Construction Equipment Service Training CX SERIES EXCAVATOR Section 1 -- GENERAL INTRODUCTION CNH Engine Diagnostic Class Trcini! ato 7 wa! . e rdGENERAL INTRODUCTION TABLE OF CONTENTS Section 1 - General Introduction PAGE NO, Engines... Reservoir... Falters Purnp: Pilot System Hydraulic Systems ‘Cushion Contra! Swing... Travel... ‘Cylinders. sctrical Syston CX EXCAVATORSGENERAL INTRODUCTION EXPLANATION OF CX SERIES Engines WODEL CKxieo Make | CASE Model 4TA390 HP (net) 106 Cold Start | Ether Rated rpm When programming the excaval procedures are in section 3 of this training manual tbe used. Detailed Manufacture Case model number model number SHO120 CX130 SHO150 CX160 $HO200 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 MODE MODE MODE tancuase | NO tancuace | N9 | vancuace | NO Japanese 0 | ttaian @_| Swedish 2 English Ta [Spanish 7 | Finnish a Tha 2 | Partugueze @ [Picture writing | 1 Chinese Dutch 2 Garman Danish 0 French Norwegian 77 CX EXCAVATORSGENERAL INTRODUCTION EXPLANATION OF CX SERIE: Reservoi The reservair is pressurized on ail 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 breatheripressurs reguiatorifil cap installad in the top cover of the excavators. A rubbe: covered button on top of the breather is provided to release the air pressure in the reservoir. A sight gauge mounted ta the side of the reservoir indicates the oil tevel. There is a 150-mesh screen at the outlet of the raservoir to the hydrauiic pump. Reservoir MODEL CxO cxi6o cx2i0 CX2a0 Capacity ie a a a Tank gal. Capacity 32 zy 60 ‘System gal. Filters. The oil retuming from the main conimal valve flows through the oil cooler. There ic a cooler bypass velva in the ciroult to protect the system during cold start conditions. As the oil retums from the oil cooler, it passes through = full flaw 10-micron Some of the retum ail i routed through a t-micron ultra-fine filler. Drain oil from the pilot control circuits and the case drain o@ from tha swing and travel motors is returned through the main return filter A.cariridge type fillar is installed in the outlet of the pilot pump to protect all pilot ‘contamination. All of these fiers have fiter bypass valves for cold start up protection Filters MODEL cx160 cx210 Cx240 ‘Suction 160 mesh 180-mash 150 mesh Return on | 1p 104 Ultrafine Th TH TH TH Pilot id idu CX EXCAVATORSGENERAL INTRODUCTION EXPLANATION OF CX SERIES Variable Pumps Allof tha CX Saries 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 mainiain a constant horsepower load on the engine. The theory is that when very high pressures sre required, speed isn't so Important The CX Series Excavators use & two- section variable displacement piston pump. to provide the flow required to operate the functons. Variable pumps allow the delivery of higher flow rates at lower working pressures, and then allow the pumps to reduce the flow al higher pressures, to Keep from talling the engine. The increased fiow at lower pressures makes the cycle times faster, and increases tha overall efficiency of the excavator. The engine horsepawer required to drive a hydrsulic pump depends on the Row delivered by the pump, a3 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 fequires approximately 1 engine horsepower to deliver 1 gallon per minuta of ail at 1500 psi Therefore, 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 GX Series Excavators have an automatic pump de-sttoke feature that reduces the pump flow io a minimum, when all control levers are in the neutral position. This is accomplished with @ hydraulic pilot signal from the conto! valve, This sysiem saves fuel and el wasted engine and hydraulic power. The minimum flow dalivery of the pumps incre eacavaior Size and engine horsepower. Although the pump configuration and manufacturer varies, in principal, all of the pump control systems operate the same. Pumps MODEL CxImt Cxt60 oxai0 CxO Max. pump few | 32:4 gem 36.2 gpm 53.7 oom 56 gpm Pilot pump flaw @gom 5B gpm 5 gam gpm Manufacture Uehidar Uehidal Kawasan Kawasan Kawasaki Kawasaki ‘Configuration Tandem Tandem Tandem Tandem CX EXCAVATORS‘GENERAL INTRODUCTION EXPLANATION OF CX SERIE: Pilot Controls ‘The attachment controls ard pilot operated by hand actuated controers on all models. The pilot hand controls are mounted {0 filing armrests that can be pasitoned ta provide for maximum operator comfort. The standard control patiern is the SAE pattem. The controls can be changed to other configurations by changing the pilot hose connections at the pilot manifold, Iocated behind tha cab (see Sction 8001 of the Service Manual for instructions). Thera is a pat available és an option which allows patiem changes without moving hoses. teen change When the lefl arm (s fitted up or the gate lever is up, all pilat operetiad control functions are Onvall modets, the travel system is actuated by foot pedals that also have hand control levers attached, The traval controls are pilot pressure operated on all models. The CX240 — CXB00 have a single pedal feature. By actuating a single control pedal, both travel motors will ravel at the seme speed and direction. This feature gives the operator straight-ling travel in sither forward of reverse. Pilot Controls “MODEL cxi30 =| ~=«(cxte0. =| = GX2 40 x20 Pilot a5 yes yes yes operated hand and foot controls Single pedal | ro ra ra yee travel CX EXCAVATORS(GENERAL INTRODUCTION PMN Pel hee eo) Hydraulic System Overview All models use a triple hydraubc pump assembly that is locatad on the same side of the ‘excavator as the reservoir, all of the excavators use two verlable displacement piston pumps for tha excavator functions. A fixed displacement gear pump used to supnly pilot control cil for the system. The original CX120 and C160 excavators used @ tandem mounted pump supplied by Uchida. All later excavators use a tandem mounted pump supplied by Kawesak All of the pumps have @ system to fimit the horsepower load on the engine. This system aallows the excavator to fully utlize the power available without overloading the engina. The CX Series Excavators have an electrically controlled feature that allows the hydraulic system: to operate al less than full lad t6 increase fuel economy o¢ fine touch conirofabity This feature allows for four digging modes: “Auto” -Variable- 90-85% engine spead- 93-50% hydraulic pump torqua “H" Heavy Duty 100% of engine speed - 100% hydraulic pump torque. *"S* “Standard Duly - 95% of engine speed - 90% hydraulic pump torque “L’ -Light - B5% of engine speed - 70% hydraulic pump torque, The originat excavators were in the “Auto” mode each time they were startad, newer modals default to the “H™ mode. All madals have Power Boost CX130/CX100 excavators have One-Touch Power Boost. CX210/CXB00 excavators have automatic Power Boost, CX EXCAVATORSGENERAL INTRODUCTION EXPLANATION OF CX SERIES The CX Series Hydraulic System There is a singla main relief with 2 second (power boost) setiing. Boom and arm ant-dnift valves are built info the main control valve. An auxiliary conirol valve is standard and = factory installed or feld installed kit with plumbing to the end of the arm is avaiable. Other features ‘that are built into the main control vaive are: Dual pump flow boom up Boom down regeneration tt Dual pump flow arm in and out Boom down ant Arm in regeneration Arm in anti-drift Travel proority Swing priorty Neutral pump de-strake Two slactrcal pressure switches are installed on the main contral valve, and one in the swing pilot shut 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 conirol cushion system to allow the boom and arm cylinder control spoots to gradually raturn to neutral. for shock-ree operation. This feature allows 4 lesser skilled operator to work more smoothly, With the control cushion system active. the pila aif from the hand control Bows to the atm or boam contra spool ursestricted. When the hand control is returned to neutral, the pilot of is restricted as it lgaves the control spool, This slow return of the spool accounts for the smooth operslion The sysiem can be overridden with an electrical control ewitch an the maniioriswaich panel Swing The CX Series Excavators da not have & mechanical house lock The house lock is accomplished with the swing brake. The swing brake is applied when the switch on the lef console is activated! or the engine is shut off. The swing brake is also applied 5 seconds a the hand control is returned to neutral unless “Free-Swing’ is turned on, CX EXCAVATORSGENERAL INTRODUCTION EXPLANATION OF CX SERIES Travel CX130/CX160/CX210/CX240/CX290/CX330/CX460/CX800 The travel motors am located at the ar of each track assembly. The travel system is controfiad by control spools in the main control valve located in the excavator upper section The tavel drive system has independent, compact, axial piston, two speed hydraulic motors. Each track is independently driven by @ sprocket, which is driven by a planetary reduction gear. There is a spring applied, hydraulically released disc brake bull info each motor. The travel brake is: released by the travel pressura applied to the motor. Each travel motor is equipped with a counterbalance valve and 2 dual staga relief valves for smaoth starts and stops. The counterbalance valve prevents over speading of the motor while driving dawn an incline. The shackles relief valve allows for atidiional cushioning in the circuit by allowing a Slight transfer of all bebween travel directions as the excavator is stated 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 péot system pressure fo actuate the two-speed spoo! in each travel motor. Travel drive pressure is than ported through the hvo-speed coritral spool! to the motor swash plates. The excavators. are in “LOW SPEED" bavel when the kay Is tumed an, When the travel switch is depressed, the excavator willbe in “HIGH SPEED" and if the drive load is too high, the motor will automatically shift ta "LOW SPEED", and back to “HIGH SPEED" when the load is reduced. The Dash sill indicates "HI", the change takes place in the motors The travel system hae a travel priority valve to insure straight travel, if the swing function, or any eltschment 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 ta Supply both right and left travel, while the other pump is used for the attachment functors. With one pump supplying, both travel functions, tha travel speed will naturatly be reduced significantly, Travel MODEL CxX130 cxtea cxzi0 cxz40 LSpeed 24 H Speed a4 CX EXCAVATORSGENERAL INTRODUCTION EXPLANATION OF CX SERIES Cylinders ® cushion fe a nds of indar pasitons da not CX EXCAVATORSGENERAL INTRODUCTION EXPLANATION OF CX SERIES Electrical System All model 8 24-yoit starting and charging = 12-wolt be 1S; wired in senes to olstain the 2s the compartment behind the cab: ave two jocated in here is a batlery relay connec lecirical system, The hatiery folay acis as t relay closes as the key switch is tumed to the “or CX EXCAVATORSGENERAL INTRODUCTION EXPLANATION OF CX SERIES Electrical System Ta improve engine starting during cold temperatures, the CX130 and CX160 are equipped with an ether injection system as stancerd equipment. Tha ether injecton system can only be activated when the key-switch is in the crank position, There is a rocker switch located on the jefl-hand control console for easy access to the operator. There is also a temperature switch located on the enging intake menifold to prevent engagement of the ether system when the engine is above 40°F {58°C}. On the CX210, CX240, CX290 and CX390, there is an intake manifold hester for cold starting assistance, which is tumed on with the kay switch. The CXA80 and CXA00 engines use glow plugs in each cylinder to aid cold weather starting The Altemator is rated at 24 volts. The electronic controller for the CX130'CX100 excavators require an engine speed signal from @ magnetic senscr on tha fiywheel. This engine speed ‘Signal Is extremely critical to excavator functions. The other CX excavators have electronic controlled engines. The excavator controller requires inpud fram the engine conteallar The engine, the hydraulic, and tha electrical systems are all monitored by a controller, The controler for the CX130/CX16D is different than for the CX210:GX240. The. controller receives signals from sending units. Very simply, the conboller takes the information that it has received, and then sends the required outputs to cause the excavator to perform es selected, Thase outputs may be sent to the display panel to indicate @ malfunction or to give a visual display of which performance features have bean selected. The gulputs may also be sent to the solenoid valves, which contol the excavator functions. The controller has an automatic “imp home* feature to allow the excavator to be operated to complete the job in case of controller CX EXCAVATORSFlow =(GPM) Flow =(GPM) CX210 Theoretical Pump Flow L, S & H Mode "TOG. Tachisal Serves Gooey 81-1 Mish my = 202 IL Mad mt 20 Ear) i 2 nce 120 PA i tad TID RE po ere ee er Pressure = (PSI) Pt + P2 CX210 Theoretical Pump Flow L, S & H Mode 790 Tacheieal Burien Graup 01-04 tooo seo nt) ecm]. THHOD Pressure = (PSI) Pl + P2CONTROLLER Table of Contents Section 3 - CX Series Controller CONTROLLER CALIBRATION... eters Ee 3 ‘CHANGE THE DISPLAY LANGUAGE ONLY..... CURRENT CONDITION DISPLAY coe a . 17 DIAGNOSTIC CONDITION DISPLAY .......... 32 EXCAVATOR HISTORY DISPLAY........0..0ccseccsseesescereteestencaeencansiateenine DO OPTIONAL RESET DISPLAY... cseceseccessnenssneensensarenmarenesrensresnieneere DL at CX EXCAVATORSCONTROLLER: CONTROLLER CALIBRATION and DIAGNOSTIC SYSTEM SWITCHES Work Mode Switch Buzzer Stop Switch Travel Mode Switch Auto Mode Switch Cushion Switch oe CX EXCAVATORSCONTROLLER CONTROLLER CALIBRATION PROCEDURE CONTROLLER RESET MACHINE: SH0200 -3 TERRITORY: 2 LANGUAGE: 1 CONT. PIN 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. oe 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 normai mode screen by pressing and releasing the Auto Mode switch. Then press the Travel Mode and Work Made 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 10°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 180°F, tum off the Engine. Turn the Key Switch on and press the Auto mode switch for 10 seconds to Retum to the Controller Reset Screen. All Excavators: Press the Auto mode switch for 10 seconds to clear ail data in this screen. All data will change to “?" and the buzzer will sound. MACHINE: SH ? -3 TERRITORY: ? LANGUAGE: 7 ‘CONT. PIN KHR XXXX Turn off the key switch to finish clearing the data. aa CX EXCAVATORSCONTROLLER CONTROLLER CALIBRATION PROCEDURE . Tum the key switch “ON” 4°?" is shown at MACHINE, TERRITORY and LANGUAGE areas. A°?" shown with dark background means that item is selected and ready to be changed. MACHINE: SH © =3 TERRITORY: 7? LANGUAGE: ? A“-3" means CX series CONT. PIN KHR XXXX | 2. The machine model code will change in the dark background area every time the Travel mode switch is pressed MACHINE: SH. <3 TERRITORY: ? LANGUAGE: ? CONT. P/N KHR XXXX Select the correct model code that corresponds with the machine: Machine Gode | __Gase NA SHO120 CxX130 }__CXi69 _ SHO200 CX210 J} CX800 =a 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. $H0120 (UCHIDA PUMP) SHO121 (KAWASAKI PUMP) CxX130 -DACO7 13246 & After SHO150 (UCHIDA PUMP) SHO151 (KAWASAKI PUMP) Cx160 DACO7 16270 & After SHO200 (KAWASAKI PUMP) $HO0202 (LIFTING MAGNET M/C) Cx210 SH0220 (KAWASAKI PUMP) $H0222 (LIFTING MAGNET M/C) cx240 SHO02Z50 (KAWASAK| PUMP) cx290 $H0300 (UCHIDA PUMP) SHO301 (KAWASAKI PUMP) CX330 SHO302 (LIFTING MAGNET M/C) 5H0400 (KAWASAK] PUMP) CxX460 SHO800 (KAWASAKI PUMP) Cx800 The C130 PIN Break for the change to the Kawasaki Pump is DAC0713246, code SHO121 The CX160 PIN Break for the change to. the Kawasaki Pump is DACO7 16270, code SHO151. All North American CX330 excavators have the Kawasaki Pump, therefore the code must be changed to SHO301. a8 CX EXCAVATORSCONTROLLER CONTROLLER CALIBRATION PROCEDURE 4. After selecting the mode! code, press the Work mode switch to select the Territory field MACHINE: SH0200 -3 TERRITORY: * LANGUAGE: ? 4°?" shown with a dark background means that item is selected. 5, The Territory will-change everytime the Travel made 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 MP2 and temperature in “C. To switch between European and US units, press the Working Light Key MACHINE: SH0200 -3 TERRITORY: © LANGUAGE: ? KHR XXXX i CX EXCAVATORSCONTROLLER CONTROLLER CALIBRATION PROCEDURE 6. Press the Work mode switch to select the language field MACHINE: SHO200 -3 (i TERRITORY: 2 LANGUAGE: a CONT. PIN KHR XXXX A°?" shown with dark background means that item is selected. 7. Press the Travel mode switch to change the lanquage. See language selection chart below. Language Language Language Language Code Code 0 Japanese | a ~ Portuguese 1 English | 3 utah 2 | Thai | 10 Danish | 3 Chinese | n Norwegian 4 | German 12 Swedish 5 | French | 13 Finnish 6 Italian | 14 icons | 7 Spanish [ 15 = CX EXCAVATORSCONTROLLER CONTROLLER CALIBRATION PROCEDURE MACHINE: SH0200 -3 TERRITORY: 2 LANGUAGE: 1 ‘CONT. PIN 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, tum 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 itis finished. Note: Coolant temperature must be above 122°F (S0°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 thrattie control again. 9. Press the Auto mode switch to finish, and return to the normal display. aon CX EXCAVATORSCONTROLLER CONTROLLER CALIBRATION PROCEDURE Cx210/ Cx800 40. After inputting all machine information, push the Auto made switch. The CASE logo will be displayed, then automatically scroll to the normal display below. : = CX EXCAVATORSCONTROLLER CONTROLLER CALIBRATION PROCEDURE MACHINE: SH0200 -3 TERRITORY: 2 LANGUAGE: CONT. PIN KHR XXXX To change the language only. display the machine selection screen by pressing the Auto made 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. Tum the key switch off to complete the process ae CX EXCAVATORSCONTROLLER DIAGNOSTIC MODE FLOW CHART NORMAL DISPLAY DIAGNOST! MODE MODE fi EXCAVAT L 7 RESETTING OR RST1 HISTORY | CURRENT 2. DIAGNOSTIC CONDITION SYSTEM CHK1 DIAG1 pL (piae2 14g [ DIAGS | 3 1=(T +W)> 3 Seconds 5=T> 10 Seconds, CHKE displays Auto beeping occurs. Alam Stop (Buzzer'Stop) 6 = To erase see Page 3-14 description. 4=T> 1 10 Seconds (Push and hold to read CHKS) To record faults, with the Key off, Hold down the One-Touch Idle & tum the Key on, release the Idle key and the computer will self check. ioe 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 concitions 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 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. 4A Selt-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. Ifno over-current is detected, the travel alarm will sound To find the shorted circuit. go immediately to the CHK1 screen without tuming 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 ‘GHKS screen. Recorded TR1, TR2 and TR3 faults will be displayed_ Sif you hold the Travel switch dawn longer than 10 seconds the CHK Screen appears and the buzzer beeps intermittently, The same faults are displayed in the CHKE screen. Tuming off the Key switch erases the codes and silences the buzzer Ee CX EXCAVATORSCONTROLLER CURRENT CONDITION CHK1 Poesy oo oo Jar [eee os oolrs §«—ERT oo ob oom es Ge ee ee ee a * Mode: To reach this screen, Press and hold both the Travel and Work mode switches more than 3 seconds. Pa: Main Pump Pressure (P+) P2: Main Pump Pressure (P2) Nr Negative Control Pressure of pump supplying Ann 4 Spool ENG: Engine RPM I Current for Pump Proportional Solenoid WT: Water Temperature OT: Hydraulic Oil Temperature Use this screen to check main relief and power boast settings. Verify negative control pressure from the arm/swing pump. engine RPM, controller signal to the proportional solenoid on the pump and hydraulic cil 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 CHK? screen. CX EXCAVATORSCONTROLLER CURRENT CONDITION CHK2 +R Engine Load Ratio (CX210/CX240) * FT: Fuel Temperature (CX210/CX240) * TV: Throttle Volume * TRi: Transistor Output Engine Load Ratio * TR2: Transistor Output * TR3: Transistor Output ((Q-Qn) / (Qf-An)) * TR4: Not Used Fuel Flow: Q-Current ‘Qn - No Load Of — Maximum Flow R: CX210/0X240 Information sent from the engine controller to the main contoller. Tha main controller uses this information for recording purposes. The controller aisa uses: this information plus pump pressure to determine when to activate Auto Power Boost FT: X210/CX240 Information sent from the engine contratier ta the main contoller Tha main controller uses this information for recording monitering purposes TV: Use this field to verify that the controller is receiving the signal from the throttle sontrai knob, TR1, TR2, TR3: Thess fields can be used to verily that the conboller is sending the signal fo turn these various circuits on and off as they are selected by the operator a8 CX EXCAVATORSCONTROLLER CURRENT CONDITION CHK2 ces ao aa 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 contol 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. Slovly raise tha boom until screen Indicates swing brake is turned off, Retum boom control to neutral. Swing brake should be tumad on5 saconds later « High Speed Travel & Travel Alarm — Press the Iravel swilth to select high-speed travel, Tha 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 ses the alarm field change to & 1 and change back to 0 when the foot control is released. * Power Boost — CX210/CX240 -Move one of the stlachments to end of stroke. As the pressure increases the power boos! field should change to a 1 as the Auto Power Boost is engaged. Power boost should be on for B seconds. Selact L made with the Work mode switch, Power boost should be turned an until another work mode is selected «| Power Boost — CX130/CX160 — Press the ane-touch switch on the front of the right hand control. The power boost fale! shauid change toa 1 for 8 seconds. Select L mode with the Wark mode switch, Pawer boost should ba turned on until anather work mode is selected, ear CX EXCAVATORSCONTROLLER CURRENT CONDITION CHK2 Continued eflooilod L. Battery Relay * Cushion Valve (oifion) * 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. aoe CX EXCAVATORSCONTROLLER CURRENT CONDITION CHK2 Continued Eco oo + Free Swing «Thief Proof + NotUsed = NotUsed TRANSISTOR OUTPUT (O=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. * Not Used | * Not Used * Not Used * Not Used Seis CX EXCAVATORSCONTROLLER CURRENT CONDITION CHK3 This screen is used to verify that the controtler 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. * SWS: Swing lock switch, emergency stop switch, work light and wiper switch + SWE: Windshield washer switch, travel alarm and hammer mode switch, and Material Handling (LIM) mode * SW7: Thief Proof. Key switch. and Overioad (EU), ara CX EXCAVATORSCONTROLLER CURRENT CONDITION CHK3 Continued « 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. CX EXCAVATORSCONTROLLER CURRENT CONDITION CHK3 Continued | + Engine oil pressure switch * Coolant level switch * Auxiliary Pressure Switch * Notused SWITCH INPUT (O=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 L. Alternator signal * Notused Not used « Notused «* Observe with engine running. Should be “ON”. same CX EXCAVATORSCONTROLLER CURRENT CONDITION CHK3 Continued Lswa ]o 0 0 0 | « Cushion switch (offfon) * 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 0 0 oO : L. Swing lock switch * Emergency Stop switch «© Work light switch * Wiper switch * These’are momentary switches. They ara "ON" only while they are being preased ana CX EXCAVATORSCONTROLLER CURRENT CONDITION CHK3 Continued 7 L. Windshield washer switch © Travel alarm offfon switch * Hammer. Mode switch —— Material Handling (LM) SWITCH INPUT {0=OFF, 1=ON) Key Switch “ON” Washer switch is a momentary switch. Itis "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 °O" 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 ae2a CX EXCAVATORSCONTROLLER CURRENT CONDITION CHK3 Continued 0 0.0 +] +] + Thief Pro’ = Key switch + Notused * Notused SWITCH INPUT (0=OFF, 1=ON) Key Switch “ON” © "ON" when the key switch is, CX EXCAVATORSCONTROLLER: CURRENT CONDITION CHK4 + FS: — Fuel Sensor Resistance * AC: — Coolant Temperature for A/C Control + TRS: NotUsed « TG: Target Engine RPM = BP: — NotUsed + SP1: Not Used * SP2: Not Used a*28 CX EXCAVATORSCONTROLLER CURRENT CONDITION CHK4 Continued * 1: Water temperature: <86°F : Water temperature is between: 86°F & 113°F : Water temperature is between: 113°F & 149°F : Water temperature is between: 149°F & 176°F wn Press the Buzzer stop switch to return fo CHK1 ac2r CX EXCAVATORSCONTROLLER PRESENT OVER LOAD CONDITION CHK5 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 S — TR4: 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 over- current is detected, the travel alarm will sound. Ita short is indicated, do not tum 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 CHKS screen, The CHKS 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 tumed 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 a CX EXCAVATORSCONTROLLER PAST OVER LOAD CONDITION CHK5 Continued 0 0]00 L. Swing Park Brake * High Speed Travel * Travel Alarm * Power Boost TRANSISTOR OUTPUT (0 = No Overload, 1 = Overload) L. Battery Relay « Cushion Valve + Swing Shut OfF + Swing Priority sie CX EXCAVATORSCONTROLLER PAST OVER LOAD CONDITION CHK5 Continued Eo oo L. Free Swing Thief Proof * Not Used = Not Used TRANSISTOR OUTPUT (0 = No Overload, 1 = Overload) * Not Used KK Not Used «* Not Used « Not Used aot CX EXCAVATORSCONTROLLER SELF - CHECK CHK6 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 aver current Not Used goa? 228 gf z & NOTE: While viewing the CHK5 screen, if the Travel mode switch is heid longer than 10 seconds, the CHK 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 de 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. Ifa short circuit is detected. the buzzer will sound intermittently and “ELECTRICAL PROBLEM" will be displayed on the screen. The CHKS screen will indicate which circuit the fault is in. See pages 3-29 and 3-30 for identification of the fault location. a28! CX EXCAVATORSCONTROLLER DIAGNOSTIC SYSTEM CX210/CX240 DIAG1 — Current Engine Failure Condition E 0000 No Failures E 0711 ECM internal Hardware Emor E 0115 Noengine speed detected at engine shied sensor, E 0122 High voltage detected at Boost pressure senspe E 0123 Low witags detected at Boost pressure sensor. 0131 Throttle position sensor 0132. Throttle position sensor 0135. Ol pressure tigh 0141 Gi pressure sensor low 0143. Of pressure sensor /EPF O14 Coolant temp sensor high ‘0145 Coolant temp sensor low 0146 Coolant temp sensor /EPF 0151 Coolant temp sensar ! PF 0153. Iniake air temp sensor high OS Intake air temp sensor low Q155 Intake air temp sensor! EPF 0234 ESS, crankshaft postion sensor 0235 Coolant level sensor / EPF 0261 Fuel temp sensor pump overheat 0264 VPM4 fuel temp sensor 0278 Lift pump relay 0283 E55/Crankshafi position sensor high O2Bd E5S/Crankshaft position sensor low 0365 VP44 fuel-systam low 0366 VP44 fusl sysiem measurement amor 0367 VP44 fuel system IAT oar 0358 VPd4 fuel sysiam timing error 0369 VPdd fuel sysiam sync ero 0372 VP44 fuel system idle validation eror 0373 VPAd tual system FSO teh 0374 VP44 fuel system shutoff error 0376 VP4d fuel system mismatch etar 0377 Fuel pump power shutoff relay 0381 Intake ar heater canto! ear, relay 2 0386 Engine sensor voltage supply high 0391 Fuel pump power shutoff relay O475. Oil pressure sensor / EPF 0418. Water in fuel sensor 0422 Caoiant level sensor 0428. Water in fuel sensor 0431 Throttle postion sensoriow 0133. Boost pressura high O44 ECM 0441 Battery voltage low (442. Battery voltage tigh 0443. Thrattis position sensor 0488. Intake air temp sensor / EPF O517 Fuel pump has a stuck control valve O524 High speed govemor droop switch OTT mm mm mm mT eM mm mm 0379 EECM 0614 Hot shutdown error 0352 Sensor voltage supply 0361 VPA fusl system high current ‘Note: Go to Section 8, Page 19~24 for the 0962 VP44 fuelsysten value open fault description in more detail. 0363 VFM fuel system feed back error 0364 WP44 fuel system com error Mmmm nnn mmm mmm mmm mmm mo CX EXCAVATORSCONTROLLER DIAGNOSTIC SYSTEM CX210/CX240 DIAG2 — Past Engine Failure Condition E 0000 No Failures E 0111 ECM interns! Hardware Eror E 0115 No engine speed detected at engine speed sensor. E 0122 HighVoltage detected at Boost pressure sensor. E 0123 Low vollage detected atBoost pressure sensor. 0131 Throttle position sansor 0132 Throttle position sansar 0135 Of pressure high 0141 O8 pressure sensor low 0143. O32 pressure sensor /EPF 0144 Coolant temp sensor high 0145. Coolant temp sensor low 0146 Coolant temp sensor / EPF 0151 Coolant temp sensor / EPF (0153. Intake air temp sencor high 0154. Intake air temp sensor iow O158 Intake ak temp sengor / EPF 0234 ESS, crankthalt position sersar 0236 Coolant level sansor / EPE 0281 Fuel temp sensor pump overheat 0264 VP44 fuel temp sensor 0278 Lift pump relay 0283. ESS/Crankshafl position sensor high 0284 ESS/Crankshaft position sensor low 0319 EECM 0982 Sensor voltage supply 0361 VAM fue! sysiam high cusent 0962 VP4d fuel system value open 0363 VRHA fuel system fead back error 0264 VP44 fuel system com ertor 0365 VPM4 fuel system low 0366 VPM4 fusl system measurement amor 0367 VPid fuel system IAT eer 0368 \VPAd fuel system timing error 0369 VP fuel system sync error 0372 VPM4 fuel system idle validation error 373. VPMd fool system FSO high 0374 VP4d fuel system shutoff error 0376 VPdd fucl system mismatch arar 0377 Fuel pump power shutoff relay 0381 Intake air heater contin! ewor, relay 2 0386 Engne sensor voltage supply high 0291 Fuel pump power shutof relay 415 Oil pressure sensor/ EPF 0418 Wetter in fuel sensor 0422 Coolant lewel sensor 0425. Water in fuel sensor 0431 ‘Throie postion sensoriow 0433 Boost pressure high O44 ECM 0441 Battery voltage low 0442 Batiory voltage high D443 Throttle posifion sensor 488 Intake air temp sonsor | EPF O517 Fuel pump has a stuck control valve O84 Highspeed govemor droop swith 0611 Hot shutdown esor Ton mom mmm mmm mmm mmm mm Note: Go to Section 8, Page 19-24 for the fault description in more detail. nono mmm Mmmm mm mmm mm i CX EXCAVATORSCONTROLLER DIAGNOSTIC SYSTEM CX210/CX240 DIAG3 — Past Engine Failure Condition (Hour) e 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 waming buzzer will sound, Turn OFF the key switch to complete the process. ao04 CX EXCAVATORS0000: O010: 0020 0030 0040 0050 0060 0070 0080 o0g0 O0A0 o0D0 ODEO OOFO CONTROLLER DIAGNOSTIC SYSTEM DIAG4 — Current Machine Failure Condition No Failure Transistor output short circuit, (see page 3-28) Hydraulic ofl temperature sensor Fuel sensor Pressure sensor (P1) Pressure sensor (P2} Pressure sensor (NZ, 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) CX EXCAVATORSCONTROLLER DIAGNOSTIC SYSTEM DIAGS — Past Machine Failure Condition | MODE HH 0000: 0010: 0020 0030 0040 0050 O06O oo7o 0080 oog0 ooDd OED OOFO I iN No Failure 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 (CX240/CX240) Computer reset Throttie motor related problem (CX130/CX160) Coolant level sensor (CX130/CX%160) RPM sensor (CX130/CX160) 2 CX EXCAVATORSCONTROLLER DIAGNOSTIC SYSTEM DIAG6 — Past Machine Failure Condition (Hours) MODE Hi. H * The hours that fault occurred will be displayed in the same window as the fault code that was detected in DIAGS, * Past fault codes and hours will be cleared if the Work made switch is pressed for 10 seconds. * Hours shown in DIAG6 is computer “ON” hours since the lasi time the data was cleared. Not excavator hour-meter hours. Note: To erase machine fault codes switch to DIAGS and press the Work mode switch for 10 seconds. The warning buzzer will sound. Turn OFF the key switch to complete the process B28 CX EXCAVATORSCONTROLLER EXCAVATOR HISTORY HR1 S&S MODE Hii, H Cease] t= ENG: Hour Meter, hours (engine running) since last cleared WRK: Operating hours (pressure siwitch “ON") Upper operating hours Travel operating hours 8: Swing operating hours PU: Power Boost operating hours BRK: 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 hoid the Work mode switch for 10 seconds (buzzer will sound). Turn OFF key. ae CX EXCAVATORSCONTROLLER EXCAVATOR HISTORY HR2 MODE Hi, H H work mode operating hours 8 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 ofl temperature recorded since the last time the data was cleared Maximum fuel temperature recorded since the last time the data was cleared (CX210/CX240) a ie CX EXCAVATORSCONTROLLER EXCAVATOR HISTORY HR3 Computer power "ON" hours Low speed operating hours High speed operating hours Independent travel operating hours Maintenance timer au CX EXCAVATORSCONTROLLER EXCAVATOR HISTORY HR4 MODE Hi, H P1 Pressure Distribution (pump 1) 1 P14 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 P11 operating hours, 4351 to 5076 PSI a 2 ow Fe oN P1 operating hours, over 5076 PSI aout CX EXCAVATORSCONTROLLER EXCAVATOR HISTORY HRS P2 Pressure Distribution (pump 2) P2 operating hours, under 1450 PSI 2: P2 operating hours, 1450 to 2176 PSI 2 P2. operating hours, 2176 to 2901 PSI 4: P2 operating hours, 2901 to 3626 PSI 5 P2 operating hours, 3626 to 4351 PSI 6: P2 operating hours, 4351 to S076 PSI é P2 operating hours, aver 5076 PSI 2 CX EXCAVATORSCONTROLLER EXCAVATOR HISTORY HRE Engine Speed (RPM) Distribution fe - Hours, Hours. Hours, Hours, Hours. Hours. Hours. under 1175 RPM . 1175to 1375 RPM 1375 to 1575 RPM , 1575 to 1775 RPM . 1775 to 1975 RPM 1975 to 2175 RPM over 2175 RPM CX EXCAVATORSCONTROLLER EXCAVATOR HISTORY HR7 MOOE Hi Coolant Temperature Distribution ng Hours, under 171°F (1" and 2” Bars} 2: Hours, 171°F to 180°F (3" Bar) & Hours, 180°F to 207°F (4™ Bar) 4: Hours, 207°F to 212°F (5" Bar) 5: Hours, 212°F to 217°F (6" Bar) 6: Hours, 217°F io 221°F (7" Bar) Tr: Hours, over 221°F sa CX EXCAVATORSCONTROLLER EXCAVATOR HISTORY HRB Hydraulic Oil Temperature Distribution oe 2 & # at Hours, under 113°F (1 and'2™ Bars} Hours, 113°F to 140°F (3 Bar} Hours, 140°F to 176°F (4" Bar) Hours, 176°F to 190°F (5" Bar} Hours, 190°F to 203°F (6" Bar) Hours, 203°F to 208°F (7 Bar) Hours, aver 208°F 3-45 CX EXCAVATORSCONTROLLER EXCAVATOR HISTORY CX210/CX240 HRQ Fuel Temperature Distribution 4: Hours, See Poe Hours, Hours. Hours, Hours, Hours, Hours, under 86°F BB°F to 104°F 104°F to 122°F 122°F to 140°F 140°F to 158°F 158°F to 176°F over 176°F a6 CX EXCAVATORSCONTROLLER EXCAVATOR HISTORY CX210/CX240 HR10 Load Ratio Distribution 4: Hours, under 30% z Hours, 30% to 40% & Hours, 40% to 50% 4: Hours, 50% to 60% & Hours, 60% to 70% 8: Hours, 70% ta 80% ti Hours, over 80% sd CX EXCAVATORSCONTROLLER EXCAVATOR HISTORY CX210/CX240 HR11 Load Ratio Distribution in H Mode, High Idle in Hours, under 30% z Hours, 30% to 40% = Hours, 40% to 50% a Hours, 50% to 60% 5: Hours, 60% to 70% 6: Hours, 70% to 80% T: Hours, over 80%. nae CX EXCAVATORSCONTROLLER EXCAVATOR HISTORY CX210/CX240 HR12 MODE Hi, Load Ratio Dis! in S Mode, High Idle * Hours, under 30% =: Hours, 30% to 40%. = Hours, 40% to 50% a Hours, 50% to 60% &: Hours, 60% to 70% 6; Hours, 70% to 80% T Hours, over BO% aes CX EXCAVATORSCONTROLLER RESETTING RST1 BRK: Programmed RPM for Hammer mode LM: ‘Old computer Not Used, New Computer includes this feature for Material Handling, Al ‘Auto-Idie setting time, (1 to 30 seconds) factory setting is 5 seconds PA: 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. AU: Auto Power Boost Cancellation (0 = off, 1 = on) Not available on CX130 or CX160_ Does not turn off Power Boost in L Mode. HLD: Hold previous (default) data (0 = with, 1 = without) OuT: Not Used Use the Buzzer stop switch to scroll through Resetting. ac CX EXCAVATORSCONTROLLER RESETTING Engine Speed for Hammer Mode Push the Buzzer stop switch lo 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 made switch for 10 seconds to select the displayed RPM. The buzzer will sound to notify that 10 seconds have elapsed. Tum the throttle to low idle. Turn the key switch off CX210/CX240 Startthe 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 § seconds for a RPM change to occur. Press and hold the work mode ewitch for 10 seconds. The slarm buzzer will sound. Press the buzzer switch twice to change the display to Al. Tum 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. aa CX EXCAVATORSCONTROLLER RESETTING MOOE HH LIM: Not used OUT: Not used a ee CX EXCAVATORSCONTROLLER: RESETTING Altitude Compensation (pump power set) MODE FH po ob Ca og oo Push the Buzzer stop switch to select PA (item selected will have a light background) PA: 0 = Normal Mode PA: 1, 20r3 = 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. Ww Turn the key switch off to complete the procedure ar ae CX EXCAVATORSCONTROLLER RESETTING Auto Power Boost Set (CX210/CX240) MODE Hi H To] RPM sec Push the Buzzer stop switch to select AU (item selected will have a light background) 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 O. To save the data push the Work mode switch for 10 seconds. The buzzer will sound to indicate that 10 seconds have elapsed. AU: 0 = With Automatic Power Boost Turn the key switch off to complete the procedure. Note: This will not eliminate L mode full time power boost. 558 CX EXCAVATORSCONTROLLER RESETTING Previous Data Holding MOE Hi Push the Buzzer stop switch to select HLD (item selected will have a light background). 0 = Will hold default data 4 = Will turn off default data, will return to setting when key is turned off To set previous data holding feature, push the Travel made 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. Turn the key switch off to complete the procedure: = CX EXCAVATORSCONTROLLER RESETTING Previous Data Holding oe L. Auto Mode « Work Mode * Travel Mode * Maintenance Timer 0 = Will hold default data 1 = Will return to setting when key was tumed off. Auto Mode 0 = Auto Made is the default mode whenever the key switch is tumed 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 O= 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 tured on. 1/= Whichever speed range was on when the key was turned off will be the speed when the key is tumed on. Maintenance Timer Cancellation 0 = Maintenance timer “ON” 4 = Maintenance timer “OFF” Soe CX EXCAVATORSCONTROLLER Service Due Warning When the CX series was first introduced the service due maintenance timer was set at 2 500-hour interval an¢ was unchangeable, Excavators equipped with controller part number KHR2873 and after have adjustable timer intervals. The selected intervals are 50, 250. 500, 1000, 2000 or 5000 hours The controller part number for each excavatoris 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 refums to the normal screen by pushing the auto mode switch. Use the included procedure to change tie Urrver interval, Dieplay the reset screen (Figure 1: RST). Use the shop manuel {sector 4001-36} for this procedure. RST MODE 2 H 1 Pa aa Rn a Co] pe a] see | Cour T Figure 4: RST4 (Reset Servan} Press the buzzer stop switch eight mes and the window mutomaticaly changes to the RST 2 screen (Figure 2: RST2). The RST 2 sczeen fs the maintenance timer Interval change screen. Ly [oatToa] Figure 2: AST2 (Reset Sercen) a-58 CX EXCAVATORSCONTROLLER ‘Area 1 displays the remaining time before the SERVICE DUE waming 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 2009. 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. Tum the key switch off until the monitor window goes dark. Tum 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 secands while the service due waming is displayed to cancel the service due waming from displaying in th monitor. NOTE: There are no audible wamings after the reset is completed. After 20 to 30 seconds tum the key switch off. NOTE: This procedure only resets the service due warming. This does not cancel the service due waming from displaying in the monitor at the next predetermined service interval time. To completely tum off the SERVICE DUE warning feature, use the procedure on the previous page (3-57. RST1 screen, the HLD area, Maintenance Timer Cancellation) CX EXCAVATORSCX Series Diagnostic Screen Data Sheet SCK DATE DEALERSHIP. HOUR METER MODEL. 4: STATUS INDICATION HK Ee cuca TH | cums Sw a x TRE 1 [ew S05) ez [a [ wr Fr | fsaz SWE H[é [or wv | [ews SUT, ones TE FS TRE aC Tea TS TR 2, DIAGNOSIS 3: MACHINE HISTORY HRY T He 2 A | wR ENG E Hi WT | = WRK Pu 5 a | = u BRA Ec ia 1 3 7 WRa a HR 5. 4 HR 1 = 7 al 5 2 z Fi a z= = a Z i Z a z HR? a he 6. a Hea 7 = i S 2 & 2 é z z HR 4 | waz = 1 =] | 7 z 2 & | z z a Z | aCX Series Diagnostic Screen Data Sheet ‘Tecrical Serpce Group - F200) ‘Cistd Information Key 4: STATUS INDICATION ‘CHAT through CHME (CHK? and CHIC" included) Guplay current conditions an the machine, Please use the service mutual lor delssied debonghon of thee else. 2: DIAGNOSIS DIAG 1 ‘Current Erigine Faull Codes DIAG 4 ‘Curnend Michie Fault Cou 3: MACHINE HISTORY HRY ENG engine hours since list cleared WRK operinng hours (press. swat an} U unper operating hour Travel operating howe 3 swing operaling hours PU primer fogs uperating hours BRK Tearnmer apmiesing hours HR4 Pt Presse Distrution aur - under 1450 gh baure~ 1450 19 2179 pi hours - 2176 is 2801 pl ours = 2901 to 3625 psi baure - 3826 ta 4351 psi hours 4951 to 5078 psi ours - over S076 psi 2 a 4 5 6 7 HRT Weir Termp Distributive 1 hauls undee 171F (122 bar) 2 hours 171 lo THF (are bar) 3 aur 180 lo 207F (2h bar) 4 haus 207 to 212F (5th tite) 5 hours +212 lo 217F fo bas) EB haure- 217 ia 221F (7h bac) Touts - aves 221 Red Lad Ralio (LR) Diribation 1 Dare - ueder 30% 2 hawe-20% 40% 3 hours 40% w 50% 4 howe -S0% m 60% 5 haure- 60% 70% 6 hours 70% ta BO% 7 ours - ower a0% Diag 2 DIAG 3 Putst Engine Fault Codes ‘Hour - Pusst Engine Faull Coders DIAG S DIAGE Past Machine Faull Code Hous - Piset Machine Fant Code HR2 i HRS sone wns He someone oe 1 Made eperaling hours S Made: operaling hours L Mode operating hours Auto Mode operating hours mc weer leg 2c fb her fiace Pp berg ace Bae chee ren Sal Lamp aloe beet lec P2Pidseure Distibuoon hours - under 1890 gat hours 1450 0 2778 pst hours 2278 lo 2001 pat are - 2901 bo 3628 pt aure +9626 to 4351 pst hours +4351 wo 5076 pat hours - ort SO7B pst = z wannun-2 sogeuns3 Hyd Temp Daiibusan HRO Pours - under 113F {1 82 bar) hours ~ 113 to 1406 (3rd box) hours - 140 fo 176F (din bar) hours = 178 fo 1906 (Bt bar) owes - 190 to 2036 (eh ber) Hours - 203 to 20BF (7th bar) hours - ort 208F ted sue LR -H Madi High idke co hours under 30% hour -30%6 lo 4% hows - 40% lo SI% hour -50% 16 60% hours - 60% lo 70% foun 70% Wo BD hours ont 80% Senioe mame grevides simone detsiied desoripson of these diagnostic semen ‘cdenpuler ‘ON hours Low soned eperaling hour Fagh: speed operating tou independent raved bows Mabulersanice cnr RPM Distribuwan Thou = incker 11715 pen hhaurs = 1975 lo 1375 spit hours - 1375 lo 1575 a hay - 1975 to 1775 spn haus + 175 to 1975 spun hoi ~ 1975 to 2975 pm haus. over 2175 pen Fusl Teing Devintiuiioa ours - under 86 hourd - BS to 104F fours ~ 104 la 122F bouts = 722 to 140F hours - 140 to 158 hours - 188 lo 178F hours - over 176 LR-S Mode High ite ours = unidee 30% hours - 304% uo 405% ours - 40% to 50% hour - 505% lo 60% ours - 0% lo 705% hours - 70% io BO" hours. - over 20%ELECTRICAL ELECTRIC/HYDRAULIC Pump Control, All Models. In'S, H and Auto modes supply current to Electro-magnebc proparfional solenoid valve on the side of the pump, will control the HP requirement of hydraulic pumps P1 and 2 Note: The controller needs ain RPM signal from the engine for the proportional solenoid valve pump control to function, H-MODE: For the pump flow to reach 100% canacity, 2 variable electrical signal is sent to the proportional solenoid valve. The current varies with the engine spaed. S-MODE: For the nump flow to reach 95% capacity, = variable clactrical signal is sant to the proportional solenoid valve. The current varies with the engine speed L-MODE: For the pump fiaw to reach 70% proportional solenoid valy capanity, no electncal signal is sant to the AUTO -MODE: For the pump Raw to work between 90% to 99% capacity of the engine target torque. an electrical signal is sent to the proportional solenoid valve based on the controler selected mode. The controller switches the moves between the Sa mode and tha La mode, dapending on conditions: The maximum current will aqua! the S mods current +.40m A for the SA mode. The maximum current will equal the S mode for the La mode. When operating in the aulo-mode and the Sa mode is active, when the travel prassure switch i aciieled (closed), the excavator will stay in the SA mode until the travel switch opens. If the exceveloris in the Ls mode wher the travel pressure switch closes, the excavatar wid 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 ram before the controller sends current to the puma proportional solenoid valve CX EXCAVATORSELECTRICAL ELECTRIC/HYDRAULIC MODE HMODE S MODE L MODE AUTO MODE MODEL | MAX MIN | Sa La exiao | soama | asoma | 450ma a 490mA | asa mA Cx160 600 610 510 0 | 550 510 cx2io | 407 282 292 0 332 292 Cx240 424 307 307 o | MT 307 CX EXCAVATORSELECTRICAL POWER BOOST Circuit Configuration Power Boost-switch Main Controiar Power Boost solansid valve ‘Travel pilot pressure switch fe Ne Maint ralief valve Pressure increase in each work mode ‘CX130/CX160 AMODE STOUE 4970 -+ 5260 psi (8 seconds) LMODE 4970 —+ 5200 (constant) | AUTO MODE 4970 —+ 5280 (8 seconds} CX EXCAVATORSELECTRICAL Paes ee Re Automatic Power Boost, CX2Z10/CX240 1) Inthe Hand the S work modes. the controller will automatically activate the Power Boost solenoid veilve to ineréase the main relief pressure 2) This increase is automatic without action by the operator 3} The increase wil activate for only, 8 seconds, 4) Tha Power Boost is on full time in the L mode Note: Th function, controller needs an RPM signal fram the engine controller for Power Boast ta ‘When operating in either the H or S madie, the main controSer monitors the ratio between: - Tha load on the engine transmitted by the engine contralier. = Tha load on the hydraulic system transmitted by the pr and pump P2 sssure transducers on pump Pt the pressure of P1 or P2 is higher than 4251 psi (300 bar} and the load raiio remains within a range of ¢ 5% for 2 seconds. the controller ial to activate the Power Boast sofsnoid for 8 seconds which increases the main pressure. The instrument panel wil display “Power Up". To reactivate automatic Power Boost the load must be released and applied again. When either the travel o ted, the ‘controBer deactivates the Powar Boost zolencid valve ‘The Power Boost solenaid valve is located in the six solenoid valve bank jocatad in the pump compartment CX EXCAVATORSELECTRICAL AUTOMATIC POWER BOOST Circuit Configuration Main Controller 6. Engine Gontralier Pressufe detector PY 7. Main relief valve Pressure detector P2 8. Power Boost solenoid valve, Travel pilot pressure switch Option plot pressure switch ween Pressure increase in each work mode T CX210/CX240 ] H MODE 5410 psi (B seconds) #410 (constant) AUTO MODE | 4970 — 5410 (8 seconds) CX EXCAVATORS