0278 Lift pump relay E 0283 ESS/Crankshaft position sensor high E 0284 ESS/Crankshaft position sensor low E 0319 EECM E 0352 Sensor voltage supply E 0361 VP44 fuel system high current E 0362 VP44 fuel system value open E 0363 VP44 fuel system feed back error E 0364 VP44 fuel system com error
E E E E E E E E E E E E E E E E E E E E E E E E E E E
0365 0366 0367 0368 0369 0372 0373 0374 0376 0377 0381 0386 0391 0415 0418 0422 0429 0431 0433 0434 0441 0442 0443 0488 0517 0524 0611
VP44 fuel system low VP44 fuel system measurement error VP44 fuel system IAT error VP44 fuel system timing error VP44 fuel system sync error VP44 fuel system idle validation error VP44 fuel system FSO high VP44 fuel system shutoff error VP44 fuel system mismatch error Fuel pump power shutoff relay Intake air heater control error, relay 2 Engine sensor voltage supply high Fuel pump power shutoff relay Oil pressure sensor / EPF Water in fuel sensor Coolant level sensor Water in fuel sensor Throttle position sensor low Boost pressure high ECM Battery voltage low Battery voltage high Throttle position sensor Intake air temp sensor / EPF Fuel pump has a stuck control valve High speed governor droop switch Hot shutdown error
Note: Go to Section 8, Page 19~24 for the fault description in more detail.
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CX EXCAVATORS
CONTROLLER

DIAG3 Past Engine Failure Condition (Hour)
DIAG 3 E E E MODE Hi, H E 0 0 0 0 0 0 0 0 0 0 0 0 E E E 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
The hours that fault occurred will be displayed in the same window as the fault code that was detected in DIAG2. Past fault codes and hours will be cleared if the Work mode switch is pressed for 10 seconds. Hours shown in DIAG3 is computer ON hours since the last time the data was cleared. Not excavator hour-meter hours. Note: To erase engine fault codes switch to DIAG2 and press the Work mode switch for 10 seconds. The warning buzzer will sound. Turn OFF the key switch to complete the process.
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CX EXCAVATORS
CONTROLLER
DIAGNOSTIC SYSTEM
DIAG4 Current Machine Failure Condition
DIAG 4 M M M MODE Hi, H M 0 0 0 0 0 0 0 0 0 0 0 0 M M M 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
M 0000: No Failure M 0010: M 0020 M 0030 M 0040 M 0050 M 0060 M 0070 M 0080 M 0090 M 00A0 M 00D0 M 00E0 M 00F0 Transistor output short circuit, (see page 3-28) Hydraulic oil temperature sensor Fuel sensor Pressure sensor (P1) Pressure sensor (P2) Pressure sensor (N2, negative control) Key switch Pressure switch (upper or travel) CAN communication error (CX210/CX240) Computer reset Throttle motor related problem (CX130/CX160) Coolant level sensor (CX130/CX160) RPM sensor (CX130/CX160)
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CX EXCAVATORS
CONTROLLER
DIAGNOSTIC SYSTEM
DIAG5 Past Machine Failure Condition
M 0000: No Failure M 0010: M 0020 M 0030 M 0040 M 0050 M 0060 M 0070 M 0080 M 0090 M 00A0 M 00D0 M 00E0 M 00F0 Transistor output short circuit Hydraulic oil temperature sensor Fuel sensor Pressure sensor (P1) Pressure sensor (P2) Pressure sensor (N2, negative control) Key switch Pressure switch (upper or travel) CAN communication error (CX210/CX240) Computer reset Throttle motor related problem (CX130/CX160) Coolant level sensor (CX130/CX160) RPM sensor (CX130/CX160)
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CX EXCAVATORS
CONTROLLER
DIAGNOSTIC SYSTEM
DIAG6 Past Machine Failure Condition (Hours)
The hours that fault occurred will be displayed in the same window as the fault code that was detected in DIAG5. Past fault codes and hours will be cleared if the Work mode switch is pressed for 10 seconds. Hours shown in DIAG6 is computer ON hours since the last time the data was cleared. Not excavator hour-meter hours. Note: To erase machine fault codes switch to DIAG5 and press the Work mode switch for 10 seconds. The warning buzzer will sound. Turn OFF the key switch to complete the process.
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CX EXCAVATORS
CONTROLLER
EXCAVATOR HISTORY
HR1
HR 1 ENG WRK U MODE Hi, H T 0 0 0 0 0 0 0 0 0 0 0 0 HR HR HR S PU BRK 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 HR HR HR HR
ENG: WRK: U: T: S: PU: BRK:
Hour Meter, hours (engine running) since last cleared Operating hours (pressure switch ON) Upper operating hours Travel operating hours Swing operating hours Power Boost operating hours Hammer operating hour
Use the Buzzer stop switch to scroll through the HR screens.
Note: To erase the work history data from all of the HR screens, scroll to the HR1 screen, press and hold the Work mode switch for 10 seconds (buzzer will sound). Turn OFF key.
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CX EXCAVATORS
CONTROLLER
EXCAVATOR HISTORY
HR2
HR 2 H S L MODE Hi, H A 0 0 0 0 0 0 0 0 0 0 0 0 HR HR HR WT OT FT 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 HR F F F
H: S: L: A: WT: OT: FT:
H work mode operating hours S work mode operating hours L work mode operating hours Auto work mode operating hours Maximum coolant temperature recorded since the last time the data was cleared Maximum hydraulic oil temperature recorded since the last time the data was cleared Maximum fuel temperature recorded since the last time the data was cleared (CX210/CX240)
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CX EXCAVATORS
CONTROLLER
EXCAVATOR HISTORY
HR3
HR 3 1 2 3 MODE Hi, H 4 0 0 0 0 0 0 0 0 0 0 0 0 HR HR HR 5 6 7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 HR F F F
1: 2: 3: 4: 5:
Computer power ON hours Low speed operating hours High speed operating hours Independent travel operating hours Maintenance timer
3 - 40
CX EXCAVATORS
CONTROLLER
EXCAVATOR HISTORY
HR4
HR 4 1 2 3 MODE Hi, H 4 0 0 0 0 0 0 0 0 0 0 0 0 HR HR HR 5 6 7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 HR HR HR HR
P1 Pressure Distribution (pump 1) 1: 2: 3: 4: 5: 6: 7: P1 operating hours, under 1450 PSI P1 operating hours, 1450 to 2176 PSI P1 operating hours, 2176 to 2901 PSI P1 operating hours, 2901 to 3626 PSI P1 operating hours, 3626 to 4351 PSI P1 operating hours, 4351 to 5076 PSI P1 operating hours, over 5076 PSI
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CX EXCAVATORS
CONTROLLER
EXCAVATOR HISTORY
HR5
P2 Pressure Distribution (pump 2) 1: 2: 3: 4: 5: 6: 7: P2 operating hours, under 1450 PSI P2 operating hours, 1450 to 2176 PSI P2 operating hours, 2176 to 2901 PSI P2 operating hours, 2901 to 3626 PSI P2 operating hours, 3626 to 4351 PSI P2 operating hours, 4351 to 5076 PSI P2 operating hours, over 5076 PSI
3 - 42
CX EXCAVATORS
CONTROLLER
EXCAVATOR HISTORY
HR6
Engine Speed (RPM) Distribution 1: 2: 3: 4: 5: 6: 7: Hours, under 1175 RPM Hours, 1175 to 1375 RPM Hours, 1375 to 1575 RPM Hours, 1575 to 1775 RPM Hours, 1775 to 1975 RPM Hours, 1975 to 2175 RPM Hours, over 2175 RPM
3 - 43
CX EXCAVATORS
CONTROLLER
EXCAVATOR HISTORY
HR7
Coolant Temperature Distribution 1: 2: 3: 4: 5: 6: 7: Hours, under 171F (1st and 2nd Bars) Hours, 171F to 180F (3rd Bar) Hours, 180F to 207F (4th Bar) Hours, 207F to 212F (5th Bar) Hours, 212F to 217F (6th Bar) Hours, 217F to 221F (7th Bar) Hours, over 221F
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CX EXCAVATORS
CONTROLLER
EXCAVATOR HISTORY
HR8
Hydraulic Oil Temperature Distribution 1: 2: 3: 4: 5: 6: 7: Hours, under 113F (1st and 2nd Bars) Hours, 113F to 140F (3rd Bar) Hours, 140F to 176F (4th Bar) Hours, 176F to 190F (5th Bar) Hours, 190F to 203F (6th Bar) Hours, 203F to 208F (7th Bar) Hours, over 208F
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CX EXCAVATORS
CONTROLLER
EXCAVATOR HISTORY CX210/CX240

HR9
Fuel Temperature Distribution 1: 2: 3: 4: 5: 6: 7: Hours, under 86F Hours, 86F to 104F Hours, 104F to 122F Hours, 122F to 140F Hours, 140F to 158F Hours, 158F to 176F Hours, over 176F
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CX EXCAVATORS
CONTROLLER

HR10
HR 10 1 2 3 M O D E H i, H 4 0 0 0 0 0 0 0 0 0 0 0 0 HR HR HR 5 6 7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 HR HR HR HR
Load Ratio Distribution 1: 2: 3: 4: 5: 6: 7: Hours, under 30% Hours, 30% to 40% Hours, 40% to 50% Hours, 50% to 60% Hours, 60% to 70% Hours, 70% to 80% Hours, over 80%
3 - 47
CX EXCAVATORS
CONTROLLER

HR11
Load Ratio Distribution in H Mode, High Idle 1: 2: 3: 4: 5: 6: 7: Hours, under 30% Hours, 30% to 40% Hours, 40% to 50% Hours, 50% to 60% Hours, 60% to 70% Hours, 70% to 80% Hours, over 80%
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CX EXCAVATORS
CONTROLLER

HR12
Load Ratio Distribution in S Mode, High Idle 1: 2: 3: 4: 5: 6: 7: Hours, under 30% Hours, 30% to 40% Hours, 40% to 50% Hours, 50% to 60% Hours, 60% to 70% Hours, 70% to 80% Hours, over 80%
3 - 49
CX EXCAVATORS
CONTROLLER
RESETTING
RST1
RST 1 BRK L/M AI MODE Hi, H PA 0 0 Not 0 0 0 0 RPM Used RPM 0 0 SEC AU HLD OUT 0 0 0 0 0 0 Not 0 0 0 0 0 0 Used
BRK: L/M: AI: PA:
Programmed RPM for Hammer mode Old computer Not Used, New Computer includes this feature for Material Handling. Auto-Idle setting time, (1 to 30 seconds) factory setting is 5 seconds Altitude compensation (0 = off, 1, 2 or 3 = on), Each reduces the pump output by reducing the current to the proportional valve by 100, 150 or 200 MA. This feature can be used for a sick engine to cut back pump flow. Auto Power Boost Cancellation (0 = off, 1 = on) Not available on CX130 or CX160. Does not turn off Power Boost in L Mode. Hold previous (default) data (0 = with, 1 = without) Not Used
AU:
HLD: OUT:
Use the Buzzer stop switch to scroll through Resetting.
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CX EXCAVATORS
CONTROLLER
RESETTING
Engine Speed for Hammer Mode
RST 1 BRK L/M AI MODE Hi, H PA 0 0 0 0 RPM RPM SEC AU HLD OUT 0 0 0 0 0 0 0 0 0 0 0 0
Not 0 0
Used 0 0
Not
Used
Push the Buzzer stop switch to select BRK (item selected will have a light background). CX130/CX160 To set engine speed for hammer mode, start the engine and adjust RPM with the throttle control. Monitor will show actual RPM. Press the Work mode switch for 10 seconds to select the displayed RPM. The buzzer will sound to notify that 10 seconds have elapsed. Turn the throttle to low idle. Turn the key switch off. CX210/CX240 Start the engine and adjust engine speed to desired RPM using the Free Swing switch to increase RPM and the Cushion switch to decrease RPM. The switches must be held for 5 seconds for a RPM change to occur. Press and hold the work mode switch for 10 seconds. The alarm buzzer will sound. Press the buzzer switch twice to change the display to AI. Turn the throttle to idle and turn off the key switch.
To confirm, start the engine, turn up the RPM, access the CHK1 screen and observe the RPM when the hammer circuit is activated.
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CX EXCAVATORS
CONTROLLER
RESETTING
Not 0 0
Used 0 0
Not
Used
L/M: Not used OUT: Not used
3 - 52
CX EXCAVATORS
CONTROLLER
RESETTING
Auto Idle Time Set
Not 0 0
Used 0 0
Not
Used
Push the Buzzer stop switch to select AI (item selected will have a light background).
To set the Auto-Idle time from 0 through 30 seconds, press the Travel mode switch until the number changes to your selection. The number increases by 1 every time the switch is pushed.
To save this data press and hold the Work mode switch for 10 seconds. The buzzer will sound to notify when 10 seconds have elapsed.
Turn the key switch off to complete the procedure.
3 - 53
CX EXCAVATORS
CONTROLLER
RESETTING
Altitude Compensation (pump power set)
Not 0 0
Used 0 0
Not
Used
Push the Buzzer stop switch to select PA (item selected will have a light background)
PA:
0 = Normal Mode
PA: 1, 2 or 3 = Low Power Mode settings, reduces the pump output by decreasing the maximum current to the proportional valve by 100, 150 or 200. MA The engine stays the same speed. To set the lower pump power mode (altitude compensation), push the Travel mode switch to change the 0 to 1, 2 or 3 for a lower power mode or 0 for normal power mode.
To save the data, press the Work mode switch for 10 seconds. The buzzer will sound to notify when 10 seconds have elapsed.
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CX EXCAVATORS
CONTROLLER
RESETTING
Auto Power Boost Set (CX210/CX240)
Not 0 0
Used 0 0
Not
Used
Push the Buzzer stop switch to select AU (item selected will have a light background)
AU:
0 = With Automatic Power Boost
AU: 1 = Without Automatic Power Boost (No Automatic Power Boost in the H & S modes, Power Boost will still be on in the L Mode). To set press the Travel mode switch to select 1 or 0.
To save the data push the Work mode switch for 10 seconds. The buzzer will sound to indicate that 10 seconds have elapsed.
Turn the key switch off to complete the procedure. Note: This will not eliminate L mode full time power boost.
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CX EXCAVATORS
CONTROLLER
RESETTING
Previous Data Holding
Not 0 0
Used 0 0
Not
Used
Push the Buzzer stop switch to select HLD (item selected will have a light background).
0 = Will hold default data 1 = Will turn off default data, will return to setting when key is turned off To set previous data holding feature, push the Travel mode switch until the numbers change to the predetermined value in each column.
To set this data, press the Work mode switch for 10 seconds. The buzzer will sound to indicate when 10 seconds have elapsed.
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CX EXCAVATORS
CONTROLLER
RESETTING
Previous Data Holding
HLD
0 0
0 0
Auto Mode Work Mode Travel Mode Maintenance Timer
0 = Will hold default data 1 = Will return to setting when key was turned off. Auto Mode 0 = Auto Mode is the default mode whenever the key switch is turned on. 1 = Whatever Mode was on when the key switch was turned off will be on the next time the key is turned on. Work Mode 0 = Same as above 1 = H Mode will be the default mode if Auto Mode is 1. Travel Mode 0 = Low speed is the default whenever the key is turned on. 1 = Whichever speed range was on when the key was turned off will be the speed when the key is turned on. Maintenance Timer Cancellation 0 = Maintenance timer ON 1 = Maintenance timer OFF
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CX EXCAVATORS
CONTROLLER
Service Due Warning

When the CX series was first introduced the service due maintenance timer was set at a 500-hour interval and was unchangeable. Excavators equipped with controller part number KHR2673 and after have adjustable timer intervals. The selected intervals are 50, 250, 500, 1000, 2000 or 5000 hours. The controller part number for each excavator is determined by pushing and holding the auto mode switch for 10 seconds. The selection confirmation screen for the excavator displays the controller part number. The timer interval is adjustable if the controller part number is KHR2673 or higher. The display returns to the normal screen by pushing the auto mode switch.
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CX EXCAVATORS
CONTROLLER Area 1 displays the remaining time before the SERVICE DUE warning displays in the monitor. Area 2 displays the current (set) service due interval. Areas 3 through 7 are not currently used. With Area 2 highlighted, push the travel mode switch until the predetermined value is displayed in the window. The timer interval selections are: 0500 (default), 0050, 0250, 0500, 1000, and 2000. Stop when the desired interval is displayed. Push and hold the work mode switch for 10 seconds to set the maintenance timer service interval. The service interval is changed after the buzzer sounds. Turn the key switch off until the monitor window goes dark. Turn the key switch back on and the service interval is set.
SERVICE DUE WARNING CANCELLATION PROCEDURE
Hold the buzzer stop switch for 20 to 30 seconds while the service due warning is displayed to cancel the service due warning from displaying in the monitor.
NOTE: There are no audible warnings after the reset is completed. After 20 to 30 seconds turn the key switch off. NOTE: This procedure only resets the service due warning. This does not cancel the service due warning from displaying in the monitor at the next predetermined service interval time.
To completely turn off the SERVICE DUE warning feature, use the procedure on the previous page (3-57, RST1 screen, the HLD area, Maintenance Timer Cancellation).
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CX EXCAVATORS
CX Series Diagnostic Screen Data Sheet

Technical Service Group - 3/5/2003 CHECK DATE: MODEL: 1: STATUS INDICATION CHK 1 P1 P2 N CHK 4 FS AC TR5 2: DIAGNOSIS DIAG 1 E E E DIAG 4 M M M E E E E M M M M DIAG 2 E E E DIAG 5 M M M E E E E M M M M DIAG 3 E E E DIAG 6 M M M E E E E M M M M d d d ENG I WT OT TG BP SP1 SP2 CHK 2 R FT TV CHK 2 R FT TV TR1 TR2 TR3 TR4 TR1 TR2 TR3 TR4 CHK 3 SW1 SW2 SW3 CHK 2 R FT TV SW4 SW5 SW6 SW7 TR1 TR2 TR3 TR4 CUSTOMER: SERIAL NO.: DEALERSHIP: HOUR METER:
3: MACHINE HISTORY HR 1 ENG WRK U HR 4 1 2 3 HR 7 1 2 3 HR 10 1 2 3 T S PU BRK 4 5 6 7 4 5 6 7 4 5 6 7 HR 2 H S L HR 5 1 2 3 HR 8 1 2 3 HR 11 1 2 3 A WT OT FT 4 5 6 7 4 5 6 7 4 5 6 7 HR 3 1 2 3 HR 6 1 2 3 HR 9 1 2 3 HR 12 1 2 3 4 5 6 7 4 5 6 7 4 5 6 7 4 5 6 7
CX Series Diagnostic Screen Data Sheet

Technical Service Group - 3/5/2003 Field Information Key 1: STATUS INDICATION CHK1 through CHK6 (CHK2' and CHK2'' included) display current conditions on the machine. Please use the service manual for detailed descriptions of these fields.
2: DIAGNOSIS DIAG 1 Current Engine Fault Codes DIAG 4 Current Machine Fault Code
DIAG 2 Past Engine Fault Codes DIAG 5 Past Machine Fault Code
DIAG 3 Hour - Past Engine Fault Codes DIAG 6 Hour - Past Machine Fault Code
3: MACHINE HISTORY HR 1 HR 2 ENG engine hours since last cleared H WRK operting hours (press. switch on) S U upper operating hours L T travel operating hours A S swing operating hours WT PU power boost operating hours OT BRK hammer operating hours FT HR 4 1 2 3 4 5 6 7 HR 7 1 2 3 4 5 6 7
HR10
H Mode operating hours S Mode operating hours L Mode operating hours Auto Mode operating hours max water temp since last cleared max hyd temp since last cleared max fuel temp since last cleared P2 Pressure Distribution hours - under 1450 psi hours - 1450 to 2176 psi hours - 2176 to 2901 psi hours - 2901 to 3626 psi hours - 3626 to 4351 psi hours - 4351 to 5076 psi hours - over 5076 psi Hyd Temp Distribution hours - under 113F (1 & 2 bar) hours - 113 to 140F (3rd bar) hours - 140 to 176F (4th bar) hours - 176 to 190F (5th bar) hours - 190 to 203F (6th bar) hours - 203 to 208F (7th bar) hours - over 208F LR - H Mode High idle hours - under 30% hours - 30% to 40% hours - 40% to 50% hours - 50% to 60% hours - 60% to 70% hours - 70% to 80% hours - over 80%
HR 3 1 2 3 4 5 6 7 HR 6 1 2 3 4 5 6 7 HR 9 1 2 3 4 5 6 7
HR12
computer 'ON' hours Low speed operating hours High speed operating hours Independent travel hours Maintenance timer
P1 Pressure Distribution hours - under 1450 psi hours - 1450 to 2176 psi hours - 2176 to 2901 psi hours - 2901 to 3626 psi hours - 3626 to 4351 psi hours - 4351 to 5076 psi hours - over 5076 psi Water Temp Distribution hours - under 171F (1 & 2 bar) hours - 171 to 180F (3rd bar) hours - 180 to 207F (4th bar) hours - 207 to 212F (5th bar) hours - 212 to 217F (6th bar) hours - 217 to 221F (7th bar) hours - over 221F Load Ratio (LR) Distribution hours - under 30% hours - 30% to 40% hours - 40% to 50% hours - 50% to 60% hours - 60% to 70% hours - 70% to 80% hours - over 80%
HR 5 1 2 3 4 5 6 7 HR 8 1 2 3 4 5 6 7
HR11
RPM Distribution hours - under 1175 rpm hours - 1175 to 1375 rpm hours - 1375 to 1575 rpm hours - 1575 to 1775 rpm hours - 1775 to 1975 rpm hours - 1975 to 2175 rpm hours - over 2175 rpm Fuel Temp Distribution hours - under 86F hours - 86 to 104F hours - 104 to 122F hours - 122 to 140F hours - 140 to 158F hours - 158 to 176F hours - over 176F LR - S Mode High idle hours - under 30% hours - 30% to 40% hours - 40% to 50% hours - 50% to 60% hours - 60% to 70% hours - 70% to 80% hours - over 80%
1 2 3 4 5 6 7
1 2 3 4 5 6 7
1 2 3 4 5 6 7
The service manual provides a more detailed description of these diagnostic screens.
ELECTRICAL
ELECTRIC/HYDRAULIC
Pump Control, All Models
1) In S, H and Auto modes supply current to Electro-magnetic proportional solenoid valve on the side of the pump, will control the HP requirement of hydraulic pumps P1 and P2. Note: The controller needs an RPM signal from the engine for the proportional solenoid valve pump control to function. H -MODE: For the pump flow to reach 100% capacity, a variable electrical signal is sent to the proportional solenoid valve. The current varies with the engine speed. S -MODE: For the pump flow to reach 95% capacity, a variable electrical signal is sent to the proportional solenoid valve. The current varies with the engine speed. L -MODE: For the pump flow to reach 70% capacity, no electrical signal is sent to the proportional solenoid valve. AUTO -MODE: For the pump flow to work between 90% to 93% capacity of the engine target torque, an electrical signal is sent to the proportional solenoid valve based on the controller selected mode. The controller switches the modes between the SA mode and the LA mode, depending on conditions. The maximum current will equal the S mode current + 40m A for the SA mode. The maximum current will equal the S mode for the LA mode. When operating in the auto-mode and the SA mode is active, when the travel pressure switch is activated (closed), the excavator will stay in the SA mode until the travel switch opens. If the excavator is in the LA mode when the travel pressure switch closes, the excavator will stay in the LA mode until the travel pressure switch opens. When operating in the L mode and the travel pressure switch closes, the excavator will operate with the mA current of the S mode. If the hammer pressure switch closes, the excavator will operate with the mA current of the S mode. The engine speed must exceed 1500 rpm before the controller sends current to the pump proportional solenoid valve.
4 - 24
CX EXCAVATORS
ELECTRICAL
ELECTRIC/HYDRAULIC
MODE MODEL CX130 CX160 CX210 CX240 H MODE MAX 600 mA 600 407 424 MIN 450 mA 510 292 307 450 mA 510 292 307 0 0 0 0 S MODE L MODE AUTO MODE SA 490 mA 550 332 347 LA 450 mA 510 292 307
4 - 25
CX EXCAVATORS
ELECTRICAL
ELECTRIC/HYDRAULIC
Power Boost, CX130/CX160
1) Increases power when more force is required for digging operations. 2) By pushing the button on the front of the right joystick the main relief pressure is increased for 8 seconds in the H and S modes. 3) The Power Boost works at all times in the L mode. Note: The controller needs an RPM signal from the engine for the Power Boost to function. When the one-touch Power Boost switch is pressed ON (when working in the H or S mode), the signal enters in the main controller. 24v is sent to a solenoid valve from the controller and the solenoid valve switches. The pilot pressure enters the main relief valve and the pressure setting increases. POWER UP is displayed on the monitor. The increase in pressure is activated for 8 seconds. The instrument panel will display Power Up, even if the Power Boost switch is pressed for a long time, the pressure setting increases only for 8 seconds. The Power Boost can not be reactivated until the 8 second time frame has passed and the switch is released and pressed again. In L mode Power Boost is active full time. When the travel or the hydraulic option pressure switch closes.(ON) the controller will turn off the Power Boost solenoid. The Power Boost solenoid is in the six solenoid valve located in the pump compartment.
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CX EXCAVATORS
ELECTRICAL
POWER BOOST
Circuit Configuration
1. Power Boost switch 2. Main Controller 3. Power Boost solenoid valve 4. Travel pilot pressure switch 5. Main relief valve Pressure increase in each work mode CX130/CX160 H MODE S MODE L MODE AUTO MODE 4970 5260 psi (8 seconds) 4970 5260 (constant) 4970 5260 (8 seconds)
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CX EXCAVATORS
ELECTRICAL
ELECTRIC/HYDRAULIC
Automatic Power Boost, CX210/CX240
1) In the H and the S work modes, the controller will automatically activate the Power Boost solenoid valve to increase the main relief pressure. 2) This increase is automatic without action by the operator. 3) The increase will activate for only 8 seconds. 4) The Power Boost is on full time in the L mode. Note: The controller needs an RPM signal from the engine controller for Power Boost to function. When operating in either the H or S mode, the main controller monitors the ratio between: The load on the engine transmitted by the engine controller. The load on the hydraulic system transmitted by the pressure transducers on pump P1 and pump P2.
If the pressure of P1 or P2 is higher than 4351 psi (300 bar) and the load ratio remains within a range of 5% for 2 seconds, the controller sends a 24 volt signal to activate the Power Boost solenoid for 8 seconds which increases the main pressure. The instrument panel will display Power Up. To reactivate automatic Power Boost the load must be released and applied again. When either the travel or the hydraulic option pressure switch is activated, the controller deactivates the Power Boost solenoid valve. The Power Boost solenoid valve is located in the six solenoid valve bank located in the pump compartment.
4 - 28
CX EXCAVATORS
ELECTRICAL
AUTOMATIC POWER BOOST

Circuit Configuration
1. 2. 3. 4. 5.
Main Controller Pressure detector P1 Pressure detector P2 Travel pilot pressure switch Option pilot pressure switch
6. Engine Controller 7. Main relief valve 8. Power Boost solenoid valve
Pressure increase in each work mode CX210/CX240 H MODE S MODE L MODE AUTO MODE 4970 5410 psi (8 seconds) 4970 5410 (constant) 4970 5410 (8 seconds)
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CX EXCAVATORS

Case CX 210 Exc Trainnig Service

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Case CX 210 Exc Trainnig Service

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Construction Equipment Service Training

Section 1 -GENERAL INTRODUCTION CNH Engine Diagnostic Class

CNH America LLC

2004 All Rights Reserved

Manufacture model number SHO120 SHO150 SHO200 SHO220

Case model number CX130 CX160 CX210 CX240

Single pedal no travel

Cushion Control System

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CX130 Theoretical Pump Flow L, S & H Mode

CX130 Theoretical Pump Flow L, S & H Mode

H Mode mA = 600 S Mode mA = 450

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

CX160 Theoretical Pump Flow L, S, & H Mode

CX160 Theoretical Pump Flow L, S, & H Mode

CX210 Theoretical Pump Flow L, S & H Mode

30 25.8 23 20 14.5 10 10 8.4 23.7

CX210 Theoretical Pump Flow L, S & H Mode

CX240 Theoretical Pump Flow L, S, & H Mode

CX240 Theoretical Pump Flow L, S, & H Mode

CX290 Theoretical Pump Flow L, S, & H Mode

CX290 Theoretical Pump Flow L, S, & H Mode

Construction Equipment Service Training

CNH America LLC

2004 All Rights Reserved

CONTROLLER CALIBRATION and DIAGNOSTIC SYSTEM

Work Mode Switch Travel Mode Switch

Buzzer Stop Switch

Auto Mode Switch

CONTROLLER CALIBRATION PROCEDURE

MACHINE: SH0200 3 TERRITORY: 2 LANGUAGE: 1

CONTROLLER CALIBRATION PROCEDURE

Turn off the key switch to finish clearing the data.

CONTROLLER CALIBRATION PROCEDURE

Case NA CX130 CX160 CX210 CX240 CX290 CX330 CX450 CX800

CONTROLLER CALIBRATION PROCEDURE

CX130 CX160 CX210 CX240 CX290 CX330 CX460 CX800

CONTROLLER CALIBRATION PROCEDURE

CONTROLLER CALIBRATION PROCEDURE

CONTROLLER CALIBRATION PROCEDURE

CONTROLLER CALIBRATION PROCEDURE

CONTROLLER CALIBRATION PROCEDURE

The language is changed by pressing the Travel mode switch.

DIAGNOSTIC MODE FLOW CHART

CURRENT CONDITION CHK1

CURRENT CONDITION CHK2

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

CURRENT CONDITION CHK2

CURRENT CONDITION CHK2

CURRENT CONDITION CHK2

CURRENT CONDITION CHK3

CURRENT CONDITION CHK3

CURRENT CONDITION CHK3

Observe with engine running. Should be ON.

CURRENT CONDITION CHK3

CURRENT CONDITION CHK3

CURRENT CONDITION CHK3

CURRENT CONDITION CHK4

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

CURRENT CONDITION CHK4

Press the Buzzer stop switch to return to CHK1.

PRESENT OVER LOAD CONDITION CHK5

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

PAST OVER LOAD CONDITION CHK5