Case CX Series Service Training Manual
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Case CX Series Service Training Manual

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  • Page 3 CX SERIES EXCAVATORS Service Training Manual Table of Contents Section 1 ..General Introduction Section 2 ..Component Locations - Hydraulics / Electrical Section 3 ..Controller Section 4 ..Electrical – “How it Works” Section 5 ..Hydraulic – CX130/CX160 “How it Works” Section 6 ..Hydraulic – CX210/CX240 “How it Works”...
  • Page 4 Construction Equipment Service Training CX SERIES EXCAVATOR Section 1 -- GENERAL INTRODUCTION (2001)
  • Page 5 CASE CORPORATION     2001 Case Corporation 700 STATE STREET All Rights Reserved RACINE, WI 53404 U.S.A. CASE CANADA CORPORATION 3350 SOUTH SERVICE ROAD BURLINGTON, ON L7N 3M6 CANADA Printed in U.S.A.

  • Page 6: Table Of Contents

    GENERAL INTRODUCTION TABLE OF CONTENTS Section 1 - General Introduction PAGE NO. Engines ........................2 Reservoir........................3 Filters ......................... 3 Pumps........................4 Pilot System ....................... 6 Hydraulic Systems ....................6-7 Cushion Control ......................7 Swing ......................... 7 Travel .........................8 Cylinders ........................9 Electrical System....................10-11 CX EXCAVATORS 1 - 1...

  • Page 7: Engines

    GENERAL INTRODUCTION EXPLANATION OF CX SERIES Engines MODEL CX130 CX160 CX210 CX240 CASE CASE CASE CASE Make 4TA390 4TA390 6TAA590 6TAA590 Model HP (net) Cold Start Ether Ether Electric Electric Rated rpm 2200 2200 1950 2150 When programming the machines, the manufacture model number must be used. Detailed procedures are in section 7 of your service manual.

  • Page 8: Reservoir

    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.

  • Page 9: Pumps

    EXPLANATION OF CX SERIES Variable Pumps All of the CX Series Excavators use an open center hydraulic system, in that there is always an output flow from the hydraulic pump flowing through the system. The CX Series Excavators use a variable volume piston pump system to be able to fully use the engine horsepower available.
  • Page 10 GENERAL INTRODUCTION EXPLANATION OF CX SERIES Pilot Controls The attachment controls are pilot operated by hand actuated controllers on all models. The pilot hand controls are mounted to tilting armrests that can be positioned to provide for maximum operator comfort. The standard control pattern is the SAE pattern. The controls can be changed to other configurations by changing the pilot hose connections at the pilot manifold, located behind the cab (see Section 3 of this manual for instructions).
  • Page 11 This system allows the unit 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.

  • Page 12: Cushion Control

    Cushion Control System The CX Series units 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.

  • Page 13: Travel

    GENERAL INTRODUCTION EXPLANATION OF CX SERIES Travel CX130/CX160/CX200/CX220 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 machine upper section. The travel drive system has independent, compact, axial piston, two speed hydraulic motors.

  • Page 14: Cylinders

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

  • Page 15: Electrical System

    EXPLANATION OF CX SERIES Electrical System All models have a 24-volt starting and charging system. The CX Series Excavators have two 12-volt batteries, wired in series to obtain the 24-volt capacity. These batteries are located in the compartment behind the cab.
  • Page 16 GENERAL INTRODUCTION EXPLANATION OF CX SERIES Electrical System To improve starting at 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 in the left-hand control console for easy access to the operator.
  • Page 17 Construction Equipment Service Training CX SERIES EXCAVATOR Section 2 -- Component Locations (2001)
  • Page 18 CASE CORPORATION     2001 Case Corporation 700 STATE STREET All Rights Reserved RACINE, WI 53404 U.S.A. CASE CANADA CORPORATION 3350 SOUTH SERVICE ROAD BURLINGTON, ON L7N 3M6 CANADA Printed in U.S.A.
  • Page 19 COMPONENT LOCATIONS Table of Contents Section 2 - Component Locations PAGE NO. MAIN COMPONENTS CX130/CX160 ........................2 CX210/CX240 ........................3 ELECTRICAL COMPONENTS CX130/CX160 .........................4-6 CX210/CX240 .........................7-9 All Models........................10-12 CONTROL VALVE PORTS CX130/CX160 ......................13-15 PUMP PORTS CX130/CX160 ........................16 CONTROL VALVE PORTS CX210/CX240 ......................17-18 PUMP PORTS CX210/CX240 ........................

  • Page 20: Section 2 - Component Locations

    COMPONENT LOCATIONS MAIN COMPONENTS CX130/CX160 The CX130/CX160 could be considered sister machines because they are so similar. Electrically they are identical. Hydraulically the components are the same except for greater flow rates required by larger machines. CX EXCAVATORS 2 - 2...

  • Page 21: Cx210/Cx240

    COMPONENT LOCATIONS MAIN COMPONENTS CX210 / CX240 The CX210 / CX240 could be considered sister machines because they are so similar. Electrically they are identical. Hydraulically the components are the same except for greater flow rates required by larger machines. CX EXCAVATORS 2 - 3...

  • Page 22: Electrical Components

    COMPONENT LOCATIONS ELECTRICAL COMPONENTS CX130 / CX160 Because of the similarity, the component locations are the same between CX130/CX160 . Next Page: Out side of cab 1. Free swing solenoid valve 14. Six solenoid valve bank 2. Travel alarm 15. Negative (de-stroke) pressure 3.
  • Page 23 COMPONENT LOCATIONS ELECTRICAL COMPONENTS OUTSIDE OF THE CAB CX EXCAVATORS 2 - 5...
  • Page 24 COMPONENT LOCATIONS ELECTRICAL COMPONENTS INSIDE THE CAB CX EXCAVATORS 2 - 6...

  • Page 25: Cx210/Cx240

    COMPONENT LOCATIONS ELECTRICAL COMPONENTS CX210 / CX240 Because of the similarity, the component locations are the same between CX210 / CX240. Next Page: Outside the Cab 1. Free swing solenoid valve 13. Pump proportional solenoid 2. Travel alarm 14. Six solenoid valve 3.
  • Page 26 COMPONENT LOCATIONS ELECTRICAL COMPONENTS Outside the Cab CX EXCAVATORS 2 - 8...
  • Page 27 COMPONENT LOCATIONS ELECTRICAL COMPONENTS Inside the Cab CX EXCAVATORS 2 - 9...
  • Page 28 COMPONENT LOCATIONS ELECTRICAL COMPONENTS Fuse Box All Models (in cab) 10A: Data test link 20A: Controller/Instrument/Switch Panel 20A: Controller power 10A: Pilot solenoid (gate lever) 15A: Option 20A: Option 20A: Fuel feed pump 10A: Air suspension seat 10A: Condenser fan 10A: Auxiliary hydraulic solenoid valve 10A:...
  • Page 29 COMPONENT LOCATIONS ELECTRICAL COMPONENTS Main Fuses and Battery Relay All Models (battery compartment) Battery disconnect relay Fuse 65A: fuse circuits F3 to F10 and F13 to F20 Fuse 20A: fuse circuits F1, F11 and F12 Fuse 20A: fuse circuits F2 Battery cables CX EXCAVATORS 2 - 11...
  • Page 30 COMPONENT LOCATIONS ELECTRICAL COMPONENTS Instrument Panel All models Travel mode switch Hourmeter Work mode switch Cushion switch (off) Auto work mode switch Free swing switch Buzzer stop switch 10. Work light switch Swing lock switch 11. Windshield wiper switch Engine emergency stop switch 12.

  • Page 31: Control Valve Ports

    COMPONENT LOCATIONS CONTROL VALVE PORTS CX130 / CX160 Port Description Bucket close Bucket open Boom lower Boom raise LH forward travel LH reverse travel Arm (dipper) retract (close) Arm (dipper) extend (open) RH swing LH swing Option circuit Option circuit RH forward travel RH reverse travel PR –...

  • Page 32: Cx130/Cx160

    COMPONENT LOCATIONS CONTROL VALVE PORTS CX130 / CX160 CX EXCAVATORS 2 - 14...
  • Page 33 COMPONENT LOCATIONS CONTROL VALVE RELIEF VALVES CX130 / CX160 Item Description Pressure change with one turn or one shim Main relief (standard pressure) Main relief (boost pressure) Boom raise secondary relief 2840 psi Boom lower secondary relief 2840 psi Arm (dipper) extend secondary relief 2840 psi Arm retract secondary relief 2840 psi...
  • Page 34 COMPONENT LOCATIONS PUMP PORTS CX130 / CX160 Port Description A1 - A2 Pump output (P1-P2) Pilot pump output Main pump intake Pilot pump intake Return from pilot circuit relief valve PZ1 - PZ2 Neutral de-stoke signal (P1-P2) Neutral de-stroke signal pressure transducer (arm pump) G1 - G2 Pressure P1-P2 (plugged) Proportional valve pressure (plugged)

  • Page 35: Cx210/Cx240

    COMPONENT LOCATIONS CONTROL VALVE PORTS CX210 / CX240 Port Description Port Description Bucket open P3-P4 Option circuit Bucket close T1-T2 Return Boom lower Ps1-Ps2 Neutral de-stroke Boom raise Travel pressure switch LH forward travel Power boost pilot signal LH reverse travel Upper pressure switch Arm (dipper) extend Leak-off return...
  • Page 36 COMPONENT LOCATIONS CONTROL VALVE RELIEF VALVES CX210 / CX240 Pressure change with one turn or one shim Item Description CX210 CX240 Main relief (standard pressure) 3090 psi Main relief (boost pressure) 4120 psi Boom raise secondary relief 3075 psi Boom lower secondary relief 3075 psi Arm (dipper) extend secondary relief 3075 psi...

  • Page 37: Pump Ports

    COMPONENT LOCATIONS PUMP PORTS CX210 / CX240 Port Description A1-A2 Pump output (P1-P2) Main pump intake Fill and bleed port Accumulator pressure Pi1-Pi2 Neutral de-stroke signal a1-a2 Pump pressure transducers (P1-P2) a3-a4 Proportional valve pressure port Pilot pump outlet Pilot pump intake CX EXCAVATORS 2 - 19...

  • Page 38: Six Solenoid Valve All Models

    COMPONENT LOCATIONS SIX SOLENOID VALVE All Models Swing shutoff solenoid, green wire band Power boost solenoid, yellow wire band Travel speed solenoid, red wire band Cushion (off) solenoid, light green wire band Swing brake solenoid, pink wire band Pilot pressure solenoid, blue wire band CX EXCAVATORS 2 - 20...
  • Page 39 Construction Equipment Service Training CX SERIES EXCAVATOR Section 3 -- Controller (2001)
  • Page 40 CASE CORPORATION     2001 Case Corporation 700 STATE STREET All Rights Reserved RACINE, WI 53404 U.S.A. CASE CANADA CORPORATION 3350 SOUTH SERVICE ROAD BURLINGTON, ON L7N 3M6 CANADA Printed in U.S.A.
  • Page 41 CONTROLLER Table of Contents Section 3 - CX Series Controller CONTROLLER CALIBRATION..............3 CURRENT CONDITION DISPLAY ............11 DIAGNOSTIC CONDITION DISPLAY............30 MACHINE HISTORY DISPLAY ..............36 OPTIONAL RESET DISPLAY..............48 3- 1 CX EXCAVATORS...
  • Page 42 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...
  • Page 43 CONTROLLER CONTROLLER CALIBRATION PROCEDURE CONTROLLER RESET MACHINE: SH0200 –3 TERRITORY: 2 LANGUAGE: 1 CONT. P/N KHR XXXX Machine confirmation In the normal display mode, if the Auto mode switch is pressed for 10 seconds the machine selection screen will be displayed. Display will return to normal mode if the Auto mode switch is pushed again.
  • Page 44 CONTROLLER CONTROLLER CALIBRATION PROCEDURE CONTROLLER RESET Resetting/clearing computer data. Pressing the Auto mode switch for 10 seconds will clear all data in this screen. All data will change to “?” and the buzzer will sound. MACHINE: SH ? –3 TERRITORY: ? LANGUAGE: ? CONT.
  • Page 45 “?” shown with dark background means that item is selected and ready to select. MACHINE: SH –3 − − − − 3 means CX series TERRITORY: ? LANGUAGE: ? CONT. P/N KHR XXXX 2. The machine model code will change in the dark background area every time the Travel mode switch is pressed.
  • Page 46 “?” shown with a dark background means that item is selected. 4. 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. MACHINE: SH0200 –3 TERRITORY: LANGUAGE: ? CONT.
  • Page 47 CONTROLLER CONTROLLER CALIBRATION PROCEDURE 5. Press the Work mode switch to select the language field. MACHINE: SH0200 –3 TERRITORY: 2 LANGUAGE: CONT. P/N KHR XXXX “?” shown with dark background. 6. Press the Travel mode switch to change the language. See language selection chart.
  • Page 48 CONTROLLER CONTROLLER CALIBRATION PROCEDURE MACHINE: SH0200 –3 TERRITORY: 2 LANGUAGE: 1 CONT. P/N KHR XXXX CX130 / CX160 7. After inputting all machine information, start the engine and push the Cushion switch. The engine will go to full RPM then slowly lower to idle. Note: Coolant temperature must be above 122°F.
  • Page 49 CONTROLLER CONTROLLER CALIBRATION PROCEDURE CASE CX210 / CX240 9. After inputting all machine information push the Auto mode switch. The CASE logo will be displayed then automatically scroll to the normal display. 3 - 9 CX EXCAVATORS...
  • Page 50 CONTROLLER CONTROLLER CALIBRATION PROCEDURE MACHINE: SH0200 –3 TERRITORY: 2 LANGUAGE: 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.
  • Page 51 CONTROLLER DIAGNOSTIC MODE FLOW CHART NORMAL DISPLAY DIAGNOSTIC MODE MODE RESETTING CURRENT DIAGNOSTIC MACHINE RST1 CONDITION SYSTEM HISTORY CHK1 DIAG1 CHK2 DIAG2 HR12 CHK3 DIAG3 HR11 CHK4 DIAG4 HR10 DIAG5 CHK5 DIAG6 CHK6 3 - 11 CX EXCAVATORS...
  • Page 52 CONTROLLER DIAGNOSTIC MODE Current Condition Displays the machine’s current condition. Diagnostic System (CHK1-CHK6) (DIAG1-DIAG6) Displays recorded fault codes of current and past conditions for the engine and machine. Records computer hours of detection of fault. Machine History (H1-HR12) Displays recorded computer hours of each machine operation. Resetting (RST1) Displays the machine’s current settings and allows for the changing of machine setup.
  • Page 53 CONTROLLER CURRENT CONDITION CHK1 MODE 2 H • Mode: Selected Travel and Work mode. Main Pump Pressure (P1) • Main Pump Pressure (P2) • Negative Control Pressure • ENG: Engine RPM • Current for Pump Proportional Solenoid • Water Temperature •...
  • Page 54 CONTROLLER CURRENT CONDITION CHK2 MODE 2 H 0 0 % 0 0 F 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 •...
  • Page 55 CONTROLLER CURRENT CONDITION CHK2 Continued • 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).
  • Page 56 CONTROLLER CURRENT CONDITION CHK2 Continued • Battery Relay • Cushion Valve (off/on) • Swing Shut Off • Not Used TRANSISTOR OUTPUT (0=OFF, 1=ON) • Battery Relay – Should be a 1 here anytime the key switch is turned on. Can not observe off signal. •...
  • Page 57 CONTROLLER CURRENT CONDITION CHK2 Continued • Free Swing • Not Used • Not Used • Not Used TRANSISTOR OUTPUT (0=OFF, 1=ON) • Free Swing – With the engine running press the free swing switch the free swing field should change to a 1. When the switch is pressed again the 1 should be changed back to 0.
  • Page 58 CONTROLLER CURRENT CONDITION CHK3 MODE 2 H 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. •...
  • Page 59 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. •...
  • Page 60 CONTROLLER CURRENT CONDITION CHK3 Continued • Engine oil pressure switch • Coolant level switch • Not used • Not used SWITCH INPUT (0=OFF, 1=ON) • Engine oil pressure switch is “ON” with low pressure or when engine is off. CX130/CX160 ONLY. •...
  • Page 61 CONTROLLER CURRENT CONDITION CHK3 Continued • Cushion switch (off/on) • Free Swing switch • 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.
  • Page 62 CONTROLLER CURRENT CONDITION CHK3 Continued • Window washer switch • Travel alarm off/on switch • Auxiliary Hyd. Mode switch • Not used SWITCH INPUT (0=OFF, 1=ON) Key Switch “ON” • Washer switch is a momentary switch. It is “ON” only while the switch is being pressed.
  • Page 63 CONTROLLER CURRENT CONDITION CHK3 Continued • Not used • Key switch • Not used • Not used SWITCH INPUT (0=OFF, 1=ON) Key Switch “ON” • “ON” when the key switch is. 3 - 23 CX EXCAVATORS...
  • Page 64 CONTROLLER CURRENT CONDITION CHK4 MODE 2 H OHMS • 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 3 - 24 CX EXCAVATORS...
  • Page 65 CONTROLLER CURRENT CONDITION CHK4 Continued • 1: Water temperature: <86°F • 2: Water temperature is between: 86°F & 113°F • 3: Water temperature is between: 113°F & 149°F • 4: Water temperature is between: 149°F & 176°F Press the Buzzer stop switch to return to CHK1. 3 - 25 CX EXCAVATORS...
  • Page 66 CONTROLLER PAST OVER LOAD CONDITION CHK5 MODE 2 H • R: Engine Load Ratio (CX210/CX240) • FT: Fuel Temperature (CX210/CX240) • TV: Throttle Volume • TR1: Transistor output has detected an over current • TR2: Transistor output has detected an over current •...
  • Page 67 CONTROLLER PAST OVER LOAD CONDITION CHK5 Continued • Swing Park Brake • High Speed Travel • Travel Alarm • Power Boost TRANSISTOR OUTPUT (0 = No Overload, 1 = Overload) • Battery Relay • Cushion Valve (off/on) • Swing Shut Off •...
  • Page 68 CONTROLLER PAST OVER LOAD CONDITION CHK5 Continued • Free Swing • Not Used • Not Used • Not Used TRANSISTOR OUTPUT (0 = No Overload, 1 = Overload) • Not Used • Not Used • Not Used • Not Used 3 - 28 CX EXCAVATORS...
  • Page 69 CONTROLLER SELF - CHECK CHK6 MODE 2 H 0 0 % 0 0 % • R: Engine Load Ratio (CX210/CX240) • FT: Fuel Temperature (CX210/CX240) • TV: Throttle Volume • TR1: Transistor output has detected an over current • TR2: Transistor output has detected an over current •...
  • Page 70 CONTROLLER DIAGNOSTIC SYSTEM CX210/CX240 DIAG1 – Current Failure Condition on Engine DIAG MODE 2 H E 0000 No Failures E 0111 EECM E 0115 ESS, crankshaft position sensor E 0366 VP44 fuel system measurement error E 0122 Boost pressure sensor high E 0367 VP44 fuel system IAT error E 0123 Boost pressure sensor low E 0368 VP44 fuel system timing error...
  • Page 71 CONTROLLER DIAGNOSTIC SYSTEM CX210/CX240 DIAG2 – Past Failure Condition on Engine DIAG MODE 2 H E 0000 No Failures E 0366 VP44 fuel system measurement error E 0111 EECM E 0367 VP44 fuel system IAT error E 0115 ESS, crankshaft position sensor E 0368 VP44 fuel system timing error E 0122 Boost pressure sensor high E 0369 VP44 fuel system sync error...
  • Page 72 CONTROLLER DIAGNOSTIC SYSTEM CX210/CX240 DIAG3 – Past Failure Condition on Engine (Hour) DIAG MODE Hi, H • 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.
  • Page 73 CONTROLLER DIAGNOSTIC SYSTEM DIAG4 – Current Failure Condition on Machine DIAG MODE Hi, H M 0000: No Failure M 0010: Transistor output short circuit M 0020 Hydraulic oil temperature sensor M 0030 Fuel sensor M 0040 Pressure sensor (P1) M 0050 Pressure sensor (P2) M 0060 Pressure sensor (N2, negative control)
  • Page 74 CONTROLLER DIAGNOSTIC SYSTEM DIAG5 – Past Failure Condition on Machine DIAG MODE Hi, H M 0000: No Failure M 0010: Transistor output short circuit M 0020 Hydraulic oil temperature sensor M 0030 Fuel sensor M 0040 Pressure sensor (P1) M 0050 Pressure sensor (P2) M 0060 Pressure sensor (N2, negative control)
  • Page 75 CONTROLLER DIAGNOSTIC SYSTEM DIAG6 – Past Failure Condition on Machine (Hours) DIAG MODE Hi, H • 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.
  • Page 76 CONTROLLER MACHINE HISTORY MODE Hi, H ENG: Hour Meter, hours (engine running) since last cleared WRK: Operating hours (pressure switch “ON”) Upper operating hours Travel operating hours Swing operating hours Power Boost operating hours BRK: Hammer operating hour Use the Buzzer stop switch to scroll through the HR screens. Note: To erase work history data from the HR1 screen press and hold the Work mode switch for 10 seconds (buzzer will sound).
  • Page 77 CONTROLLER MACHINE HISTORY MODE Hi, H H work mode operating hours S work mode operating hours L work mode operating hours Auto work mode operating hours Maximum coolant temperature recorded since the last time the data was cleared Maximum hydraulic oil temperature recorded since the last time the data was cleared Maximum fuel temperature recorded since the last time the data was cleared (CX210/CX240)
  • Page 78 CONTROLLER MACHINE HISTORY MODE Hi, H Computer power “ON” hours Low speed operating hours High speed operating hours Independent travel operating hours Maintenance timer 3 - 38 CX EXCAVATORS...
  • Page 79 CONTROLLER MACHINE HISTORY MODE Hi, H P1 Pressure Distribution (pump 1) P1 operating hours, under 1450 PSI P1 operating hours, 1450 to 2176 PSI P1 operating hours, 2176 to 2901 PSI P1 operating hours, 2901 to 3626 PSI P1 operating hours, 3626 to 4351 PSI P1 operating hours, 4351 to 5076 PSI P1 operating hours, over 5076 PSI 3 - 39...
  • Page 80 CONTROLLER MACHINE HISTORY MODE Hi, H P2 Pressure Distribution (pump 2) P2 operating hours, under 1450 PSI P2 operating hours, 1450 to 2176 PSI P2 operating hours, 2176 to 2901 PSI P2 operating hours, 2901 to 3626 PSI P2 operating hours, 3626 to 4351 PSI P2 operating hours, 4351 to 5076 PSI P2 operating hours, over 5076 PSI 3 - 40...
  • Page 81 CONTROLLER MACHINE HISTORY MODE Hi, H Engine Speed (RPM) Distribution Hours, under 1175 RPM Hours, 1175 to 1375 RPM Hours, 1375 to 1575 RPM Hours, 1575 to 1775 RPM Hours, 1775 to 1975 RPM Hours, 1975 to 2175 RPM Hours, over 2175 RPM 3 - 41 CX EXCAVATORS...
  • Page 82 CONTROLLER MACHINE HISTORY MODE Hi, H Coolant Temperature Distribution Hours, under 171°F (1 and 2 Bars) Hours, 171°F to 180°F (3 Bar) Hours, 180°F to 207°F (4 Bar) Hours, 207°F to 212°F (5 Bar) Hours, 212°F to 217°F (6 Bar) Hours, 217°F to 221°F (7 Bar) Hours, over 221°F...
  • Page 83 CONTROLLER MACHINE HISTORY MODE Hi, H Hydraulic Oil Temperature Distribution 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)
  • Page 84 CONTROLLER MACHINE HISTORY CX210/CX240 MODE Hi, H Fuel Temperature Distribution Hours, under 86°F Hours, 86°F to 104°F Hours, 104°F to 122°F Hours, 122°F to 140°F Hours, 140°F to 158°F Hours, 158°F to 176°F Hours, over 176°F 3 - 44 CX EXCAVATORS...
  • Page 85 CONTROLLER MACHINE HISTORY CX210/CX240 HR10 M O D E H i, H Load Ratio Distribution Hours, under 30% Hours, 30% to 40% Hours, 40% to 50% Hours, 50% to 60% Hours, 60% to 70% Hours, 70% to 80% Hours, over 80% 3 - 45 CX EXCAVATORS...
  • Page 86 CONTROLLER MACHINE HISTORY CX210/CX240 HR11 MODE Hi, H Load Ratio Distribution in H Mode, High Idle Hours, under 30% Hours, 30% to 40% Hours, 40% to 50% Hours, 50% to 60% Hours, 60% to 70% Hours, 70% to 80% Hours, over 80% 3 - 46 CX EXCAVATORS...
  • Page 87 CONTROLLER MACHINE HISTORY CX210/CX240 HR12 MODE Hi, H Load Ratio Distribution in S Mode, High Idle Hours, under 30% Hours, 30% to 40% Hours, 40% to 50% Hours, 50% to 60% Hours, 60% to 70% Hours, 70% to 80% Hours, over 80% 3 - 47 CX EXCAVATORS...
  • Page 88 CONTROLLER RESETTING RST1 MODE Hi, H 0 0 RPM Used RPM 0 0 SEC Used BRK: Programmed RPM for Hammer mode L/M: Not Used Auto-Idle setting time (1 to 30 seconds) Altitude compensation (0=off, 1=on) Auto Power Boost Cancellation (0=off, 1=on) HLD: Hold previous (default) data (0=with, 1=without) OUT:...
  • Page 89 CONTROLLER RESETTING Engine Speed for Hammer Mode MODE Hi, H Used Used Push the Buzzer stop switch to select BRK (item selected will have a light background). CX130/CX160 To set engine speed for hammer mode, start the engine and adjust RPM with the throttle control.
  • Page 90 CONTROLLER RESETTING MODE Hi, H Used Used L/M: Not used OUT: Not used 3 - 50 CX EXCAVATORS...
  • Page 91 CONTROLLER RESETTING Auto Idle Time Set MODE Hi, H Used Used Push the Buzzer stop switch to select AI (item selected will have a light background). To set the Auto-Idle time from 0 through 30 seconds, press the Travel mode switch until the number changes to your selection. The number increases by 1 every time the switch is pushed.
  • Page 92 CONTROLLER RESETTING Altitude Compensation (pump power set) MODE Hi, H Used Used Push the Buzzer stop switch to select PA (item selected will have a light background) 0 = Normal Mode 1,2,3 = Low Power Mode settings To set the low pump power mode (altitude compensation), push the Travel mode switch to change the to 1 for low power mode or 0 for normal power mode.
  • Page 93 CONTROLLER RESETTING Auto Power Boost Set (CX210/CX240) MODE Hi, H Used Used Push the Buzzer stop switch to select AU (item selected will have a light background) 0 = With Automatic Power Boost 1 = Without Automatic Power Boost (No Power Boost H & S mode) To set press the Travel mode switch to select 1 or 0.
  • Page 94 CONTROLLER RESETTING Previous Data Holding MODE Hi, H Used Used Push the Buzzer stop switch to select HLD (item selected will have a light background). 0 = Will hold default data 1 = Will turn off default data, will return to setting when key is turned off To set previous data holding feature, push the Travel mode switch until the numbers change to the predetermined value in each column.
  • Page 95 CONTROLLER RESETTING Previous Data Holding • Auto Mode • Work Mode • Travel Mode • Maintenance Timer 0 = Will hold default data 1 = Will return to setting when key was turned off. Maintenance Timer Cancellation 0 = Off (maintenance timer ON) 1 = ON 3 - 55 CX EXCAVATORS...
  • Page 96 Construction Equipment Service Training CX SERIES EXCAVATOR Section 4 -- Electrical “How it Works” (2001)
  • Page 97 CASE CORPORATION     2001 Case Corporation 700 STATE STREET All Rights Reserved RACINE, WI 53404 U.S.A. CASE CANADA CORPORATION 3350 SOUTH SERVICE ROAD BURLINGTON, ON L7N 3M6 CANADA Printed in U.S.A.
  • Page 98 ELECTRICAL Table of Contents Section 4 - Electrical PAGE NO....................2-3 PERATION UNCTION UMMARY RPM CONTROL ......................4-5 HROTTLE OTOR .......................6-7 NGINE RPM ONTROL .......................8-9 DLING ONTROL (H, S, L ”A ”) ............10-19 ONTROL FOR ....................20-21 NGINE ...................22-23 REAKER EVOLUTION ONTROL ELECTRIC OVER HYDRAULIC CONTROLS ......................24-25 ONTROL...

  • Page 99: Throttle Motor

    ELECTRICAL RPM CONTROL Operation Function Explanation Throttle Motor 1) Engine speed on the CX130/CX160 excavators See pages (CX130/CX160) is adjusted with a stepper motor. 2) The stepper motor is controlled by the controller through the throttle driver. 3) The throttle motor requires calibration. Engine RPM 1) Engine speed on the CX210/CX240 excavators See pages...
  • Page 100 ELECTRICAL ELECTRIC / HYDRAULIC CONTROL Operation Function Explanation Pump Control 1) In S, H and Auto work modes current supplied to See pages the Electro-magnetic proportional valve built into 24-25 the pump, will control the HP requirement of hydraulic pumps P1 and P2. Power Boost 1) Increases hydraulic power when more force is See pages...
  • Page 101 ELECTRICAL RPM CONTROL Throttle Motor, CX130/CX160 1) The engine speed on the CX130/CX160 excavators is adjusted with a stepper motor. Stepping Motor A stepping motor is a motor that rotates when synchronization is turned into a pulse signal from a pulse oscillator. When using a stepping motor, the pulse oscillator is what determines rotational speed and rotation degree.
  • Page 102 ELECTRICAL RPM CONTROL A. Voltage (Max 4.5 V) 2. Controller B. Clockwise 3. Motor driver C. Counterclockwise 4. Throttle motor D. Pulse oscillation 5. Engine throttle lever 1. Throttle volume 1. Limit switch 2. Drain hose 3. Power shaft 4. Reduction gears 5.

  • Page 103: Engine Rpm Control

    ELECTRICAL RPM CONTROL Engine rpm Control, CX130/CX160 1) Engine idle rpm for both models is permanently stored in the controller memory. 2) Programming the controller to the proper machine model number and allowing the controller to calibrate the throttle motor will determine the idling speed. 3) The throttle will return to set rpm’s with high precision.
  • Page 104 ELECTRICAL RPM CONTROL 1. Computer 2. Throttle control A. Degree B. Pulse FULL: H MODE MAX Revolutions CX130/CX160 RS : S MODE MAX Revolutions - 200 RL : L MODE MAX Revolutions - 300 RI : IDLE Revolutions 1050 F1 Spring deflection range F2 Spring deflection range M Full N Engine revolution (rpm)

  • Page 105: Idling Control

    ELECTRICAL RPM CONTROL Idling Control, All Models 1) The operator can select one touch idle, or he can select auto idle. 2) Auto idle time can be programmed from 1 to 30 seconds. One Touch Idle To select one touch idle push and hold the button on top of the right control handle for three seconds.
  • Page 106 ELECTRICAL RETURN TO IDLE CIRCUIT CONFIGURATION CX130/CX160 1. Instrument panel 6. Travel pilot pressure switch 2. Audible warning device 7. Throttle motor driver 3. Return to idle control 8. Throttle motor 4. Main Controller 9. Engine 5. Upper pilot pressure switch CX210/CX240 1.
  • Page 107 ELECTRICAL RPM CONTROL Work Mode Selection, All Models 1) When the ignition is switched on, "Auto" is selected by default. 2) When “Auto” mode is running, if the work mode switch is pressed, the mode does not change. Work Mode Change Work mode changes can not be done while in the “Auto”...
  • Page 108 ELECTRICAL WORK MODE SELECTION CIRCUIT CONFIGURATION CX130/CX160 1. Working mode switch 5. Throttle motor driver 2. Instrument panel 6. Throttle motor 3. Main Controller 7. Engine 4. Proportional Solenoid CX210/CX240 1. Working mode switch 6. Engine Controller 2. Automatic mode switch 7.

  • Page 109: Rpm Control For Each Mode (H, S, Land "Auto ")

    ELECTRICAL RPM CONTROL Rpm Control for Each Mode (H, S and L), CX130/CX160 1) Maximum rpm is obtained by selecting H mode. 2) S mode speed is 200 rpm less than H mode. 3) L mode speed is 300 rpm less than H mode. 4) Auto mode speed varies, 150 rpm less than H mode to 250 rpm less than H mode.
  • Page 110 ELECTRICAL RPM CONTROL Circuit Configuration 1. Work mode switch 5. Throttle driver 2. Instrument panel 6. Engine 3. Main controller 7. Throttle motor 4. Proportional solenoid 8. Power Boost solenoid Values set for each mode Mode Item CX130 CX160 Power Boost Engine rpm (max) 2470 ±...
  • Page 111 ELECTRICAL RPM CONTROL Rpm Control for Each Mode (H, S and L), CX210/CX240 1) Maximum rpm is obtained by selecting H mode. 2) S mode speed is 200 rpm less than H mode. 3) L mode speed is 300 rpm less than H mode. 4) Auto mode speed varies, 150 rpm less than H mode to 250 rpm less than H mode.
  • Page 112 ELECTRICAL RPM CONTROL Circuit Configuration 1. Proportional solenoid 4. Engine controller 2. Power boost solenoid 5. Engine 3. Main controller 6. Electronic injection pump Values set for each mode Mode Item CX210 CX240 Power Boost Engine rpm (max) 2000 ± 10 2200 ±...
  • Page 113 ELECTRICAL RPM CONTROL RPM Control for Automatic Work Mode, CX130/CX160 1) When the key switch is turned “ON” the machine will be in Auto mode. 2) With “Auto” mode selected the machine operates in 2 modes, S and L depending on conditions.
  • Page 114 ELECTRICAL RPM CONTROL Circuit Configuration 1. Proportional solenoid 7. De-stroke signal transducer 2. Power Boost solenoid 8. Travel pressure switch 3. Main controller 9. Throttle driver 4. Hydraulic oil temperature sender 10. Engine 5. Pump1 pressure transducer 11. Throttle motor 6.
  • Page 115 ELECTRICAL RPM CONTROL RPM Control for Automatic Work Mode, CX210/CX240 1) When the key switch is turned “ON” the machine will be in Auto mode. 2) With “Auto” mode selected the machine operates in 2 modes, S and L depending on conditions.
  • Page 116 ELECTRICAL RPM CONTROL Circuit Configuration Pump2 pressure transducer De-stroke signal transducer (N) Proportional solenoid Travel pilot pressure switch Power Boost solenoid Engine controller Main controller 10. Engine Hydraulic oil temperature sender 11. Electronic injection pump Pump1 pressure transducer 12. Water temperature sender CX210 CX240 Engine rpm (max)
  • Page 117 ELECTRICAL RPM CONTROL Auto Warm-Up, All Models Increases engine rpm by steps over a 15-minute period or until operating temperature is reached if: Water temperature is below 122°F Hydraulic functions are not operated for 12 seconds. (pressure switches off) One touch or Auto idle is off. If any functions is operated or throttle movement, auto warm-up is canceled.
  • Page 118 ELECTRICAL RPM CONTROL Circuit Configuration CX130/CX160 Instrument panel Throttle control One-Touch idle switch Throttle motor driver Main controller Throttle motor Upper pilot pressure switch Engine coolant temperature sender Travel pilot pressure switch 10. Engine CX210/CX240 Throttle control Instrument panel Engine controller One-Touch idle switch Electronic injection pump Main controller...

  • Page 119: Breaker Revolution Control

    ELECTRICAL RPM CONTROL – ALL MODELS Breaker Revolution Control, All Models 1) When the breaker pressure switch is hydraulically closed, the engine rpm will decrease to a preset speed. 2) The throttle control knob speed setting must be set higher than the preset speed. Breaker / Aux.
  • Page 120 ELECTRICAL RPM CONTROL Circuit Configuration CX130/CX160 5. Throttle control 1. Auxiliary hydraulic switch 6. Throttle motor driver 2. Hammer pilot switch 7. Throttle motor 3. Main controller 8. Engine 4. Proportional solenoid CX210/CX240 1. Auxiliary hydraulic switch 5. Throttle volume 2.
  • Page 121 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 a RPM signal for proportional solenoid pump control. H -MODE: when pump torque amounts to 100% of engine target torque a variable electrical signal is sent to the proportional solenoid.
  • Page 122 ELECTRICAL ELECTRIC/HYDRAULIC MODE H MODE S MODE L MODE AUTO MODE MODEL CX130 600mA 450mA 450mA 490mA 450mA CX160 CX210 CX240 CX EXCAVATORS 4 - 25...
  • Page 123 ELECTRICAL ELECTRIC/HYDRAULIC Power Boost, CX130/CX160 1) Increases power when more force is required for digging operations. 2) By pushing a button, the main relief pressure is increased for 8 seconds, in H and S mode. 3) Power Boost works at all times in L mode. Note: The controller needs a RPM signal for Power Boost.

  • Page 124: Power Boost

    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 →...
  • Page 125 ELECTRICAL ELECTRIC/HYDRAULIC Automatic Power Boost, CX210/CX240 1) In H and S work mode the controller will activate the power boost solenoid to increase main relief pressure. 2) This increase is automatic with out action by the operator. 3) The increase will activate for 8 seconds. 4) Power boost is on full time in L mode.
  • Page 126 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 →...

  • Page 127: 2- Speed Travel

    ELECTRICAL ELECTRIC/HYDRAULIC 2–Speed Travel, All Models 1) The machine will default to low speed when the key switch is turned ON. 2) When high speed is selected the swash plates in the travel motors is shifted to minimum angle. (see section 4) 3) Travel speed will shift into low speed automatically when the pump pressure reaches approximately 4200 psi (see section 4).
  • Page 128 ELECTRICAL TRAVEL SPEED Circuit Configuration 1. Instrument panel 6. De-stroke pressure transducer 2. Travel speed switch 7. Travel pilot pressure switch 3. Main controller 8. Travel speed solenoid valve 4. Pressure transducer pump1 9. RPM sensor 5. Pressure transducer pump2 CX EXCAVATORS 4 - 31...
  • Page 129 ELECTRICAL ELECTRIC/HYDRAULIC Cushion (on/off), All Models 1) Controls the pilot oil of the boom and arm spools. 2) This feature can be turned off by the operator. 3) Each time the machine is started, it will be in Cushion ON. Note: The controller needs a RPM signal for cushion Off.

  • Page 130: Cushion ( On / Off )

    ELECTRICAL CUSHION OFF Circuit Configuration 1. Instrument Panel 2. Cushion switch 3. Main controller 4. Cushion valve 5. Cushion solenoid 6. RPM sensor CX EXCAVATORS 4 - 33...
  • Page 131 ELECTRICAL ELECTRIC/HYDRAULIC Swing Brake, All Models 1) The mechanical swing brake will apply 5 seconds after the swing hand control is returned to neutral. 2) The brake solenoid valve is turned on when the key switch is turned on. When the swing and an attachment function are operated simultaneously, the mechanical swing brake is automatically released.

  • Page 132: Swing Brake /Swing Lock And Free Swing

    ELECTRICAL SWING BRAKE Circuit Configuration Instrument panel Swing brake switch Starter motor switch Main controller Swing pilot pressure switch Pilot pressure switch Travel pressure switch Pressure transducer P1 Pressure transducer P2 10. Swing brake 11. Swing brake solenoid valve CX EXCAVATORS 4 - 35...
  • Page 133 ELECTRICAL ELECTRIC/HYDRAULIC Swing Lock, All Models 1) When the swing brake switch is pressed the swing brake will apply. 2) The swing control will be locked in neutral. When the swing brake switch is pressed the controller sends 24v to the swing brake solenoid, which shifts and allows the swing brake to apply.
  • Page 134 ELECTRICAL SWING LOCK Circuit Configuration Instrument panel Swing brake switch Starter motor switch Main controller Swing pilot pressure switch Pilot pressure switch Travel pressure switch Pressure transducer P1 Pressure transducer P2 10. Swing brake 11. Swing brake solenoid valve CX EXCAVATORS 4 - 37...
  • Page 135 ELECTRICAL ELECTRIC/HYDRAULIC Free Swing, All Model 1) Free swing allows the upperstructure to “coast” to a stop. 2) The swing brake does not apply while free swing is on. Note: The controller needs a RPM signal for free swing. When the free swing switch is pressed the controller sends 24v to energize the free swing solenoid.
  • Page 136 ELECTRICAL FREE SWING Circuit Configuration 1. Free swing switch 2. Main controller 3. Free swing solenoid valve 4. Orifice Ø 2.5 5. Swing motor CX EXCAVATORS 4 - 39...
  • Page 137 ELECTRICAL ELECTRIC/HYDRAULIC Lever Lock (pilot lockout), All Models 1) When the gate lever or the left console is raised the pilot controls will be disabled. The pilot pressure solenoid receives 24v from the pilot pressure fuse through a limit switch in the left console.

  • Page 138: Lever Lock

    ELECTRICAL LEVER LOCK (PILOT LOCKOUT) Circuit configuration 1. Battery 2. Battery relay 3. Main protective fuse 4. Fuse box 5. Control cancellation lever switch 6. Pilot pressure control solenoid valve CX EXCAVATORS 4 - 41...
  • Page 139 Construction Equipment Service Training CX SERIES EXCAVATOR Section 5 -- Hydraulic - CX130/CX160 “How it Works” (2001)
  • Page 140 CASE CORPORATION     2001 Case Corporation 700 STATE STREET All Rights Reserved RACINE, WI 53404 U.S.A. CASE CANADA CORPORATION 3350 SOUTH SERVICE ROAD BURLINGTON, ON L7N 3M6 CANADA Printed in U.S.A.
  • Page 141 HYDRAULICS – CX130/CX160 Table of Contents Section 5 - Hydraulic PAGE NO. Operation / Function Summary.....................2-4 TRAVEL Low Speed Travel......................6-7 High Speed Travel......................8-11 Straight Travel......................12-15 SWING Swing Operation......................16-19 Swing Lock ........................20-21 Swing Priority ......................22-23 ATTACHMENT Boom Raise ........................24-25 Boom Lower ........................26-27 Arm Open (Out)......................28-29 Arm Close (In) ......................30-31 Cushion Operation (ON) .....................32-35...
  • Page 142 HYDRAULICS – CX130/CX160 TRAVEL Operation Function Explanation Low Speed 1) The swash plate angle of a travel motor is shifted to See pages Travel maximum angle. Low-speed is the default mode. High Speed 1) The Travel Speed solenoid is energized and the swash See pages Travel plate angle of the travel motors is shifted to minimum...
  • Page 143 HYDRAULICS – CX130/CX160 ATTACHMENT Operation Function Explanation Boom Raise 1) With boom up only operation two pump flows inside the See pages control valve are combined, when the boom1 and 24-25 boom2 spools are shifted. Boom Lower 1) When a built-in anti-drift valve in the control valve is See pages opened and boom1 spool is shifted, the boom can be 26-27...
  • Page 144 HYDRAULICS – CX130/CX160 FEATURES Operation Function Explanation One Touch 1) When the Power boost button is pressed, the power See pages Power boost boost solenoid is energized and the main relief 38-39 pressure will be raised approximately 8%. 2) This power boost increase will occur for 8-second intervals.
  • Page 145 HYDRAULICS – CX130/CX160 This page left blank intentionally. CX EXCAVATORS 5 - 5...
  • Page 146 HYDRAULICS – CX130/CX160 TRAVEL Low Speed Travel 1) The swash plate angle of the travel motors is set to maximum angle, low-speed travel occurs. The monitor display will indicate low-speed (LO). 2) The machine will default to Low-Speed when the machine is started. Low-speed is the normal travel speed.

  • Page 147: Travel

    HYDRAULICS – CX130/CX160 LOW SPEED TRAVEL Travel Pressure Switch CONTROLLER Travel Alarm Gate Limit Switch Pilot Pressure Solenoid Foot Controls Control Valve CX EXCAVATORS 5 - 7...
  • Page 148 HYDRAULICS – CX130/CX160 TRAVEL High Speed Travel 1) The travel-speed solenoid is energized and the swash plate angle of a travel motor is shifted to minimum angle, high-speed travel occurs. The monitor display will indicate high-speed (Hi). 2) The travel motors will switch to low-speed automatically at approximately 4200 psi and switch back to high-speed when the travel pressure is reduced.

  • Page 149: High Speed Travel

    HYDRAULICS – CX130/CX160 HIGH SPEED TRAVEL Travel Switch Travel Pressure RPM Signal Switch HERTZ CONTROLLER Travel High Speed Alarm Pilot Pressure Solenoid 550/600 psi 2-speed valve 2-speed valve TRAVEL MOTORS CX EXCAVATORS 5 - 9...
  • Page 150 HYDRAULICS – CX130/CX160 DRIVE MOTOR Pilot pressure from the Travel Speed Solenoid DRIVE MOTOR CX EXCAVATORS 5 - 10...
  • Page 151 HYDRAULICS – CX130/CX160 This page left blank intentionally. CX EXCAVATORS 5 - 11...

  • Page 152: Straight Travel

    HYDRAULICS – CX130/CX160 TRAVEL Straight Travel 1) When performing travel operation + attachment operation or travel operations + swing operation, one pump is dedicated to the travel motors. The other pump will supply oil to the other functions. An example of straight travel is explained using the example of travel + boom raise operation.
  • Page 153 HYDRAULICS – CX130/CX160 ESERVOIR Return Circuit Return Circuit Upper signal circuit Arm 2 Arm 1 Bucket Option Boom 2 Boom 1 Upper signal circuit Swing Travel left Travel right Straight Travel Valve Travel signal circuit Straight Travel Pilot Valve CX EXCAVATORS 5 - 13...
  • Page 154 HYDRAULICS – CX130/CX160 ESERVOIR Return Circuit Return Circuit Upper signal circuit Arm 2 Arm 1 Option Bucket Boom 1 Boom 2 Upper signal circuit Swing Travel left Travel right Straight Travel Valve Travel signal circuit Straight Travel Pilot Valve CX EXCAVATORS 5 - 14...
  • Page 155 HYDRAULICS – CX130/CX160 ESERVOIR Return Circuit Return Circuit Upper signal circuit Arm 2 Arm 1 Option Bucket Boom 1 Boom 2 Swing Travel left Travel right Straight Travel Valve Travel signal circuit Straight Travel Pilot Valve Upper signal circuit CX EXCAVATORS 5 - 15...

  • Page 156: Swing

    HYDRAULICS – CX130/CX160 SWING Swing Operation 1) The swing holding brake prevents the upper structure from drifting on a hillside until the swing hand control is moved or either main pump pressure is raised to +2050 psi. 2) Pilot oil from the swing brake solenoid valve releases the swing brake. 3) The machine uses flow from one pump during swing operation.
  • Page 157 HYDRAULICS – CX130/CX160 SWING BRAKE ON CONTROLLER Swing pressure switch Pilot Swing hand control Pressure Pilot control solenoid Swing shuttle valve Swing brake solenoid Control Valve Swing Motor CX EXCAVATORS 5 - 17...
  • Page 158 HYDRAULICS – CX130/CX160 SWING BRAKE OFF With Swing Operation CONTROLLER Swing pressure switch Pilot Swing hand control Pressure Pilot control solenoid Swing shuttle valve Swing brake solenoid Control Valve Swing Motor CX EXCAVATORS 5 - 18...
  • Page 159 HYDRAULICS – CX130/CX160 SWING BRAKE OFF With Pump Pressure CONTROLLER Pilot Arm Control Pressure Pump Pressure Transducer Signal Pilot control solenoid Swing brake solenoid Pump Pressure Transducer Pump Pressure 2050 psi Control Valve Swing Motor CX EXCAVATORS 5 - 19...
  • Page 160 HYDRAULICS – CX130/CX160 SWING Swing Lock 1) The swing-brake solenoid is activated allowing the spring-applied brake to fully apply. 2) The swing-shutoff solenoid is activated, hydraulically locking the swing spool. 3) This swing lock condition is maintained, even if the key switch is turned “OFF” and “ON”...

  • Page 161: Swing Lock

    HYDRAULICS – CX130/CX160 SWING LOCK CONTROLLER Swing Brake Solenoid Pilot Pressure 550/600 psi Swing Shutoff Solenoid Swing Shuttle Valve Control Valve Swing Motor CX EXCAVATORS 5 - 21...
  • Page 162 HYDRAULICS – CX130/CX160 SWING Swing Priority 1) A priority circuit assures swing operation when swing and arm is operated at the same time. When operating the swing and arm simultaneously as in bank shaving or bank cutting operation, a priority circuit in the control valve achieves swing priority. Oil flow from pump2 (rear pump) enters the PL port of the control valve and flow from pump1 (front pump) enters the PR port.

  • Page 163: Swing Priority

    HYDRAULICS – CX130/CX160 SWING PRIORITY Cut Valve ) ( W Swing Priority Valve Arm1 Arm2 Bucket Option Boom2 Boom1 Swing Travel Travel Pilot Oil from hand control CX EXCAVATORS 5 - 23...

  • Page 164: Attachment

    HYDRAULICS – CX130/CX160 ATTACHMENT Boom Raise 1) Two pump flows inside the control valve are combined, when the boom1 and boom2 spools are shifted. Oil flow from pump1 (front pump) enters the PR port of the control valve and oil from pump2 (rear pump) enters the PL port.

  • Page 165: Boom Raise

    HYDRAULICS – CX130/CX160 BOOM RAISE ) ( W Cut Valve Swing Priority Valve Arm1 Arm2 Bucket Option Boom2 Boom1 Swing Travel Pilot Oil from Travel hand control CX EXCAVATORS 5 - 25...

  • Page 166: Boom Lower

    HYDRAULICS – CX130/CX160 ATTACHMENT Boom Lower 1) When a built-in anti-drift valve in the control valve is opened and boom1 spool is shifted, the boom can be lowered. 2) A regeneration circuit inside the control spool and valve provides additional speed. 3) Only one pump flow is used.
  • Page 167 HYDRAULICS – CX130/CX160 BOOM OPERATION RIFT AND EGENERATION Cylinder Return Boom up Cylinder Supply From boom2 spool (pump 2) Anti-Drift Valve and Check Valve Pilot oil from From Pilot system hand control Boom down Open Center Cylinder Supply Cylinder Return Pilot oil from Pump Supply hand control...
  • Page 168 HYDRAULICS – CX130/CX160 ATTACHMENT Arm Open (Out) 1) Two pump flows inside the control valve are combined, when the arm1 and arm2 spools are shifted. The oil flow from pump1 (front pump) enters the PR port of the control valve and the oil flow from pump2 (rear pump) enters the PL port.

  • Page 169: Arm Open (Out)

    HYDRAULICS – CX130/CX160 ARM OPEN (OUT) Cylinder Return Cylinder Supply Arm 1 Arm 2 Option Pilot oil from Bucket hand control Boom 2 Boom 1 Swing Travel Travel CX EXCAVATORS 5 - 29...

  • Page 170: Arm Close (In)

    HYDRAULICS – CX130/CX160 ATTACHMENT Arm Close (In) 1) Two pump flows inside the control valve are combined, when the arm1 and arm2 control spools are shifted. 2) A regeneration valve inside the main control valve provides additional speed. 3) When an anti-drift valve in the arm close circuit is opened, arm-closing movement is achieved.
  • Page 171 HYDRAULICS – CX130/CX160 ARM OPERATION With Anti-Drift and Regeneration Cylinder Return Arm Out Cylinder Supply From arm2 spool (pump 1) Anti-Drift and Check Valve Pilot oil from hand control From Pilot System Arm In From arm2 spool (pump 1) Cylinder Supply Cylinder Return Pilot oil from hand control...
  • Page 172 HYDRAULICS – CX130/CX160 FEATURES Cushion Operation (ON) (Boom and Arm) 1) As a control spool returns to neutral (center) position, the pilot oil must return through an orifice in the cushion valve. 2) The slow movement of the spool provides the cushion feature. 3) The Cushion only occurs in the boom and arm circuits.
  • Page 173 HYDRAULICS – CX130/CX160 CUSHION VALVE (NEUTRAL) Control Valve Down Boom 1 Cushion Valve Boom Control Down Pilot Solenoid 550/600 psi CX EXCAVATORS 5 - 33...

  • Page 174: Cushion Operation (On)

    HYDRAULICS – CX130/CX160 CUSHION OPERATION (BOOM UP) Control Valve Down Boom 1 Cushion Valve Boom Control Down Pilot Solenoid 550/600 psi CX EXCAVATORS 5 - 34...
  • Page 175 HYDRAULICS – CX130/CX160 CUSHION OPERATION (BOOM UP RELEASED) Control Valve Down Boom 1 Cushion Valve Boom Control Down Pilot Solenoid 550/600 psi CX EXCAVATORS 5 - 35...
  • Page 176 HYDRAULICS – CX130/CX160 FEATURES Cushion Operation (OFF) (Boom and Arm) 1) When pilot oil from the cushion solenoid is sent to the cushion valve, the orifices are shifted out of the circuit and the cushion feature will not function. Note: The Controller needs a RPM signal for Cushion Off. During cushion off operation, the dirt release from the attachments is improved by the sudden stopping (shock) of the arm and boom operations.

  • Page 177: Cushion Off Operation (Off)

    HYDRAULICS – CX130/CX160 CUSHION OFF RPM Signal Hertz CONTROLLER Pilot Solenoid Cushion Solenoid 550/600 psi Cushion Valve CX EXCAVATORS 5 - 37...

  • Page 178: Features

    HYDRAULICS – CX130/CX160 FEATURES One Touch Power Boost 1) When the Power boost button is pressed in H and S mode, the pressure setting of main relief increases from approximately 4900 psi to approximately 5300 psi and digging force is increased. 2) This power boost increase will occur for 8-second intervals.
  • Page 179 HYDRAULICS – CX130/CX160 POWER BOOST CONTROLLER RPM Signal Hertz Power Boost Switch Pilot Solenoid Power Boost Solenoid 550/600 psi Control Valve Arm 1 Arm 2 Option Bucket Boom 2 Boom 1 Swing Travel Travel CX EXCAVATORS 5 - 39...

  • Page 180: Main Relief Valve

    HYDRAULICS – CX130/CX160 FEATURES Main Relief Valve The Main Relief has two adjustments: Standard Main Relief pressure Power Boost Pressure When pilot signal port is pressurized, power boost piston shifts to the position shown. Thus the pilot spring force rises, and pressure increases (POWER BOOST). 1.
  • Page 181 HYDRAULICS – CX130/CX160 MAIN RELIEF STANDARD RELIEF POSITION Power Boost Piston Main Relief Pilot Poppet Main Poppet POWER BOOST RELIEF POSITION From Power Boost Solenoid CX EXCAVATORS 5 - 41...

  • Page 182: Neutral Pump De-Stroke (Negative Flow Control)

    HYDRAULICS – CX130/CX160 FEATURES Neutral Pump De-Stroke 1) If the flow output of P1 or P2 hydraulic pump is not needed the output is kept at a minimum flow rate (negative control flow rate), and energy consumption is reduced. The negative flow control sets the hydraulic pump at minimum flow rate and reduces energy consumption in neutral no-load mode.
  • Page 183 HYDRAULICS – CX130/CX160 PUMP DE-STROKE (NEUTRAL) Pump De-Stroke Valves To Reservoir Arm 2 Arm 1 Option Bucket Boom 2 Boom 1 Swing Travel Travel Pump Regulators CX EXCAVATORS 5 - 43...

  • Page 184: Free Swing Operation

    HYDRAULICS – CX130/CX160 FEATURES Free Swing Operation 1) An orifice leak is opened between the A and B ports of the swing motor. This will provide smoother starts and stops of the swing during hoisting operations. Note: The controller needs a RPM signal for Free Swing. The free swing operation dampens the oil pressure and flow surges to the swing motor during starting and stopping.
  • Page 185 HYDRAULICS – CX130/CX160 FREE SWING RPM Signal Hertz CONTROLLER 550/600 PSI Free Swing Solenoid Swing Brake Pilot Solenoid Free Swing Solenoid Orifice Control Valve Swing Motor CX EXCAVATORS 5 - 45...
  • Page 186 HYDRAULICS – CX130/CX160 OPTIONS Auxiliary Attachments There are three auxiliary hydraulic options: 1) Hammer kit (one direction, one pump flow) 2) Multi-kit (two direction or one direction. One or two pump flows) 3) Thumb kit (two direction, one pump flow) CX EXCAVATORS 5 - 46...
  • Page 187 HYDRAULICS – CX130/CX160 CX EXCAVATORS 5 - 47...
  • Page 188 Construction Equipment Service Training CX SERIES EXCAVATOR Section 6 -- Hydraulic – CX210/CX240 “How it Works” (2001)
  • Page 189 CASE CORPORATION     2001 Case Corporation 700 STATE STREET All Rights Reserved RACINE, WI 53404 U.S.A. CASE CANADA CORPORATION 3350 SOUTH SERVICE ROAD BURLINGTON, ON L7N 3M6 CANADA Printed in U.S.A.
  • Page 190 HYDRAULICS – CX210/CX240 Table of Contents Section 6 - Hydraulic PAGE NO....................2-4 PERATION UNCTION UMMARY TRAVEL ......................6-7 PEED RAVEL High Speed Travel ......................8-10 Straight Travel......................12-15 SWING Swing Operation......................16-19 Swing Lock........................20-21 Swing Priority ......................22-23 ATTACHMENT Boom Raise ........................24-25 Boom Lower ........................26-27 Arm Open (Out)......................28-29 Arm Close (In) ......................30-31 (ON) ....................32-35...
  • Page 191 HYDRAULICS – CX210/CX240 TRAVEL Operation Function Explanation Low Speed 1) The swash plate angle of the travel motors is shifted See pages Travel to maximum angle. High Speed 1) The Travel Speed solenoid is energized and the See pages Travel swash plate angle of the travel motors is shifted to 8-11 minimum angle, high-speed travel occurs.
  • Page 192 HYDRAULICS – CX210/CX240 ATTACHMENT Operation Function Explanation Boom Raise 1) Two pump flows inside the control valve are See pages combined, when the boom1 and boom2 control 24-25 spools are shifted. Boom Lower 1) When a built-in anti-drift valve in the control valve is See pages opened and boom1 spool is shifted, the boom can be 26-27...
  • Page 193 HYDRAULICS – CX210/CX240 FEATURES Operation Function Explanation Automatic 1) When main pump pressure reaches approximately See pages 4350 psi and the load ratio fluctuation of the engine is Power Boost 38-39 ±5% for two seconds. The controller will energize the power boost solenoid and increase main relief approximately 8%.
  • Page 194 HYDRAULICS – CX210/CX240 This page left blank intentionally. CX EXCAVATORS 6 - 5...
  • Page 195 HYDRAULICS – CX210/CX240 TRAVEL Low Speed Travel 1) The swash plate angle of the travel motors is set to maximum angle, low-speed travel occurs. The monitor display will indicate Low-speed (LO). 2) The machine will default to Low-Speed when the machine is started. Low-Speed is the normal travel speed.

  • Page 196: Travel

    HYDRAULICS – CX210/CX240 LOW SPEED TRAVEL Travel Pressure Switch CONTROLLER Travel Alarm Gate Limit Switch Pilot Pressure Solenoid Foot Controls Control Valve CX EXCAVATORS 6 - 7...
  • Page 197 HYDRAULICS – CX210/CX240 TRAVEL High Speed Travel 1) The Travel Speed solenoid is energized and the swash plate angle of the travel motors is shifted to minimum angle, high-speed travel occurs. The monitor display will indicate high speed (HI). 2) The travel motors will switch to low-speed automatically when the travel pressure reaches approximately 4200 psi and switches back to high-speed when the travel pressure is reduced.

  • Page 198: High Speed Travel

    HYDRAULICS – CX210/CX240 HIGH SPEED TRAVEL Travel Switch Travel Pressure Switch Engine Controller CONTROLLER Travel Travel Speed Alarm Pilot Pressure Solenoid 550/600 psi 2-speed valve 2-speed valve TRAVEL MOTORS CX EXCAVATORS 6 - 9...
  • Page 199 HYDRAULICS – CX210/CX240 DRIVE MOTOR Pilot pressure from the Travel Speed Solenoid DRIVE MOTOR CX EXCAVATORS 6 - 10...
  • Page 200 HYDRAULICS – CX210/CX240 This page left blank intentionally. CX EXCAVATORS 6 - 11...

  • Page 201: Straight Travel

    HYDRAULICS – CX210/CX240 TRAVEL Straight Travel 1) When performing travel operation + attachment operation or travel operations + swing operation, one pump is dedicated to the travel motors. The other pump will supply oil to the other functions. The operating method that follows uses travel + boom raise as an example. During travel operation, pressurized oil from P1 (front pump) enters the P1 port of the control valve.
  • Page 202 HYDRAULICS – CX210/CX240 ESERVOIR Return Circuit Return Circuit Upper signal circuit Arm 2 Arm 1 Boom 2 Boom 1 Swing Bucket Option Travel Upper signal circuit Travel Travel signal circuit Straight Travel Valve CX EXCAVATORS 6 - 13...
  • Page 203 HYDRAULICS – CX210/CX240 ESERVOIR Return Circuit Return Circuit Upper signal circuit Arm 2 Arm 1 Boom 1 Boom 2 Swing Bucket Option Travel Upper signal circuit Travel Travel signal circuit Straight Travel Valve CX EXCAVATORS 6 - 14...
  • Page 204 HYDRAULICS – CX210/CX240 ESERVOIR Return Circuit Return Circuit Upper signal circuit Arm2 Arm1 Boom1 Boom2 Bucket Swing Option Travel Upper signal circuit Travel Straight Travel Valve Travel signal circuit CX EXCAVATORS 6 - 15...

  • Page 205: Swing

    HYDRAULICS – CX210/CX240 SWING Swing Operation 1) The swing holding brake prevents the upper structure from drifting on a hillside until the swing hand control is moved or either main pump pressure is raised to +2050 psi. 2) Pilot oil from the swing brake solenoid valve releases the swing brake. 3) The machine uses flow from one pump during swing operations.
  • Page 206 HYDRAULICS – CX210/CX240 SWING BRAKE ON CONTROLLER Swing pressure switch Pilot Swing hand control Pressure 550/600 psi Pilot control solenoid Swing shuttle valve Swing brake solenoid Control Valve Swing Motor CX EXCAVATORS 6 - 17...
  • Page 207 HYDRAULICS – CX210/CX240 SWING BRAKE OFF With Swing Operation CONTROLLER Swing pressure switch Pilot Swing hand control Pressure 550/600 psi Pilot control solenoid Swing shuttle valve Swing brake solenoid Control Valve Swing Motor CX EXCAVATORS 6 - 18...
  • Page 208 HYDRAULICS – CX210/CX240 SWING BRAKE OFF With Pump Pressure CONTROLLER Pilot Arm Control Pressure 550/600 psi Pump Pressure Transducer Signal Pilot control solenoid Swing brake solenoid Pump Pressure Transducer Pump Pressure +2050 psi Control Valve Swing Motor CX EXCAVATORS 6 - 19...
  • Page 209 HYDRAULICS – CX210/CX240 SWING Swing Lock 1) The swing-brake solenoid is energized allowing the spring-applied brake to fully apply. 2) The swing shut off solenoid is energized hydraulically locking the swing spool. 3) This swing lock condition is maintained, even if the key switch is turned “OFF” and “ON”...

  • Page 210: Swing Lock

    HYDRAULICS – CX210/CX240 SWING LOCK CONTROLLER Swing Brake Solenoid Pilot Pressure 550/600 psi Swing Shuttle Valve Swing Shutoff Solenoid Control Valve Swing Motor CX EXCAVATORS 6 - 21...
  • Page 211 HYDRAULICS – CX210/CX240 SWING Swing Priority 1) A priority circuit assures swing operation when swing and arm is operated at the same time. When operating the swing and arm simultaneously as in bank shaving or bank cutting operation, a priority circuit in the control valve achieves swing priority. Oil flow from pump1 (front pump) enters the P1 port of the control valve and flow from pump2 (rear pump) enters the P2 port.

  • Page 212: Swing Priority

    HYDRAULICS – CX210/CX240 SWING PRIORITY Arm1 Arm2 From Swing Hand Control Swing Priority Valve Boom2 Boom1 Swing Bucket Option Travel Travel CX EXCAVATORS 6 - 23...

  • Page 213: Attachment

    HYDRAULICS – CX210/CX240 ATTACHMENT Boom Raise 1) Two pump flows are combined inside the control valve, when the boom1 and boom2 control spools are shifted. Oil flow from pump1 (front pump) enters the P1 port of the control valve and oil from pump2 (rear pump) enters the P2 port.

  • Page 214: Boom Raise

    HYDRAULICS – CX210/CX240 BOOM RAISE Arm1 Arm2 Boom2 Boom1 Swing Bucket Option Travel Travel CX EXCAVATORS 6 - 25...

  • Page 215: Boom Lower

    HYDRAULICS – CX210/CX240 ATTACHMENT Boom Lower 1) When a built-in anti-drift valve in the control valve is released and boom1 control spool is shifted, the boom can be lowered. 2) A regeneration valve inside the boom1 control spool provides additional speed. 3) Only one pump flow is used.
  • Page 216 HYDRAULICS – CX210/CX240 BOOM OPERATION RIFT AND EGENERATION Anti-Drift Pilot Valve Boom Up Anti-Drift Valve Cylinder Supply From boom2 spool (pump1) Cylinder Return From boom hand control pump2 Boom Down Cylinder Return Cylinder Supply From boom hand control Open center “bleed” through circuit pump2 CX EXCAVATORS...
  • Page 217 HYDRAULICS – CX210/CX240 ATTACHMENT Arm Open (Out) 1) Two pump flows inside the control valve are combined, when the arm1 and arm2 control spools are shifted. The oil from pump1 (front pump) enters the P1 port of the control valve and the oil from pump2 (rear pump) enters the P2 port.

  • Page 218: Arm Open (Out)

    HYDRAULICS – CX210/CX240 ARM OPEN (OUT) Arm1 Arm2 Boom2 Boom1 From arm hand control Swing Bucket Option Travel Travel CX EXCAVATORS 6 - 29...

  • Page 219: Arm Close (In)

    HYDRAULICS – CX210/CX240 ATTACHMENT Arm Close (In) 1) Two pump flows inside the control valve are combined, when the arm1 and arm2 control spools are shifted. 2) When a built-in anti-drift valve in the control valve is opened and the arm1 spool is shifted, arm closing is achieved.
  • Page 220 HYDRAULICS – CX210/CX240 ARM OPERATION With Anti-Drift and Regeneration Arm Open (Out) Anti-Drift Pilot Valve Anti-Drift Valve Cylinder Supply Cylinder Return From arm hand control From arm2 spool (pump2) Pump1 Arm Close (In) Cylinder Return Cylinder Supply From arm hand control From arm2 spool (pump2) Pump1 CX EXCAVATORS...
  • Page 221 HYDRAULICS – CX210/CX240 FEATURES Cushion Operation (ON) (Boom and Arm) 1) As a control spool returns to neutral (center) position, the pilot oil must return through an orifice in the cushion valve. 2) The slow movement of the spool provides the cushion feature. 3) Cushion control only occurs in the boom and arm circuits.
  • Page 222 HYDRAULICS – CX210/CX240 CUSHION VALVE (NEUTRAL) Control Valve Down Boom 1 Cushion Valve Boom Control Down Pilot Solenoid 550/600 psi CX EXCAVATORS 6 - 33...

  • Page 223: Cushion Operation (On)

    HYDRAULICS – CX210/CX240 CUSHION OPERATION (BOOM UP) Control Valve Down Boom 1 Cushion Valve Boom Control Down Pilot Solenoid 550/600 psi CX EXCAVATORS 6 - 34...

  • Page 224: Cushion Operation (Off)

    HYDRAULICS – CX210/CX240 CUSHION OPERATION (BOOM UP RELEASED) Control Valve Down Boom 1 Cushion Valve Boom Control Down Pilot Solenoid 550/600 psi CX EXCAVATORS 6 - 35...

  • Page 225: Features

    HYDRAULICS – CX210/CX240 FEATURES Cushion Operation (OFF) (Boom and Arm) 1) When pilot oil from the cushion solenoid is sent to the cushion valve, the orifices are shifted out of the circuit and the cushion feature will not function. Note: The Controller needs an input signal from the engine controller for cushion off. During cushion off operation, the dirt release from the attachments is improved by the sudden stopping (shock) of the arm and boom operations.
  • Page 226 HYDRAULICS – CX210/CX240 CUSHION OFF Engine Controller CONTROLLER Pilot Solenoid Cushion Solenoid 550/600 psi Cushion Valve CX EXCAVATORS 6 - 37...
  • Page 227 HYDRAULICS – CX210/CX240 FEATURES Automatic Power Boost 1) When auto power boost is activated in H or S mode, the pressure setting of the main relief increases from approximately 4900 psi to approximately 5400 psi and digging force is increased. 2) This power boost increase will occur for 8-second intervals.
  • Page 228 HYDRAULICS – CX210/CX240 POWER BOOST Load Ratio ± 5% Engine Controller MACHINE CONTROLLER Transducer Signal Pilot Solenoid Power Boost Solenoid 550/600 psi Control Valve Arm 1 Arm 2 Option Bucket Boom 2 Boom 1 Swing Travel Travel RESSURE RESSURE Transducer Transducer CX EXCAVATORS 6 - 39...

  • Page 229: Main Relief Valve

    HYDRAULICS – CX210/CX240 FEATURES Main Relief Valve The Main Relief has two adjustments: 1) Standard Main Relief pressure 2) Power Boost Pressure When pilot signal port is pressurized the power boost piston shifts to the position shown (POWER BOOST). Thus the pilot spring force rises, and the pressure setting increases. a) In H or S mode, when the controller activates auto power boost, power boost operation is executed for 8 seconds.
  • Page 230 HYDRAULICS – CX210/CX240 MAIN RELIEF STANDARD RELIEF POSITION Power Boost Piston Main Relief Pilot Poppet Main Poppet POWER BOOST RELIEF POSITION Pilot signal from Power Boost solenoid CX EXCAVATORS 6 - 41...

  • Page 231: Neutral Pump De-Stroke (Negative Flow Control)

    HYDRAULICS – CX210/CX240 FEATURES Neutral Pump De-Stroke 1) If the flow output of P1 or P2 hydraulic pump is not needed the output is kept at a minimum flow rate (negative control flow rate), and energy consumption is reduced. The negative flow control sets the hydraulic pump at minimum flow rate and reduces energy consumption in neutral no-load mode.
  • Page 232 HYDRAULICS – CX210/CX240 PUMP DE-STROKE (NEUTRAL) Pump De-Stroke Valves To Reservoir Arm 2 Arm 1 Option Boom 1 Boom 2 Bucket Swing Travel Travel Pump Regulators CX EXCAVATORS 6 - 43...

  • Page 233: Free Swing Operation

    HYDRAULICS – CX210/CX240 FEATURES Free Swing Operation 1) An orifice leak is opened between the A and B ports of the swing motor. This will provide smoother starts and stops of the swing during hoisting operations. Note: The controller needs an input signal from the engine controller for free swing. The free swing operation dampens the oil pressure and flow surges to the swing motor during starting and stopping.
  • Page 234 HYDRAULICS – CX210/CX240 FREE SWING Engine Controller CONTROLLER 550/600 PSI Free Swing Solenoid Swing Brake Pilot Solenoid Free Swing Solenoid Orifice Control Valve Swing Motor CX EXCAVATORS 6 - 45...

  • Page 235: Options

    HYDRAULICS – CX210/CX240 OPTIONS Auxiliary Attachment Operation There are three auxiliary hydraulic options 1) Hammer kit (one direction, one pump flow) 2) Multi-kit (one or two direction, one or two pump flows) 3) Thumb kit (two direction, one pump flow) CX EXCAVATORS 6 - 46...
  • Page 236 HYDRAULICS – CX210/CX240 CX EXCAVATORS 6 - 47...
  • Page 237 Construction Equipment Service Training CX SERIES EXCAVATOR Section 7 -- Pressure Data Sheets (2001)
  • Page 238 CASE CORPORATION     2001 Case Corporation 700 STATE STREET All Rights Reserved RACINE, WI 53404 U.S.A. CASE CANADA CORPORATION 3350 SOUTH SERVICE ROAD BURLINGTON, ON L7N 3M6 CANADA Printed in U.S.A.
  • Page 239 PRESSURE TESTING Table of Contents Section 7 - Pressure Specifications DATA SHEET CX130 PRESSURE SPECIFICATION DATA SHEET CX160 PRESSURE SPECIFICATION DATA SHEET CX210 PRESSURE SPECIFICATION DATA SHEET CX240 PRESSURE SPECIFICATION CX EXCAVATORS 7 - 1...
  • Page 240 PRESSURE TESTING CX130 PRESSURE TESTING PRESSURE SPECIFICATIONS Name: PIN # CX130 Condition Work mode S : Standard Mode Hydraulic oil temperature 55 ° C ~ 131 °F Full Throttle No-load engine 2150 r.p.m. (H Mode) H Mode revolutions in: Part Name Measuring Reading Pressure...
  • Page 241 PRESSURE TESTING CX160 PRESSURE TESTING PRESSURE SPECIFICATIONS Name: PIN # CX160 Condition Work mode S : Standard Mode Hydraulic oil temperature 55 ° C ~ 131 °F Full Throttle No-load engine 2150 r.p.m. (H Mode) H Mode revolutions in: Part Name Measuring Reading Pressure...
  • Page 242 PRESSURE TESTING CX210 PRESSURE TESTING PRESSURE SPECIFICATIONS Name: PIN # Condition CX210 Work mode S : Standard Mode Hydraulic oil temperature 55 ° C ~ 131 °F Full Throttle No-load engine 1950 r.p.m. H Mode (H Mode) revolutions in: Part Name Measuring Reading Pressure...
  • Page 243 PRESSURE TESTING CX240 PRESSURE TESTING PRESSURE SPECIFICATIONS Name: PIN # Condition CX240 Work mode S : Standard Mode Hydraulic oil temperature 55 ° C ~ 131 °F Full Throttle Loaded engine 2150 r.p.m. H Mode (H Mode) revolutions in: Part Name Measuring Reading Pressure...
  • Page 244 Construction Equipment Service Training CX SERIES EXCAVATOR Section 8 -- Engine Electronic Fuel System (2001)
  • Page 245 CASE CORPORATION     2001 Case Corporation 700 STATE STREET All Rights Reserved RACINE, WI 53404 U.S.A. CASE CANADA CORPORATION 3350 SOUTH SERVICE ROAD BURLINGTON, ON L7N 3M6 CANADA Printed in U.S.A.
  • Page 246 CX210/CX240 ELECTRONIC FUEL SYSTEM Table of Contents Section 8 – Engine Electronic Fuel System PAGE NO. Engine Component Changes ----------------------------------------------------------------------------------- 2 Electronic Control System --------------------------------------------------------------------------------------- 3 Speed Sensor Ring------------------------------------------------------------------------------------------------ 6 Engine Component Location (left side) ---------------------------------------------------------------------- 7 Engine Component Location (right side)--------------------------------------------------------------------- 8 Fuel System Function--------------------------------------------------------------------------------------------- 9 Air Heater -----------------------------------------------------------------------------------------------------------12 Fuel Connectors---------------------------------------------------------------------------------------------------14...

  • Page 247: Engine Component Changes

    CX210/CX240 ELECTRONIC FUEL SYSTEM ENGINE COMPONENT CHANGES The new 24 valve, 5.9 Liter engines have a full authority electronic control fuel injection system. Numerous changes have been implemented into the Engine, compared to the lower horsepower 5.9 Liter Family I engines. These engines have four valves per cylinder to optimize air flow, fuel economy and emissions.

  • Page 248: Electronic Control System

    CX210/CX240 ELECTRONIC FUEL SYSTEM ELECTRONIC CONTROL SYSTEM The electronic control system for the Case 24 valve 5.9 Liter Engine uses input information from a number of sensors to determine the quantity and timing of the fuel delivery to the engine.
  • Page 249 CX210/CX240 ELECTRONIC FUEL SYSTEM ELECTRONIC CONTROL SYSTEM Outputs • The electrically operated lift pump is located at the left rear of the engine and is controlled by the Electronic Control Module (ECM). The pump will operate for 2 seconds when the key is first turned on.
  • Page 250 CX210/CX240 ELECTRONIC FUEL SYSTEM FLOW CHART Idle Water Engine Intake Man. Intake Manifold Validation In Fuel Position Pressure Heater Engine Intake Man. Cold Speed Sensor Pressure Air Temp. Throttle Start Coolant Power Temp. Supply J1939 Data Buss EECM Front Connector Rear Connector Injection Pump...

  • Page 251: Speed Sensor Ring

    CX210/CX240 ELECTRONIC FUEL SYSTEM ENGINE SPEED SENSOR RING CX EXCAVATORS 8 - 6...

  • Page 252: Engine Component Location (Left Side)

    CX210/CX240 ELECTRONIC FUEL SYSTEM ENGINE COMPONENT LOCATION LEFT SIDE 1. Engine Air Inlet 11. Fuel Filter/ Water Separator 2. VP44 Connector 12. Oil Pressure Switch 3. 23 pin OEM Connector 13. WIF Sensor 4. High Pressure Fuel Lines 14. Fuel Water Drain 5.

  • Page 253: Engine Component Location (Right Side)

    CX210/CX240 ELECTRONIC FUEL SYSTEM ENGINE COMPONENT LOCATION RIGHT SIDE 8. Thermostat Housing 1. Turbocharger Outlet Connection 9. Coolant Line Connector 2. Exhaust Manifold 10. Oil Filter 3. Turbocharger 11. Coolant Inlet 4. Turbocharger Inlet Connection 12. Oil Cooler 5. Oil Fill 13.

  • Page 254: Fuel System Function

    CX210/CX240 ELECTRONIC FUEL SYSTEM FUEL SYSTEM FUNCTION Fuel is drawn from the fuel tank and passes through an inline filter prior to entering the fuel lift pump. The 24 Volt DC pump is controlled by the Electronic Control Module through pulse width modulation (PWM).
  • Page 255 CX210/CX240 ELECTRONIC FUEL SYSTEM FUEL SYSTEM FUNCTION Fuel from the injection pump is sent to the injectors through high pressure injection lines in accordance with the engines firing order. The high pressure lines are connected to the distributor housing fittings at the pump and at fuel connectors at the cylinder head. The connectors direct the fuel through edge filters and on to the injectors.
  • Page 256 CX210/CX240 ELECTRONIC FUEL SYSTEM FLOW CHART Distributor Injectors Return Overflow and Check valve Temp. Sensor Lift Filter Pump Metering valve Timing Sensor Advance Transfer pump Fuel Tank Timing control Valve CX EXCAVATORS 8 - 11...

  • Page 257: Air Heater

    CX210/CX240 ELECTRONIC FUEL SYSTEM AIR HEATER An air heater at the inlet of the intake manifold, assists in cold starting of the engine and the reduction of white smoke during warm-up. The air heater is a solenoid operated integrated grid device, installed at the entrance to the intake manifold and is controlled by the ECM. The ECM determines when to actuate the air heater based on intake air temperature and fuel temperature.
  • Page 258 CX210/CX240 ELECTRONIC FUEL SYSTEM AIR HEATER CX EXCAVATORS 8 - 13...

  • Page 259: Fuel Connectors

    CX210/CX240 ELECTRONIC FUEL SYSTEM FUEL CONNECTORS The high pressure fuel lines are connected between the injection pump and the left side of the cylinder head. The injectors are mounted perfectly vertical, from the top of the cylinder head, at the center of the piston. High pressure fuel flows from the high pressure lines, through connectors, and into the injectors.
  • Page 260 CX210/CX240 ELECTRONIC FUEL SYSTEM FUEL CONNECTOR CX EXCAVATORS 8 - 15...

  • Page 261: Fuel System Troubleshooting

    CX210/CX240 ELECTRONIC FUEL SYSTEM FUEL SYSTEM TROUBLESHOOTING Retrieval of fault code information from the Case 24 Valve Engine Control Module can be done from the vehicle instrument monitor. The Service manual and the troubleshooting section of this manual cover the fuel system diagnostics.
  • Page 262 CX210/CX240 ELECTRONIC FUEL SYSTEM FUEL SYSTEM DIAGRAM 1. Fuel Supply from Tank 2. Electronic lift pump 3. Fuel Filter /Water Separator 4. Low Pressure Supply Lines 5. Bosch VP44 Injection Pump 6. Fuel Drain Line 7. High Pressure Supply Lines 8.

  • Page 263: Fault Code Conditions

    CX210/CX240 ELECTRONIC FUEL SYSTEM FAULT CODE CONDITIONS The instrument panel provides fault code information to the operator. They consist of Engine Control fault codes and Engine Protection fault codes. These fault codes can be ACTIVE (currently present) or INACTIVE (not currently present). Engine Protection fault codes consist of the following: High Coolant Temperature a de-rate of engine performance &...

  • Page 264: Fault Code Listings

    CX210/CX240 ELECTRONIC FUEL SYSTEM FAULT CODE LISTING Fault Associated Hardware Reason Effect (only with active code) F111 Electronic Control Module ECM internal hardware Possible no effect, rough error running engine or no start. F115 Crankshaft position No speed or position signal Engine power de-rate sensor at pin 17 of engine harness...
  • Page 265 CX210/CX240 ELECTRONIC FUEL SYSTEM FAULT CODE LISTING Fault Associated Hardware Reason Effect (only with active code) F151 Coolant temp. sensor/ Coolant temp. has Power de-rate, possible exceeded maximum engine shut-down protection limits F153 Intake air temp. sensor High voltage at pin 34 of Default value used.
  • Page 266 CX210/CX240 ELECTRONIC FUEL SYSTEM FAULT CODE LISTING Fault Associated Hardware Reason Effect (only with active code) F284 ESS crankshaft position Low voltage at pin 8 of ECM will use injection sensor low. engine harness. pump speed as back up. Possible white smoke and power loss.
  • Page 267 CX210/CX240 ELECTRONIC FUEL SYSTEM FAULT CODE LISTING Fault Associated Hardware Reason Effect (only with active code) F367 VP44 fuel system IAT Fuel pump position sensor Fueling to injectors is error signal lost. stopped and engine shuts down. F368 VP44 Fuel system timing Fuel pump controller can Significant engine power error.
  • Page 268 CX210/CX240 ELECTRONIC FUEL SYSTEM FAULT CODE LISTING Fault Associated Hardware Reason Effect (only with active code) F386 Engine sensor voltage High voltage at engine Default value used. high. position sensor 5VDC at Engine will de-rate to no pin 10 of the engine boost fueling with loss of harness.
  • Page 269 CX210/CX240 ELECTRONIC FUEL SYSTEM FAULT CODE LISTING Fault Associated Hardware Reason Effect (only with active code) F441 Battery voltage low Voltage detected at ECM Engine will stop running power supply, pins 38, 39 or run rough. and 40 of the engine harness indicates voltage is below 6 VDC.
  • Page 270 Construction Equipment Service Training CX SERIES EXCAVATOR Section 9 -- Miscellaneous (2001)
  • Page 271 CASE CORPORATION     2001 Case Corporation 700 STATE STREET All Rights Reserved RACINE, WI 53404 U.S.A. CASE CANADA CORPORATION 3350 SOUTH SERVICE ROAD BURLINGTON, ON L7N 3M6 CANADA Printed in U.S.A.
  • Page 272 Construction Equipment Service Training CX SERIES EXCAVATOR Section 10 -- Schematics (2001)
  • Page 273 CASE CORPORATION     2001 Case Corporation 700 STATE STREET All Rights Reserved RACINE, WI 53404 U.S.A. CASE CANADA CORPORATION 3350 SOUTH SERVICE ROAD BURLINGTON, ON L7N 3M6 CANADA Printed in U.S.A.

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