4001-66 Example: : . In the screen opposite, the language code has MACHINE : SH0120- 3 changed from 5 (French) to 1 (English). TERRITORY :3 LANGUAGE: 1 CONT. PIN KHR2668 CHANGING THE ACCESS CODE FOR THE ANTI-THEFT SYSTEM 1. Remove the hood (1) located behind the 3. Tum the key switch to ON and then OFF. operator's seat. 4. Reconnect the two wires (2) (3) which authorize the intitheft system (see paragraph 2). 5. To save the new access code, consult the anti-theft protection section in the operator's manual 1 Hood - 2. Disconnect the two wires (2) (3) which authorize the ‘anti-theft sytem, 2. Violet wire marked 469 female plug 3. Black wire marked 621 male plug XB Radio connector cre 7-2772468 Issued 05-054001-67 (Check the quantity of coolant Fill with coolant TROUBLESHOOTING Prior inspections item Target Retion POINTS TO BE CHECKED WHEN STARTING Lubricants - Coolants 7. Check the quantity of fel = ‘dd fost 2. Check hat felis not contaminated = Clean, drain 3. Check te quantity of hysraulc fis = Fil with Mid 4 Inspect the hydraulic Mud fiter = Drain, clean 55. Check me quantity of on each reduction gear = Fil with of 6. Check the quantity of engine oil = Fill with oil 7 8. (Check the fiter restriction indicator (dust) Clean or replace Electrical equipment ‘9. Check the battery terminals and wiring for tightness and corrosion 410. Check the alternator terminals and wiring for lightness and corrosion ‘11. Check the starter motor terminals and wiring for tightness and corrosion Tighten or replace Tighten or replace Tighten or replace OTHER POINTS TO CHECK Hydraulic system - Mechanical equipment "12, Abnormal noise or smell = Repair 43. Check for ol leaks _ Repair 414, Airin the system _ Bleed the air Electrical system - Electrical equipment 15. Check the battery voltage (with the engine shut down) 23-26V Replace 46. Check the quantity of fluid in the battery - ‘Add or replace 17. Make sure that the cables are not discoloured, burnt or stripped - Replace 48. Check for missing or loose cable retaining clips - Repair 19. Check for damp on cables (especially on connectors and terminals) - Disconnect and dry if damp 20. Check fuses for condition and corrosion - Replace 21. Check the alternator voltage (with the engine speed above the 27.5-29.5V Replace throttle mid-point) (when battery charge is insufficient, there can be 25 V only at start up) 22. Noise from relay battery (with starter motor ON or OFF) - Replace ramace4001-68 Reading the organisation charts Error code and description of problem ‘The error code and the description of the problem are shown in the organisation charts. Error code Description of the problem 7 The message Is sill displayed even after refueling 2 ‘The message is stil displayed even after adding coolant solution Prior checks. Before identifying the cause of the problem, always make prior checks. How to proceed ‘Aller checking or measuring the items described in fone step, depending on the results, choose YES or NO and pass on to the next step. ‘The description in the YES or NO branches refers directly to the cause of the problem as the result of checks or measurements made. Refer to the description of the cause and carry out the repair procedures described on the right-hand side. ‘The inspection —methods/measurements are described in one step. YES should be chosen if the criteria or questions meet the situation; NO if they do snot meet it. The necessary preparation work, operating method and the criteria are described under one step. This should be carefully read before starting the inspection and Ure measurements and he procedures should be followed, starting with step (1) since negligent preparation work or incorrect operating methods can cause damage to the machine. cre 7-2772468 Wire colour When troubleshooting, refer to the table below for the wire colours. (For connector numbers, refer to the following pages). Table showing wire colours Symbol | Colour | Symbol | Colour B Black R Red Ww ‘Waite ¥ Yalow Br Brown To | Uohtgreen P Pink ‘Sb ‘Sky blue Vv Violet T Blue G Green Gr Grey ° ‘Orange BR indicates a wire of colour B striped with R. Example: BR indicates a black wire with red stripes IMPORTANT: Before removing or installing a connector. always turn the key switch OFF. Issued 05-054001-69 Procedures 1. This is how one has to proceed to detect defects when the message is still displayed after all necessary ‘measures have been taken to correct the error. Message displayed Description of the problem Problem No. LOW FUEL ‘The message is stil displayed even after refiling the fuel tank 7 TOW COOLANT ‘The message is sil displayed even afler refiling with coolant 2 solution LOW OIL PRESS. ‘The message is sil displayed even after adjusting the engine 3 oll pressure ‘OVER HEAT "The message is siil displayed even when the hydraulic oil a temperature is 84°C or less and the engine coolant temperature is 92°C or loss ‘ALTERNATOR The message is stl displayed 5 ELEC. PROBLEM The message ie ail deplayed @ 2. Thisis how one has to proceed if the problem is not indicated by @ message but machine operation is not correct. A. Engine Description of the problem Problem No. The engine does | ELE. PROBLEMT is shown on he monton [pe|6 not start. NO 7 Le 3. Problem without message. Description of the problem Problem No. Impossible to change travel speed | ____w|s ramace4001-70 Low fuel Description of problem No. 1 ~ The message is still displayed even after refilling the fuel tank. wll ‘AL Computer RS Fuel sensor Troubleshooting Cause | Action Rey suttch ON sur tne te Scocorestnee (8). YES lac tne ting raitenance Detective eet support CHK. (Refer computer (at) | meu to the table below for oy testes). Key switch OFF scone he ul Sonar tener) Gmessuehe no No Repace reaanes onthe Ful snsee heck nu Connect tte hl (re) anos | Seka Disconectne ch2e Soaedar wears no aes . ves the esltarcs beeen et tenon | Seen Satrcor | eomect ithe veo othe 7s une Disconnect connector Chto mesa te ves fahulicetetmen’ct NO. |oaa ean cnt femal nd GND cath ecmectonon |emmeston Geemetoe™ tm | etonn | oes Sebo torte rane Dstcive | Relae ne ves compute at) | elon jews somecton jsonnection tenninal Note: Althe bac graph nde re of when the ct open Resistance between GL and BG Resistance (OF 2075 wear war arar Para} aoa ei cre 7-2772468 Issued 05-05Add coolant solution Description of problem No. 2 - The message is stil displayed even after adding coolant solution. Oe 4001-71 At Computer 855 Minimum coolant solution level switch Troublecheating Cause | Action Key switch ON Disconnect hein yes Detective __|Reviae ne Coot soliton vel uch mn costae | 4H onoter(SS5)oses the |SSuronive"™ [2008 message disappears: ‘switeh (S55) switch (S55) Shortcut on ves fae Gre No Disconnect coed 4 fo Daten |e we Seeittn messag dseppears ——————————P> nina ca nn (9) ond ehee Sher uit on NO Disconnect connector CNS to YES | wire Ge Repair wire sorta menage aupears P |toween cxze [ere snaeNs No ouecte | Repice ne compar (As) [estas tt) cre 727724684001-72 Low engine oil pressure Description of problem No. 3 - The message is stil displayed even when the engine oil level is satisfactory. Fg alle laa a feet fe: ves | f= 1 Computer B21 Engine oil pressure switch Troubleshooting Cause | Action “Gheck the flowing pols during the 12 seconds folovng artng te engine Disconnect ihe engine ol yes Oipressuce | Replace the pressure svitch connector Chores lenge ol (G21) to see ifthe message aii (8 pressure disappears wich (621) Shor-creit on ves wire La No Disconnect connector CN2A to between the | Repair wire soe the message disappears, ————B> | engine oi lov Pressure switch (624) ana.CN24 Yes. | Shortcut on No Disconnect connector CN to wire La¥ Repair wire seeifthe message disappears Wm |petwoen cNz4 | Lav ‘and CNS No ge | Deietve Replace the computer (At) computer (At) cre 7-2772468 Issued 05-054001-73, Overheating Description of problem No. 4 - The message is stil displayed even when the actual temperature is lower than the following} ‘Temperature of hydraulic oll 84°C, temperature of coolant 92°C Prior check: 1. Make sure that 8 bars are displayed on the hydraulic oil and engine coolant temperature gauge bar-graphs. @ Fie BP 1) c= ==)@3) At Computer B1 Coolant temperature sensor ‘A2 Engine controller B2 Hydraulic oll temperature sensor Issued 05-05 cre 727724684001-74 ‘Troubleshooting ‘Cause Action Ths Bas at oan operate ba graph ae GapySE Key switch ON soe eeasooeea seme =o us cen cee sensrurt wees ere gate ne corre hard See sane nen ~ ae ostane |Repce ne Sess ce oeeere [See ‘connector (B1) to | temperature | temperature See ce secuy |aaret Dore oes eee OSes rein [ccm ne Een rmeto [ose ves Lop epezmegr gs |e soe soars sro [Scan cerca ee Se [een maces a — Sobcnente come vs feorcetotmoonite NO |S. cman ee ae and BP. (Refer to the jon CN24 cN24 ae cones ooncan [oie a ves Sees [Se wee lace east lems, Srcors [Eras Eve how: ns eta shot te tae ney coe rara008 woiesosas‘Overheating (continued) 4001-75 Troubleahosting Cause] _Aation 2, The hydrauls temperalure bar-graph displays 8 bars. Key switch ON Theyre ot temperature sensor (B2}tomperure's Sonoma compared 0 vine ves Seattance CHK {comparson between theatalonpertee and atte) See naraute ot temperate n CHK Y OF Manse the act temperature ‘See problem cose 1020 frie a temperate sensor (Ga)eaing mamtonnce Sioonoste (AGS) wy Diaconnect he temperate senor No Daactve | Repace ne omecte (2) 0 ryareute ot ryote ot measuetnerestance, ———————# temperate |tmperaie (Refer to the table ‘sensor (B2) | sensor (B2) Below othe restances) as Dicconnect the CNA, connection | lean the troresstnce between NO coe a (nya ves ‘hemale terminals OL. —_____gp | drauteo8 temperature TP and80. (Retro the temperature Jenson ‘nia ina rhe Somectr | temnat 2) 6 Cxtomessine tte resistance between the No. | Bod Clean the ves female terminals OL connections |eemnecing tert onenat owe tears) stecive conpuer computer |(at}or dean ves tanorsea {tne Connecion [eomecing cnent|iemnainen ew Noten the event of short-orcult, the bar-graph goes off completely. cre 72772468 Issued 05-054001-76 Coolant and hydraulic oil temperature sensor resistances NOTE: The resistance varies with temperature. Coolant o hysrauie oi Coolant temperature sensor (31) | HP@Aul ol temperature sensor 20°C 608 KD 245K 30°C 42a T66KD FOC BORE TIS KD 80°C 218K BT KO 60°C TeTKa O58 KQ 70°C 720K oaska 80°C O9T KA O32 KQ Defective battery charge circuit Description of problem No. 5 = The message is sil displayed. ‘At Computer G2 Alternator K7 Relay battery cre 7-2772468 M1 Starter motor PS Hourmeter 81. Key switch Issued 05-054001-7 ‘Troubleshooting ‘Cause Action Teoma Te caacmmcum Sea mesure vlogs YES erecting Treteumateresisoesoat Ps Rosanne GS. JONCNS or Seto ‘Sins one sis ete) rence nvear Ove 10 met 5) No | sad conection Disconnect N26 0 Imeeuretevotage ves [°%N25% | ian tina en wen ees ss Nis ropa teal on re ees se rss le ones Sat eare Owe Between yes Disconnect the connector fom termi wt measure the ollage YES between the female terminal on wire R543 and each, Over 10 Disconnect CN to measure the vollage YES between wie BrR5KS at the computer end (A) and earth Over 10 No > ——> 1 Ron the atemator(G2) (G2) and earth. Over 10.V ves. Disconnect CN22 to measure Ime votage Detween the male terminal on wie LOR and fearth Over 10V ves cre 72772468 No) ad connection Jon CN22 or short-circuit on BiRs44 between JoN26 ang CN22 short-circuit on ire RSA between Cn22 andthe atemator(62}or Setectve atemator (G2) Bad connection Jon CNT or Setectve computer (At) Sherteeulton ice R543 Detween CH and OND Defective atiemator (52) 8 connection at terminal Rot ne aterator| 62} or snort eri on wire LoR between JEN22 and the ettemator (G2) short-circuit on ice LgRA0 switch ($1) and JoN22 oF Selective key stn ($1) ean the terminal ‘00 CN22 or repair BrRsas Ropatr wre BrR54 oF change the atemator (G2) ean the connecting terminal on CNA or replace the computer (A) Repair wire oes Replace the atemater (62) ‘ean the terminal ire LaR between (CN22 and the ‘temater (G2) Repair wire UgRS40 orreplace the key switch ey Issued 05-054001-78 Electrical system troubleshooting Description of problem No. 6 - The message is still displayed aynaso ols eS jvRaso| wreat fe a “ ip OOOO) 1 1 Engine ‘Al Computer ‘AZ Engine controller ‘A3_ Electronic acceleration Bat Engine rpm sensor F4 Fuse 10 A; cancellation of hydraulic controls K7_ Relay battery cre 7-2772468 ‘Swing pilot shut-off solenoid valve (green band) Pilot pressure solenoid valve (blue band) ‘Swing brake solenoid vaive (pink band) 2 stage travel solenoid valve (red band) Power-up solenoid vaive (yellow band) ‘Cushion control solenoid valve (ight green band) Main pump proportional solenoid Issued 05-054001-79 Troubleshooting Cause Aetion ‘Troubleshooting using the diagnostic system Key switch ON No Faiure cade dpayed in DINGY ToDAGe ves Seay c0091 ves Deecv election acceleration | check he lato oly erat) acceleration (AS) 8 ves Problem wt rack detector signal Diepay E0082 Pree wl Same os above 0 Dipay E0041 ves Problem wth TOC deacon Faire code dared h AGE ves ves Replace he engine ‘0060 Fauty enn conotar(aay | Renae WO MOOT] Check hat he transistors not short cuted Yes TORK ves elas code dapper decomecingibesooraW] YES [tec cre)solmodvane | eptetbesteras valve connector vale Yn) NO Te are code disappears er daconnecngComedor yes___|shorctcutonwie between | aera new owe zz‘ Sten vane | REP te won NO The are code disposer ater isconnecting connector ves __|Shor-raton wre btwoen ones C23 ade sleoid vave | RePa the wing WO Theale code disappear er dsconnactngComedor yes___[shortoreutonwie between | agar ne wi ons Res and ONS erate wing NO The fur code disappears afer connecng connedor yes __|shortcicuton wire between ons N22 and CS Repetto wing No ve computer (A eolace te Detective computer (At) computer tt) ce 7277.08 tosued 05-054001-80 Description of problem No. 7 The engine will not start even when the message "ELEC. PROBLEM" is not displayed. Prior checks 4- Make sure that there are no problems with the engine and in the fuel system. 2- Make sure that the fuses are intact. 3- Make sure that the starler motor is working and turning the engine. bls @ (ss) a oe, F8 Fuse 15 A; engine emergency stop motor 1. Stop position 2 Start position K1_ Relay-engine emergency stop 3 Cab end M2 Engine emergency stop motor 4 Service connector end ‘$9 Engine emergency stop switch cre 7-2772468 Issued 05-054001-81 Troubleshooting Cause Action Rey salt ON “The fuel inlet cut-off NO Problem with | Check the rr i poston) Sram seen Dzone! omer Noe tom eon pen chet Sp tr Cea orenet be woroptae soc Sian he Swtor yo wo engi op ves Soci CRD ate trae reparhe ‘engine hamess end, —. connector | wire i ronureevsiane tion CERT Ca an eee tretemro The Potean ne ra ede eee ‘Stan 20 an 0 V curate, ck br Conta boon ves nga sup. | rence YES ‘wires L and LW: engine sine | Reni Key switch ON: $$$ itor (2) J engine stop, Key Soectte mtn oy Smith OFF v0 ease th age t trecnge enero Sap rey ome soothe Someones Lend yo [emine [Reece wo co) frwraeney (73M, Rigs ommaecy sep Be |eapiay_|eTazenc seach (GB) ON= OV (eh act seh Engine emergency stop « Snes SO Sree a Open cet Youcan alo cece enlace he ne sari oyrenccn, Tseng |oraseny taper one v5 feces Sopp bere hom be rosy |b erp Soares chant ieee oe 7ar72408 sss.4001-82 Travel Description of problem No. 8 - Not possible to change travel speed No. Test Result Repair ‘Check the signal al conneclor ‘CNG terminal 64 on the computer (at) (0 Volt continuous, repiace the computer (A1) Changing to second speed is not 1, _ [shown on the monitor display (P4) cere rece” when pressing the travel mode Check the signal at connector terminals 3.and 64 switch (S2) ‘CN13 terminal 3on the instrument panel (1) 5 Valls continuous when pressing the switch, replace the travel mode switch ($2) “The electrical hamess between the computer (At) and the 2 stage travel solenoid valve (red band) The travel mode changes when _|(4) is defective the travel mode switch (S2)is held [The voltage is equal to 24 V at the | Check the solenoid valve and the 2 | pressed down for over two ‘output from the computer (CN6 | hydraulic system (see hydraulic |seconds terminal 28) system troubleshooting) The valage Bbw 25 Vata ‘output of the computer (A1) (CN6 | Replace the hamess terminal 28) The eee TaD namo mate CH hen conpur arte tv ict Rea hohaess rove pot poser sun (27) |imcomputr ane evel 3 [does not change to ON when the Pressure switch (B27) is out eae Sone Te wat pt essue vich [Renae te vave pai resus (82/) 1s detective sswiten (8227) “The electrical hamess between the computer (At) and the In diagnostic made CHK3:the | pressure switch (B27)is short | Repair the hamess 4 [upper pill pressure suite (yellow) (826) stays ON Created "The upper plot pressure switch [Replace the upper pilot pressure (yellow) (B26) is defective switch (yellow) (826) Check the pressure Sensors P1 [One of the hamesaos ie defeative [Repair the harness 5 |(642).P2 (B44) and the pressure | Voltage under 5 V, at the input to sensor (nega-cont) (B43) using | one ofthe sensors (842), (B44) or | Replace tne computer (A) mode CHK1 (843) "The electrical hamess between the hydraulic oil temperature ‘sensor (B2) and the computer | Repair the electrical hamess (CN1 terminal 6 and 13) (A1) is The hydraulic ol temperature is | @etectve 6 _|not displayed or is below 25°C on |Voltage under 5 V, at the input to {the CHK1 monitor display the hydraulic olltemperature | Replace the computer (A1) ‘sensor (B2) Voltage equal to 5V, atthe inputto the hydraulic oil temperature ‘sensor (B2) Replace the hydraulic oll temperature sensor (B2) cre 7-2772468 Issued 05-054001-83, ELECTRICAL INSPECTION OF COMPONENTS Inspection equipment Tool: See "Special tools” Details of service connector kit |. For harness end of engine emergency stop motor (6P) 1. Notused For solenoid valve and fuel gauge 2. Not used 3. For engine emergency stop motor (6P) 8. For pressure switch (2P) cre 72772468 Issued 05-054001-84 9. For harness end of pressure switch eo 2g 10. For air conditioning compressor clutch switch (2P) 11, Not used 12. Not used 13.Not used cre 7-2772468 Ss 14.Not used @" 19 @” 15. For hydraulic oil and coolant solution temperature sensor 16. For engine rpm sensor 17.For pressure sensor - Issued 05-0518.For electronic acceleration (RED4) 19. For electronic acceleration (RED4) Ey 20. For electronic acceleration (RED) 4001-85, Proportional solenoid CX130/CX160/CX180 4. Disconneet connector (1) from the main pump proportional valve (Y7) 2. Connect the appropriate service connector (2P) (4) between the connector at the pump end (2) and the connector at the main hamess end (3) and install the meter (5). NOTE: The > terminal of the meter should be ‘connected to wire BrB (brownvblack) on the service connector coming from the main hamess and the terminal to wire BrB (brown/black) on the service ‘connector coming from the hydraulic pump. Issued 05-054001-86 3. When the connections have been mado, start the ‘engine and check the current on the meter (5) in leach work mode, at maximum speed. Current in ma, wea] 7a were bya twe) © | & Pe Pa type x " cexiaa | 00 | «80 [aso | 22°] aa0 | aso 600 | 490 | 490 | 782°} 30 | 490 extea ee BAIT Sor sar | 20 | ane a | ame com ie cxaea | ace | aor | ar | 22°] ser | aor Engine emergency stop motor 1. Disconnect the connector (1) from the engine emergency stop motor (M2). 2 2. Connect the appropriate service connector (61) (4) to the connector at the main hamess end (2) only. 3. Make eure that wire LR (blusired) on the eervice connector (4) is connected to wire LR on the main hhamess (2) and install the meter (3). NOTE: The + terminal on the meter must be connected to wire LR (blue/red) on the service ‘connector and the - terminal to the machine earth, cre 7-2772468 4. Tum tho starter switch key to "ON", tho motor reading should be 24 V. 6 solenoid valve block 4. Disconnect connector (1) from one of the solenoids on the 6 solenoid valve bank (52) Ma Function Bana Yi__ [Swing pot shutoff solenoid valve [Green ¥__[Ponersap saienaa vane Yalow Ya__ [lage wove solenoid vale Red YE___ [Cushion canter solenox valve Tantgreen YS__| Swing brake solenoid vale Pink Y2__| Pot pressure solenoid valve Bue Issued 05-052. Connect the appropriate service connector (3) (3) to the connector on the disconnected solenoid (1) only (Yin) and instal the meter (2). 3. When the connection has been made, the solenoid resistance reading on the meter (2) should be 45 0 at 20°C. NOTE: The value of the resistance varies with temperature. Engine rpm sensor CX130/CX160/CX180 4001-87 ©X210/CX230/CX240 4. Disconnect the connector (1) from the engine mpm. sensor (B41). 2. Connect the appropriate service connector (2P) (2) to the connector (1) on the engine speed sensor (841) only and instal the meter (3). 3. When the connection has been made, the rpm sensor (B41) resistance read on the meter (3) should be U./ kid at 25°C. NOTE: The value of the resistance varies with temperature. Issued 05-054001-88 Engine coolant and hydraulic temperature sensor CX130/CX160/CX180 1. Disconnect the connector (1) for the coolant temperature sensor (B81) or the connector (2) for the oil temperature sensor (B2). Then remove the coolant temperatura sensor (B1) or the oil temperature sensor (B2) from the machine, cre 7-2772468 Service connector (2°) ‘Thermometer Beaker ‘Temperature sensor (B1) or (82) Tripod Spit lamp Meter Connect the appropriate service connector (2P) (3) to the temperature sensor (Bt) or (B2) connector (1) or (2) and install the meter (3). . When the connection has been made, place the temperature sensor (B1) or (82) in the beaker (5) containing water. Place the beaker (5) on the tripod (7). Using the spirit lamp (8) gradually increase the water temperature in the beaker (6). Using the meter (9), check the resistance value in function of the temperature read on the thermometer (4) (see table below). Temperature coor Oil temperature Be oe Ka 2asKa 306 4240 166K a0 soak TER we 2IaKG TaTK ore Tar ToT 706 720K ask sore asi ka. oases. Issued 05-054001-89 Pressure sensor CX130/CX160/CX180 2. Connect the appropriate service connector (3P) (4) between sensor (B42), (B43) or (B44) and the corresponding connector (1), (2) or (3) of the main ames (5) and install the meter (6). NOTE: The + terminal on the meter should be ‘connected to wire YL (yellow/blue) on the service ‘connector and the - terminal to the machine earth. 3. When the connection has been made, start the engine and check the voltages read on the meter (6) in accordance with the pressures indicated in the table below. Pump pressure sensor P1 and P2 4. Disconnect the connector (1) for the pump 1 (B42) pressure sensor or the connector (2) fr the Pressure Pa) Yoraae 7 ump 2 (B44) pressure sensor or the connector % 15 (8) for the negative pressure sensor (843). wT 7 % 2 1s 1 3 35 Pressure sensor (nega-cont) Pressure (MPa) aa 375 250 125 0 cre 72772468 Issued 05-054001-90, cre 7-2772468 Issued 05-05Section 4002 INSPECTION AND MAINTENANCE OF BATTERIES AND CONNECTING A BOOSTER BATTERY Printed n Frence Case re 7-27921G8 ‘Apel 20014002-2 TABLE OF CONTENTS ‘SAFETY INSTRUCTIONS... o ssn soo B ‘SPECIFICATIONS, 3 MAINTENANCE 4 Electrolyte level... sos 4 Inspecting and cleaning the battery 4 INSPECTING THE BATTERY. 5 Visual checks... sv 5 Checking the specific gravity, 5 Charge test. oa 8 CHARGING THE BATTERY 7 BATTERY CHARGING GUIDE 8 PREPARING A DRY CHARGED BATTERY FOR USE. 8 CONNECTING A BOOSTER BATTERY. soon eons o 9 : This symbol is used in this manual to indicate important safety messages. Whenever you see WARNING this symbol, carefully read the message which follows. Your safely depends on i cre 7-2792168, Issued 04-014002-3 SAFETY INSTRUCTIONS WARNING: Never try fo charge a battery which has frozen electrolyte, WARNING: Nover cause sparks and never smoke noe? bateroe. which ere. boing QM chargea"or wtich” nave recently boen charge. WARNING: When disconnecting cables from batteries, always disconnect the earth cable first. When reconnecting cables to a battery, ahways reconnect the earth cable last WARNING: Some batteries have a breather tube. Ifthe breather tube contains battery acid, it could spil out when the battery is tumed round, When you tum the battery round, always keep the end of the ventilation tube away trom yourself and persons in the vicinity. Battery acid can cause very severe buns. WARNING: Batlery acid causes very severe bums. Batteries contain sulphuric acid. Avoid all contact with the skin, eyes and clothes. Antidote: EXTERNAL - Rinse copiously with plenty of water. INTERNAL - Drink farge quantities of water or ‘milk. Follow this with milk of magnesia, a beaten egg or vegetable oil Consult a doctor immediately. EYES - Rinse copiously with plenty of water for 15 minutes and obtain medical assistance Immediately. Batteries produce explosive gases, Keop sparks, flames and cigarettes well away. If you use or charge a battery in a confined space, make sure that it is well ventilated. Always protect your eyes when you are working near batteries. Keep batteries and the acid they contain out of the roach of childron. SPECIFICATIONS See Section 1002 ramice4002-4 MAINTENANCE Electrolyte level Ifthe battery is a maintenance-free battery, check the electrolyte level every 1000 hours of use or every six ‘months, whichever comes first. For all other batteries, check the electrolyte level every 250 working hours. Inspecting and cleaning the battery If the battery is damaged and leaks, it must be replaced. Regularly check for contamination, corrosion land deterioration of the battery. If the top of the battery 's contaminated by impurities or electrolyte, the battery may become discharged, since the current can pass across the terminals, WARNING: When disconnecting cables from the battery, always disconnect the earth cable first. When reconnecting cables to the battery, always reconnect the earth cable last. cre 7-2792168, I the battery has to be cleaned, remove the battery from its retaining bracket and clean the battery, the cable terminals and the battery retaining bracket. If possible, use CASE Battery Saver and Cleaner, following the instructions on the cartridge. CASE Battery Saver and Cleaner also fights corrosion. If CASE Battery Saver and Cleaner is not available, use bicarbonate of soda and water. MAKE SURE that you do not allow the cleaning product to enter the battery cells. WARNING: When disconnecting cables from the battery, always disconnect the earth cable first. When reconnecting cables to the battery, always reconnect the earth cable last. Reinstall the battery on the machine and check that the retainers are fully tightened. Apply CASE Battery ‘Saver and Cleaner or a urethane product to the battery terminals to prevent corrosion. Refer to the Parts Catalogue. Do not use grease. Issued 04-014002-5 INSPECTING THE BATTERY NOTE: To carry out @ correct inspection of the battery, carry out each step of the inspection; this will ‘enable you fo find out the real condition of the battory. Visual checks = Check cable connections are clean and correctly lightened. Remove all foreign bodies from the top of the battery. ~ Check there is no damage to the battery housing, terminals and cables. = Check the electrolyte level, see page 4. ~ ITyou have added water to the baltery, charge the battery for 15 minutes at between 15 and 25 amps to allow te water to mix correctly with the electrolyte, Checking the specific gravity Use an acid hydrometer to check the specific gravity of the electrolyte. The specific gravity shows the charge level in each cell ‘Acid hydrometers are designed to show the correct specific gravity when the electrolyte is at a temperature of 26.7°C. Before checking the specific gravity, check the temperature of the electrolyte. If the hydrometer does not have a thermometer, use a thermometer to measure the temperature of the clectrolyte. The thermometer must be graduated to at least 52°C. 1. Remove enough electrolyte from each cell to allow the float to move freely in the tube. NOTE: If itis not possible to check the specific gravity without first adding water to each cell, charge the battery for 15 minutes at between 15 and 25 amps to allow the water to mix correctly with the electrolyte Then check the specific gravity ramice 2. Read the float, 3. Read the thermometer if the reading is higher than 26.7°C, add specific gravity points to the reading to obtain the specific gravity. If the reading is lower than 26.7°C, subtract specific gravity points trom the reading to obtain the specific gravity. See the stration betow and add or subtract specie gravity points as required, 44. Record the corrected specific gravity for each cel. '5. If the difference between the high and low readings is minimum 0,050, charge the battery and check the specific gravity again. If, after charging, the diference is still minimum 0.050, install a-new battery. NOTE: When the battery is changed, do not install a used battery with @ new battery. That would reduce the life-time of the new battery.40026 6. The corrected specific gravity shows the charge level for each cell, The charge level for each cell should be 75% minimum. For maintenance-free batteries, the charge level is 75% minimum when. the corrected specific gravity is 1.240 minimum. For all other batteries the charge level is 75% minimum when the corrected specific gravity is 1.230 ‘minimum, 7. Ifthe difference between the high and low readings is lower than 0.050 and the charge level is 75% ‘minimum in each call, carry out the charge test. 8. Ifthe difference between the high and low readings is lower than 0.050 but the charge level is lower than 75% in one of the cells, charge the battery and check the specific gravity again. I ater charging ‘A. The charge level is lower than 75% in one of the calls, replace the battery by a new battery 'B. The charge level is 75% minimum in each of the cells, carry out the charge test. cre 7-2792168, Charge test For this check, use a variable charge tester such as the Sun Electric VAT-33 or an equivalent machine. Connect the tester as per the manufacturer's instructions. 4. Tho charge level should bo at least 75%. Carry ut the specific gravity check in this section. 2. Prepare the tester for the tests (the diagram shows a Sun Electric VAT-33). ‘A Select the voltmeter range between 1 and 18 volts B. Check that the charge control knob is in the OFF position. C.Select the ammeter range between 0 and 1000 amps, D. Move the voltmeter switch to the INT position. 1. CHARGE CONTROL KNOB. 2. AMMETER CLAMP (WITH THE POINT OF THE ARROW DIRECTED AWAY FROM THE BATTERY) NOTE: Never apply the charge for more than 15 seconds. Every 15 seconds, tum the charge control knob to OFF for at least 1’ minute. Issued 04-013. Apply a charge of 15 amps to the battery for 18 seconds. Wait at least 3 minutes before continuing the test. 4, Measure and note the temperature of the electrolyte. 5. Refer to specifications for the correct charge for this test, 6. The correct charge corresponds to helf the value of the cold start current (-17°C), 7. Tum the charge control knob until the ammeter shows the current required. Maintain the charge for 1 seconds and read the volimeter. Tum the charge control knob to OFF. 4002-7 8 Compare the reading and the olectrolyto temperature with the values shown below. Electrolyte temperature ‘2PC minimum 76°C 10°C #C °C TC Ke 18°C ‘A If the result ofthe test is higher than or equal to the voltage shown, the battery is in good condition. B.If the result of the test is less than the voltage shown, replace the battery with a new battery. CHARGING THE BATTERY WARNING: Never try to charge a battery which has frozen electrolyte. Before charging the battery, check the electrolyte level. Itis difficult to state an exact charging rate since the following conditions are variable: (1) temperature of the electrolyte, (2) charge level, and (3) condition of the battery. Refer to the Charging Guide for correct charging time. ramice Refer to Specifications on page 3 for the reserve battery charge of this machine. Reduce the rate of charge if 1. The electrolyte spills out of the cells since they are producing too much gas. 2. The temperature ofthe electrolyte exceeds 52°C. NOTE: For optimum charging, select slow charging rales. The battery is fully charged when, after slow ‘charging for 3 hours, no cell is producing too much gas and the specific gravity remains unchanged.4002-8 BATTERY CHARGING GUIDE Recommended rates" and duration for a completely discharged battery. Capacity of the battery ‘See "Reserve" in the ‘specifications on page 3 Slow charging Quick charging ‘80 minutes maximum TO hours at 5 amps Shours at 10 amps 25 hours at 20 amps 41.5 hour at 30 amps Between 80 and 125 minutes TS hours at 5 amps 7.5 hours at 10 amps ‘7s haurs at 20 amps 1.5 hour at 50 amps Between 125 and 170 minutes 20 hours at amps 10 hours at 10 amps Shours at 20 amps Zhours at 50. amps ‘Beween 170 and 260 minutes ‘BO nours ats amps 18 hours at 10 amps 7.5 nours at 20 amps hours at 0 amps Th excess of 250 minutes 2a hours at 10 amps S hours at 40 amps 4 hours at 60. amps * Tnilial rate for a standard charger. PREPARING A DRY CHARGED BATTERY FOR USE 4. Remove the plugs from the battery 2. Fill each cell with electrolyte, up to the top of the separators. This is because the electrolyte volume can increase when it's heated by being on charge. 3. Install the plugs on the battery 4. Connect the battery charger to the battery. cre 7-2792168, 5. Charge the battery at 30 amps until the specific gravity roaches 1.250 minimum and the temperature of the electrolyte reaches at least 155°C 6. If necessary, add electrolyte to each cell until the ‘maximum level indicator is reached (uppers) which corresponds to a value of 10 to 15 mm above the battery polarity plates, Issued 04-014002-9 CONNECTING A BOOSTER BATTERY 4. Open the left-hand side access doors. Remove WARNING: When a battery is frozen it may explode if (1) you try to charge itor (2) you try {o start the engine using jump leads. To BA 2mvent the slectroytetreszing, alvays keep the battery fully charged. Non-observance of these instructions can endanger your safety and that of those around you, WARNING: Batons contin acid and txposve gases. A spark fame or ncorect table connection can cause the batty fo explode. "The conect procedure for AX comectng jump ieads 10° tho machine's battery is explained on this page. Non- bservance ofthese nstuctons may lead 0 Serious o ata muy WARNING: Batons produce explosive gases, Koop all geotes, sparks and fares fuay fom the area. Ifyou charge or uso 2 LN battryina conned space, make sure that is wol vontleted. Aways protect your eves then working noar bts. WARNING: When connecting he jump leads, do not allow the postive (+) and negative (-) cables to touch each othor WARNING: Incorrect connecting of jump leads may cause an accident. Always proceed with the greatest caution. ramice the lid and the screws (1) from the batteries. . While seated in the operator's seat, ask your assistant to carty out the connections. Check that the voltage of the booster batteries is indeed 24 volts, If the connection is being made from another ‘machine, make sure that the two machines do not touch each other. 1. Connect the positive jump lead (+) (1) to the positive terminal (+) on the battery 5. Connect the negative jump lead (-) (2) to a clean vat, away fern Ue ballery. Iosued 06.014002-10 6. If the connection is being made from another machine, start the machine and run it at half of ‘maximum engine speed. 7. Start the engine of the machine requiring the booster connection and ask your assistant 10 disconnect the negative jump lead (-) first and the positive jump lead (*) last 8. Install the lid on the battery and close the left-hand access doors. 9. Do not stop the engine for at least 20 minutes. This is to allow the batteries to recharge correctly. cre 7-2792168, Issued 04-01Section 4003 MAIN ELECTRONIC CONTROL BOX ENGINE ELECTRONIC CONTROL BOX Copyright © 2005 CNH France SA, Printed in France CNH re 7-2793368 May 2005,4003-2 TABLE OF CONTENTS MAIN ELECTRONIC CONTROL BOX AND ENGINE ELECTRONIC CONTROL BOX Removal o Main electronic control box Engine electronic control box. Installation re 7-2798068, Issued 05.054003-3 MAIN ELECTRONIC CONTROL BOX AND ENGINE ELECTRONIC CONTROL BOX Removal CX210/CX230/CX240 STEP 1 Park the machine on hard, flat ground. Lower the attachment to the ground STEP2 Shut down the engine and position the starter switch on OFF. STEP 3 X130/CX160/CX180 cre 7-2790968 Disconnect the main earth cable (-) (A) from the battery. STEP 4 Remove the panel (A) located behind the operator's seat. taking care to disconnect the connector from the cigarette lighter (B) and the solar radiation detector (C). Issued 05.054003-4 Main electronic control box Disconnect the connectors CN1 to ONG from the ‘main electronic control box (B). STEP 6 Remove the 4 retaining screws (A) from the main ‘electronic control box (B). STEP7 Remove the main electronic control box (B). re 7-2798068, Engine electronic control box STEP 5 Identify and remove the engine stop relay (A) and the rotary light relay (). STEP 6 Disconnect the connectors CNAQ, CNA1, ON7 and CNB from the engine electronic control box (C). STEP7 Remove the 4 retaining screws (D) from the engine electronic control box (C). STEP 8 Remove the engine electronic control box (C). Installation To install, proceed in the reverse order from that of removal NOTE: To rebooting the main and engine electronic control boxes, see Section 4001 Issued 05.05