Case cx290b crawler excavator service repair manual by 163757

CRAWLER EXCAVATOR CX290B SERVICE MANUAL TABLE OF CONTENTS DIVISION/SECTION

SECTION N°

REFERENCE N°

GENERAL INFORMATION Safety, general information and standard torque data .....................................1001 General specifications and special torque setting............................................1002

7-27691EN SC290B1002-0EN

ENGINE Engine specifications ............................................................................................. * Disassembly and assembly of the engine.............................................................. *

FUEL SYSTEM Fuel tank ..........................................................................................................3001 Fuel engine system................................................................................................ *

ELECTRICAL SYSTEM Electrical system, electrical and electronic troubleshooting.............................4001 Electrical equipment and electrical circuit diagrams ........................................4020

SC210B4001-1EN SC210B4020-0EN

UNDERCARRIAGE Removal and installation of tracks ...................................................................5001 Sprocket ...........................................................................................................5004

SM160B5001-0EN SM160B5004-0EN

DRIVE TRAIN Drive motor and final drive transmission removal and installation ...................6001 Travel reduction gear assembly and disassembly............................................6005

SM160B6001-0EN SM290B6005-0EN

UNDERCARRIAGE HYDRAULICS

UPPERSTRUCTURE HYDRAULICS Depressurising and decontaminating the hydraulic system, use of the vacuum pump and bleeding the components ..............................................8000 Specifications, troubleshooting, checks and hydraulic pressure settings.........8001 Hydraulic reservoir removal and installation ....................................................8002 Main and pilot pumps, removal and installation ...............................................8003 Main hydraulic control valve, removal and installation .....................................8004 Pilot blocs, removal and installation .................................................................8007 Main hydraulic pump, disassembly and assembly ...........................................8010 Hand control levers, disassembly and assembly .............................................8013 Foot control levers, disassembly and assembly ...............................................8014 Caution valve, disassembly and assembly.......................................................8016 Hydraulic functions...........................................................................................8020 Travel hydraulic motor, disassembly and assembly..........................................8021 Hydraulic Component Functions......................................................................8030

SM160B3001-0EN

SM160B8000-0EN SC290B8001-0EN SM160B8002-0EN SM210B8003-0EN SM210B8004-0EN SM160B8007-0EN SM210B8010-0EN SM160B8013-0EN SM160B8014-0EN SM160B8016-0EN SC290B8020-0EN SM290B8021-0EN SC290B8030-0EN

DIVISION/SECTION 9

SECTION N°

REFERENCE N°

UPPERSTRUCTURE Quick coupler..................................................................................................... 9000 Boom, dipper and bucket ................................................................................... 9003 Seat, removal and installation............................................................................ 9004 Cab and cab equipment..................................................................................... 9005 Air conditioner functions and troubleshooting .................................................... 9006 Large size hydraulic schematics ......................................................................Pocket Large size electrical schematics ......................................................................Pocket

SM160B9000-0EN SM160B9003-0EN SM160B9004-0EN SM160B9005-0EN SC210B9006-0EN 87600999A 87601005A

* Consult the Engine Service Manual NOTE: CNH Company reserves the right to make changes in the specifica tion and design of the machine without prior notice and without incurring any obligation to modify units previously sold. The description of the models shown in this manual has been made in accordance with the technical specifications known as of the date of design of this document.

Lep SM290BTOC-0EN

Issued 05-07

1001 SAFETY, GENERAL INFORMATION AND TORQUE SPECIFICATIONS

CNH

Lep 7-27691EN

1001

Section

1001-2

TABLE OF CONTENTS GENERAL INFORMATION .......................................................................................................................................3 SAFETY..................................................................................................................................................................... 4 STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS............................................................................... 6

WARNING : This symbol is used in this manual to indicate important safety messages. Whenever you see this symbol, carefully read the message that follows, as there is a risk of serious injury.

Lep 7-27691EN

Issued 02-06

1001-3

GENERAL INFORMATION Cleanning

Gears

Clean all metal par ts except bear ings, in a suitab le cleaning so lvent or b y ste am clea ning. Do not use caustic sod a f or st eam clean ing. After clea ning, dry and put o il on al l pa rts. Clea n o il p assages with compressed air. Clean bearings in a suitable cleaning solvent, dry th e be arings completely an d pu t oil on the bearings.

Check all gears for wear and damage. Replace gears that have wear or damage.

Inspection Check a ll parts whe n th e pa rts ar e disassemb led. Replace a ll pa rts t hat h ave wear o r d amage. Small scoring or g rooves can be r emoved wit h a ho ne o r crocus clot h. Com plete a visual in spection for indications of w ear, p itting an d the r eplacement o f parts necessary to prevent early failures.

Bearings Check b earings f or easy actio n. If be arings ha ve a loose f it or ro ugh act ion r eplace t he bea ring. W ash bearings wit h a suitable cle aning solvent a nd p ermit to air dr y. DO NO T DR Y BEARIN GS WITH COMPRESSED AIR.

Needle bearings Before y ou pr ess nee dle bearings in a bore always remove any metal protrusions in the bore or edge of the bore. Before you press bearings into position put petroleum jelly on the inside and outside diameter of the bearings.

Lep 7-27691EN

Oil seals, O-rings and gaskets Always install new oil seals, O-rings and gaskets. Put petroleum jelly on seals and O-rings.

Shafts Check all shaf ts t hat ha ve w ear or dam age. Ch eck the bearing a nd oil seal surfaces of t he sha fts f or damage.

Service parts Always install gen uine Case ser vice par ts. When ordering refer to the Parts Catalog for the correct part number of t he g enuine Case r eplacement ite ms. Failures due to the use of other than ge nuine Ca se replacement parts are not covered by warranty.

Lubrication Only use t he o ils and lubr icants spe cified in t he Operatorâ&#x20AC;&#x2122;s or Service Ma nuals. Failures du e to th e use o f no n-specified o ils an d lub ricants are not covered by warranty.

Issued 02-06

1001-4

SAFETY

This symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED. The message that follows the symbol contains important information about safety. Carefully read the message. Make sure you fully understand the causes of possible injury or death.

To prevent injur y always follow the Warning, Caution and Danger notes in t his section and throughout the manual. Put th e warning t ag sh own be low on th e key for t he keyswitch w hen ser vicing or repairing the machine . One warning t ag is supplied with ea ch m achine. Additional ta gs Part Numb er 331-4614 are available from your service parts supplier

WARNING: Before starting engine, study Operator’s Manual safety messages. Read all safety signs on machine. Clear the area of other persons. Learn and practice safe use of controls before operating. It is your responsibility to understand and f o l l o w m a n u f a c tu r e r s i n s tr u c t i o n s o n machine operation, service and to observe pertinent laws and regulations. Operator’s and Service Manuals may be obtained from your Case dealer.

WARNING: If you wear clothing that is too loose or do not use the correct safety equipment for your job, you can be injured. Always wear clothing that will not catch on objects. Extra safety equipment that can be required includes hard hat, safety shoes, ear protection, eye or face protection, heavy gloves and reflector clothing.

WARNING: When working in the area of the fan belt with the engine running, avoid loose clothing if possible, and use extreme caution.

WARNING: When doing checks and tests on the equipment hydraulics, follow the procedures as they are written. DO NOT change the procedure.

WARNING: When putting the hydraulic cylinders on this machine through the necessary cycles to check operation or to remove air from a circuit, make sure all people are out of the way.

WARNING: Read the operator’s manual to familiarize yourself with the correct control functions.

WARNING: Operate the machine and equipment controls from the seat position only. Any other method could result in serious injury.

WARNING: This is a one man machine, no riders allowed.

Lep 7-27691EN

Issued 02-06

1001-5

WARNING: When servicing or repairing the machine, keep the shop floor and operatorâ&#x20AC;&#x2122;s compartment and steps free of oil, water, grease, tools, etc. Use an oil absorbing material and/or shop cloths as required. Use safe practices at all times.

WARNING: Some components of this machine are very heavy. Use suitable lifting equipment or additional help as instructed in this Service Manual.

WARNING: Engine exhaust fumes can cause death. If it is necessary to start the engine in a closed place, remove the exhaust fumes from the area with an exhaust pipe extension. Open the doors and get outside air into the area.

WARNING: When the battery electrolyte is frozen, the battery can explode if (1), you try to charge the battery, or (2), you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured.

WARNING: Use insulated gloves or mittens when working with hot parts.

WARNING: Lower all attachments to the ground or use stands to safely support the attachments before you do any maintenance or service. WARNING: Pin sized and smaller streams of hydraulic oil under pressure can penetrate the skin and result in serious infection. If hydraulic oil under pressure does penetrate the skin, seek medical treatment immediately. Maintain all hoses and tubes in good condition. Make sure all connections are tight. Make a replacement of any tube or hose that is damaged or thought to be damaged. DO NOT use your hand to check for leaks, use a piece of cardboard or wood.

WARNING: When removing hardened pins such as a pivot pin, or a hardened shaft, use a soft head (brass or bronze) hammer or use a driver made from brass or bronze and a steel head hammer.

WARNING: When using a hammer to remove and install pivot pins or separate parts using compressed air or using a grinder, wear eye protection that completely encloses the eyes (approved goggles or other approved eye protectors).

WARNING: Use suitable floor (service) jacks or chain hoist to raise wheels or tracks off the floor. Always block machine in place with suitable safety stands.

Lep 7-27691EN

Issued 02-06

1001-6

STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS Tightening of cap screws, nuts Tighten alternately so that tightening torque can be applied evenly. The numbers in the figure below indicate the order of tightening.

JS00481A

Cap screws which have had Loctite used (white residue remains after removal) should be cleaned with loght oil or suitable cle aning solvent and dr ied. Apply 2- 3 d rops of Lo ctite t o t he th read p ortion o f th e cap screw an d t hen tighten.

Torque table Tighten cap screws and nuts according to the table below if there are no other special instructions.

Cap Screw Name Size (Size) Spanner Cap Screw Tightening torque

Socket Head Cap Screw

Lep 7-27691EN

Spanner Tightening torque

M6 [mm]

M10

M12

M14

M16

M18

M20

[in.]

0.39

0.51

0.67

0.75

0.87

0.95

1.06

1.18

[Nm]

6.9

19.6

39.2

58.8

98.1

156.9

196.1

294.2

[lb-ft]

5.1

14.5

28.9

43.4

72.3

115.7

144.6

217

[mm]

[in.]

0.20

0.24

0.32

0.39

0.47

0.55

0.67

[Nm]

8.8

21.6

42.1

78.5

117.7

176.5

245.2

343.2

[lb-ft]

6.5

15.9

31.1

57.9

86.9

130.2

181

253.2

Issued 02-06

Section 1002

1002

SPECIFICATIONS AND SPECIAL TORQUE SETTINGS

CNH

Lep SC290B1002-0EN

1002-2

TABLE OF CONTENTS

WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see this symbol, carefully read the message which follows. Your safety depends on it.

TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE..................................................................................................... 3 Machine ....................................................................................................................................................................... 3 Engine .......................................................................................................................................................................... 3 Serial numbers of the components .............................................................................................................................. 3 FLUIDS AND LUBRICANTS ............................................................................................................................................ 4 Hydraulic fluid .............................................................................................................................................................. 4 Transmission component oil ........................................................................................................................................ 4 Grease ......................................................................................................................................................................... 4 Engine Oil .................................................................................................................................................................... 5 Engine fuel, maintenance of fuel filters and fuel storage ............................................................................................. 6 Anti-freeze/Anti-corrosion............................................................................................................................................. 8 Environment ................................................................................................................................................................. 8 Plastic and resin parts.................................................................................................................................................. 8 SPECIFICATIONS ........................................................................................................................................................... 9 Main data ..................................................................................................................................................................... 9 Performance ................................................................................................................................................................ 9 Complete machine dimensions .................................................................................................................................... 9 Main body dimensions ................................................................................................................................................. 9 Engine ........................................................................................................................................................................ 10 Cooling system .......................................................................................................................................................... 10 Capacity of coolant and lubricants ............................................................................................................................. 10 Hydraulic oil filter........................................................................................................................................................ 10 Fuel filter .................................................................................................................................................................... 10 Operating devices ...................................................................................................................................................... 11 Hydraulic system........................................................................................................................................................ 12 Swing unit .................................................................................................................................................................. 14 Travel lower body....................................................................................................................................................... 14 Work Unit ................................................................................................................................................................... 15 Digging force (ISO 6015) ........................................................................................................................................... 15 COMPONENT WEIGHT................................................................................................................................................. 16 Major component weight ............................................................................................................................................ 16 Other component weight ............................................................................................................................................ 17 SPECIAL TORQUE SETTINGS..................................................................................................................................... 18 MACHINE OVERALL DIMENSIONS ............................................................................................................................. 22

Lep SC290B1002-0EN

Issued 02-07

1002-3

TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE For all part orders, request for information or assistance, always specify the type and the serial number of the machine to your Case dealer. Fill in the following lines with the required information: Type, serial number, year of manufacture of the machine and the serial numbers of the hydraulic and mechanical components.

Machine 1 2

CT04A171A

(1) Type ....................................................................................................................................................................... (2) Serial number ........................................................................................................................................................ (3) Year of manufacture...............................................................................................................................................

Engine Make and type............................................................................................................................................................. Serial number..............................................................................................................................................................

Serial numbers of the components Hydraulic pump ........................................................................................................................................................... Swing reduction gear .................................................................................................................................................. Travel reduction gears ................................................................................................................................................. Control valve ...............................................................................................................................................................

SC290B1002-0EN

Issued 02-07

1002-4

FLUIDS AND LUBRICANTS Lubricants must have the correct properties for each application.

WARNING: The conditions of use for individual fluids and lubricants must be respected.

Hydraulic fluid CASE/AKCELA hydraulic fluid is specially designed for high pressure applications and for the CASE hydraulic system. The type of fluid to be used depends on the ambient temperature. Temperate climates: -20°C to +40°C (-4° to 104° F) CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID (MS 1230. ISO VG 46. DIN 51524 PART 2 HV) Hot climates: 0°C to +50°C (32° to 122° F) CASE/AKCELA: AW HYDRAULIC FLUID 68 HV (MS 1216. ISO VG 68. DIN 51524 PART 3 CATEGORY HVLP) Cold climates: -25°C to +20°C (-13° to 68° F) CASE/AKCELA: AW HYDRAULIC FLUID 32 (MS 1216. ISO VG 32. DIN 51524 PART 2) Biodegradable fluid: -30°C to +40°C (-22° to 104° F) This yellow-colored fluid is miscible with standard fluid. If used to change standard fluid, it is advised to drain the circuit completely before refilling with this fluid. CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID BIO (MS 1230. ISO VG 46. DIN 51524 PART 2 HV)

Transmission component oil Extreme pressure oil used for enclosed transmission components. CASE/AKCELA: GEAR 135H EP (SAE 80W-90. API GL 5. MIL-L-2105 D. MS 1316. ZF TE-ML 05A)

Grease CASE/AKCELA: MOLY GREASE 251H EP-M (251H EP-M. NLGI 2) "Extreme Pressure" multipurpose grease with lithium soap and molybdenum disulphide. CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (251H EP. NLGI 2) "Extreme Pressure" multipurpose grease with lithium soap and calcium. CASE/AKCELA: PREMIUM GREASE EP2 (NLGI 2) "Extreme Pressure" multipurpose grease with lithium soap.

Hydraulic breakers CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (NLGI 2).

Lep SC290B1002-0EN

Issued 02-07

1002-5

Engine Oil THE CASE/AKCELA No. 1 engine oil is re commended for y our e ngine. Th is o il en sures p roper lubr ication of your engine for all operating conditions. If the CASE/AKCELA Multigrade "No. 1 EN GINE OIL" cannot be obtained, use the oil corresponding to one of the following categories: ACEA E7. API CI-4.

CP02N001

Oil viscosity / Oil range

1 2 3 3

CT02M001

1) With mineral base (2) With semi-synthetic base (3) With synthetic base

Lep SC290B1002-0EN

Issued 02-07

1002-6

Engine fuel, maintenance of fuel filters and fuel storage In order to meet the emission control regulation of 3rd-stage, the engine components have been made precisely and they are to be used under high-pressure conditions. Therefore, the specified fuel must be used for the engine. As a matter of course, not only the guarantee will not be given for the use of a fuel other than the specified but also it may invite a serious breakdown. In addition, since suitable specifications for the fuel filter elements have been established for this engine, use of the genuine filter is essential. The following describes the specifications and the requirements of the fuel to be applied, and maintenance of the fuel and the fuel elements.

Fuel to be applied Selection of fuel Following conditions must be met for the diesel engines, that is the one; 1 In which no dust even fine one is mixed, 2 With proper viscosity, 3 With high cetane rating, 4 With good flow properties in lower temperature, 5 With not much sulfur content, and 6 With less content of carbon residue Applicable standards for diesel fuel Applicable Standard

Recommendation

JIS (Japanese Industrial Standard)

NO.2

DIN (Deutsche Industrie Normen)

DIN 51601

SAE (Society of Automotive Engineers) Based on SAE-J-313C

NO. 2-D

BS (British Standard) Based on BS/2869-197

Class A-1

EN590 If a standard applied to the fuel for the diesel engine is stipulated in your country, check the standard for details. Requirements for diesel fuel Although conditions required for the diesel fuel are illustrated above, there are other requirements exerting a big influence on its service durability and service life. Be sure to observe the following requirements for selecting fuel. Sulfur content............................................................................... 2500 ppm or less HFRR*.......................................................................................... 460 mm or less Water content............................................................................... 0.05 wt% or less * HFRR (High-Frequency Reciprocating Rig.): An index showing lubricating properties of the fuel. Sulfur content reacts to moisture to change into sulfuric acid after combustion. Use of a fuel containing much sulfur content allows it to accelerate internal corrosion and wear. In addition, much sulfur content quickens deterioration of engine oil allowing its cleaning dispersive property to be worse which results in acceleration of wear of sliding portions. HFRR is an index that indicates lubricating property of a fuel. Large value of the index means poor lubrication so that seizure of the machine components may result if such a fuel is used. Since a fuel with high HFRR value also has lower viscosity, it can easily be leaked out. Lep SC290B1002-0EN

Issued 02-07

1002-7 If the fuel is mixed with the engine oil, the oil is diluted to deteriorate its lubricating property resulting in acceleration of wear. Water content allows inside of the fuel tank to rust which in turn blocking the fuel line and the fuel filter. IMPORTANT : In cold weather, fill the fuel tank at the end of the day's work, in order to prevent the formation of condensation. This may also cause wear and seizure of the machine components. If atmospheric temperature goes below the freezing point, moisture content in the fuel forms fine particle of ice allowing the fuel line to be clogged. IMPORTANT : Obtain table of analysis for the fuel you are using from the fuel supplier to confirm that it meets the criteria described above. IMPORTANT : If a fuel which does not meet the specifications and the requirements for the diesel engine, function and performance of the engine will not be delivered. In addition, never use such a fuel because a breakdown of the engine or an accident may be invited. Guarantee will not be given to a breakdown caused by the use of a improper fuel. Some fuels are used with engine oil or additives mixed together with diesel engine fuel. In this case, do not use these fuels because damage to the engine may result as the fuel has been contaminated. It is natural that the emission control regulation of 3rd-stage will not be cleared in case where a fuel that does not meet the specifications and the requirements is used. Use the specified fuel for compliance of the exhaust gas control. IMPORTANT : It you use diesel fuel which contains much sulfur content more than 2500 ppm, be sure to follow the items below for the engine oil selection and maintenance of engine parts. Guarantee will not be given to breakdowns caused by not to follow these items. 1 Selection of engine oil Use API grade CF-4 or JASO grade DH-1. 2 Exchange the engine oil a nd engine oil f ilter element by the periodical interval reported on t he Operator’s Manual. 3 Inspect and exchange the EGR (*)parts and fuel injector parts of engine every 3000 hour of use. * EGR: Exhaust Gas Recircultion

Maintenance of fuel filters Be sure to use the genuine fuel filters. The fuel injection system is precisely constructed and the genuine filter employs finer mesh than conventional filters to improve protection of machine equipment. If a filter with coarse mesh is used, foreign object passing through the filter enters into the engine so that machine equipment can wear out in a short period of time. IMPORTANT : If a fuel filter other than the genuine filter is used, guaranty will not be applied to a fault caused by the use of a wrong filter. Two kinds of fuel filter, the pre-filter and the main filter, are mounted on the machine. Be sure to use the genuine fuel filters and replace them at the periodic intervals reported on the operator’s Manual. IMPORTANT : Since the pre-filter also has a function of water separation, discharge water and sediment when the float reaches lower part of the filter elements. CHECK EVERY DAY before to start the engine. Time to replace filters may be advanced according to properties of the fuel being supplied. • Therefore, take measures to prevent dust or water from being entered in the fuel tank when supplying fuel. • When supplying fuel directly from a fuel drum can, leave the drum as it stands for a long period of time to supply clean fuel standing above a precipitate. • If it is hard to leave the drum for a long period of time, install a fuel strainer and a water separator before the fuel tank of the machine to supply clean fuel. Water drain cock is provided on the bottom side of the fuel tank. • Drain water before starting the engine every morning. • In addition, remove the cover under the tank once a year to clean up inside of the tank.

Lep SC290B1002-0EN

Issued 02-07

1002-8

Fuel storage Long sto rage ca n le ad to t he accum ulation of im purities and cond ensation in t he f uel. Engine trouble can often be traced to the presence of water in the fuel. The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off water and impurities regularly.

Anti-freeze/Anti-corrosion Use anti-freeze in all seasons to protect the cooling system from corrosion and all risk of freezing. CASE/AKCELA: PREMIUM ANTI-FREEZE (MS 1710) For areas where the temperature goes down to -38Â°C (-36.4Â°F), mix 50/50 with water. IMPORTANT : Do not mix products of a different origin or brand. The same product must be used when topping up the system.

Environment Before carrying out a ny maintenance o peration on t his ma chine an d b efore disposing o f used f luids o r lubricants, always think of the environment. Never throw oil or fluid on the ground and never place it in leaking receptacles. Contact your local ecological recycling ce ntre or your CASE Dealer to obtain information on the correct method of disposing of these lubricants.

Plastic and resin parts When cleaning plastic parts, the console, the instrument panel, the indicators etc... avoid using petrol, kerosene, paint solvents etc... Use only water, soap and a soft cloth. The use of petrol, kerosene, paint solvents etc... causes discoloration, cracks or deformation of these parts.

Lep SC290B1002-0EN

Issued 02-07

1002-9

SPECIFICATIONS Main data Model name ......................................................................................................................... CX290B Hydraulic Excavator Operating weight ...............................................................................................................................29800 kg (65698 lbs) Engine output ....................................................................................................................................... 154 kW / 1800 rpm

Performance

Swing speed..................................................................................................................................................... 10.2 Tr/min. Travel speed ................................................................................................................... Low Speed 3.2 km/h (1.99 mph) ........................................................................................................................................High Speed 5.6 km/h (3.48 mph) Maximum drawbar pull ..................................................................................................................... 234.6kN (52740.2 lbf) Grade ability ........................................................................................................................................................70% (35Â°) Ground pressure ............................................................................................... 56 kPa (600 mm (23.62 in) grouser shoe) .......................................................................................................................... 49 kPa (700 mm (27.56 in) grouser shoe) .......................................................................................................................... 43 kPa (800 mm (31.50 in) grouser shoe)

Complete machine dimensions

Lenght (without attachment) Lenght (with attachment) Height (with attachment)

3180 mm (125.20 in) 5590 mm (220.08 in) 10450 mm (411.4 in) 3260 mm (128.35 in)

Arm (dipper) 2650 mm (104.33 in) 5590 mm (220.08 in) 10480 mm (412.6 in) 3340 mm (131.5 in)

3600 mm (141.73 in) 5590 mm (220.08 in) 10470 mm (412.2 in) 3460 mm (136.22 in)

Main body dimensions

Main body width .............................................................................................................. See machine overall dimensions Upper side swing body width ............................................................................................................ 2870 mm (112.99 in) Cab width ............................................................................................................................................ 1000 mm (39.37 in) Main body height............................................................................................................................... 3110 mm (122.44 in) Engine displacement......................................................................................................................... 3160 mm (124.41 in) Swing body tail distance.................................................................................................................... 3150 mm (124.01 in) Swing body rear section bottom height ............................................................................................... 1190 mm (46.85 in) Distance between tumblers............................................................................................................... 3980 mm (156.69 in) Overall track length ........................................................................................................................... 4850 mm (190.94 in) Width of track shoe ................................................. 600 mm (23.62 in) (Optional: 700 mm (27.56 in), 800 mm (31.50 in) Minimum ground clearance.........................................................................470 mm (18.50 in) (To bottom of lower frame)

SC290B1002-0EN

Issued 02-07

1002-10

Engine

Name.......................................................................................................................................................... ISUZU, 6HK1X Type: ....................................................... 4-cycle, water-cooled, overhead camshaft, vertical in-line, direct injection type ............................................................................................................................... (electronic control), with turbocharger. No. of cylinders - bore x stroke.............................................................................6 - Ø115 mm x 125 mm (4.53 x 4.92 in) Displacement............................................................................................................................................ 7.79 L (2.06 gal) Compression ratio ....................................................................................................................................................... 17.5 Rated output.......................................................................................................................................154 kW / 1800 min-1 Maximum torque.......................................................................................................... 850 N.m (626.93 lb-ft) / 1500 min-1 Engine dimensions (LxWxH) .................................................................... 1357x995.4x1141 mm (53.42 x39.19x44.92 in) Oil pan ..................................................................................................................................All direction 35 rad, inclinable Oil pan capacity................................................ Maximum: 38 L (10.04 gal) Minimum: 28 L (7.40 gal) (excluding oil filter) Direction of rotation ...................................................................................................................... Right (as seen from fan) Starter, reduction type ...................................................................................................................................... .24 V, 5 kW Alternator, AC type ............................................................................................................................................. 24 V, 50 A Battery ................................................................................................................................................ 2 x 12V,128 Ah/5 Hr

Cooling system

Fan type.......................................... Ø 850 mm (33.46 in), suction type - 6 blades, plastic with belt mouth-type fan guide Pulley ratio................................................................................................................................................. 0.80 (reduction) Radiator Fin type .................................................................................................................................................................. wavy Fin pitch ............................................................................................................................................. 2.0 mm (0.078 in) Oil cooler Fin type .................................................................................................................................................................. wavy Fin pitch ........................................................................................................................................... 1.75 mm (0.069 in) Inter-cooler Fin type ...............................................................................................................................................triangular straight Fin pitch ............................................................................................................................................. 2.0 mm (0.078 in) Fuel cooler Fin type .................................................................................................................................................................. wavy Fin pitch ............................................................................................................................................. 2.0 mm (0.078 in) Coolant capacity................................................................................................................. 14.5 L (3.83 gal) (engine only)

Capacity of coolant and lubricants

Coolant ........................................................................................................................................................ 29 L (7.66 gal) Fuel ....................................................................................................................................................... 450 L (118.88 gal) Lubricant for engine................................................................................................................................... 38 L (10.04 gal) Lubricant for travel reduction gear (per side).............................................................................................. 9.1 L (2.40 gal) Lubricant for swing reduction gear (per side) ................................................................................................ 6 L (1.58 gal) Hydraulic oil ............................................................................................................................................. 300 L (79.25 gal) Capacity of hydraulic oil tank................................................................................................................... 147 L (38.43 gal)

Hydraulic oil filter

Suction filter (inside tank) ....................................................................................................................................150 mesh Return filter (inside tank) ............................................................................................................................................ 6 µm Pilot line filter (inside housing).................................................................................................................................... 8 µm

Fuel filter

Main filter.................................................................................................................................................................... 4 µm Pre-filter...................................................................................................................................................................... 8 µm

SC290B1002-0EN

Issued 02-07

1002-11

Operating devices

Operator's seat Location: left side Structure: Adjustable forward and back and up and down, reclining mechanism, with seat suspension. Cab Sealed steel type, all reinforced glass. Levers and pedals For travel use: Lever and pedal type (hydraulic pilot type) (x2) For operating machine use: Lever type (hydraulic pilot type) (x2) Instruments and switches Work mode select switch: 3 modes (SP / super power, H / heavy duty, A / automatic) Travel mode select switch: Low-speed / high-speed switch type One-touch idle: Knob switch type Engine emergency stop: Switch type Monitor device Machine status display (full-dot liquid crystal) Work mode selection status: SP / H / A Instruments (full-dot liquid crystal, except for hour meter) Fuel gauge: bar graph indicator Engine coolant temperature gauge: bar graph indicator Hydraulic oil temperature gauge: bar graph indicator Hour meter: digital type Machine Status and Warning Alarms (full-dot liquid crystal and warning tone) *Items have a warning alarm Over heat* Battery charge* Faulty electrical system* Refill fuel*

Engine oil pressure*

Refill coolant*

Engine preheat

Auto warm-up

Air cleaner clogged

Anti-theft device triggered

Faulty engine system

Engine emergency stop

Lighting Working light

Interior light

Tank:

24V, 70W (x1)

Boom:

24V, 70W (x1)

Cab:

24V, 70W (x2) 24V, 10W (x1)

Horn: electric horn (x2) Other Wiper with intermittent function, Window washer, Air conditioner, Rear view mirrors (left and right), DC converter, Clock

SC290B1002-0EN

Issued 02-07

1002-12

Hydraulic system Hydraulic pump drive system, directly coupled to the engine (no transmission) Main pump Manufacturer............................................................................................................................................... Kawasaki Pump type .............................................................................................. double variable displacement piston pump Displacement volume ................................................................................................ 136.7 cm3 (8.34 cu in) x 2 /rev Rated operating pressure .......................................................................................................... 34.3 MPa (4975 psi) Maximum operating pressure .................................................................................................... 37.3 MPa (5410 psi) Input revolution speed.............................................................................................................................. 1800 min-1 Maximum discharge flow .............................. 246 L/min (64.99 gpm) x 2 / 243 L/min (64.19 gpm) x 2 at 1800 min-1 Pilot pump Pump type ............................................................................................................................................... Gear pump Displacement volume ............................................................................................................ 15 cm3 (0.91 cu in)/rev Operating pressure ...................................................................................................................... 3.92 MPa (568 psi) Maximum flow ................................................................................................... 27 L/min (7.13 gpm) (at 1800 min-1) Input horsepower ............................................................................................................................................ 2.8 kW Control method Hydraulic simultaneous constant output control. Maximum flow adjustment control through external commands (negative control). Setting horsepower adjustment control through external command current. Control Valve Model; 4-spool section: integrated (1) or 5-spool section: integrated (1) Operation method: hydraulic pilot method: travel, swing and operating machine Maximum flow .......................................................................................................................... 243 L / min (64.19 gpm) Main relief set pressure........................................... standard; 34.3 MPa (4975 psi), power boost 37.3 MPa (5410 psi) Overload set pressure..................................................................when boom down; 29.4 ± 0.5 MPa (4264 ± 72.5 psi) .............................................................................................................................................other: 39.2 MPa (5685 psi) Foot relief set pressure ............................................................................................................... 2.55 MPa (369.85 psi) Functions Straight travel circuit Boom up / arm 2 pumps internal flow Boom and arm load holding circuit Boom-down regenerative circuit Bucket-close regenerative circuit Arm-in forced regenerative circuit Swing priority variable orifice (for arm operation) 2 pumps flow Variable foot relief Hydraulic Cylinders Boom cylinder (x2) Cylinder bore .............................................................................................................................Ø140 mm (Ø5.51 in) Rod diametre ...............................................................................................................................Ø95 mm (Ø3.74 in) Maximum retracted lenghth ........................................................................................................ 1918 mm (75.51 in) Stroke ......................................................................................................................................... 1369 mm (53.90 in) Arm (dipper) cylinder Cylinder bore .............................................................................................................................Ø150 mm (Ø5.90 in) Rod diametre .............................................................................................................................Ø105 mm (Ø4.13 in) Maximum retracted lenghth ........................................................................................................ 2205 mm (86.81 in) Stroke ......................................................................................................................................... 1569 mm (61.77 in) Bucket cylinder Cylinder bore .............................................................................................................................Ø135 mm (Ø5.31 in) Rod diametre ...............................................................................................................................Ø90 mm (Ø3.54 in) Maximum retracted lenghth ........................................................................................................ 1692 mm (66.61 in) Stroke ......................................................................................................................................... 1078 mm (42.44 in)

SC290B1002-0EN

Issued 02-07

1002-13 Rotating Joint Operating pressure High pressure passage (ABCD) ............................................................................................... 34.3 MPa (4975 psi) Drain port (E)................................................................................................................................. 1.0 MPa (145 psi) Pilot port (F)................................................................................................................................... 3.9 MPa (566 psi) Flow High pressure passage (ABCD) ............................................................................................ 360 L/min (95.10 gpm) Drain port (E)........................................................................................................................... 40 L/min (10.57 gpm) Pilot port (F)............................................................................................................................... 31 L/min (8.19 gpm) Torque, when pressurizing 2 ports.....................................................................................................196 Nm (145 lb-ft) Port A; forward right ...................................................................................................................................................G1 Port B; forward left .....................................................................................................................................................G1 Port C; backward right ...............................................................................................................................................G1 Port D; backward left..................................................................................................................................................G1 Port E; drain port ....................................................................................................................................................G1/2 Port F; pilot port ..................................................................................................................................................... G1/4 Solenoid Valve Maximum flow .......................................................................... P -> B: 25 L/min (6.60 gpm) Other: 5 L/min (1.32 gpm) Rated pressure ............................................................................................................................. 4.5 MPa (652.67 psi) Port size P, T, B port ..........................................................................................................................................................G3/8 C1, C2, C3, C4, C5 port .....................................................................................................................................G1/4 Solenoid specifications Operating voltage ................................................................................................................................ DC 20 to 32 V Power consumption .................................................................................................................................. 17 W max. Hand control valve Manufacturer................................................................................................................................................... Kawasaki Operating pressure .......................................................................................................................... 3.92 MPa (569 psi) Secondary pressure, primary short type .......................................................... 0.64 to 2.45 MPa (92.82 to 355.34 psi) Operating angle Ports 1, 3 .............................................................................................................................................................. 19Â° Ports 2, 4 .............................................................................................................................................................. 25Â° Port 1, 3

3.0 2.0

1.0

0 0

Port 2, 4

4.0 Secondary pressure (MPa)

Secondary pressure (MPa)

4.0

2 4 6 Push rod stroke (mm)

5 10 15 Operating angle (deg.)

3.0 2.0

1.0 0

4 6 Push rod stroke (mm)

10 15 20 Operating angle (deg.)

9.4 25

RST-03-01-001B

SC290B1002-0EN

Issued 02-07

1002-14 Foot control valve Manufacturer ................................................................................................................................................... Kawasaki Operating pressure .......................................................................................................................... 3.92 MPa (569 psi) Secondary pressure, primary short type........................................................... 0.64 to 2.45 MPa (92.82 to 355.34 psi) Operating angle...................................................................................................................................................... 12.4Â°

Secondary pressure (MPa)

3.9 3.0 2.0

1.0 0

2 4 5.5 Push rod stroke (mm) 0

5 10 12.4 Operating angle (deg.) RST-03-01-001D

Swing unit

Swing circle ...........................................................................................................Swing bearing type (with internal gear) Swing parking brake ................................................................................ Mechanical lock (operational lever linkage type) Swing hydraulic motor .....................................................................................................Fixed displacement piston motor Displacement ...................................................................................................................... 164.7 cm3 (10.05 cu in)/rev Operating pressure ........................................................................................................................ 29.4 MPa (4264 psi) Operating flow ............................................................................................................................. 217 L/min(57.32 gpm) Mechanical brake torque.....................................................................................................1013 Nm (747.15 lb-ft) min. Brake off pressure................................................................................................................ 3.1 MPa (449.62 psi) max. Relief valve set pressure........................................................................................................... 29.3 MPa (4249.61 psi) Reduction gear .......................................................................................................Planetary gear 2-stage reduction gear Reduction ratio .................................................................................................................................................... 27.143

Travel lower body

Travel hydraulic motor (x2) ......... Variable displacement piston motor, automatic 2-speed switch-over with parking brake Displacement .................................................................................................... 244.3/141.1 cm3 (14.91/8.61 cu in)/rev Operating pressure ........................................................................................................................ 34.3 MPa (4975 psi) Operating flow ............................................................................................................................ 243 L/min (64.19 gpm) Brake torque............................................................................. 36 KNm (26552.2 Ib-ft) min. (including reduction gear) Relief valve set pressure .................................................................................. 36.2 to 39.7 MPa (5250.37 to 5758 psi) automatic 2-speed switch-over pressure..................................................................................... 26.5 MPa (3843.5 psi) Reduction gear .......................................................................................................Planetary gear 2-stage reduction gear Reduction ratio .................................................................................................................................................... 39.875 Travel brake .................................................................................................................................................. Hydraulic lock Parking brake ................................................................................................... Mechanical lock (travel lever linkage type) Track shoe Model ....................................................................................................................... Assembly type triple grouser shoe Number of shoes (per side)........................................................................................................................................ 50 Shoe width standard........................................................................................................................................ 600 mm (23.62 in) optional .......................................................................................................... 700 mm (27.56 in), 800 mm (31.50 in) Grouser height ...................................................................................................................................... 26 mm (1.02 in) Link pitch ............................................................................................................................................. 203 mm (7.99 in)

SC290B1002-0EN

Issued 02-07

1002-15 Roller Number of upper rollers (per side) ...............................................................................................................................2 Number of lower rollers (per side) ...............................................................................................................................9 Track belt tension adjuster ...............................................................................Grease cylinder type (with cushion spring) Mounting length of spring ................................................................................................................. 774 mm (30.47 in)

Work Unit

Model ................................................................................................................................................. Backhoe attachment Components / dimensions / working dimensions Standard boom

Arm (dipper) length

Standard arm

Short arm

Long arm

3180 mm 125.20 in

2650 mm 104.33 in

3600 mm 141.73 in

6150 mm 242.12 in

Boom length (Standard boom spec.)

1571.2 mm 61.86 in

Bucket radius Bucket wrist angle

176Â°

Maximum digging radius

10670 mm 420.08 in

10220 mm 402.36 in

11160 mm 439.67 in

Maximum digging radius at ground line

10500 mm 413.38 in

10040 mm 395.27 in

10990 mm 432.68 in

Maximum digging depth

7100 mm 279.53 in

6570 mm 258.66 in

7580 mm 298.42 in

Maximum vertical straight wall digging depth

6120 mm 240.94 in

5760 mm 226.77 in

6720 mm 264.57 in

Maximum digging height

10060 mm 396.06 in

9930 mm 390.94 in

10390 mm 409.05 in

Maximum dump height

7090 mm 279.13 in

6940 mm 273.23 in

7390 mm 290.94 in

Minimum swing radius at front

3920 mm 154.33 in

4000 mm 157.48 in

Height for minimum swing radius at front

8190 mm 322.44 in

8220 mm 323.62 in

8170 mm 321.65 in

Digging force (ISO 6015) Arm (dipper) 3.18 m (125.20 in)

2.65 m (104.33 in)

3.60 m (141.73 in)

Arm (dipper) digging force (standard)

121.6 kN (27336.8 lbf)

140.2 kN (35518.2 lbf)

109.8 kN (24684 lbf)

Arm (dipper) digging force (power up)

132.4 kN (29764.7 lbf)

153.0 KN (34395.8 lbf)

118.7 kN (26684.8 lbf)

Bucket digging force (standard)

174.6 kN (39251.6 lbf)

Bucket digging force (power up)

190.2 kN (42758.7 lbf)

SC290B1002-0EN

Issued 02-07

1002-16

COMPONENT WEIGHT Major component weight B A

E D

RST-11-001A

Weight information is approximate A) Operating weight ......................................................................................................................29800 kg (65698 lbs) B) Upper mechanism (including counterweight and turntable bearing) ...................................... 12600 kg (27778 lbs)) C) Counterweight .......................................................................................................................... 5410 kg (11927 lbs)) D) Lower mechanism (with standard grouser shoe) ................................................................... 11100 kg (24471 lbs)) E) Main Unit Weighty .................................................................................................................. 23700 kg (52249 lbs)) F) Attachments.............................................................................................................................. 5400 kg (11904 lbs)) G) Boom (including cylinders) ......................................................................................................... 3100 kg (6834 lbs)) H) Arm (dipper) (including cylinders and linkage) ........................................................................... 1360 kg (2998 lbs))

SC290B1002-0EN

Issued 02-07

1002-17

Other component weight Engine .....................................................................................................................................................696 kg (1534 lbs) Air cleaner .................................................................................................................................................. 13.6 kg (30 lbs) Hydraulic pump ......................................................................................................................................... 156 kg (344 lbs) Attachment control valve ........................................................................................................................... 220 kg (485 lbs) Swing motor and reduction gear assembly .............................................................................................464 kg (1023 lbs) Travel motor and reduction gear assembly .............................................................................................456 kg (1005 lbs) Rotary joint..................................................................................................................................................58 kg (128 lbs) Solenoid valve bank .................................................................................................................................. 6.7 kg (14.8 lbs) Cushion valve..........................................................................................................................................12.5 kg (26.6 lbs) Hand control valve ......................................................................................................................................1.9 kg (4.2 lbs) Foot control valve ...................................................................................................................................... 7.8 kg (17.2 lbs) Boom.....................................................................................................................................................2110 kg (4652 lbs) Standard arm (dipper).............................................................................................................................860 kg (1896 lbs) Short arm (dipper)...................................................................................................................................760 kg (1676 lbs) Long arm (dipper) ...................................................................................................................................990 kg (2183 lbs) Boom cylinder (one) .................................................................................................................................. 237 kg (522 lbs) Arm (dipper) cylinder................................................................................................................................. 335 kg (739 lbs) Bucket cylinder .......................................................................................................................................... 207 kg (456 lbs) Fuel tank ................................................................................................................................................... 169 kg (373 lbs) Hydraulic oil tank....................................................................................................................................... 152 kg (335 lbs) Turntable bearing ....................................................................................................................................543 kg (1197 lbs) Muffler ........................................................................................................................................................ 20 kg (44.1 lbs) Radiator total weight ................................................................................................................................. 170 kg (375 lbs) Oil cooler................................................................................................................................................ 26 kg (57.3 lbs) Radiator ..............................................................................................................................................19.4 kg (42.8 lbs) Air cooler.............................................................................................................................................18.7 kg (41.2 lbs) Fuel cooler ............................................................................................................................................ 1.2 kg (2.65 lbs) Idler wheel................................................................................................................................................. 165 kg (364 lbs) Upper roller ................................................................................................................................................... 44 kg (97 lbs) Lower roller ..............................................................................................................................................56 kg (123.5 lbs) Recoil spring assembly ............................................................................................................................. 263 kg (580 lbs) Recoil spring ................................................................................................................................... 119.4 kg (263.2 lbs) Grease cylinder assembly .................................................................................................................. 41.4 kg (91.3 lbs) Threaded rod ....................................................................................................................................50.3 kg (110.9 lbs) Yoke ....................................................................................................................................................39.8 kg (87.7 lbs) Track chains (per side) 600 mm (23.62 in).............................................................................................................................1860 kg (4101 lbs) 700 mm (27.56 in).............................................................................................................................2040 kg (4497 lbs) 800 mm (31.5 in)...............................................................................................................................2210 kg (4872 lbs)

SC290B1002-0EN

Issued 02-07

1002-18

SPECIAL TORQUE SETTINGS No.

Screw

Wrench (mm)

Travel motor and reduction gear assembly

M24

900-1051 Nm (664 - 775 lb-ft)

Drive sprocket

M20

521-608 Nm (385-448 lb-ft)

Idler wheel

M16

267-312 Nm (197-230 lb-ft)

Upper roller

M20

521-608 Nm (385-448 lb-ft)

Lower roller

M20

521-608 Nm (385-448 lb-ft)

Component

Torque setting

Track guard

M20

521-608 Nm (385-448 lb-ft)

Shoe bolt

M20

813-911 Nm (600-671 lb-ft)

Counterweight

M33

1548-1764 Nm (1142-1301 lb-ft)

Turntable bearing (lower frame)

M24

784-914 Nm (579-674 lb-ft)

10*

Turntable (swing frame)

M24

784-914 Nm (579-674 lb-ft)

11 *

Swing unit

M24

784-914 Nm (579-674 lb-ft)

12 *

Engine (engine mount)

M12

109-127 Nm (80-94 lb-ft)

13 *

Engine bracket

M10

64-74 Nm (47.20-54.58 lb-ft)

M16

Radiator

15 *

Hydraulic pump

16 *

Hydraulic reservoir

17 * 18 * 19 20*

M10 M20

147-177 Nm (109-130 lb-ft) 64-74 Nm (47.20-54.58 lb-ft) 367-496 Nm (271-365 lb-ft)

M16

232-276 Nm (172-203 lb-ft)

Fuel reservoir

M16

232-276 Nm (172-203 lb-ft)

Control valve

M16

267-312 Nm (197-230 lb-ft)

M12

109-127 Nm (80-94 lb-ft)

M16

267-312 Nm (197-230 lb-ft)

Hydraulic swivel

Cab

M16

245-294 Nm (181-216 lb-ft)

Battery

M10

16-20 Nm (11.8-14.75 lb-ft)

NOTE: Use Loctite 262 or an equivalent on retaining screws of those components marked with an asterisk (*).

Lep SC290B1002-0EN

Issued 02-07

1002-19

18 12, 13 8

14 22 19, 20

7 1, 2 9, 10

5 6

4 3

2 6

BI08003-001

Lep SC290B1002-0EN

Issued 02-07

1002-20

BI08003-002

Lep SC290B1002-0EN

Issued 02-07

1002-21

15 16

19 18

21 22

BI08003-003

Lep SC290B1002-0EN

Issued 02-07

1002-22

MACHINE OVERALL DIMENSIONS NOTE: Numbers are subject to change without notice due to design change or other reasons. The figures give values that include the shoe lug height (26 mm (1.02 in)) Standard arm (3.18 m (125.20 in))

10450

2870 1460

1410

3110

3150

470 600 2600 2390 (NLC)

3980 4850

1040 0

1190 0

3260

3080

7300

3200 2990 (NLC) BB03003-004

Short arm (2.65 m (104.33 in))

2870 1460

26 3980 4850

470

104

1190 0

3080

1410

600 2600 2390 (NLC) 3200 2990 (NLC)

3110

3150

3340

7330

10480

BB03003-005

Lep SC290B1002-0EN

Issued 02-07

1002-23 Long arm (3.6 m (141.73))

2870

10470

1410

3980 4850

600 2600 2390 (NLC)

104

3080

3110

1460

3150

3460

7320

3200 2990 (NLC) BB03003-006

Lep SC290B1002-0EN

Issued 02-07

1002-24

NOTE ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... Lep SC290B1002-0EN

Issued 02-07

3001

Section 3001 REMOVAL AND INSTALLATION OF THE FUEL RESERVOIR

CNH

Lep SM160B3001-0EN

3001-2

TABLE OF CONTENTS SPECIFICATIONS ..... .................................................................................................................................................... 2 FUEL RESERVOIR ........................................................................................................................................................ 3 Removal . ..................................................................................................................................................................... 3

SPECIFICATIONS See Section 1002

Lep SM160B3001-0EN

Issued 05-07

3001-3

FUEL RESERVOIR Removal STEP 1

STEP 6

JS00163A

Park th e ma chine o n ha rd, f lat g round. L ower th e attachment to the ground.

STEP 2

Reduce the engine speed to idle for 30 seconds, then shut down the engine.

Remove the filter (1).

STEP 7 Drain the fuel.

STEP 8

STEP 3

Turn t he ig nition k ey t o "O N" without starting the engine.

STEP 4

Attach a "D O NOT OPERATE" tag to the ignition key in the cab.

STEP 5

Disassemble t he r etaining scre ws ( 1), an d t hen remove the top cover (2).

STEP 9

Remove the cap (1).

Disassemble t he r etaining scre ws ( 1), an d t hen remove the cover (2).

Lep SM160B3001-0EN

Issued 05-07

3001-4

STEP 10

STEP 12

Disassemble t he r etaining scre ws ( 1), an d t hen remove the under cover (2).

STEP 13

Disassemble t he r etaining scre ws (1 ) a nd ( 2), an d then remove the handle (3).

STEP 11

Loosen the hoseb ands, and th en r emove t he hoses (1) and (2). Mark t he fu el t ank an d ho ses so that they ca n b e connected correctly at the time of assembly. Attach ca ps or plu gs to th e fu el ta nk a nd hoses to prevent entry of water, dust or dirt.

STEP 14

Remove the connector (1). Disassemble t he r etaining scre ws (1 ) a nd ( 2), an d then remove the side cover (3).

Lep SM160B3001-0EN

Issued 05-07

3001-5

STEP 15

STEP 18

Disassemble the retaining screws (1).

STEP 16

Connect the 4 shackles to the eyebolts, and then use the wires and crane to lift the fuel tank. Thoroughly ch eck t hat the lo cation is saf e before lowering the fuel tank on a crosstie. NOTE: When installing, proceed in the reverse order from that of removal.

Disassemble t he r etaining scr ews (1 ) an d ( 2), an d then remove the side cover.

STEP 17

Install 4 1 2-mm eyebolts (1) on to p o f t he fu el t ank. Spray lubricating oil on the eyebolts. Fully tighten the eyebolts, and then loosen them by a half turn.

Lep SM160B3001-0EN

Issued 05-07

3001-6

NOTES ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... .....................................................................................................................................................................................

Lep SM160B3001-0EN

Issued 05-07

Section 4001

4001

ELECTRICAL AND ENGINE FUNCTIONS, & SERVICE SUPPORT

CNH

Lep SC210B4001-1EN

4001-2

TABLE OF CONTENTS ELECTRIC CIRCUITS OPERATION EXPLANATION ........... ....................................................................................... 5 Explanation of Electrical Functions ..................................................................................................................... 5 Engine Speed Control ............................................................................................................................................ 7 Throttle Control .................................................................................................................................................... 7 Idling Control (auto / one-touch) ......................................................................................................................... 11 Idling Start .......................................................................................................................................................... 12 Idle Up ................................................................................................................................................................ 13 Auto Warm Up .................................................................................................................................................... 13 Engine Start / Stop Control ................................................................................................................................. 15 Engine Start / Stop Judgment ............................................................................................................................ 15 Power-Cut Delay ................................................................................................................................................ 16 Engine Emergency Stop .................................................................................................................................... 17 Neutral Start ....................................................................................................................................................... 18 Pump Control ....................................................................................................................................................... 19 Work Mode Control ............................................................................................................................................ 19 Pump Added Horsepower Control ..................................................................................................................... 20 Pump Horsepower Cut Control .......................................................................................................................... 21 Power Save Control ........................................................................................................................................... 21 Swing ..................................................................................................................................................................... 24 Swing Brake ....................................................................................................................................................... 24 Free Swing (North America Only) ...................................................................................................................... 25 Swing Lock (for maintenance) ............................................................................................................................ 26 Swing Relief Cut ................................................................................................................................................. 27 Travel ..................................................................................................................................................................... 29 Travel Speed Switchover ................................................................................................................................... 29 Travel Alarm (North America only) ..................................................................................................................... 30 Valve Control ........................................................................................................................................................ 32 Lever Lock .......................................................................................................................................................... 32 Solenoid Sticking Prevention ............................................................................................................................. 33 Pressure Boost Control ...................................................................................................................................... 34 Monitor Control .................................................................................................................................................... 36 Bar Graph (coolant temperature gauge, oil temperature gauge, fuel gauge) .................................................... 36 Accessories . ......................................................................................................................................................... 42 Horn . .................................................................................................................................................................. 42 Working Light ..................................................................................................................................................... 43 Wiper & Washer ................................................................................................................................................. 44 Room Lamp ........................................................................................................................................................ 46 Radio Mute ......................................................................................................................................................... 48 Others .................................................................................................................................................................... 49 Anti-Theft ............................................................................................................................................................ 49 Battery Save Function ........................................................................................................................................ 50 Alternator Power Generation Detection ............................................................................................................. 51 Overload Alarm (Europe only) ............................................................................................................................ 52 Options .................................................................................................................................................................. 54 Option Line Control ............................................................................................................................................ 54 Option Line Control ............................................................................................................................................ 57 Feed Pump Automatic Stop ............................................................................................................................... 59 Return Filter Clogging Detected ......................................................................................................................... 62 Beacon (Europe Only) ........................................................................................................................................ 63 ENGINE SUMMARY .................................................................................................................................................... 65 Engine System Diagram .................................................................................................................................... 65 Fuel System Diagram ......................................................................................................................................... 66 Detailed Part ...................................................................................................................................................... 69 Lep SC210B4001-1EN

Issued 03-07

4001-3 Engine Control Summary ....................................................................................................................................74 EXPLANATION OF ENGINE FUNCTION ....................................................................................................................75 Engine Function Explanation table .....................................................................................................................75 EGR (Exhaust Gas Recirculation) ......................................................................................................................77 Relationship between ECM and sensor actuators ..............................................................................................78 Cautions for Maintenance ...................................................................................................................................79 Explanation of Engine Control ............................................................................................................................81 Engine Start/Stop Judgment ...............................................................................................................................84 SERVICE SUPPORT ....................................................................................................................................................85 Screen Operations ................................................................................................................................................85 Screen Display List ...............................................................................................................................................87 CHK (status display) Screen List ........................................................................................................................87 MAIN . ..............................................................................................................................................................87 MNT .. ..............................................................................................................................................................90 H / W-A ...........................................................................................................................................................92 H / W-B ...........................................................................................................................................................95 H / W-M ...........................................................................................................................................................98 DIAG (trouble diagnosis) Screen ........................................................................................................................99 Screen . ...........................................................................................................................................................99 Operation .... ..................................................................................................................................................100 Reset ... .........................................................................................................................................................100 HR (usage log) Screen List ...............................................................................................................................101 MAIN . ............................................................................................................................................................101 ENG .. ............................................................................................................................................................103 CFG (setting change) Screen ...........................................................................................................................106 Operation .... ..................................................................................................................................................106 Screen . .........................................................................................................................................................107 CAL (troubleshooting support) Screen ..............................................................................................................109 Operation .... ..................................................................................................................................................109 Screen . .........................................................................................................................................................109 Check the Monitor Switch (Self-diagnosis function) ..........................................................................................111 Screen . .........................................................................................................................................................111 Configuration . ...............................................................................................................................................111 Differences from CHK screen [CHK | H/W-M | 1] .........................................................................................112 Option Flow Setting ...........................................................................................................................................113 Screen . .........................................................................................................................................................113 Flow setting ...................................................................................................................................................113 Anti-theft Setting ...............................................................................................................................................115 Anti-theft setting and password registration ..................................................................................................115 Anti-theft function operation ..........................................................................................................................116 Model Setting ....................................................................................................................................................117 Engine Screen Information ...............................................................................................................................119 Purpose .. ......................................................................................................................................................119 How to go to this screen ...............................................................................................................................119 Engine start restriction ..................................................................................................................................119 Screen . .........................................................................................................................................................119 Monitor operation method .............................................................................................................................120 Engine Information (Q resistance, QR code, engine serial number) Copying Method .................................121 Rewriting Injector QR Codes ........................................................................................................................122 When Replacing Computer A at the Same Time ..........................................................................................123 Engine Information Obtained Timing ............................................................................................................123 Redoing Engine Information Obtained ..........................................................................................................123 Trouble Display .............................................................................................................................................123 Screen Display Details .......................................................................................................................................124 Message Display List ........................................................................................................................................124 Trouble Display ...................................................................................................................................................126 Diagnostic Trouble Code Display ......................................................................................................................126 Main Unit Diagnostic Trouble Code List ............................................................................................................127 Lep SC210B4001-1EN

Issued 03-07

4001-4 Diagnostic Trouble Code (Monitor Display) ..................................................................................................... 133 Sensor Trouble Operation Table ...................................................................................................................... 138 EPF (engine protection feature) ....................................................................................................................... 140

CNH-EST DIAGNOSTIC TOOL

The EST (Electronic Service Tool) system allows diagnoses on machines and engines by detecting the operating parameters of electronic control components (control units, sensors etc.). It is also capable of reading fault codes. To use this tool, please refer to the book provided during the CXB series training sessions.

Lep SC210B4001-1EN

Issued 03-07

4001-5

ELECTRIC CIRCUITS OPERATION EXPLANATION Explanation of Electrical Functions No.

Item

Engine Speed Control

Engine Start / Stop Control

Control Throttle Control

2 3 4

Idling Control Idling Start Idle Up

Auto Warm Up

Engine Start / Stop Judgment Power-Cut Delay

2 3 4 1 2

Pump Control

Swing

Travel

Valve Control

Monitor Control

Lep SC210B4001-1EN

Engine Emergency Stop Neutral Start Control Work Mode Control Pump Added Horsepower Control Pump Horsepower Cut Control

Power Save Control

Swing Brake

2 3

Swing Free Swing (option) Swing Lock

Swing Relief Cut

Travel Speed Switchover Travel Alarm Lever Lock Solenoid Sticking Prevention Pressure Boost Control

Monitor Function

Monitor Bar Graph

2 1 2

Contents The engine speed, work mode, and boosted pressure state are switched by the throttle volume. With auto / one-touch switchover function Runs the engine at low idle speed when it starts up. In order to prevent the engine from stalling, during operation, raises the low idle speed to the auto idle speed. If the coolant temperature is low, warm-up operation is executed automatically when the engine starts Judgment based on engine speed from ECM When key ON OFF, 4-second delay; when engine running OFF, 7-second delay When the emergency stop switch is pressed, the ECM recognizes this and stops the engine. Engine start load (cell not turning) when lever locked Linked with the throttle, the SP / H / A mode is switched over and the pump horsepower is controlled. The pump horsepower milli-amp is raised when there is a high load or sharp load. The pump horsepower milli-amp is reduced by the transient load control, engine stall prevention control, and PID control conditions. The negative control relief pressure for non-operation is varied and the negative control pressure is lowered to reduce the pump load. When the upper and swing are not operated, the swing brake is operated automatically and during travelling too Swing option for North America There is a swing lock function (for servicing) with monitor operations. When a swing starts, the flow is reduced with the front side proportional valve and the excess oil is eliminated. Travel speed low-speed / high-speed switchover Buzzer sounded (for 10 seconds) during travel Operation is not possible unless the gate lever is raised. When key ON, solenoid switched ON / OFF for 0.25 second. The computer automatically raises the pressure from 34.3 MPa (433 bar / 4975 psi) => 36.8 MPa (368 bar / 5338 psi) when necessary. Output port control method change, lift crane and option screen added to display screens, etc. Bar graph display of coolant temperature, oil temperature, and fuel level on monitor

Issued 03-07

4001-6 No.

Item

Accessories

Others

Control 1

Horn

Working Light

3 4

Wiper & Washer Room Lamp

5 1 2

Radio Mute Anti-Theft Battery Save Function

Alternator Power Generation Detection Overload Alarm Option Line Control Option Line Control

4 1 2

Options

3 4 5 6

Engine

Lep SC210B4001-1EN

DC-DC Converter Feed Pump Automatic Stop Return Filter Clogging Detected Beacon Control (rotating light)

Contents Switching between one or two horns with horn volume select switch Right housing and boom light illumination (option setting for two lights at top of cab) Wiper with rise-up used (intermittent, continuous, washer) The room lamp lights up when the door is opened and lights up for exactly 30 seconds from when the door is opened with the key OFF. Mute switch setting on the knob Anti-theft set with password input to monitor When the key is ON, no output to travel switchover, boost, power save, bucket lock, option switchover and free swing solenoid valve. Alternator L terminal voltage judged with 10 V comparator Only mounted on machines for Europe Switchover crusher / breaker with just rocker switch in cab There are five flow settings each for the breaker and crusher, for a total of 10 settings. Convert 24 V into 12 V Feed pump automatic stop. Full tank detected by fuel level sensor and the pump stopped automatically Alarm issued when return filter clogged (only for breaker specifications) Standard for Europe. Commun rail control

Issued 03-07

4001-7

Engine Speed Control 1. Throttle Control 1) Throttle display a) Configuration

Throttle display data

Throttle display

Target engine speed

1 2

3 4

Monitor Computer A

Engine Throttle volume

b) Summary The throttle volume voltage signal is first input to Computer A. Computer A converts the voltage signal to a target speed and sends it to the ECM with CAN communications. At the same time, Computer A sends the throttle display data to the monitor. 2) Throttle volume position detection a) Configuration

1 2 3

Lep SC210B4001-1EN

Throttle volume Computer A Potentiometer

Issued 03-07

4001-8 b) Structure The detent and notches provide a click feel (15 notches; Notch 1 is the "SP mode" position). Hysteresis about 2.5Â°

Small notch: 4 to 15

Right turn

Left turn

Large notch: 1 to 3

(Right turn) When the detent reaches the N- position, it is judged to beat Notch N. (Left turn) When the detent reaches the N+ position, it is judged to be at Notch N.

Notch number (1 to 15) Notch N detent position detection: Hysteresis is used to absorb error.

Detent

c) Characteristic Hysteresis

Detent position (notch number)

(AUTO)

Lep SC210B4001-1EN

Issued 03-07

4001-9 d) Potentiometer characteristic Voltage (V)

Angle (deg) Throttle operation range Trouble

Normal

Trouble

Potentiometer operation range

e) Throttle volume degree of opening calculation The throttle volume degree of opening (%) that can be checked on the CHK screen is calculated with the standard below. 100% => When the detent is in the 1+ position 0% => When the detent is in the 15- position Therefore, even if the detent is in the 1 position (SP), this does not necessarily mean that the degree of opening is 100%. In the same way, even if the detent is in the 0 position, the degree of opening is not necessarily 0%.

Lep SC210B4001-1EN

Issued 03-07

4001-10 f) Table For the angle, voltage, and degree of opening for each detent position, see the following table.

Lep SC210B4001-1EN

Detent

Angle [degree]

Voltage [V]

1+ 1 12+ 2 23+ 3 34+ 4 45+ 5 56+ 6 67+ 7 78+ 8 89+ 9 910+ 10 1011+ 11 1112+ 12 1213+ 13 1314+ 14 1415+ 15 15-

131.2 128.7 126.2 109.6 107.1 104.6 95.2 92.7 90.2 88.0 85.5 83.0 80.8 78.3 75.8 73.6 71.1 68.6 66.4 63.9 61.4 59.2 56.7 54.2 52.0 49.5 47.0 44.8 42.3 39.8 37.6 35.1 32.6 30.4 27.9 25.4 23.2 20.7 18.2 16.0 13.5 11.0 8.8 6.3 3.8

4.86 4.77 4.67 4.06 3.97 3.87 3.53 3.43 3.34 3.26 3.17 3.07 2.99 2.90 2.81 2.73 2.63 2.54 2.46 2.37 2.27 2.19 2.10 2.01 1.93 1.83 1.74 1.66 1.57 1.47 1.39 1.30 1.21 1.13 1.03 0.94 0.86 0.77 0.67 0.59 0.50 0.41 0.33 0.23 0.14

Degree of opening [%] 100.0 98.0 96.1 83.0 81.1 79.1 71.7 69.8 67.8 66.1 64.1 62.2 60.4 58.5 56.5 54.8 52.8 50.9 49.1 47.2 45.2 43.5 41.5 39.6 37.8 35.9 33.9 32.2 30.2 28.3 26.5 24.6 22.6 20.9 18.9 17.0 15.2 13.3 11.3 9.6 7.6 5.7 3.9 2.0 0.0

Issued 03-07

4001-11

2. Idling Control (auto / one-touch)

1 2 3 4

Monitor display Computer A Engine Coolant temperature sensor

5 6 7 8

One-touch idle switch Throttle volume Pressure sensor (upper) Pressure sensor (swing)

9 10 ECM

Pressure sensor (travel) Pressure sensor (arm-in) Engine Control Module

Operation explanation: a) Auto / one-touch switchover function The operator can switch between one-touch and auto by pressing the auto idle switch on the monitor in the figure below. When auto idle is ON, the LED at the side of the switch lights up.

b) Auto idle control (A) 1. When auto idle is set, if the lever is left continuously unoperated for 5 seconds, the engine speed automatically becomes the auto idle speed (1200 min-1). This five-second setting for auto idle operation is the default value. This setting can be changed to from 1 to 30 seconds with service support operations. 2. When the lever is operated, the engine speed is automatically returned to the engine speed set for the throttle volume. 3. Even with auto idle set, it is p ossible to move to auto idle or return from auto idle by pressing the knob switch (one-touch idle switch) on the right operation lever. c) One-touch idle control When auto idle is no t set, regardless of lever operation, it is po ssible to move to auto idle or r eturn from auto idle by pressing the knob switch (one-touch idle switch) on the right operation lever. The idling speed for one-touch idle control is 1000 min-1 on CX160B to CX240B and 900 min-1 on CX290B.

Lep SC210B4001-1EN

Issued 03-07

4001-12 d) Idling speed 1. Auto idling speed => 1200 min-1 2. One-touch idling speed => 1000 min-1 on CX160B to CX240B and 900 min-1 on CX290B. 3. Low idling speed => 1000 min-1 on CX160B to CX240B and 900 min-1 on CX290B. The speeds above are the default values. They can be set to from 900 to 1600 min-1 with service support operation (See Screen Operation in Ser vice Support). However, the settings are based on the following conditions. Low idle speed = One-touch idle speed â&#x2030;¤ Auto-idle speed (The one-touch idle speed and auto-idle speed settings can be changed).

3. Idling Start

a) When the engine starts, the engine speed becomes the low idle speed regardless of the throttle position. b) When the low idle speed is changed, the engine speed is controlled at this new speed. c) During an idling start, the idling icon (A) is displayed at the top left of the monitor. No message is displayed

d) An idling start is ended in the following cases and control becomes normal. 1. When the one-touch idle switch is pressed 2. When the throttle volume is operated 3. When the operation lever is operated (upper, travel, swing, arm-in pressure sensor ON) e) Back-up operation 1. Sensor trouble If trouble occurs in a sensor (upper, travel, swing, arm-in), the idling start is ended. 2. Throttle volume trouble Even if the throttle volume is operated, the idling start is not ended. Also, even if the idling start is ended with some other method, the throttle cannot be adjusted. 3. One-touch idle switch trouble Even if the switch is pressed, the idling start is not ended.

Lep SC210B4001-1EN

Issued 03-07

4001-13

4. Idle Up

A function that when the engine speed is less than the idlin g speed, causes lever operation to automatically raise the engine speed to the auto idling speed (Idle speed engine stall prevention function).

Operation conditions: a) Control only when the engine speed is lower than the auto idling speed b) The idle up speed is the same as the auto idling speed (Factory setting 1200 min-1). c) This control does not operate when the idling speed is higher than the auto idling speed. Also, when auto idling is operated, normally the auto idling function operates. d) Even with one-touch idling operating, this control operates to raise the idling speed. e) A lever is judged to have been operated when any pressure sensor (upper, travel, swing, arm-in) comes ON. f) If trouble occurs in any of the above pressure sensors, idle up control is not executed. Auto idle (down) Throttle volume operation

Idle up

Idle up speed (auto-idle speed)

Engine speed

5 seconds

Pressure sensor SIG (operation lever)

5. Auto Warm Up

If the coolant temperature is low when the engine starts up, warm-up operation is executed, automatically raising the engine speed in steps. a) Auto warm up is used if the coolant temperature is lower than 50 °C (122°F) when the engine starts. b) If the coolant temperature is 50 °C (122°F) or higher, auto warm up is not used and an "idling start" is executed. c) Operation The engine speed is raised in steps from the low idle speed until 1800 rpm as below. When the low idle speed is changed, the engine speed starts from the newly set speed. The warm up time is the same, 14 minutes. When the coolant temperature reaches 50 °C (122°F), the engine speed falls immediately to low idle (Idling start).

Low idle

Low idle 900 or 1000min-1 5 minutes

Lep SC210B4001-1EN

3 minutes

Issued 03-07

4001-14 d) Monitor display During auto warm up, the “Auto warm up icon” (A) is displayed at the top left of the monitor.

e) In the cases below, auto warm up is ended and operation shifts to "idling start". 1. When the coolant temperature reaches 50 °C (122°F) 2. When the one-touch idle switch is pressed 3. When the entire auto warm up process ends (after 14 minutes) f) In the cases below, auto warm up is ended and operation shifts to the engine speed for the throttle position. 1. When the lever is operated (as detected by a pressure sensor) 2. When the throttle volume is operated g) Back-up operation 1. Sensor trouble If trouble occurs in a sensor ( upper, travel, swing, arm-in, coolant temperature sensor), auto warm up is not operated. Also, even trouble occurs in a sensor partway through a warm up, the warm up is ended and operation shifts to normal control. 2. One-touch idle switch trouble Even if the switch is pressed, auto warm up is not ended. 3. Throttle volume trouble Even if the throttle volume is operated, the auto warm up is not ended

Lep SC210B4001-1EN

Issued 03-07

4001-15

Engine Start / Stop Control 1. Engine Start / Stop Judgment a) Configuration

Speed

ECM

1 2 3

Computer A Cam sensor Crank sensor

b) Summary Engine start and stop is judged based on the engine speed sent from the ECM with CAN communications. c) Judgment value Start 500 min-1, Stop 200 min-1 Start

Stop

Lep SC210B4001-1EN

200 min-1

500 min-1

Issued 03-07

4001-16

2. Power-Cut Delay

a) Configuration (fuses etc. omitted)

1 2 3 4

Computer A Key switch Battery relay Battery

5 6 7 8

Load A Power supply Key switch signal Battery relay hold

b) Summary After the key is switched OFF, after the battery relay is held for a certain period, the power supply is cut off. c) Purpose 1. This secures time after the key is switched OFF for data to be written in the EEPROM in the ECM and Computer A. 2. This waits until the engine completely stops to avoid load dumping. d) Operation 1. When the key is ON, the battery relay is held by the battery relay hold output (OUT1) from the ECM and the key switch. 2. After the key is switched OFF, the battery relay is only held by the ECM. 3. After it detects the key going OFF through the key switch signal input (IN1), the ECM starts the count down. 4. After a certain time has passed, the ECM stops output to the battery relay and the battery relay goes OFF. At the same time, the power supply to electrical parts, including the ECM and computer is cut (Except the backup power supply). 5. The time from the key being switched OFF until the power supply goes OFF (the delay time) depends on whether or not the engine was started. â&#x20AC;˘ After t he k ey is switched ON, if the k ey is s witched OFF wit hout t he engine being star ted = about 4 seconds. â&#x20AC;˘ If the key is switched OFF after the engine was started = about 7 seconds.

Lep SC210B4001-1EN

Issued 03-07

4001-17

3. Engine Emergency Stop

Function for stopping the engine in an emergency When the emergency stop switch on top of the left console is pressed, the engine is stopped regardless of the key switch position.

1 2

Monitor display Computer A

3 4

Engine Emergency stop switch

a) Circuit 1. When the emergency stop switch is pressed, a 24 V signal enters the ECM input port. 2. When the 1) signal enters, the ECM controls the injector, suction control valve, and EGR valve to stop the engine. 3. The emergency stop switch signal enters computer A t oo and computer A sends the engine stop command to the ECM with CAN communications. 4. At the same time, computer A send s the emergency stop and buzzer instructions to the monitor with serial communications. b) Display, alarm 1. When the emergency stop switch is switched ON, the "ENGINE STOP" message is displayed on the monitor. 2. Even if there is another message, the "ENGINE STOP" message is displayed with priority for five seconds after the switch is switched ON. 3. At the same time as 1), the buzzer in the monitor buzzes intermittently at 1 Hz. 4. If any kind of trouble is detected during the 1 Hz intermittent buzzing of 3), after the 5-second continuous buzzing, which is the trouble alarm, the buzzing returns to the 1 Hz intermittent buzzing. 5. Even if the buzzing continues after the switch ON/OFF message display (for 5 seconds), the message display is not extended. 6. The above message display and buzzer operate whether the engine is running or stopped.

c) An emergency stop takes priority over any other control and stops the engine. â&#x20AC;˘ The engine stops even dur ing lift ing magne t sucti on, dur ing ele vator cab r ising, and f an re verse operation (large machine only). d) When an emergency stop is made, it is not recorded in the trouble log. e) The engine can be cranked with the emergency stop switch ON, but the engine will not start.

Lep SC210B4001-1EN

Issued 03-07

4001-18

4. Neutral Start

a) Purpose and summary The engine will not start with the gate lever lifted (It will not crank). This prevents accidental operation if the operation lever is accidentally bumped into when the engine is started. b) Configuration

Gate lever Down (OFF)

Up (ON)

1 2 3 4

Key switch Gate lock limit switch Starter motor Safety relay

5 6 7

Starter cut relay Lever lock solenoid Battery relay

c) Operation When the gate lever is raised (and the limit switch comes ON), the starter cut relay is excited, the excitation to the safety relay is cut off, and the engine does not crank. At this time , nothing in particular is displayed on the monitor.

Lep SC210B4001-1EN

Issued 03-07

4001-19

Pump Control 1. Work Mode Control

a) Purpose: Work mode control enables the operator to select the work mode to match the work contents, for example emphasizing speed, emphasizing fuel economy, etc. At the same time, the engine speed is adjusted (throttle adjustment).

Work mode display

Target engine speed

ECM

1 2 3 4 5

Monitor Computer A Engine Throttle volume Pump horsepower control proportional valve

6 7 8 9 10

Boost solenoid P1 pressure sensor P2 pressure sensor N1 pressure sensor N2 pressure sensor

b) Operation: 1. Manual switchover (main mode) The operator can select one of the following work modes by turning the throttle volume. For the correspondence betw een the throttle volume detents and the work modes, see the attached table. Mode

Aim

Display

Monitor buzzer

(1) SP mode

Speed emphasis

The buzzer buzzes twice when this is selected.

(2) H mode

Balances speed and fuel economy

The buzzer buzzes once when this is selected.

(3) A mode

Fuel economy emphasis

No buzzing

2. Automatic switchover (submode) Each of the main modes that can be selected manually has two sub-modes (high and low). These sub-modes are switched automatically based on the sensor input values. For the high and lo w milli-amp, refer to the explanation of the 2. Pump Added Horsepower Control in next page. Lep SC210B4001-1EN

Issued 03-07

4001-20

2. Pump Added Horsepower Control

a) Purpose: To prevent drop in the e ngine speed when the lever is ope rated sharply, when there is hig h load, when travelling, etc.

Control milli-amp Volume position (detent position) Models Work mode Engine speed (min-1) CX160B Max High Pump type horsepower Max Low CX180B milli-amp (mA) Min Engine speed (min-1) CX210B Max High Pump type horsepower Max Low CX230B milli-amp (mA) Min Engine speed (min-1) Max High Pump type CX240B horsepower Max Low milli-amp (mA) Min Engine speed (min-1) Max High Pump type CX290B horsepower Max Low milli-amp (mA) Min Boosted pressure

4 to 8

9 to 15

SP 2000

H 1900

1800

AUTO 1799 to 1300

1299 to 1000

1800 600 586 314 2000 600 580 290 1800 600 600 314 Automatic

1700 600 570 314 1900 600 560 290 1700 600 585 314 Automatic

1600 600 570 314 1800 600 560 290 1600 600 510 314

1599 to 1300 314 314 314 1799 to 1300 290 290 290 1599 to 1300 405 405 405 Normal

1299 to 1000 50 50 50 1299 to 1000 50 50 50 1299 to 900 50 50 50

b) Operation: 1. Reduces the amount of speed drop under high load (SP-H mode) Operation conditions => For high load When the P1 + P2 pressure becom es high voltage, the milli-amp to t he pump horsepower control proportional valve Imax is changed Low => High to increase the pump flow. 2. Reduces the amount of speed drop under high load when digging with the arm-in (SP-H mode) When the arm-in operation is detected by the arm-in pilot pressure sensor, high load is detected faster than for other operations. 3. Rise speed up for sharp lever operation Operation conditions => For sharp lever operation When sharp lever operation is detected by the N1 or N2 negative control pressure sensor, the milli-amp to the pump horsepower control proportional valve Imax is changed Low => High to increase the pump flow. 4. For travel operation For travel operation, the pump milli-amp is fixed to 600 mA. However, if the engine speed is 1300 min -1 or less, the pump milli-amp is f ixed to 50 mA (Prevention of engine stalling is given priority).

Lep SC210B4001-1EN

Issued 03-07

4001-21

3. Pump Horsepower Cut Control

a) Purpose: The pump milli-amp is controlled in order to prevent black smoke under overload and engine speed drop and in order to improve energy saving. The control methods are the following three. 1. Overload reduction control 2. Engine stalling prevention control 3. PID control

ECM

1 2 3 4

Computer A Pump Engine P1 pressure sensor

5 6 7 8

P2 pressure sensor N1 pressure sensor N2 pressure sensor Pump horsepower control proportional valve

b) Overload reduction control When the engine is under overload, the milli-amp to the pump horsepower proportional valve first drops to 50mA. After that, the milli-amp is gradually raised while watching the difference between the actual engine speed and the target engine speed. Overload reduction control is executed in all work modes. â&#x20AC;˘ The engine is judged to be overloaded when the following conditions are met. 1. Sharp lever operation When there is sharp lever operation, this is judged from the upper pressure sensor state. 2. Operation for high loads and sharp loads Judged from the P1 or P2 pump pressure sensor and from the pump main pressure boost state. c) Engine stalling prevention control When the target engine speed is 1300 min-1 or less, the milli-amp is 50 mA. d) PID control When the engine actual speed f alls 30 min -1 or more belo w the target engine spe ed, the milli-amp is gradually lowered to I Min. When the difference of the actual engine speed from the target engine speed falls below 30 min-1 the milliamp rises to the I Max High for the each mode. Backup control If trouble occurs in a pressure sensor (P1, P2, upper), the overload restriction control is not carried out. If trouble occurs in the pump horsepower control proportional valve, the output from the computer stops.

4. Power Save Control

a) Purpose: When no lever is operated, the pump load is reduced with the control below to reduce fuel consumption.

Lep SC210B4001-1EN

Issued 03-07

4001-22 The control methods are the following two. 1. The negative control relief pressure is varied and the negative control pressure is lowered to reduce the pump load. 2. The pump discharge amount is set to the minimum flow.

1 2 3 4 5

Computer A Control valve Power save solenoid Upper pressure sensor Swing pressure sensor

Lep SC210B4001-1EN

6 7 8 9 10

Travel pressure sensor Negative control foot relief valve Pump 1 Pump 2 P1 flow control proportional valve

Issued 03-07

4001-23 b) Operation explanation: 1. Normal operation If more than one second passes with all the sensor signals to the computer OFF (upper, travel, and swing pressure), the computer judges that no lever is being operated and outputs to the P1 flow control proportional valve and the power save solenoid valve. 1. P1 pump discharge reduced a)The P1 flow volume proportional valve milli-amp is increased from 50 mA to 740 mA. b)The P1 pump swash plate is switched to the minimum tilt revolution and the discharge amount is set to its minimum. 2. P2 pump discharge reduced a)When the power sa ve soleno id valve is switched, t he pilot source pressure is fed t o t he P2 pump negative control port via the solenoid valve. b)The P2 pump swash plate is switched to the minimum tilt revolution and the discharge amount is set to its minimum. 3. Negative control pressure reduction a)When the po wer sa ve solenoid valve is switched, the negat ive contr ol f oot relief v alve spr ing chamber is linked with the tank line and the negative control foot relief valve setting pressure drops from 3 MPa (30 bar / 435 psi) to 1 MPa (10 bar / 145 psi). b)By reducing the negativ e control relief pressure , the pressure within the circuit is redu ced, and t he horsepower used by the pump is reduced. This saves energy. 2. Operation when the engine is stopped with the key ON. Even if no lever is operated, when the engine stops, the battery save function works and there is no output to the P1 flow control proportional valve or the power save solenoid. 3. Operation for trouble If an abnormality occurs on either the input side (upper, swing, travel pressure sensors) or the output side (P1 flow control proportional valve, power save solenoid valve), the system treats this as operation being underway and control is fixed to the following. milli-amp to the P1 flow volume valve => 50 mA, the power save solenoid valve is always OFF. Caution: During a trouble, even if the abnormality is ended, trouble mode does not end until the key is switched OFF. 1 second

1 second

Flow proportional valve Power save solenoid Pressure sensor (upper) Pressure sensor (travel) Pressure sensor (swing)

Lep SC210B4001-1EN

Issued 03-07

4001-24

Swing 1. Swing Brake

a) Configuration

For North America

1 2 3 4 5 6 7

Horn volume select switch Computer A Engine Working light switch Auto idle switch Upper pressure sensor Swing pressure sensor

Lep SC210B4001-1EN

8 9 10 11 12 13

Swing brake solenoid Accumulator Swing Motor Swing Brake Free swing solenoid Free swing switch (momentary)

Issued 03-07

4001-25 b) Braking function during upper operation When the upper pressure sensor is ON, the brake goes OFF, one second after upper pressure sensor goes OFF, the brake comes ON. c) Braking control through swing operation When the swing pressure sensor is ON, the swing brake goes OFF (Swing brake solenoid = OFF). Five seconds after the swing pressure goes OFF, the swing brake comes ON (Swing brake solenoid = ON). d) Swing lock with key OFF When the key is OFF (during power-cut delay), the swing brake comes ON unconditionally .

1 second

5 seconds

b), c)

Power-cut delay

5 seconds 1 second

Swing brake solenoid Upper pressure sensor Swing pressure sensor Swing brake solenoid Key switch

2. Free Swing (North America Only)

a) Free swing switchover When the free swing switch is pr essed, the free swing mode is switched ON <= > OFF. When t he (momentary) key is OFF, always start with free swing OFF (Previous data reset). b) Free swing control When free swing is ON, the free swing solenoid is ON and the swing brake solenoid is OFF. c) Mode display When free swing is ON, the icon in the figure below is displayed on the monitor. d) Battery save While the engine is stopped with the key ON, if free swing is switched ON, the icon is d isplayed, but the free swing solenoid valve does not come ON. It does come ON after the engine starts.

Free swing

Lep SC210B4001-1EN

Issued 03-07

4001-26

3. Swing Lock (for maintenance)

This is used for measuring the swing relief pressure and other maintenance tasks. a) Swing lock switching In order to prevent accidental operation under certain special circumstances, sometimes the swing brake need to be left ON all t he time. "Swing lock" At this time, the swing lock can be switched ON / OFF by holding down the "horn volume select switch", the "working light switch", and the "auto idle switch" at the same time for 3 seconds. When turning the key to ON, always start with the swing lock OFF (Previous data reset). b) Swing lock control When the swing lock is ON, even if the upper or the swing is operated, the swing brake keep working. Be particularly careful about swing operation because the swing brake plate is dragged. (The swing pilot pressure is not shut off. This is no more than a simple swing lock). c) Competition with free swing If the swing lock is used, even if free swing is ON, the swing brake solenoid comes ON and the free swing solenoid goes OFF (Swing lock priority). d) Mode display When free swing is ON, the icon in the figure below is displayed on the monitor.

Swing lock

e) Time chart (free swing & swing lock) Power-cut delay

Power-cut delay

Swing brake solenoid Free swing solenoid Engine state

Key swing

Free swing

Swing lock

3-b)

2-d)

3-c)

2-a) Previous data reset

3-a)

Previous data reset

f) Trouble mode If trouble occurs in an input (upper / swing pressure sensor), communications (CAN), or output (swing brake solenoid / free swing solenoid), the system goes into trouble mode. In trouble mode, the swing brake solenoid is OFF an d the free swing solenoid is OFF. Even if the trouble is recovered from, this does not recover the system from trouble mode.

Lep SC210B4001-1EN

Issued 03-07

4001-27

4. Swing Relief Cut

Purpose: When swing single operation is running, the pump flow is reduced, and the excess oil ejected from the swing motor relief valve is eliminated.

1 2 3 4 5 6 7

Computer A Throttle volume Travel pressure sensor Option 1 pressure switch N1 pressure sensor N2 pressure sensor Arm (1)

8 9 10 11 12 13 14

Boom (2) Swing Option 1 Travel (left) Arm (2) Boom (1) Bucket

15 16 17 18 19

Travel (right) P1 pressure sensor P2 pressure sensor Regulator P1 flow control proportional valve

Operation explanation: a) Operation conditions for swing relief cut control The swing relief cut control pro vides relief when the pressure is boosted for the start of the swing due to sharp swing operation and the drained off excess oil is held to the lowest amount possible. The purpose is to provide an energy saving effect. Control is executed when all the conditions below are satisfied. 1. Sharp swing operation => When the swing lever is operated, this is judged from the swing pilot pressure sensor pressure rise. 2. Within 1 second after start of swing 3. Travel non-operation => Travel pressure sensor OFF 4. No attachments other than boom down are operating. â&#x20AC;˘ That no attachment is oper ating is judge d from the N2 negativ e cont rol pressure and P1 pressure sensor. 5. Option line non-operation => Option pressure sensor OFF

Lep SC210B4001-1EN

Issued 03-07

4001-28 b) Control contents For the swing relief cut operation, after the milli-amp to the P1 flow control propor tional valve is increased and the P1 flow is reduced, while checking the P1 pump discharge pressure, the system gradually reduces the output milli-amp to the P1 flow control valve and raises the P1 pump flow to the constant swing speed. â&#x20AC;˘ Swing relief cut control flow Judged as swing single operation + sharp operation => Swing relief cut operation => Increased milli-amp to P1 flow control proportional valve. => P1 pump flow reduced => Milli-amp gradually decreased while watching swing pressure fall status => P1 pump flow increased NOTE: P1 flow control propor tional v alve: milli-amp (high) = > P1 pump fl ow (low); milli-amp (lo w) = > P1 pump flow (high) c) Swing relief cut end conditions 1. When swing operation is stopped 2. Travel O N 3. Boom up, arm out / in, bucket open / closed 4. Boom down sharp operation 5. Boom down pressure boost

Lep SC210B4001-1EN

Issued 03-07

4001-29

Travel 1. Travel Speed Switchover

The travel motor tilt revolution angle is ch anged by switching the travel speed between low speed and high speed with the switch. However, in high-speed mode, if the drive force becomes high due to the functioning of the travel motor itself, the tilt revolution angle is automatically switched to low speed. After that, when the drive force becomes low, the slope automatically returns to high speed.

Switch data

Engine actual speed

1 2 3

Computer A Engine Travel high-speed select switch

4 5 6

Travel m otor Travel high-speed solenoid Key switch

a) Operation 1. When the key is ON, the speed becomes low speed. The previous travel mode is reset. (If the service support operation is changed, it is possible to hold the previous data). 2. Each time the travel high-speed switch is pressed, the speed is s witched between low speed and high speed. During high speed, the LED at the top left of the switch lights up. 3. While the eng ine is stopped with the k ey ON, if the high spee d travel switch is pressed, the solenoid does not operate. The LED lights up. (To prevent the battery being run down). 4. In high-speed mode, the tilt revolution angle is auto matically switched between low speed and high speed by the travel motor drive force. However, the electrical control remains at high speed, the high-speed LED remains lit, and the solenoid remains ON.

Lep SC210B4001-1EN

Issued 03-07

4001-30 b) Trouble mode If an abnormality occurs in communications (CAN) or computer solenoid output, the speed is fixed to low speed (The travel high-speed solenoid comes OFF).

Key switch

Engine Travel high-speed switch LED Travel high-speed solenoid

Travel motor

High speed Low speed Drive voltage rise

Drive voltage fall

2. Travel Alarm (North America only) a) Configuration

Travel alarm

Intermittent buzzing control is handled by the travel alarm itself. In other words, while the travel alarm is ON, computer A buzzes the buzzer intermittently as it wants.

For North America: Standard

1 2

Computer A Travel pressure sensor

Travel alarm mode select switch (alternator)

b) Travel alarm (automatic stop) When the travel pressure sensor comes ON due to travel operation, the travel alarm starts 1 Hz intermittent buzzing. This buzzing automatically stops after 10 seconds. c) Travel alarm (continuous buzzing) When the travel alarm mode select switch is switched ON, the buzzer buzzes continuously during travel (Function for North America only). d) Signals when key is ON After the key is switched ON, the travel alarm sounds for 0.4 second as a signal.

Lep SC210B4001-1EN

Issued 03-07

4001-31 e) Time chart 0.4 seconds

Travel alarm

Travel pressure sensor

Key switch

Travel alarm mode select switch

10 seconds

ON OFF ON OFF ON OFF ON OFF

Mode switchover during travel

f) Trouble mode If trouble occurs in the travel pressure sensor, the machine goes into trouble mode and the tr avel alarm is always OFF.

Lep SC210B4001-1EN

Issued 03-07

Thank you very much for your reading. Please Click Here Then Get More Information.