Manual Case CX Series Excavators Introduction Engine Systems Components Controller Calibration Displays Diagnostic

Construction Equipment Service Training
CX SERIES
EXCAVATOR
Section 1 --
GENERAL INTRODUCTION
CNH Engine
Diagnostic Class
(2004)
CNH America LLC  2004
700 STATE STREET All Rights Reserved
RACINE, WI 53404 U.S.A. Printed in U.S.A.
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
CX EXCAVATORS
1-1
EXPLANATION OF CX SERIES
Engines
MODEL CX130 CX160 CX210 CX240
Make CASE CASE CASE CASE
Model 4TA390 4TA390 6TAA590 6TAA590
HP (net) 106 106 138 163
Cold Start Ether Ether Electric Electric
Rated rpm 2200 2200 1950 2150
When programming the excavators, the manufacture model number must be used. Detailed
procedures are in section 3 of this training manual.
Manufacture Case
model number model number
SHO120 CX130
SHO150 CX160
SHO200 CX210
SHO220 CX240
When programming the excavators, the following codes will be used to change the language
if necessary. Detailed procedures are in section 3 of this training manual.
MODE MODE MODE
NO. NO. NO.
LANGUAGE LANGUAGE LANGUAGE
Japanese 0 Italian 6 Swedish 12
English 1 Spanish 7 Finnish 13
Thai 2 Portuguese 8 Picture writing 14
Chinese 3 Dutch 9
German 4 Danish 10
French 5 Norwegian 11
CX EXCAVATORS
1-2
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 rubber-
covered 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
Capacity 19 32 32 32
Tank gal.
Capacity 32 38 54 59
System gal.
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
Suction 150 mesh 150 mesh 150 mesh 150 mesh
Return 10 µ 10 µ 10 µ 10 µ
Ultra-fine 1µ 1µ 1µ 1µ
Pilot 10 µ 10 µ 10 µ 10 µ
CX EXCAVATORS
1-3
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 two-
section 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
Max. pump flow 32.4 gpm 36.2 gpm 53.1 gpm 56 gpm
X2
Pilot pump flow 6 gpm 5.8 gpm 5.3 gpm 5.3 gpm
Manufacture Uchida/ Uchida/ Kawasaki Kawasaki
Kawasaki Kawasaki
Configuration Tandem Tandem Tandem Tandem
CX EXCAVATORS
1-4
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
Pilot yes yes yes yes
operated
hand and
foot controls
Single pedal no no no yes
travel
CX EXCAVATORS
1-5
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.
CX EXCAVATORS
1-6
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.
CX EXCAVATORS
1-7
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
L Speed 2.1
H Speed 3.4
CX EXCAVATORS
1-8
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.
CX EXCAVATORS
1-9
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.
CX EXCAVATORS
1 - 10
Electrical System
To improve engine starting during cold temperatures, the CX130 and CX160 are equipped
with an ether injection system as standard equipment. The ether injection system can only be
activated when the key-switch is in the crank position. There is a rocker switch located on the
left-hand control console for easy access to the operator. There is also a temperature switch
located on the engine intake manifold to prevent engagement of the ether system when the
engine is above 40°F (5°C). On the CX210, CX240, CX290 and CX330, there is an intake
manifold heater for cold starting assistance, which is turned on with the key switch. The
CX460 and CX800 engines use glow plugs in each cylinder to aid cold weather starting.
The Alternator is rated at 24 volts. The electronic controller for the CX130/CX160 excavators
require an engine speed signal from a magnetic sensor on the flywheel. This engine speed
signal is extremely critical to excavator functions. The other CX excavators have electronic
controlled engines. The excavator controller requires input from the engine controller.
The engine, the hydraulic, and the electrical systems are all monitored by a controller. The
controller for the CX130/CX160 is different than for the CX210/CX240. The controller
receives signals from sending units. Very simply, the controller takes the information that it
has received, and then sends the required outputs to cause the excavator to perform as
selected. These outputs may be sent to the display panel to indicate a malfunction or to give
a visual display of which performance features have been selected. The outputs may also be
sent to the solenoid valves, which control the excavator functions. The controller has an
automatic “limp home” feature to allow the excavator to be operated to complete the job in
case of controller failure.
CX EXCAVATORS
1 - 11
This Page is blank
CX EXCAVATORS
1 - 12
CX130 Theoretical Pump Flow L, S & H Mode
TSG - Technical Service Group 01 - 01
40
35 33.7
33.7
30.8
30.8
30 29.2 29.2
H Mode mA = 600
27.2
25.6 S Mode mA = 450
Flow = (GPM)
25 25.3
23.2
22.4 22.2
H Mode 2130 RPM
20 20.5 S mode 1950 RPM
19 19.2
17.9 L Mode 1850 RPM
16.5 16.9 16.3
15 14.1 14.9
13.5 13.7
12.4 12.1
11 11.2
10 9.9 9.9
8.3
7.9
0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000
Pressure (PSI) = P1 + P2
40
35
35
30
H Mode mA = 600
S Mode mA = 450
Flow = (GPM)
25
H Mode 2130 RPM

20 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
40.0
37.7 37.7
35.0 34.7 34.7

33.0 33.0
31
30.0 29.6
29.1
H Mode mA = 600
26.7 S Mode mA = 490
25.6 25.6
Flow = (GPM)
25.0 L Mode mA = 280

23.2
21.7 21.8 H Mode 2230 RPM
20.6
20.0 S Mode 2050 RPM
18.9 19.2 18.8
L Mode 1950 RPM
17.2
16.1
15.0 15.3 15.3
14.0 13.7
12.4 12.7
11.2 11.2
10.0 9.5
8.1
5.0
0.0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000
40.0
35.0 35.0
30.0
H Mode mA = 600
S Mode mA = 490
Flow = (GPM)
25.0 L Mode mA = 280
H Mode 2230 RPM

20.0 S Mode 2050 RPM
L Mode 1950 RPM
15.0
10.0
5.0
0.0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000
60
53.8
52.3
50
48.8 48
46.2 45.4
H Mode mA = 450
40 S Mode mA = 292
Flow = (GPM)
L Mode mA = 50
H Mode 1980 RPM

30 S Mode 1800 RPM
L Mode 1700 RPM
25.8
23 23.7
20
14.5
10 10
8.4
0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000
Pressure = (PSI) P1 + P2
60
55
50
H Mode mA = 450
40 S Mode mA = 292
Flow = (GPM)
L Mode mA = 50
H Mode 1980 RPM

30 S Mode 1800 RPM
L Mode 1700 RPM
20
10
0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000
TSG - Technical Service Group
60
56.803
54.9536
51.7832 50.9906
50 49.4054 48.877
H Mode mA = 466
40 S Mode mA = 307
L Mode mA = 50
Flow (GPM)
H Mode 2180 RPM

30 30.1188 S Mode 2000 RPM
28.0052 L Mode 1900 RPM
26.9484
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
H Mode mA = 466
40 S Mode mA = 307
L Mode mA = 50
Flow (GPM)
H Mode 2180 RPM

30 S Mode 2000 RPM
L Mode 1900 RPM
20
10
0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000
70
60 58.124
56.2746
53.3684
50.9906 52.0474
50 49.9338
H Mode mA = 466
S Mode mA = 305
Flow = (GPM)
L Mode mA = 50
40
H Mode 2230 RPM
S Mode 2050 RPM
32.2324 L Mode 1950 RPM
30 29.062 30.1188
20 20.8718
15.0594
11.3606
10
0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000
70
60
60
50
H Mode mA = 466
S Mode mA = 305
Flow = (GPM)
L Mode mA = 50
40
H Mode 2230 RPM
S Mode 2050 RPM
L Mode 1950 RPM
30
20
10
0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000
Construction Equipment Service Training
CX SERIES
EXCAVATOR
Section 3 --
Controller
(2004)
CNH America LLC  2004
700 STATE STREET All Rights Reserved
RACINE, WI 53404 U.S.A. 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

Buzzer Stop Switch
Travel Mode 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 160°F (70°C) and that the ENG section is
indicating the engine speed. To warm up the engine, watch the CHK1
Screen while holding the arm-in function at Wide-Open-Throttle. When the
temperature (WT) reaches 160°F, turn off the Engine.
Turn the Key Switch on and press the Auto mode switch for 10 seconds to
Return to the Controller Reset Screen.
All Excavators: Press the Auto mode switch for 10 seconds to clear all
data in this screen. All data will change to “?” and the buzzer will sound.
MACHINE: SH ? –3
TERRITORY: ? LANGUAGE: ?
CONT. P/N KHR XXXX
Turn off the key switch to finish clearing the data.
3- 4 CX EXCAVATORS
CONTROLLER

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.
MACHINE: SH ? –3
A “−3” means CX series
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.
CONT. P/N KHR XXXX
Select the correct model code that corresponds with the machine.
Machine Code Case NA
SH0120 CX130
SH0150 CX160
SH0200 CX210
SH0220 CX240
SH0250 CX290
SH0300 CX330
SH0400 CX450
SH0800 CX800
3- 5 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) CX130
– DAC0713246 & After
– DAC0716270 & After
SH0200 (KAWASAKI PUMP)
SH0202 (LIFTING MAGNET M/C) CX210
SH0220 (KAWASAKI PUMP)
SH0222 (LIFTING MAGNET M/C) CX240
SH0302 (LIFTING MAGNET M/C)
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.
CONT. P/N KHR XXXX
A “?” shown with a dark background means that item is selected.
5. The Territory will change everytime the Travel mode switch is pressed.
Press the Travel mode switch until the number 2 appears in the Territory
field for Case North America, pressure in psi and temperature in °F.
Other choices are: 0 for pressure in K(kg/cm² and temperture in °C.

1 for LBX North America
3 for pressure in MPa and temperature in °C.
To switch between European and US units, press the Working Light Key
TERRITORY: 2 LANGUAGE: ?
CONT. P/N KHR XXXX
3-7 CX EXCAVATORS
CONTROLLER
6. Press the Work mode switch to select the language field.
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 Language Language Language
Code Code
0 Japanese 8 Portuguese
1 English 9 Dutch
2 Thai 10 Danish
3 Chinese 11 Norwegian
4 German 12 Swedish
5 French 13 Finnish
6 Italian 14 Icons
7 Spanish 15
3-8 CX EXCAVATORS
CONTROLLER
CONT. P/N KHR XXXX
Continue with step 8 for CX130 / CX160 ONLY
(Go to the next page for CX210 / CX800 Continue with step 10)
8. After inputting all machine information, start the engine, turn the throttle
to 50% and push the Cushion switch. The engine will go to full RPM and
then slowly lower to idle. If the Auto Idle was turned off, the engine will
then speed up to 50% to confirm that it is finished.
Note: Coolant temperature must be above 122°F (50°C) before the

procedure will start. Cover the radiator if necessary to warm the engine.
The process is finished when the engine RPM can be controlled by the
throttle control again.
9. Press the Auto mode switch to finish, and return to the normal display.
3-9 CX EXCAVATORS
CONTROLLER
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.
CONTROLLER
DIAGNOSTIC MODE FLOW CHART
NORMAL
DISPLAY DIAGNOSTIC
MODE MODE
1
2 2 2
CURRENT DIAGNOSTIC EXCAVAT RESETTING
CONDITION SYSTEM OR RST1
CHK1 DIAG1 HISTORY 6
3
3 3 3 3
CHK2 DIAG2 HR12 HR2 BRK
6
3
3 3 3 3
CHK3 DIAG3 HR11 HR3 L/M
3
3 3 3 3
CHK4 DIAG4 HR10 HR4 AI
3
3 3 3 3
DIAG5 6 HR9 HR5 PA
4
3 3 3 3
CHK5 6
DIAG6 HR8 HR6 AU
5
3 3 3 3
CHK6
HR7 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.
CONTROLLER
DIAGNOSTIC MODE
Current Condition (CHK1-CHK6)
Displays the excavator’s current condition.
Diagnostic System (DIAG1-DIAG6)
Displays recorded fault codes of current and past conditions for the engine
and the excavator. Records the computer hours of the detection of the
fault.
Excavator History (HR1-HR12)
Displays recorded computer hours of each excavator operation.
Resetting (RST1-RST2)
Displays the excavator’s current settings and allows for the changing of the
excavator setup.
EXPLAINATION OF DIOGNOSTIC STEPS
1 To scroll between the Normal display and Diagnostic display screens
press the Travel and Work mode switch simultaneously for 3 seconds.
2 To scroll across between the CHK, DIAG, HR and RST screens, press
the Auto mode switch.
3 To scroll down through the CHK, DIAG, HR and RST screens, press the
Buzzer stop switch.
4 A Self-Check of the protected transistor circuits can be checked
automatically. While holding the One-Touch idle button down, turn the key
switch on, then release the idle button. The controller will energize each of
the transistor (TR) circuits automatically. If a short-circuit is detected, the
display will indicate an “ELECTRICAL PROBLEM” and sound the buzzer.
If no over-current is detected, the travel alarm will sound.
To find the shorted circuit, go immediately to the CHK1 screen without

turning off the Key Switch, then scroll to the CHK2 screen. While in the
CHK2 screen, press and hold the Travel mode switch, you will scroll to the
CHK5 screen. Recorded TR1, TR2 and TR3 faults will be displayed.
5 If you hold the Travel switch down longer than 10 seconds the CHK6
screen appears and the buzzer beeps intermittently. The same faults are
displayed in the CHK6 screen. Turning off the Key switch erases the codes
and silences the buzzer.
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.
CONTROLLER
CURRENT CONDITION CHK1
CHK MODE 2 H
1 ENG 0 0 0 0 RPM
P1 0 0 0 0 PSI I 0 0 0 0 mA
P2 0 0 0 0 PSI WT 0 0 0 0 F
N 0 0 0 0 PSI OT 0 0 0 0 F
• Mode: To reach this screen, Press and hold both the Travel and Work
mode switches more than 3 seconds.
• P1: Main Pump Pressure (P1)
• P2: Main Pump Pressure (P2)
• N: Negative Control Pressure of pump supplying Arm 1 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 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.
CONTROLLER

CHK MODE 2 H
2 TR1 0 0 0 0
R 0 0 0 0 % TR2 0 0 0 0
FT 0 0 0 0 F TR3 0 0 0 0
TV 0 0 0 0 % TR4 0 0 0 0
• R: Engine Load Ratio (CX210/CX240)

• FT: Fuel Temperature (CX210/CX240)
• TV: Throttle Volume
• TR1: Transistor Output Engine Load Ratio
• TR2: Transistor Output
• TR3: Transistor Output ((Q-Qn) / (Qf-Qn))
• TR4: 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.
CONTROLLER

Continued
TR1 0 0 0 0
• Swing Park Brake

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

• Swing Park Brake - Move the swing hand control just enough to close the swing
pressure switch. Should see the 1 change to 0. Return the hand control to neutral.
The 0 should change to 1 after 5 seconds. Slowly raise the boom until screen
indicates swing brake is turned off. Return boom control to neutral. Swing brake
should be turned on 5 seconds later.
• High Speed Travel & Travel Alarm – Press the travel switch to select high-speed
travel. The high speed travel field should change to a 1 and to 0 when the switch is
pressed again. Move a travel foot control just enough to close the travel pressure
switch. Should see the alarm field change to a 1 and change back to 0 when the foot
control is released.
• Power Boost – CX210/CX240 -Move one of the attachments to end of stroke. As

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

Continued
TR2 0 0 0 0
• Battery Relay
• Cushion Valve (off/on)
• Swing Shut Off
• Swing Priority
• 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.
CONTROLLER

Continued
TR3 0 0 0 0
• Free Swing
• Thief Proof
• Not Used
• Not Used
• 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
CONTROLLER

CHK MODE 2 H
3 SW4 0 0 0 0
SW1 0 0 0 0 SW5 0 0 0 0
SW2 0 0 0 0 SW6 0 0 0 0
SW3 0 0 0 0 SW7 0 0 0 0
This screen is used to verify that the controller is receiving the input from
the listed switches and signals.
• SW1: Upper pressure switch, travel pressure switch, swing pressure

switch and hammer pressure switch.
• SW2: Engine oil pressure switch, coolant level switch, and auxiliary
pressure switch.
• SW3: Battery charge.
• SW4: Cushion switch (off/on), free swing switch, swing priority switch
(Not used) and one touch idle switch.
• SW5: Swing lock switch, emergency stop switch, work light and wiper
switch.
• SW6: Windshield washer switch, travel alarm and hammer mode switch,
and Material Handling (L/M) mode.
• SW7: Thief Proof, Key switch, and Overload (EU).
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.
CONTROLLER

Continued
SW2 0 0 0 0
• Engine oil pressure switch

• Coolant level switch
• Auxiliary Pressure Switch
• Not used
• 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”.
CONTROLLER

Continued
SW4 0 0 0 0
• Cushion switch (off/on)

• Free Swing switch
• Swing Priority-Not used
• One touch idle switch
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.
CONTROLLER

Continued
SW6 0 0 0 0
• Windshield washer switch

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

Continued
SW7 0 0 0 0
• Thief Proof
• Key switch
• Not used
• Not used
Key Switch “ON”
• “ON” when the key switch is.
CONTROLLER

CHK MODE 2 H
4 TG 0 0 0 0 RPM
FS 0 0 0 0 OHMS BP 0 0 0 0 MPa
AC 0 0 0 0 SP1 0 0 0 0
TR5 0 0 0 0 SP2 0 0 0 0
• FS: Fuel Sensor Resistance

• AC: Coolant Temperature for A/C Control
• TR5: Not Used
• TG: Target Engine RPM
• BP: Not Used
• SP1: Not Used
• SP2: Not Used
CONTROLLER

Continued
AC 0 0 0 0
• 1: Water temperature: <86°F

• 2: Water temperature is between: 86°F & 113°F
Press the Buzzer stop switch to return to CHK1.
CONTROLLER
PRESENT OVER LOAD CONDITION CHK5
CHK MODE 2 H
5 TR1 0 0 0 0
R 0 0 0 0 % TR2 0 0 0 0
FT 0 0 0 0 F TR3 0 0 0 0
TV 0 0 0 0 % TR4 0 0 0 0

• TR1: Transistor output has detected an over current
• 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.
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.
CONTROLLER
PAST OVER LOAD CONDITION CHK5

Continued
TR1 0 0 0 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
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
CONTROLLER
SELF - CHECK CHK6

CHK MODE 2 H
6 TR1 0 0 0 0
R 0 0 0 0 % TR2 0 0 0 0
FT 0 0 0 0 F TR3 0 0 0 0
TV 0 0 0 0 % TR4 0 0 0 0

• TR4: 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.
CONTROLLER
DIAGNOSTIC SYSTEM CX210/CX240

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

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

DIAG3 – Past Engine Failure Condition (Hour)
DIAG MODE Hi, H
3 E 0 0 0 0
E 0 0 0 0 E 0 0 0 0
E 0 0 0 0 E 0 0 0 0
E 0 0 0 0 E 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.
CONTROLLER
DIAGNOSTIC SYSTEM
DIAG4 – Current Machine Failure Condition
DIAG MODE Hi, H
4 M 0 0 0 0
M 0 0 0 0 M 0 0 0 0
M 0 0 0 0 M 0 0 0 0
M 0 0 0 0 M 0 0 0 0
M 0000: No Failure
M 0010: Transistor output short circuit, (see page 3-28)
M 0020 Hydraulic oil temperature sensor
M 0030 Fuel sensor
M 0040 Pressure sensor (P1)
M 0060 Pressure sensor (N2, negative control)
M 0070 Key switch
M 0080 Pressure switch (upper or travel)
M 0090 CAN communication error (CX210/CX240)
M 00A0 Computer reset
M 00D0 Throttle motor related problem (CX130/CX160)
M 00E0 Coolant level sensor (CX130/CX160)
M 00F0 RPM sensor (CX130/CX160)
CONTROLLER
DIAGNOSTIC SYSTEM
DIAG5 – Past Machine Failure Condition
DIAG MODE Hi, H
5 M 0 0 0 0
M 0 0 0 0 M 0 0 0 0
M 0 0 0 0 M 0 0 0 0
M 0 0 0 0 M 0 0 0 0
M 0000: No Failure
M 0010: Transistor output short circuit
M 0020 Hydraulic oil temperature sensor
M 0030 Fuel sensor
M 0060 Pressure sensor (N2, negative control)
M 0070 Key switch
M 0080 Pressure switch (upper or travel)
M 0090 CAN communication error (CX210/CX240)
M 00A0 Computer reset
M 00D0 Throttle motor related problem (CX130/CX160)
M 00E0 Coolant level sensor (CX130/CX160)
M 00F0 RPM sensor (CX130/CX160)
CONTROLLER
DIAGNOSTIC SYSTEM
DIAG6 – Past Machine Failure Condition (Hours)
DIAG MODE Hi, H
6 M 0 0 0 0
M 0 0 0 0 M 0 0 0 0
M 0 0 0 0 M 0 0 0 0
M 0 0 0 0 M 0 0 0 0
• 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.
CONTROLLER
EXCAVATOR HISTORY
HR1
HR MODE Hi, H
1 T 0 0 0 0 HR
ENG 0 0 0 0 HR S 0 0 0 0 HR
WRK 0 0 0 0 HR PU 0 0 0 0 HR
U 0 0 0 0 HR BRK 0 0 0 0 HR
ENG: Hour Meter, hours (engine running) since last cleared
WRK: Operating hours (pressure switch “ON”)
U: Upper operating hours
T: Travel operating hours
S: 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 hold the Work mode switch for 10 seconds
(buzzer will sound). Turn OFF key.
CONTROLLER
EXCAVATOR HISTORY
HR2
HR MODE Hi, H
2 A 0 0 0 0 HR
H 0 0 0 0 HR WT 0 0 0 0 F
S 0 0 0 0 HR OT 0 0 0 0 F
L 0 0 0 0 HR FT 0 0 0 0 F
H: H work mode operating hours
S: S work mode operating hours
L: L work mode operating hours
A: Auto work mode operating hours
WT: Maximum coolant temperature recorded since the last

time the data was cleared
OT: Maximum hydraulic oil temperature recorded since the

last time the data was cleared
FT: Maximum fuel temperature recorded since the last time

the data was cleared (CX210/CX240)
CONTROLLER
EXCAVATOR HISTORY
HR3
HR MODE Hi, H
3 4 0 0 0 0 HR
1 0 0 0 0 HR 5 0 0 0 0 F
2 0 0 0 0 HR 6 0 0 0 0 F
3 0 0 0 0 HR 7 0 0 0 0 F
1: Computer power “ON” hours
2: Low speed operating hours
3: High speed operating hours
4: Independent travel operating hours
5: Maintenance timer
CONTROLLER
EXCAVATOR HISTORY
HR4
HR MODE Hi, H
4 4 0 0 0 0 HR
1 0 0 0 0 HR 5 0 0 0 0 HR
2 0 0 0 0 HR 6 0 0 0 0 HR
3 0 0 0 0 HR 7 0 0 0 0 HR
P1 Pressure Distribution (pump 1)
1: P1 operating hours, under 1450 PSI
2: P1 operating hours, 1450 to 2176 PSI
7: P1 operating hours, over 5076 PSI
CONTROLLER
EXCAVATOR HISTORY
HR5
HR MODE Hi, H
5 4 0 0 0 0 HR
1 0 0 0 0 HR 5 0 0 0 0 HR
2 0 0 0 0 HR 6 0 0 0 0 HR
3 0 0 0 0 HR 7 0 0 0 0 HR
P2 Pressure Distribution (pump 2)
1: P2 operating hours, under 1450 PSI
7: P2 operating hours, over 5076 PSI
CONTROLLER
EXCAVATOR HISTORY
HR6
HR MODE Hi, H
6 4 0 0 0 0 HR
1 0 0 0 0 HR 5 0 0 0 0 HR
2 0 0 0 0 HR 6 0 0 0 0 HR
3 0 0 0 0 HR 7 0 0 0 0 HR
Engine Speed (RPM) Distribution
1: Hours, under 1175 RPM
2: Hours, 1175 to 1375 RPM
3: Hours, 1375 to 1575 RPM
4: Hours, 1575 to 1775 RPM
5: Hours, 1775 to 1975 RPM
6: Hours, 1975 to 2175 RPM
7: Hours, over 2175 RPM
CONTROLLER
EXCAVATOR HISTORY
HR7
HR MODE Hi, H
7 4 0 0 0 0 HR
1 0 0 0 0 HR 5 0 0 0 0 HR
2 0 0 0 0 HR 6 0 0 0 0 HR
3 0 0 0 0 HR 7 0 0 0 0 HR
Coolant Temperature Distribution
1: Hours, under 171°F (1st and 2nd Bars)
2: Hours, 171°F to 180°F (3rd Bar)
3: Hours, 180°F to 207°F (4th Bar)
7: Hours, over 221°F
CONTROLLER
EXCAVATOR HISTORY
HR8
HR MODE Hi, H
8 4 0 0 0 0 HR
1 0 0 0 0 HR 5 0 0 0 0 HR
2 0 0 0 0 HR 6 0 0 0 0 HR
3 0 0 0 0 HR 7 0 0 0 0 HR
Hydraulic Oil Temperature Distribution
1: Hours, under 113°F (1st and 2nd Bars)
2: Hours, 113°F to 140°F (3rd Bar)
CONTROLLER
EXCAVATOR HISTORY
CX210/CX240
HR9
HR MODE Hi, H
9 4 0 0 0 0 HR
1 0 0 0 0 HR 5 0 0 0 0 HR
2 0 0 0 0 HR 6 0 0 0 0 HR
3 0 0 0 0 HR 7 0 0 0 0 HR
Fuel Temperature Distribution
1: Hours, under 86°F
2: Hours, 86°F to 104°F
3: Hours, 104°F to 122°F
4: Hours, 122°F to 140°F
5: Hours, 140°F to 158°F
6: Hours, 158°F to 176°F
CONTROLLER
EXCAVATOR HISTORY
CX210/CX240
HR10
HR M O D E H i, H
10 4 0 0 0 0 HR
1 0 0 0 0 HR 5 0 0 0 0 HR
2 0 0 0 0 HR 6 0 0 0 0 HR
3 0 0 0 0 HR 7 0 0 0 0 HR
Load Ratio Distribution
1: Hours, under 30%
2: Hours, 30% to 40%
3: Hours, 40% to 50%
4: Hours, 50% to 60%
5: Hours, 60% to 70%
6: Hours, 70% to 80%
7: Hours, over 80%
CONTROLLER
EXCAVATOR HISTORY
CX210/CX240
HR11
HR MODE Hi, H
11 4 0 0 0 0 HR
1 0 0 0 0 HR 5 0 0 0 0 HR
2 0 0 0 0 HR 6 0 0 0 0 HR
3 0 0 0 0 HR 7 0 0 0 0 HR
Load Ratio Distribution in H Mode, High Idle
1: Hours, under 30%
2: Hours, 30% to 40%
3: Hours, 40% to 50%
4: Hours, 50% to 60%
5: Hours, 60% to 70%
6: Hours, 70% to 80%
7: Hours, over 80%
CONTROLLER
EXCAVATOR HISTORY
CX210/CX240
HR12
HR MODE Hi, H
12 4 0 0 0 0 HR
1 0 0 0 0 HR 5 0 0 0 0 HR
2 0 0 0 0 HR 6 0 0 0 0 HR
3 0 0 0 0 HR 7 0 0 0 0 HR
Load Ratio Distribution in S Mode, High Idle
1: Hours, under 30%
2: Hours, 30% to 40%
3: Hours, 40% to 50%
4: Hours, 50% to 60%
5: Hours, 60% to 70%
6: Hours, 70% to 80%
7: Hours, over 80%
CONTROLLER
RESETTING
RST1
RST MODE Hi, H
1 PA 0 0 0 0
BRK 0 0 0 0 RPM AU 0 0 0 0
L/M Not Used RPM HLD 0 0 0 0
AI 0 0 0 0 SEC OUT Not Used
BRK: Programmed RPM for Hammer mode
L/M: Old computer Not Used, New Computer includes

this feature for Material Handling.
AI: Auto-Idle 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.
CONTROLLER
RESETTING
Engine Speed for Hammer Mode
RST MODE Hi, H
1 PA 0 0 0 0
BRK 0 0 0 0 RPM AU 0 0 0 0
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.
CONTROLLER
RESETTING
RST MODE Hi, H

1 PA 0 0 0 0
BRK 0 0 0 0 RPM AU 0 0 0 0
L/M: Not used
OUT: Not used
CONTROLLER
RESETTING
Auto Idle Time Set
RST MODE Hi, H
1 PA 0 0 0 0
BRK 0 0 0 0 RPM AU 0 0 0 0
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.
CONTROLLER
RESETTING
Altitude Compensation (pump power set)
RST MODE Hi, H
1 PA 0 0 0 0
BRK 0 0 0 0 RPM AU 0 0 0 0
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.
CONTROLLER
RESETTING
Auto Power Boost Set (CX210/CX240)
RST MODE Hi, H
1 PA 0 0 0 0
BRK 0 0 0 0 RPM AU 0 0 0 0
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.
Note: This will not eliminate L mode full time power boost.
CONTROLLER
RESETTING
Previous Data Holding
RST MODE Hi, H
1 PA 0 0 0 0
BRK 0 0 0 0 RPM AU 0 0 0 0
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.
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”
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.
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).
CX Series Diagnostic Screen Data Sheet
Technical Service Group - 3/5/2003
CHECK DATE: CUSTOMER: DEALERSHIP:

MODEL: SERIAL NO.: HOUR METER:
1: STATUS INDICATION
CHK 1 ENG CHK 2 TR1 CHK 3 SW4
P1 d I R TR2 SW1 SW5
P2 d WT FT TR3 SW2 SW6
N d OT TV TR4 SW3 SW7
CHK 4 TG CHK 2’ TR1 CHK 2” TR1

FS BP R TR2 R TR2
AC SP1 FT TR3 FT TR3
TR5 SP2 TV TR4 TV TR4
2: DIAGNOSIS
DIAG 1 E DIAG 2 E DIAG 3 E
E E E E E E
E E E E E E
E E E E E E
DIAG 4 M DIAG 5 M DIAG 6 M

M M M M M M
M M M M M M
M M M M M M
3: MACHINE HISTORY
HR 1 T HR 2 A HR 3 4
ENG S H WT 1 5
WRK PU S OT 2 6
U BRK L FT 3 7
HR 4 4 HR 5 4 HR 6 4
1 5 1 5 1 5
2 6 2 6 2 6
3 7 3 7 3 7
HR 7 4 HR 8 4 HR 9 4
1 5 1 5 1 5
2 6 2 6 2 6
3 7 3 7 3 7
HR 10 4 HR 11 4 HR 12 4
1 5 1 5 1 5
2 6 2 6 2 6
3 7 3 7 3 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 DIAG 2 DIAG 3
Current Engine Fault Codes Past Engine Fault Codes Hour - Past Engine Fault Codes
DIAG 4 DIAG 5 DIAG 6
Current Machine Fault Code Past Machine Fault Code Hour - Past Machine Fault Code
3: MACHINE HISTORY
HR 1 HR 2 HR 3
ENG engine hours since last cleared H H Mode operating hours 1 computer 'ON' hours
WRK operting hours (press. switch on) S S Mode operating hours 2 Low speed operating hours
U upper operating hours L L Mode operating hours 3 High speed operating hours
T travel operating hours A Auto Mode operating hours 4 Independent travel hours
S swing operating hours WT max water temp since last cleared 5 Maintenance timer
PU power boost operating hours OT max hyd temp since last cleared 6
BRK hammer operating hours FT max fuel temp since last cleared 7
HR 4 P1 Pressure Distribution HR 5 P2 Pressure Distribution HR 6 RPM Distribution

1 hours - under 1450 psi 1 hours - under 1450 psi 1 hours - under 1175 rpm
2 hours - 1450 to 2176 psi 2 hours - 1450 to 2176 psi 2 hours - 1175 to 1375 rpm
7 hours - over 5076 psi 7 hours - over 5076 psi 7 hours - over 2175 rpm
HR 7 Water Temp Distribution HR 8 Hyd Temp Distribution HR 9 Fuel Temp Distribution

1 hours - under 171F (1 & 2 bar) 1 hours - under 113F (1 & 2 bar) 1 hours - under 86F
2 hours - 171 to 180F (3rd bar) 2 hours - 113 to 140F (3rd bar) 2 hours - 86 to 104F
3 hours - 180 to 207F (4th bar) 3 hours - 140 to 176F (4th bar) 3 hours - 104 to 122F
7 hours - over 221F 7 hours - over 208F 7 hours - over 176F
HR10 Load Ratio (LR) Distribution HR11 LR - H Mode High idle HR12 LR - S Mode High idle
1 hours - under 30% 1 hours - under 30% 1 hours - under 30%
2 hours - 30% to 40% 2 hours - 30% to 40% 2 hours - 30% to 40%
7 hours - over 80% 7 hours - over 80% 7 hours - over 80%
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.
CX EXCAVATORS
4 - 24
ELECTRICAL
ELECTRIC/HYDRAULIC
MODE H MODE S MODE L MODE AUTO MODE

MODEL MAX MIN SA LA
CX130 600 mA 450 mA 450 mA 0 490 mA 450 mA
CX160 600 510 510 0 550 510
CX210 407 292 292 0 332 292
CX240 424 307 307 0 347 307
CX EXCAVATORS
4 - 25
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.
CX EXCAVATORS
4 - 26
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
4970 → 5260 psi (8 seconds)
S MODE
L MODE 4970 → 5260 (constant)
AUTO MODE 4970 → 5260 (8 seconds)
CX EXCAVATORS
4 - 27
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.
CX EXCAVATORS
4 - 28
ELECTRICAL
AUTOMATIC POWER BOOST

Circuit Configuration
1. Main Controller 6. Engine Controller

2. Pressure detector P1 7. Main relief valve
3. Pressure detector P2 8. Power Boost solenoid valve
4. Travel pilot pressure switch
5. Option pilot pressure switch
Pressure increase in each work mode

CX210/CX240
H MODE
4970 → 5410 psi (8 seconds)
S MODE
L MODE 4970 → 5410 (constant)
AUTO MODE 4970 → 5410 (8 seconds)
CX EXCAVATORS
4 - 29

Manual Case CX Series Excavators Introduction Engine Systems Components Controller Calibration Displays Diagnostic

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manual Case CX Series Excavators Introduction Engine Systems Components Controller Calibration Displays Diagnostic

Uploaded by

Copyright:

Available Formats

Construction Equipment Service Training

Section 1 - General Introduction

This feature allows for four digging modes:

Cushion Control System

This Page is blank

H Mode 2130 RPM

35.0 34.7 34.7

25.0 L Mode mA = 280

25.0 L Mode mA = 280

H Mode 2230 RPM

H Mode 1980 RPM

H Mode 1980 RPM

H Mode 2180 RPM

H Mode 2180 RPM

Section 3 - CX Series Controller

CHANGE THE DISPLAY LANGUAGE ONLY............................................ 11

CURRENT CONDITION DISPLAY ............................................................ 17

DIAGNOSTIC CONDITION DISPLAY ....................................................... 32

EXCAVATOR HISTORY DISPLAY............................................................ 38

OPTIONAL RESET DISPLAY.................................................................... 51

CONTROLLER CALIBRATION and DIAGNOSTIC

Work Mode Switch

CONTROLLER CALIBRATION PROCEDURE

CONT. P/N KHR 3311

Confirmation of the machine model, territory,

If you only need to change the language, go to page 3-11.

If you need to make changes, procede to the next page.

CONTROLLER CALIBRATION PROCEDURE

CONT. P/N KHR XXXX

Turn off the key switch to finish clearing the data.

CONTROLLER CALIBRATION PROCEDURE

A “?” is shown at MACHINE, TERRITORY and LANGUAGE areas.

CONT. P/N KHR XXXX

CONT. P/N KHR XXXX

CONTROLLER CALIBRATION PROCEDURE

SH0120 (UCHIDA PUMP)

CONTROLLER CALIBRATION PROCEDURE

CONT. P/N KHR XXXX

A “?” shown with a dark background means that item is selected.

Other choices are: 0 for pressure in K(kg/cm² and temperture in °C.

CONT. P/N KHR XXXX

CONTROLLER CALIBRATION PROCEDURE

6. Press the Work mode switch to select the language field.

CONT. P/N KHR XXXX

A “?” shown with dark background means that item is selected.

CONTROLLER CALIBRATION PROCEDURE

CONT. P/N KHR XXXX

Continue with step 8 for CX130 / CX160 ONLY

Note: Coolant temperature must be above 122°F (50°C) before the

CONTROLLER CALIBRATION PROCEDURE

CONTROLLER CALIBRATION PROCEDURE

CONT. P/N KHR XXXX

To change the language only, display the machine selection screen by

The language is changed by pressing the Travel mode switch.

DIAGNOSTIC MODE FLOW CHART

To find the shorted circuit, go immediately to the CHK1 screen without

6 To erase data in DIAG2, DIAG5, or HR1-HR12 screens, scroll to DIAG2,

CURRENT CONDITION CHK1

CURRENT CONDITION CHK2

• R: Engine Load Ratio (CX210/CX240)

CURRENT CONDITION CHK2

• Swing Park Brake

TRANSISTOR OUTPUT (0=OFF, 1=ON)