TECHNICAL HANDBOOK Proportional valve characteristic bar 50 2s 20 do 200 G0 G0 560 eho 70 8b mA Fi. 17 Control pressure as a function of input current (Fig. 17) 28 2.801 730,00 usTECHNICAL HANDBOOK Measuring port (X3) at main pumps. Fig. 18 Port (X3, Fig. 18)) serves to measure the control pressure from the proportional valve output. Depending on the preseloted power mode and the operating mode, the pressure values range from 5 bars - 40°? bars (180 mA - 800 mA), A CAUTION Individual machine types have fixed con- trol pressure values (cf. the Service Data belonging to the respective machine). 2801 730.00us, 2TECHNICAL HANDBOOK Coolant temperature sensor B13.1 /R10.2 74 cs Fate Cable (Fig. 19) 89. to central electrical system X101.6 and to on-board computer A10X1.5 174 - to grounding terminal of central electrical system Technical data Thread M 14 x 1.5 Tightening torque 20 Nm Operating temperature range - 30°C to + 180°C Transducer: NTC resistor 30 2.801 730,00 usTECHNICAL HANDBOOK Coolant temperature sensor (B13.1) (R10.2) Fig. 20 Cable (Fig. 20) 99. to central electrical syste X106.3 and to on-board computer A10X1.7 184 - to grounding terminal of central electrical system Technical data Thread M 14 x 1.5 Tightening torque 20 Nm Operating temperature range - 30°C to + 180°C Transducer: NTC resistor a 2801 730.00us, aTECHNICAL HANDBOOK Fault signalling in the ODC (ON-BOARD DIAGNOSTIC SYSTEM) 2001315 Fault code - Table The ODC constantly monitors all essential ma- chine functions for faults in the system. When a fault is detected, the indication ERROR, appears on the control panel display and a fault code indication alternates with the operating hours indicated (zB. 2345 WORKING HOUR Example: Engine coolant temperature too high. Code indication displayed: ERROR 1000 Since this is a severe fault, a buzzer in the Control panel sounds additionally and the red warming lamp signals: coolant temperature too high. 02 ERROR ‘The following fault codes can be displayed: 2345 WORKING HOUR, 100 ERROR, 02 "8000 2345 WORKING HOUR ....). 04 200 10000 08 400 10 ‘800 “40000 1000 ‘80000 72000 05 08 Eleoleielal Fat 2 2.801 730,00 usTECHNICAL HANDBOOK To evaluate the reported faults and to analyze the amount of damage (spare-parts requirements J scope of repair work), the table below (FAULT CODE) sets out the individual codes and the effect on the machine for servicing purposes. Most of the faults listed in the table are stored by the ODC automatically after occurrence of the event in a non-volatile memory in the form of text building blocks (see "Fault storage’) FAULT CODE table ‘Code Trouble Fault Effect 02 | engine temperature sensor ‘cable broken power loss 04 | engine temperature sensor ‘short-circuit power loss 05 | Centry error Centry (08 | proportional valve 1, PLC short-circuit ‘engine power reduction 09. | engine error ‘engine 10 | proportional vaive 1, PLC ‘cable broken| ‘engine power reduction 200 | hydr. temperature sensor ‘cable broken power loss 400 | hydr. temperature sensor ‘shor circuit power loss 200 | hydraulk temperature 100 high power loss 1000 | engine temperature 100 high power loss 2000 | speed 0 and DSI active power loss 8000 | intemal software error 10000 | sensor E-speed ‘cable broken! 40000 | communication error ‘control panel ‘engine power reduction 80000 | pressure sensor SLI ‘cable broken| PLC = Power-Limiting Control 2801 730.00us, 33TECHNICAL HANDBOOK Emergency operation To maintain the machine functions in the event of electronic system failures, the proportional valve is equipped with a mechanical device permitting to set a fixed contro! pressure (Fig. 2) for the electronic PCS output regulator Fo? With this setting, it is possible to continue using the machine at reduced speed without electronic. system, 2 Hex nut 13 mm width over fats 3. Allen screw 4 mm width over flats Emergency operation setting Proportional valve (1, Fig. 2): + Withdraw valve plug for emergency operation. + Remove protective cap. * Slacken lock-nut (2) by holding adjusting spin- dle (3). + Screw adjusting spindle (3) into the valve by four turns, * Start the diesel engine and allow to run at ‘maximum speed. + Fill the bucket and extend the working aquip= ‘ment completely. + Lift the boom with maximum speed, swinging the superstructure at the same time also at maximum speed. * Under these circumstances, the engine speed must not drop below nominal rpm (set control ppanel to display the engine speed). * If necessary, screw adjusting spindle (3) further down into the valve and tighten lock-nut (2) (orque: 15 Nm). * During emergency operation, the valve plug re- ‘mains disconnected from the valve. A CAUTION ‘After removal of the fault and before re- connecting of the valve plug to restore the purely electrical function, the adjusting spindle (3) must be turned out of the valve until the control pressure measured at port (X3) of the main pumps is equal to 0 bar. This procedure ensures that the spring inside the valve no longer rests on the solenoid armature. If the adjusting spindle (3) is not turned back far enough, the valve cannot reach the low pressure setting of 5.0 bars (mobil excavators). 34 2.801 730,00 usTECHNICAL HANDBOOK Failure memory The ODC internally processes the occurrence of failures together with the operating hours counter in such a way that the time at beginning and the fend of the fault event is taken (hours/minutes) and stored in a non-volatile CMOS-RAM, ‘The faults ‘speed = 0" and “low battery voltage" are not stored since they occur at every start of the system. If the failure memory (S1, Fig. 4) is not reset and if 40 faults have been reported (depending on length of text), the faults are automatically over- writen and renumbered, ‘The failure memory can be displayed, printed and stored by the EDS-diagnostic tester 3 2801 730.00us, 3TECHNICAL HANDBOOK CENTRY system - fault messages and remedial actions sore Fad The yellow waming lamp in push-button (44, fig. 3) indicates that a fault has occurred in the CENTRY system (part of the engine control unit). ‘Two indicating modes are provided: = Yellow warning lamp permanently lit CENTRY reports a non-critical fault, Contact the CUMMINS after-sales service soon and have the fault rected. = Yellow warning lamp flashing: ERROR 09 appears on display (5, Fig. 4). CENTRY reports a critical fault! Shut off the engine immediately, contact the CUMMINS after-sales service and have the fault rectified. Together with the flashing waming lamp, the buzzer sounds and the system displays "EN- GINE ERROR". Push-button (44) can be used to read out in formation about the cause of the fault from the CENTRY memory. A CAUTION Use this function of push-button (44) only in the presence of critical faults and if the CUMMINS after-sales service requests the machine user to provide information on the fault cause. Depressing push-button (44) cuts the elec trical connection between the operating panel and the engine. The buzzer stops sounding and the "EN- GINE ERROR" message on the display is extinguished. Buzzer and display are re-activated only after the key-switch of the electrical sys tem has been set first to position "0" and then back to position "I". Recalling information on the cause of faults from memory: ‘Shut off the engine Pull push-button lock backwards (arrow, Fig. 3) land depress the button ca. 2 seconds. The yellow waming lamp now emits a flash code. If several faults are stored in memory, they are displayed one by one with the help of different flash codes. The code sequences are separated by a short pause Note the flash codes and transmit them to the CUMMINS after-sales service where the codes will be analyzed and the corresponding fault causes determined. Plei@eeia) sav Fo a 36 2.801 730,00 usTECHNICAL HANDBOOK EDS special functions Deleting the NV RAM In some special cases, the NV RAM of the con- trol panel must be deleted with the EDS: «after installing a new panel ‘+ when a number > 15 appears on entering the code (starting trouble), ‘to reset the operating-hours counter. Depressing F3 in the main menu for the program- rming mode and the Fé for the control parameters and then the PaDn key displays the ‘NV RAM erase” menu" (Fig. 1). TT erase NW ran 10: FL ee Fat Depressing F1 displays the request to confirm deleting of the NV RAM (Fig. 2). SMT erase WV ran tt: FL are you sure? <1) Ee Fa? After depressing "1" (Fig. 4), the “Reset operating hours" request appears on the screen (Fig. 3) reset operating hows? Fi Fo If needed, the operating hours counter can now also be reset by depressing "1" (Fig 4). TTT Pod reset operating hows? FL are you sure? <1>=yes (O>=0 TT Fo4 2801 730.00us, a7TECHNICAL HANDBOOK Resetting the servicing interval Up to 1500 OH, after 50 OH and then at 500, 1000 and 1500 OH, the control panel automat cally displays the message ‘Next Service" (see operating instructions). Up to 1500 OH, the servicing interval display must be acknowledged with the EDS. Beyond this value, the option can be omitted in the PCS configuration menu: Depressing F6 in the “Main Menu" displays the "Special Functions" menu and F6 again the “Con- trol Panel" (Fig. 5). Protocol PRL Tine program POR File management, 3 Extension Fa control panel 2G oe Fas Alter depressing F1 (Fig. 6) the request "Reset servicing interval" appears (Fig. 7) reset servicing interval EL Immobiliser code 22 factor for specdoneter 2B resistor ewerse.tube sensor: F4 ee Fae The command is executed by depressing "1" After switching the ignition first off and then on. again, the control panel displays the next servic- ing interval (see operating instructions) PC TTT reset servicing intervalt_ are you sure? <1>=yes <0>- Fo? 38 2.801 730,00 usTECHNICAL HANDBOOK Changing the machine start disabling code In the "Control Panelt menu (Fig. 5), key F2 (Fig. 6) can be used to select the code enabling the start function of the machine from any num- ber between 0 and 15 (Fig. 8) Entering the new number with the ENTER key programs land confirming the selection with " the new code into the system (Fig. 9). Code for machine start disable 5 Co-45) —| ST om Code fiir Vegfahrsperre | 75 (0-15) Sind Sie sicher? <1)=Ja =nein Fae Foe 3 2801 730.00us, 39TECHNICAL HANDBOOK Example: Hammer current adjustment with the EDS-diagnostic tester sora The machine must be factory-equipped with origi- ral hammer hydraulics. The hammer function will then appear in cofigura- tion menu P4/2/2 (Fig. 10). Pauipnent/excavator options: i Hotor Stop speedoneter servicing interval fh Vand/tnaunl Ving: wer boost I Fig 10 For optimal hammer operation, the hydraulic-ham- mer manufacturer must have information about the volume flow and the working pressure. If these data are known, the hammer mode DSH current value can be determined as follows. Example: ‘A maximum flow rate of 100 Uimin and an operat- ing pressure of 150 bars are assumed. These values are then applied to the pump out- put diagram of the machine (see service data) and the spring-type regulator characteristic shifted onto this point (Fig. 12). The control pressure (X3) is then the value at the lower intersection of the curve (31 bars), ‘The proportional valve characteristic (Fig. 13) shows a current value of 625 mA. This value is now programmed with the EDS tester in the load- limit regulator menu in line DSH (Fig. 11). Programming: DSH current Depressing first key F3 in the *Main Menu" and then F3 again displays the "Programming Mode Menu (Fig. 11) era Perera Fett ‘The cursor is in line DSF. The arrow key moves the cursor down to line DSH The current must be entered with the numerical keyboard and programmed by depressing EN- TER. Functional sequence of hammer operation: The PCS ist configured for the hammer option. = The operator depresses the hammer key on the control panel The control panel transmits the corresponding information to the PCS. = The operator depresses the button in the con- trol lever. = The PCS switches to the HEAVY mode and presets the programmed DSH current. The ODC monitors the temperature of the en- gine and the hydraulic system. 0 2.801 730,00 usTECHNICAL HANDBOOK R (ban 280 5 10 15 20 100: a bar 40 200 qin) oases Pig 12 ber 50 4s ‘0 31 bg. 35 20 1. +0: Fi. 13 3 2801 730.00us, aTECHNICAL HANDBOOK Switching the hydraulic hammer on A WARNING Read and observe the section "Working with hydraulic hammers - Safety instruc- tions". Pat ‘+ Preselect the “Hydraulic hammer" function by depressing key (19, Fig. 1). The LED above the key lights up. ‘The PMS switches into the HEAVY mode (see: "Programming the hammer current’), 8 Fa? Hammer operation with fixed impact sequence: = Place chisel on the material and start hammer with key (82, Fig. 2) Hammer operation with variable impact sequence: = Place chisel on the material and depress pedal (60). Depressing the pedal increases the ham- ering frequence proportionately (The adjusting cylinder is deactivated in this case). Switching the hydraulic hammer off * Release key (82) or pedal (60). + Depress key (19). The LED above the key goes out. a 2 2.801 730,00 usTECHNICAL HANDBOOK 2801 730.00us, 3c Central electrical system CENTRY system - fault messages and reme- dial actions. Changing the machine start disabling code. Checking / adjusting the high IDLE speed. CCheoking the mode of operation and the spe- Gal FUNCHIONS nner son Checking the power-limiting control Cheoking the temperature control Connector (C5/C8) Gentry. Controt loop Controt Panel (A100) Coolant temperature sensor (B13.1) (R10.2) Coolant temperature sensor B13.1 / R10.2 D Deleting the NV RAM Description of PCS Diesel speed actuator (M10) E EDS special functions Emergency operation Emergency operation setting Engine STOP solenoid (Y1.4) Ensuring proper test conditions for the ma- chine Example of motor measurements Example: Hammer current adjustment with the EDS-diagnostic tester F Fallure memory Fault code - Table FAULT CODE table. Fault signalling in the ODC (ON-BOARD DI- AGNOSTIC SYSTEM), 17 39 14 14 14 16 at a7 19 8 L Locating and rectifying faults uM Magnetic PICKUP (810.1). Measuring port (X3) at main pumps N Nominal speed determination ° (ODG - On-Board Diagnostic Computer ‘On-Board Computer (A10) Pp PCS functional description PCS functional diagram. PCS Troubleshooting Power-limiting control Pressure switch - servo pressure ($10.1) Pressure switch - travelling (S10.2) Programming: DSH current Proportional valve (¥10) Proportional valve characteristic R Resetting the servicing interval s ‘Sequence of operations. ‘Simplified control loop in an electronic power- limiting control system ‘Speed poteniometer (R10) Switching the hydraulic hammer off, ‘Switching the hydraulic hammer on. v Valve connector (Y10) 13 18 29 " 16 38 10 22. 42. 42, 27LIST OF CONTENTS Diseription List of contents ENGINE. 'SMITCH OFF SERVO CONTROL POWER-SYSTEM SWITCH 7 INITIATOR 'SPEED_ ADJUSTING ACTUATOR OPERATOR'S CAB (OPERATOR'S CAB (X12) VALVES 7 GREASING PUMP VALVE 2. GEAR / TRAVEL-ALARM PILOT CONTROL _LEVER LEFT / RIGHT ‘SPECIAL EQUIPMENT (OPTIONAL) HAYMER/SHEARS/FREQUENCY (OPTIONAL) ‘AIR CONDITIONER (OPTIONAL) ‘AOKI = AvOOX2 ‘AOOK3 — ATOKT 100 = x107 x102 x104 xi06 = x07 108 = 015) X16 = XN7 xe = x19) x99 x12 xiv) x7 = x1 BFIS = X20 — OF - X67 X72 LAYOUT PLAN FUSES CABLE SETS AND PLUG SOCKET Remarks 31.050 3005 143.000 Sheet 1-28 Written x Por Sealin Sealin Sealin Sealin Sealin Sealin Sealin Sealin Sealin Senlin Senlin Sealin Sealin Sealin Sealin Senlin Senlin Sealin ‘Sealin Sealin Sealin Sealin Sealin Sealin Sealin Sealin Sealin31.050 rae ch ch -f | sien? 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