CX C Series Excavator

WORKBOOK

Rev. 01 / 2013
 CXC Excavator Workbook

Table of Contents
Classroom Outline ................................................................................................................... 3
Excavator Walk around ........................................................................................................... 5
Starting and Moving a Machine............................................................................................... 6
5 Solenoid Valve Block ............................................................................................................ 7
Swing Brake Operation............................................................................................................ 9
Flow testing the hydraulic pumps. ........................................................................................10
Hydraulic Component Locations ...........................................................................................12
Electrical Component Locations............................................................................................16
Parameter Checks ...................................................................................................................31
Engine Device Test .................................................................................................................33
Common Rail Pressure Test .................................................................................................33
Injector Balance Test (Injector cut out) ..................................................................................34
Injector Forced Drive Test (click test) ....................................................................................35
ECM Memory Clear ...............................................................................................................35
DPD Auto Regeneration ........................................................................................................36
DPD Force Regeneration ......................................................................................................37
EGR Control Valve Test ........................................................................................................38
VG Turbo Control Test ..........................................................................................................39
Intake Throttle Control Test ...................................................................................................40

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CXC Excavator Workbook

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 CXC Excavator Workbook
Classroom Outline

*** Fill in the blanks with the correct information ***

Model Offering
Past Current Future
CX130B
CX160B
CX210B
CX240B
CX290B
CX350B
CX470B
CX700B
CX800B

New Features:
CXC series excavators use a ________ cab. This means that no modifications, alterations,
welding and/or repairs can be performed on the cab.

A counterweight mounted _________________ is standard equipment. _____________

additional cameras can be mounted on the RH side of the machine and the boom.

The monitor incorporates a __________ screen for enhanced visibility and system monitoring.

Engine:
The engine monitors air quantity entering the intake using a ____________________ (MAF)
sensor. This is a 12VDC sensor and requires a ______________________ to operate properly.

The Tier IV Isuzu engine uses a __________________________ Turbocharger. The VG Turbo

controller on the CX210C is located _____________________.

6HK1X engines use a __________________ located between the common rail and fuel injectors
to block fuel flow if an injector or injector line should fail.

Fuel Injectors operate at ____VDC. Fuel pressure at the injectors is controlled by the
_____________________________(SCV).

A fuel pressure sensor monitors inlet fuel pressure at the ________________, and an alarm
sounds when the pressure reaches _________PSI.

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 CXC Excavator Workbook

Electrical:
There are _________ machine controllers(MCM) mounted in the cab. The machine controllers
used on the CXC are the same as / different than the CXB series excavators.

The CXC series uses pressure _________________ to monitor pressure in the hydraulic system.
A _____VDC reference voltage and ground is required for proper operation.

The __________________ will shut down the machine if the machine idles for a set period of
time. The _________________ will idle the machine after hydraulic functions return to neutral.

The 4 gauges displayed on the monitor are:___________________, _______________________,

_______________________ and _______________________.

Hydraulic:
The hydraulic pumps on the CXC series excavator are activated by _______________________.
The ________________________ will control the maximum available flow.

An optional feature for auxiliary controls provides a ___________________ relief valve to

adjust auxiliary system pressure. In this case one relief regulates pressure in both directions.

Two solenoids are mounted to the main hydraulic pumps:

________________________________controls the flow of both P1 and P2 pumps.
P1 flow control solenoid controls __________________________________________.

TIER IV Emissions Solution:

January 1, ____________ will begin the requirement for all engines over _______________ HP
to be Tier IV compliant.

Tier IV emissions regulations require a reduction in ______________ and ____________. NOX

is an acronym for ______________________.

The CXC series uses a DPD system to meet Tier IV emissions requirements. DPD stands for
_____________________________. The DPD's primary responsibility is to reduce___________.

NOX emissions are reduced by _________________________________________(CEGR).

EGR has been increased to approximately ______% for Tier IV compliance.

The ________________________ Valve closes during regeneration to restrict cool air entering
the engine.

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 CXC Series Excavator WALK AROUND
Place the number of the component on the machine in the column to the right

ITEM Description of location

A. Emergency Stop switch

B. Machine Control Module(MCM)

C. Pump Pressure Sensor

D. MAF Sensor

E. Pilot Filter

F. Pressure Reducing Valve

G. DPD Switch

H. EST Connection

I. Upper Pressure Sensor

J. Fuel Cooler

K. Fuse panel

L. EGR Valve

M. 2-Speed travel solenoid

N. Horsepower control solenoid

O. Fuel pump

P. Engine Oil Filter

Q. Intake Throttle Valve

R. Diode

S. Service Diagnostics Tool

T. One-Touch decel

U. VGT Controller

V. Fuel Pressure Sensor

W. Cab Air Filter

X. Fusible Link

Y. Engine Control Module(ECM)

Z. Secondary Fuel Filter

AA. Atmospheric Pressure Sensor

AB. Negative Control pressure sensor

1.) What model machine are you working on?

2.) What is the engine make and model of this machine?

3.) How many work modes are available?

4.) What will happen if the customer depresses the DPD switch during a Regeneration process?

5.) How do you access the service monitor screens?

 CXC Excavator Workbook
Starting and Moving a Machine
Review Starting Procedure:
1. What requirement needs to be met before the engine will start?

2. Prove that your answer above is true and correct

A. Raise the Gate Lock Lever.

B. Attempt to start the engine.

C. What happens?

If the safety circuit were to malfunction and either make the crank circuit inoperable or
the operation of the machine inoperable a bypass can be used to make the machine
move for technicians only.

3. In order to move a disabled machine unhook the lever lock solenoid (Blue Tape)
and plug it into the 2 speed travel wire (Red Tape). This allows the machine to be
operated for emergency purposes after the rabbit button in the dash is actuated.

4. Did this procedure work?

_____ yes _____ no

5. Hook up the solenoids to their original locations.

6. Perform the following:

A. Carefully unhook all connections Machine Controller A carefully.

B. MAKE SURE ALL BYSTANDERS ARE CLEAR OF THE MACHINE AND

ATTEMPT TO START IT.

C. Key on and start the engine.

D. What’s the display doing?

E. What’s the engine speed doing?

F. Will the machine move?

G. Shut the engine off and turn off the key.

H. Carefully hook up all Machine Controller A connections.

I. Unhook all connections to Machine Controller B and repeat steps 6-B to 6-G.

J. Carefully hook up all Machine Controller B connections.

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 CXC Excavator Workbook
5 Solenoid Valve Block
5 Solenoid Control Valve

3
4 2

1 5

Using the schematic and the machine, label by number what each solenoid is
responsible for
Lever lock (Pilot Pressure) Two Stage Relief
Swing Brake Power Save
2 Speed Travel

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 CXC Excavator Workbook

After Identifying the coils answer the following questions:

1. What controls the Lever Lock Solenoid?

2. When is power to the Lever Lock solenoid available?

3. Check for power at the 2 speed solenoid when it is off and on.

4. Is power available at both the power and ground side connections?

5. What completes the ground?

6. What condition must be met before the computer completes the ground?

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 CXC Excavator Workbook
Swing Brake Operation

1. Install a pressure gauge tee into the swing brake circuit as below.

2. Install a minimum of a 1000 psi gauge on to the pressure tap.

3. Start the machine and record the pressure observed_____________

4. Clear the area of all the students and operate the swing. What does the pressure
do? _____________________________.

5. After the machine swing is not operated what does the pressure do?

6. Disconnect the swing pressure (pilot) transducer.

7. Operate the machine again. Is there anything noticeable while operating the
machine? _____________________________________________.

8. Put machine back together the way it was before this procedure.

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 CXC Excavator Workbook
Flow testing the hydraulic pumps.
Perform the following steps:
1. Lower all equipment to the ground.
2. Shut Engine off.
3. Remove pressure from the attachment.
4. Remove pressure from the hydraulic tank.
5. Remove the top plate from the tank.
6. Replace the tank top cover with the flow test adapter supplied in kit CAS40023A.
7. Hook a vacuum pump to the flow test adapter and wait for vacuum to stabilize.
8. Remove the outlet hose from the pump.
9. Cap off the outlet hose with flange adapter set from kit CAS40023A.
10. Attach an elbow (CAS40023A) fitting to the outlet of the hydraulic pump.
11. Attach the flow meter inlet hose to the outlet of the hydraulic pump.
12. Turn the vacuum pump off and remove the vacuum from the tank.
13. Attach the outlet hose from the flow meter to the fitting on the tank
Also see the Below pictures that reference the steps listed above:

Connect hose from outlet

on flow meter to the tank
adapter bolted to top of
hydraulic tank

Vacuum Pump

Attach hose going to the

inlet of flow meter to the
90 degree flange adapter
kit mounted on the
hydraulic pump. Make
sure o-ring is in adapter

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 CXC Excavator Workbook
Flow testing the hydraulic pumps (cont.)

Insert hose in split/captive

flange from kit, this will block off
the hose removed from pump
for flow test. Make sure o-ring
is in hose end

Before flow testing, be sure to unhook the Power Save Solenoid and P1 Proportional
Solenoid. The solenoids actuation can be seen with the flow meter. Flow starts off high
and within 1 to 2 seconds after the machine is running the pumps return to a very low
flow state. To avoid having incorrect results disconnect the power save solenoid and the
P1 Proportional Solenoid.

Record your flow at the following pressures in the columns provided below:
Pressure (PSI) 1 Pump Corresponding flow (GPM)
1000
2000
3000
4000
5000

Once the flow has been recorded from 0 to 5000 psi hold the arm inward over relief.
Hold the arm in and perform the test again with the flow meter. By putting the P1 and P2
pumps online under load we can track how long the pumps stay online under heavy
horsepower consumption.
Pressure (PSI) 1 Pump to flow Corresponding flow (GPM)
meter and 1 pump stalled with
arm in
1000 (p1+p2 = 6000 psi)
2000 (p1+p2 = 7000 psi)
3000 (p1+p2 = 8000 psi)
4000 (p1+p2 = 9000 psi)
5000 (p1+p2 = 10000 psi)
When you have finished collecting the data plot out the data on the model of machine
on the next few pages. The flow data you have collected should put the machine in the
shaded area shown below.

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 CXC Excavator Workbook

Hydraulic Component Locations

Identify the components below with the corresponding table on the bottom of the page.

OVERALL VIEW

Housing left side Pump chamber Fuel

tank
Swing body center section Hydraulic oil tank

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 CXC Excavator Workbook
PUMP CHAMBER HYDRAULIC EQUIPMENT LAYOUT
Identify the components below with the corresponding table on the bottom of the page.

P2 pressure Horsepower control electro-

Hydraulic pump
sensor magnetic proportional
P1 pressure Hydraulic oil temperature
Accumulator
sensor sensor
Pilot filter Pilot pump
5 stack solenoid N2 pressure
valve sensor

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 CXC Excavator Workbook
SWING BODY CENTER SECTION HYDRAULIC EQUIPMENT
Identify the components below with the corresponding table on the bottom of the page.

Swing motor Center joint Control

valve

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 CXC Excavator Workbook
HOUSING LEFT SIDE HYDRAULIC EQUIPMENT LAYOUT
Identify the components below with the corresponding table on the bottom of the page.

Cushion valve (with heat

circuit)
Swing pilot pressure sensor

Oil cooler

Spool Stroke Control Valve

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 CXC Excavator Workbook
Electrical Component Locations
Identify the components below with the corresponding table on the next page.

Main unit Left Side Layout Diagram

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 CXC Excavator Workbook
Main unit Left Side Layout Diagram

Air cleaner Fusible link Battery relay

sensor (IGN) 65 A
Air cleaner Fuse: +B 50 Battery
A
Shuttle valve Fuse: ST 50 Receiver
A dryer sensor
Swing pilot Fuse: Washer
pressure Computer motor
sensor 20 A
Glow relay Starter relay

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 CXC Excavator Workbook
Identify the components below with the corresponding table on the next page.

Engine Section Layout Diagram

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 CXC Excavator Workbook
Engine Section Layout Diagram

Engine EGR valve Suction

coolant control valve
temperature
sensor
Boost Boost Fuel
pressure temperature temperature
sensor sensor sensor
Overheat Starter Cam
switch motor position
sensor
Common rail Engine Crank
pressure hydraulic position
sensor pressure sensor
sensor

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 CXC Excavator Workbook
Identify the components below with the corresponding table on the next page.

Engine Layout Diagram

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 CXC Excavator Workbook
Engine Section Layout Diagram

Sensor hose Pressure Thermo-

DPD FT sensor DPD sensor DPD
CT
Sensor hose Thermo- MAF sensor
DPD RR sensor DPD
FT

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 CXC Excavator Workbook
Identify the components below with the corresponding table on the next page.

Main Unit Right Side Layout Diagram (pump chamber)

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 CXC Excavator Workbook
Main Unit Right Side Layout Diagram (pump chamber)

Magnetic Lever lock Horsepower

fuel pump control
proportional
valve
P1 pressure Swing brake Oil
sensor temperature
sensor
P2 pressure 2-stage N2 pressure
sensor relief sensor
5 stack 2-stage
solenoid travel
valve
Power save Actual milli-
amp for flow
control
proportional
valve

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 CXC Excavator Workbook
Identify the components below with the corresponding table on the next the page.

Cab Layout

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 CXC Excavator Workbook
Air conditioner Rocker switch Air conditioner
sunlight sensor control panel
Monitor display Wiper motor Engine
emergency
stop switch
Knob Radio Rocker switch

Cigar lighter Throttle volume Gate lock limit

switch
Wiper Key cylinder
controller

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 CXC Excavator Workbook
Identify the components below with the corresponding table on the next the page.

Cab Layout Diagram 2

Relays

Fuses

Main
Components

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 CXC Excavator Workbook

Main Components
Computer B ECM (engine Relay
control
module)
Computer A Fuse box

Relays
No. Name No. Name No. Name

ECM relay Neutral start Beacon relay

relay
DPF relay Key ON relay Room lamp
relay
Battery relay Horn relay Right speaker
relay
Idle stop relay Boom, house Left speaker
light relay relay
Starter cut Cab top light
relay relay

Fuses
No.. Name Fuse Rating Name No Fuse Rating

Key switch 15 A Wiper, 15 A

washer
ECM (engine 20 A Travel alarm, 10 A
control signal lamp
module)
GPS 15 A Cigar lighter, 10 A
computer seat
suspension
Backup 10 A DC converter 10 A
(radio, room
lamp)
Gate lock 10 A Air 5A
lever conditioner
unit
Solenoid 10 A Air 15 A
conditioner
blower motor
Horn 10 A Air 5A
conditioner
compressor
Cab top light 15 A Option power 10 A
supply
Boom, house 15 A Feed pump 15 A
light
Option power 15 A Option line 10 A
supply solenoid

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 CXC Excavator Workbook
Identify the components below with the corresponding table on the next the page.

Layout Around Operator Seat

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 CXC Excavator Workbook
Layout Around Operator Seat

Cup holder Throttle Air

volume conditioner
control panel
Starter Tilt lever Engine
switch right emergency
stop switch
Rocker Tilt lever left Gate lever
switch space
Radio Ashtray

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 CXC Excavator Workbook
Identify the components below with the corresponding table on the bottom of the page.

Main Unit Center Section Layout Diagram

Arm Bucket
Suction air
pressure pressure
sensor
sensor sensor
Upper
N1 pressure
pressure
sensor
sensor
Boom Travel
pressure pressure
sensor sensor

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 CXC Excavator Workbook
Parameter Checks
Fill in the following questions 1 to 8, Before starting the Engine.
1. What is the Excavator Model & Hour Meter Model Hour Meter
Reading?
2. What is the hydraulic reservoir pressure before you N1 Pressure N2 Pressure
start the engine? (Hint) Check N1 and N2 before
starting the engine. What causes this pressure?
3. What is the Hydraulic Oil Temperature? °F

4. What is the Coolant Temperature? °F

5. What is the Air Inlet Temperature? °F

6. What is the Boost Temperature? °F

7. What is the Barometric Pressure? PSI

8. What is the Boost Pressure? PSI

START THE ENGINE

9. What is the Engine Speed @ low idle? RPM

10. What is N1 pressure at low idle, no load? PSI

11. What is N2 pressure at low idle, no load? PSI

12. What is the Engine Speed in the "A" Mode with no load? RPM

13. What is the Engine Speed in the "A" Mode under a load? RPM

14. What is the Engine Speed in the "H" Mode with no load? RPM

15. What is the Engine Speed in the "H" Mode under a load? RPM

16. What is the Engine Speed in the "SP" Mode with no load? RPM

17. What is the Upper Pilot Pressure at wide open throttle? (Hint
PSI
activate a upper function to observe the reading).

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 CXC Excavator Workbook
Parameter Checks (cont.)

18. What is the Travel Pilot Pressure at wide open throttle?

PSI
(Hint works best if you stall the tracks to observe the pressure).
19. What is the Swing Pilot Pressure at wide open throttle?
PSI
(Hint lock the swing and then observe the pressure)
20. Which buttons on the dash can you push to lock
the swing circuit?
21. What are the Swing Secondary Relief Pressures? Left PSI Right PSI
(Hint: lock the swing to observe these checks

22. What is the Boost Pressure at no load? PSI

23. What is the Boost Pressure at full load? PSI

24. What is the Boosted Main Pressure for P1 and P2 P1 PSI P2 PSI
pumps?
25. Which throttle mode / modes will have boosted
pressure all the time?
26. Which throttle mode / modes will have boosted
pressure for only 8 seconds?
P1 PSI P2 PSI
27. What is the main pressure of P1 and P2 pumps?

28. Which throttle mode / modes will you observe main

pressure?

29. What is N1 pressure under load? PSI

30. What is N2 pressure under load? PSI

31. What is the Engine Load Ratio during boost pressure in the "SP"
%
Mode?
32. What is the Engine Load Ratio during main pressure in the "SP"
%
Mode after 8 seconds?

33. What is the Hammer secondary relief pressure? PSI

34. What is the Crusher secondary relief pressure? PSI

Low Idle PSI High Idle PSI
35. What is the Engine Oil Pressure?

36. What is the Hydraulic Oil Temperature? °F

37. What is the Coolant Temperature? °F

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 CXC Excavator Workbook
Engine Device Test
Common Rail Pressure Test
1. Perform the Common Rail Pressure Test.

2. What is the minimum Target Common Rail Pressure that you can set?

_______________

3. What is the maximum Target Common Rail Pressure that you can set?

_______________

4. Does the Actual Common Rail Pressure meet the Target Common Rail Pressure
for the minimum and maximum settings?

_____ Yes _____ No

5. Does the engine load ratio change when you perform the test?

_____ yes _____ no

If yes, why? _________________________________________________

If no, why? _________________________________________________

6. Will the Common Rail Pressure Test disable if the engine rpm is above an idle?

_____ yes _____ no

a. If yes, at what approximate engine speed with the test disable?

_____ rpm

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 CXC Excavator Workbook
Injector Balance Test (Injector cut out)
1. Perform the Injector Balance Test for each cylinder of the engine at an idle. (This
test works out better if you can put a light load on the engine, maybe use the
auxiliary hydraulics.)

2. What is the engine speed when the following cylinder is cut out?

Cylinder 1 _____ Cylinder 2 _____ Cylinder 3 _____

Cylinder 4 _____ Cylinder 4 _____ Cylinder 6 _____

3. What is the engine load ratio for each cylinder?

Cylinder 1 _____% Cylinder 2 _____% Cylinder 3 _____%

Cylinder 4 _____% Cylinder 4 _____% Cylinder 6 _____%

4. Did the engine load ratio stay the same from cylinder to cylinder?

_____ Yes _____ No

a. If no, what could be the problem?

______________________________________________________________________

______________________________________________________________________

5. Will the Injector Balance Test disable if the engine rpm is above an idle?

_____ yes _____ no

a. If so, at what approximate engine speed with the test disable?

_____ rpm

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 CXC Excavator Workbook
Injector Forced Drive Test (click test)
1. Perform the Injector Forced Drive Test for each cylinder without the engine
running.

2. Does each injector activate properly? (Hint, listen to an injector clicking noise.)

_____ Yes _____ No

a. If no, What could be the problem?

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

3. Will this test work if the engine is running?

_____ yes _____ no

a. If the Injector Forced Drive Test works with the engine running, will the
test disable if the engine rpm is above an idle?

_____ yes ______ no

i. If so, at what approximate engine speed with the test disable?

_____ rpm

ECM Memory Clear

1. Perform ECM Memory Clear

2. Under what conditions would you perform an ECM Memory Clear?

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

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 CXC Excavator Workbook
DPD Auto Regeneration
1. Warm up the engine to operating temperature.

2. What is the Exhaust Temp at the (DOC)?

_____ °F

3. What is the Exhaust Temp at the (DPD)?

_____ °F

4. What is the DPD differential pressure?

_____ psi

5. Start Auto Regeneration.

a. What is the Exhaust Temp at the (DOC) at the start of Auto Regeneration?

_____ °F

b. What is the Exhaust Temp at the (DPD) at the start of Auto Regeneration?

_____ °F

c. What is the Max (DOC) temp you observed during Auto Regeneration?

_____ °F

d. What is the max (DPD) temp you observed during auto Regeneration?

_____ °F

e. What is the DPD differential pressure at the end of Auto Regeneration?

_____ psi

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 CXC Excavator Workbook
DPD Force Regeneration
1. Perform the DPD Forced Regeneration process.
a. What is the Exhaust Temp at the (DOC) at the start of Forced
Regeneration?

_____ °F

b. What is the Exhaust Temp at the (DPD) at the start of Forced

Regeneration?

_____ °F

c. What is the current mA to the Pump – Flow Proportional Solenoid at the

beginning of DPD Forced Regeneration process?

_____ mA

d. What is the current mA to the Regeneration Assist Proportional Solenoid

at the beginning of the DPD Forced Regeneration process?

_____ mA

e. What is the current mA to the Pump – Flow Proportional Solenoid near the
end of DPD Forced Regeneration process?

_____ mA

f. What is the current mA to the Regeneration Assist Proportional Solenoid

near the end of the DPD Forced Regeneration process?

_____ mA

g. What is the Max (DOC) temp you observed during Forced Regeneration?

_____ °F

h. What is the max (DPD) temp you observed during Forced Regeneration?

_____ °F

i. What is the DPD differential pressure at the end of Forced Regeneration?

_____ psi

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 CXC Excavator Workbook
EGR Control Valve Test
1. Start the engine and run at idle.

2. What is the minimum EGR Valve Target that you can set?

______ %

a. With the EGR Valve Target set to minimum, does the EGR valve actual %
meet the target?

_____ yes _____ no

b. What is the boost pressure with the EGR target set to minimum?

_____ psi

3. What is the maximum EGR Valve Target that you can set?

_____ %

a. With the EGR Valve Target set to maximum, does the EGR valve actual %
meet the target?

_____ yes _____ no

b. What is the boost pressure with the EGR target set to maximum?

_____ psi

4. Will the EGR Valve Control Test disable if the engine rpm is above an idle?

_____ yes _____ no

a. If so, at what approximate engine speed with the test disable?

_____ rpm

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 CXC Excavator Workbook
VG Turbo Control Test
1. Start the engine and run at idle.

2. What is the minimum VGT Target that you can set?

______ %

a. With the VGT Target set to minimum, does the VGT actual % meet the
target?

_____ yes _____ no

b. What is the boost pressure with the VGT target set to minimum?

_____ psi

3. What is the maximum VGT Target that you can set?

_____ %

a. With the VGT Target set to maximum, does the VGT valve actual % meet
the target?

_____ yes _____ no

b. What is the boost pressure with the VGT target set to maximum?

_____ psi

4. Will the VGT Test disable if the engine rpm is above an idle?

_____ yes _____ no

a. If so, at what approximate engine speed with the test disable?

_____ rpm

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 CXC Excavator Workbook
Intake Throttle Control Test
1. Turn the key switch on but do not start the engine.

2. What is the minimum Intake Throttle Target that you can set?

______ %

a. With the Intake Throttle Target set to minimum, does the Intake Throttle
Actual % meet the target?

_____ yes _____ no

3. What is the maximum Intake Throttle Target that you can set?

_____ %

a. With the Intake Throttle Target set to maximum, does the Intake Throttle
actual % meet the target?

_____ yes _____ no

4. Start the engine.

a. Will the Intake Throttle Control Test work if the engine is running?

_____ yes _____ no

b. If the Intake Throttle Control test will work with the engine running, does
the boost pressure change while performing the test?

_____ yes _____ no

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