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CASE CX135SR Service Repair Workshop Manual PDF
CASE CX135SR Service Repair Workshop Manual PDF
CX135SR
9-40641 1 14/12/2004
Contents
INTRODUCTION
DISTRIBUTION SYSTEMS A
POWER PRODUCTION B
TRAVELLING D
BODY AND STRUCTURE E
FRAME POSITIONING F
WORKING ARM H
TOOLS AND COUPLERS J
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INTRODUCTION
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Contents
INTRODUCTION
Foreword ( - A.10.A.40) 3
CX135SR
Torque ( - A.90.A.10) 7
CX135SR
Torque ( - A.90.A.10) 8
CX135SR
Dimension ( - A.92.A.30) 11
CX135SR
Weight ( - A.92.A.40) 14
CX135SR
Consumables ( - A.92.A.55) 15
CX135SR
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INTRODUCTION
Foreword ( - A.10.A.40)
CX135SR
Information search
CRIL03J033E01 1
• The function and information types are codied and appear in parentheses after the title and separated by a dash:
(1) Function
(2) Information type.
• Only the rst letter (A) and the rst number (B) of the function need to be used for the information search.
The rst letter (A) corresponds to the sections of the repair manual.
The rst number (B) corresponds to the chapters of the repair manual.
The rst part of the (A.B) code is reected in the page numbering.
THE REST OF THE CODING IS NOT LISTED IN ALPHA-NUMERIC ORDER IN THIS MANUAL.
• You will nd a table of contents at the beginning and end of each section and chapter.
You will nd an alphabetical index at the end of each chapter.
• Therefore it is the rst part of the (A.B) coding, then the tables of contents and index (page numbers) which will allow you to
quickly nd the information you are looking for.
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INTRODUCTION
CAUTION
M171C - THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL.
WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO
THE POSSIBILITY OF DEATH OR SERIOUS INJURY.
ATTENTION: To avoid injury, always observe the Safety Notices, CAUTION and ATTENTION, contained in this
section and throughout the manual.
Place a “Do not start the machine” warning notice on the starter switch key before all maintenance or repair
operations.
CAUTION
M489 - Read the operators manual to familiarize yourself with the correct control functions.
CAUTION
M490 - Operate the machine and equipment controls from the seat position only. Any other method could
result in serious injury.
CAUTION
M265A - A frequent cause of personal injury or death is persons falling off and being run over. Do not
permit anyone to ride on the machine.
CAUTION
SB055 - Before starting engine, study operators manual safety messages. Read all safety signs on machine.
Clear the area of other persons. Learn and practice safe use of controls before operation. It is your
responsibility to understand and follow manufacturers instructions on machine operation, service, and to
observe pertinent laws and regulation. Operators and service manuals can be obtained from your dealer.
ATTENTION: You risk injury if you wear loose clothing or if you do not use safety equipment for your work. Always
wear clothes which are unlikely to become caught in the machinery. Other safety equipment may be required, in
particular: hard hat, safety boots, ear protectors, safety goggles or mask, thick gloves and reective clothing.
CAUTION
M124A - Rotating machine parts, stay clear, keep shields installed to help protect from clothing
entanglement and injury. Wear close-tted clothing.
CAUTION
SB071 - Rotating fan and belts: Contact will cause injury. Keep clear.
ATTENTION: Follow the procedures exactly when carrying out checks or inspections on the vehicle’s hydraulic
systems. DO NOT CHANGE the procedures.
ATTENTION: Before running the hydraulic cylinders in this vehicle through the cycles necessary for checking their
functioning or for draining a circuit, warn people nearby to move away.
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INTRODUCTION
CAUTION
SM121A - Always wear heat protective gloves to prevent burning your hands when handling heated parts.
CAUTION
M132B - Lower or block elevated implements and other attachments before servicing or when leaving the
equipment.
CAUTION
R149C - Hydraulic oil or diesel fuel leaking under pressure can penetrate the skin and cause infection
or other injury. To Prevent Personal Injury: Relieve all pressure, before disconnecting uid lines or
performing work on the hydraulic system. Before applying pressure, make sure all connections are tight
and components are in good condition. Never use your hand to check for suspected leaks under pressure.
Use a piece of cardboard or wood for this purpose. If injured by leaking uid, see your doctor immediately.
ATTENTION: To remove a hardened pin, such as a pivot pin, or a hardened shaft, use a soft-headed hammer
(brass or bronze) or a brass or bronze peg and a steel-headed hammer.
CAUTION
M428 - Always wear safety glasses when using a drill, hammer, saw, or other tools that may cause chips
to y.
ATTENTION: Use suitable servicing jacks or a chain hoist for raising the wheels or tracks. Always chock the
vehicle in place with suitable safety supports.
ATTENTION: When carrying out maintenance or repair operations on the vehicle, keep the workshop oor, the
driving position and the steps free from oil, water, grease, tools, etc... Use an oil absorbent material and/or workshop
cloths as necessary. Always use sound methods.
ATTENTION: Some parts of this vehicle are very heavy. Use lifting devices or additional assistance recommended
in the Operator’s Manual.
CAUTION
M532 - Do not operate the engine in a closed building. Proper ventilation is required under all circumstances.
CAUTION
M503 - 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.
CAUTION
M244A - BATTERIES CONTAIN ACID AND EXPLOSIVE GAS. EXPLOSION CAN RESULT FROM SPARKS,
FLAMES, OR WRONG CABLE CONNECTIONS. TO CONNECT JUMPER CABLES OR CHARGER, SEE
MANUAL(S) FOR THE CORRECT PROCEDURE. FAILURE TO FOLLOW THE ABOVE INSTRUCTIONS CAN
CAUSE SERIOUS PERSONAL INJURY OR DEATH.
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INTRODUCTION
GENERAL
Cleaning
Clean all metal parts except the bearings with white spirit or steam. Do not use caustic soda for steam cleaning.
After each cleaning, dry and oil all parts. Clean the oil ducts with compressed air. Clean the bearings with parafn,
then dry them completely and lubricate them.
Inspection
Check all the parts when they are disassembled. Replace all parts that show signs of wear or damage. Supercial
scratches and grooves can be removed with an oil stone or with a cloth dipped in red oxide. A complete visual
inspection is necessary to detect wear and pitting, and replacing parts as soon as it becomes necessary will help to
avoid premature breakdowns.
Bearings
Check that the bearings turn freely. Replace them if their adjustment is too free or if their functioning is irregular.
Wash the bearings with a good solvent or parafn and allow them to air dry.
DO NOT DRY THE BEARINGS WITH COMPRESSED AIR.
Needle bearings
Before pushing needle bearings into a cylinder bore, always remove all metallic projections from the bore and its
edges. Before pushing in bearings with a press, coat the inside and edges of the bearings with Vaseline.
Gears
Check all the gears and ensure that they do not show any signs of wear or damage. Replace the worn out
or damaged gears.
Shaft
Check all shafts showing wear or damage. Enusre that the surface of a shaft carrying a bearing or gasket is
not damaged.
Spare parts
Always use CASE spare parts. To order these, refer to the Spare Parts Catalogue and indicate the correct reference
number of the CASE spare parts.
Breakdowns caused by the use of parts other than CASE spare parts are not covered by the warranty.
Lubrication
Use only the oils and lubricants specied in the Operator’s Manual or the Service Manual.
Breakdowns caused by the use of oils and lubricants not specically listed are not covered by the warranty.
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INTRODUCTION
Torque ( - A.90.A.10)
CX135SR
CRIL03H012E01 1
The numbers in the diagrams represent the order of tightening.
Tightening torque
Where there are no special instructions, tighten cap nuts screws to the torques given in the table below.
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INTRODUCTION
Torque ( - A.90.A.10)
CX135SR
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INTRODUCTION
CRIL03L001H01 1
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INTRODUCTION
CRIL03L002H01 2
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INTRODUCTION
Dimension ( - A.92.A.30)
CX135SR
CRIL03L003G01 1
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INTRODUCTION
CRIL03L004G01 2
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INTRODUCTION
CRIL03L005G01 3
Dippers 2.11 m
(A1) 3.54 m (A2) 2.87 m (B) 2.75 m (C) 7.47 m
(D) 2.26 m (E) 2.41 m (F) 0.88 m (G) 1.48 m
(H) 3.51 m (I) 2.78 m (J) 1.99 m (K) 0.60 m
(L) 2.59 m (M) 0.43 m (N1) 5.27 m (N2) 5.20 m
(P) 1.24 m (Q) 1.17 m (R) 2.49 m (S) 0.57 m
(T) 1.15 m (U) 1.18 m (V) 0.21 m
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INTRODUCTION
Weight ( - A.92.A.40)
CX135SR
Weight of machine
Conguration Weight Ground
pressure
With 600 mm track pads, monobloc boom, 2.40 m dipper, 380 kg backhoe bucket, 13200 kg 0.36 bar
operator and full fuel tank
With 600 mm track pads, monobloc boom, 2.40 m dipper, 380 kg backhoe bucket, 14 100 kg 0.38 bar
operator and full fuel tank
With 600 mm track pads, backhoe-offset boom, 2.10 m dipper, 380 kg backhoe 14 200 kg 0.38 bar
bucket, dozer blade, operator and full fuel tank
Weight of components
Components Mono boom Mono boom Offset
dozer blade backhoe
boom dozer
blade
Engine 363 kg
Hydraulic pump 91 kg 94 kg
Attachment control valve 140 kg 180 kg
Swing motor and reduction gear assembly 103 kg
Travel motor and reduction gear assembly 144 kg
Boom cylinder 121 kg
Dipper cylinder 157 kg
Bucket cylinder 93 kg
Dozer blade cylinder 50 kg
Offset backhoe boom cylinder 71 kg
Counterweight 3330 kg 2770 kg 2780 kg
Cab kg
Turntable 177 kg
Upperstructure assembly 8990 kg 8490 kg 9150 kg
Hydraulic swivel 26 kg 56 kg
Undercarriage assembly 4170 kg 4970 kg
Machine without attachment 11040 kg 11340 kg 11350 kg
Attachment 2140 kg 2770 kg
Boom assembly 1210 kg 1900 kg
Dipper assembly 550 kg 520 kg
Dozer blade 680 kg
Radiator and oil-cooler assembly 55 kg
Fuel tank 62 kg
Hydraulic reservoir 88 kg
Idler wheel 61 kg
Upper roller 16 kg
Lower roller 20 kg
Tension shock absorber 77 kg
Track 500 mm 711 kg
Track 600 mm 793 kg
Track 700 mm 943 kg
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INTRODUCTION
Consumables ( - A.92.A.55)
CX135SR
Hydraulic uid
CASE AKCELA hydraulic uid is specially designed for high pressure applications and for the CASE hydraulic
system.
The type of uid to be used depends on the ambient temperature.
• TEMPERATE COUNTRIES - 20 °C to + 40 °C
CASE AKCELA HYDRAULIC EXCAVATOR FLUID
(MS 1230. ISO VG 46. DIN 51524 PART 2 HV)
• HOT COUNTRIES 0 °C to + 60 °C
CASE AKCELA HYDRAULIC EXCAVATOR FLUID "HOT CLIMATE"
(MS 1230. ISO VG 100. DIN 51524 PART 2 HV)
• COLD COUNTRIES - 40 °C to + 20 °C
CASE AKCELA HYDRAULIC EXCAVATOR FLUID "COLD CLIMATE"
(MS 1230. ISO VG 22. DIN 51524 PART 2 HV)
• BIODEGRADABLE FLUID - 30 - +40 °C
This yellow uid can be mixed with standard uid.
If this liquid is used, it is advisable to completely drain the hydraulic circuit .
CASE AKCELA HYDRAULIC EXCAVATORS FLUID BIO
(MS 1230. ISO VG 46. DIN 51524 PART 2 HV)
Grease
"Extreme Pressure" multi-purpose grease
• CASE AKCELA MOLY GREASE 241H EP-M (251H EP-M NLGI2)
with lithium and molybdenum bisulphide soap.
• CASE AKCELA 251H EP MULTI-PURPOSE GREASE (251H EP. NLGI 2)
with lithium and calcium soap.
• CASE AKCELA PREMIUM GREASE EP-2 (NLGI 2)
with lithium soap.
HYDRAULIC HAMMERS
Use only CASE AKCELA PREMIUM GREASE EP-2 (NLGI 2) grease with lithium soap.
Engine oil
CASE AKCELA NO. 1 ENGINE OIL is recommended for the engine.
This oil provides correct lubrication for your engine in all working conditions.
If CASE AKCELA NO. 1 ENGINE OIL Multigrade cannot be obtained, use oil corresponding to one of the following
categories: ACEA E5. MS 1121. API CH-4.
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INTRODUCTION
CRIL03H015F01 1
OIL USE RANGE
1. Mineral-based
2. Semi-synthetic based
3. Synthetic based
Fuel
Use fuel that is compliant with ASTM (American Society for Testing and Materials) standard D975.
• Use Grade No 2 fuel. The use of other types of fuel can result in a loss of power and may cause high fuel
consumption.
• When the temperature is very cold, the use of a mixture of No 1 and No 2 fuel is permitted. See your fuel
vendor for winter fuel requirements in your area.
• If the temperature falls below the fuel cloud point (point at which wax begins to form) the wax crystals will
cause power loss or will prevent the engine from starting.
IMPORTANT: In cold weather, ll the fuel tank at the end of the day’s work to prevent condensation from forming.
FUEL STORAGE
Long storage can lead to the accumulation of impurities and condensation in the fuel tank. 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 LRD -25°C
For environments with temperatures falling to - 25 °C, do not mix with water.
CASE AKCELA PREMIUM ANTI-FREEZE (MS 1710)
For environments with temperatures falling to - 38 °C, use with water in a proportion of 50/50.
IMPORTANT: Do not mix products of a different origin or a different make.
The system must be topped up with the same product.
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INTRODUCTION
Environment
Before carrying out any servicing operation on this machine and before disposing of used uids or lubricants, always
think of the environment. Never throw uid or oil on the ground and never keep them in leaking receptacles.
Contact your local ecological recycling centre for information on appropriate ways to dispose of these substances.
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INTRODUCTION
General
Contamination of the hydraulic system is a major cause of incorrect operation of hydraulic components.
Contamination is indicated by the presence of foreign particles in the hydraulic uid.
Contamination of the hydraulic system can occur in any of the following situations:
1. When draining the uid or disconnecting a hydraulic line.
2. When disassembling a component.
3. Due to normal component wear.
4. Due to damaged or worn seals.
5. Due to a damaged component in the hydraulic system.
All hydraulic systems can function even if they are slightly contaminated. The components of the hydraulic system
are designed to support slight contamination. Any increase in the degree of contamination can cause serious
problems in the hydraulic system.
If any of the above situations occurs, it is an indication of excessive contamination of the hydraulic system.
To eliminate contamination, effectively, refer to PRIMARY HYDRAULIC POWER SYSTEM - Decontaminating
(A.10.A - F.30.A.60).
Types of contamination
Contamination exists basically in two forms: microscopic or visible.
We speak of microscopic contamination when very small particles of foreign bodies are in suspension in the
hydraulic uid. These particles are too small to be seen or felt. Microscopic contamination can be detected by
identifying the problems relating to microscopic contamination or by laboratory tests.
We speak of visible contamination when the presence of foreign bodies can be detected visually, by touch or by
smell. Visible contamination can cause the sudden failure of a component.
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INTRODUCTION
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INTRODUCTION
NOTE: For all parts orders, requests for information or assistance, always specify the type and the serial number of
the machine to your CASE dealer.
Fill out the following lines with the required information: type, year of manufacture, serial number of the machine
(manufacturer’s plate), mark, type and serial number of the engine, and serial numbers of hydraulic components.
Manufacturer’s plate
CRIL03H001E01 1
Engine
MAKE TYPE SERIAL NUMBER
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INTRODUCTION
NOTE: For all parts orders, requests for information or assistance, always specify the type and the serial number of
the machine to your CASE dealer.
Fill out the following lines with the required information: type, year of manufacture, serial number of the machine
(manufacturer’s plate), make, type and serial number of the engine and serial numbers of hydraulic components.
Manufacturer’s plate
CRIL03I175E01 1
Engine
MAKE TYPE SERIAL NUMBER
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INTRODUCTION
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REPAIR MANUAL
DISTRIBUTION SYSTEMS
CX135SR
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Contents
DISTRIBUTION SYSTEMS - A
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DISTRIBUTION SYSTEMS - A
CX135SR
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Contents
DISTRIBUTION SYSTEMS - A
TECHNICAL DATA
PRIMARY HYDRAULIC POWER SYSTEM - General specication (A.10.A - D.40.A.10) 5
CX135SR
Hydraulic pump
Hydraulic pump - Special tools (A.10.A.20 - D.20.A.40) 13
CX135SR
FUNCTIONAL DATA
PRIMARY HYDRAULIC POWER SYSTEM - Static description (A.10.A - C.30.A.20) 15
CX135SR
Stack valve
Stack valve - External view (A.10.A.18 - C.10.A.40) 19
CX135SR
Hydraulic pump
Hydraulic pump - Sectional view (A.10.A.20 - C.10.A.30) 27
CX135SR
Sensing system
Sensing system Temperature sensor - Electronic schema (A.10.A.95.90 - C.20.A.50) 32
CX135SR
SERVICE
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PRIMARY HYDRAULIC POWER SYSTEM - Warm up (A.10.A - F.35.A.40) 33
CX135SR
Stack valve
Stack valve - Remove (A.10.A.18 - F.10.A.10) 41
CX135SR
Relief valve
Relief valve - Disassemble (A.10.A.16 - F.10.A.25) 50
CX135SR
Hydraulic pump
Hydraulic pump - Remove (A.10.A.20 - F.10.A.10) 53
CX135SR
Compensator
Compensator - Disassemble (A.10.A.23 - F.10.A.25) 65
CX135SR
Reservoir
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Reservoir - Remove (A.10.A.22 - F.10.A.10) 69
CX135SR
Oil lter
Oil lter - Remove (A.10.A.24 - F.10.A.10) 72
CX135SR
Sensing system
Sensing system Temperature sensor - Electrical test (A.10.A.95.90 - F.40.A.50) 74
CX135SR
DIAGNOSTIC
PRIMARY HYDRAULIC POWER SYSTEM - Troubleshooting (A.10.A - G.40.A.10) 75
CX135SR
Stack valve
Stack valve - Troubleshooting (A.10.A.18 - G.40.A.10) 75
CX135SR
Relief valve
Relief valve - Troubleshooting (A.10.A.16 - G.40.A.10) 76
CX135SR
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Capacities
Total hydraulic circuit 125 L
Hydraulic uid reservoir 81 L
Coolant only 7L
Calibration pressure
Pilot circuit main relief valve (± 1 bar) 39 bar
Main relief valve (standard) (± 3 bar) 343 bar
Main relief valve (option) (± 3 bar) 206 bar
Secondary relief valve (boom, dipper and bucket) ( ± 5 bar) 378 bar
Secondary relief valve (swing) (± 4 bar) 280 bar
Secondary relief valve (travel) (± 5 bar) 343 bar
Secondary relief valve (dozer blade) (± 5 bar) 235 bar
Secondary relief valve (backhoe offset) (± 5 bar) 235 bar
Secondary relief valve (boom and dipper) (± 5 bar) 378 bar
Boom cylinder
Barrel diameter 105 mm
Rod diameter 75 mm
Stroke 1120 mm
Dipper cylinder
Barrel diameter 115 mm
Rod diameter 80 mm
Stroke 1108 mm
Bucket cylinder
Barrel diameter 95 mm
Rod diameter 65 mm
Stroke 881 mm
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Backhoe-offset cylinder
Barrel diameter 120 mm
Rod diameter 65 mm
Stroke 863 mm
Control valve
Five-section control valve for dipper, boom acceleration, swing, option and right travel.
Four-section control valve for dipper acceleration, bucket, boom and left travel.
Two-section control valve for dozer blade and backhoe-offset boom.
Load holding relief valve for boom and dipper.
Swing motor
Fixed ow motor with axial pistons.
Automatic disk brakes.
Travel motor
Two-speed motor with axial pistons.
Automatic disk brake.
Attachment
Breakout force 8970 daN
Breakout force (dipper 2.11 m - backhoe-offset) 5950 daN
Breakout force (dipper 2.39 m) 6390 daN
Breakout force (dipper 2.85 m) 5960 daN
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
CRIL03K035H01 1
Location of secondary relief valves
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Calibration pressure
Item Description Secondary Nominal Pressure For pressure setting
relief pressure with one procedures,
pressure read on the turn of the refer to:
setting machine screw
(or for a
shim*)
Main pump negative pressure 27 bar Hydraulic pump - Pressure
test (A.10.A.20 - F.40.A.30)
Pilot accumulator check Accumulator - Check
(A.14.A.30 - F.40.A.11)
(A) Main relief valve(standard 343 bar to 346 bar 178 bar Relief valve - Pressure setting
pressure) 60 L/min (A.10.A.16 - F.45.A.70)
(B) Boom raising port secondary 378 bar to 391 bar 212 bar Relief valve - Pressure test
relief 20 L/min (H.20.B.16 - F.40.A.30)
(B1) Boom cylinder safety valves 378 bar to 391 bar - Safety valve - Pressure
(B2) secondary relief 20 L/min setting (H.20.B.15 - F.45.A.70)
(C) Boom lowering port secondary 378 bar to 385 bar 212 bar Relief valve - Pressure test
relief 20 L/min (H.20.B.16 - F.40.A.30)
(D) Dipper out port secondary relief 378 bar to 395 bar 212 bar Relief valve - Pressure test
20 L/min (H.25.B.16 - F.40.A.30)
(D1) Dipper cylinder safety valves 378 bar to 395 bar - Safety valve - Pressure
secondary relief 20 L/min setting (H.25.B.15 - F.45.A.70)
(E) Dipper in port secondary relief 378 bar to 393 bar 212 bar Relief valve - Pressure test
20 L/min (H.25.B.16 - F.40.A.30)
(F) Bucket open port secondary 378 bar to 395 bar 212 bar Relief valve - Pressure test
relief 20 L/min (H.30.C.16 - F.40.A.30)
(G) Bucket close port secondary 378 bar to 397 bar 212 bar Relief valve - Pressure test
relief 20 L/min (H.30.C.16 - F.40.A.30)
(H) Pilot circuit main relief 42 bar 39 bar 20 bar Relief valve - Pressure test
(A.14.A.16 - F.40.A.30)
(I) RH swing port secondary relief 280 bar to 285 bar 117 bar Relief valve - Pressure test
78 L/min (F.40.C.16 - F.40.A.30)
(J) LH swing port secondary relief 280 bar to 285 bar 117 bar Relief valve - Pressure test
78 L/min (F.40.C.16 - F.40.A.30)
(K) Forward travel secondary relief 348 bar 348 bar 10 bar* Relief valve - Pressure test
(F.10.F.16 - F.40.A.30)
(L) Reverse travel secondary relief 348 bar 348 bar 10 bar* Relief valve - Pressure test
(F.10.F.16 - F.40.A.30)
(O) Backhoe-offset to the right 275 bar to 230 bar 212 bar Relief valve - Pressure test
secondary relief 20 L/min (H.20.D.16 - F.40.A.30)
(P) Backhoe-offset to the left 216 bar to 188 bar 212 bar Relief valve - Pressure test
secondary relief 20 L/min (H.20.D.16 - F.40.A.30)
(S) Dozer blade and backhoe-offset 206 bar to 215 bar 212 bar Relief valve - Pressure test
main relief 54 L/min (A.12.A.16 - F.40.A.30)
(T) Dozer blade lowering secondary 235 bar to 250 bar 212 bar Relief valve - Pressure test
relief 20 L/min (J.40.F.16 - F.40.A.30)
(U) Dozer blade raising secondary 235 bar to 250 bar 212 bar Relief valve - Pressure test
relief 20 L/min (J.40.F.16 - F.40.A.30)
(W1) Option circuit secondary relief As recom- 212 bar
mended by
manufac-
turer
(W2) Option circuit secondary relief As recom- 212 bar
mended by
manufac-
turer
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
CRIL03G253E00 1
DESCRIPTION QUANTITY CODE
Tester assembly for Multi-Handy 2051 - E54444449
Multi-Handy 2051 tester 1 D5444448
Pressure sensor (0 bar to 600 bar) 2 V5344460
Straight union for sensor 2 W5344461
Elbow union for sensor 1 X5344462
Engine speed sensor 1 Z5344463
Cable (length 5 m) 3 E3144472
Electric plug 220 volts 50 Hz 1 D5344467
Cigarette lighter cable 1 E5344468
Instruction Sheet 1 -
Carrying case 1 N5344476
CRIL03G254E00 2
DESCRIPTION QUANTITY CODE
Turbine 1 RE3 Z5344486
Plates M45x2 2 D4323359
Flange diameter 24 mm 2 B8230183
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Semi-ange 4 D4024267
Screw M12 length 75 mm 8 Z1232983
CRIL03G258E00 3
DESCRIPTION CODE
Union assembly for testing pressure and ow CAS30038
CRIL03G259E00 4
DESCRIPTION CODE
Set of high pressure hoses CAS30036
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
CRIL03G255E00 1
DESCRIPTION CODE
Digital tester assembly for pressure measurement OEM1652
CRIL03G256E00 2
DESCRIPTION CODE
Digital tester assembly for pressure and temperature measurement OEM1653
Flowmeter
CRIL03G257E00 3
DESCRIPTION CODE
Flowmeter for a ow of < 75 GPM CAS10280
Flowmeter for a ow of > 75 GPM OEM1240
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
CRIL03G258E00 4
DESCRIPTION CODE
Union assembly for testing pressure and ow CAS40023A + CAS40035
CRIL03G259E00 5
DESCRIPTION CODE
Set of high pressure hoses CAS30036
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
CRIL03K87F01 1
Main pump ow curve and pressure
CRIL03G165E01a 1
Pump bracket (shaft side)
Used to secure the pump in the upright position during pump removal and assembly. To be made locally.
(A) Diameter 150 mm
(B) Diameter 50 - 80 mm
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(C) 65 mm
Overhaul dimension of the cylinder block, the valve plate and the swash plate
Valve plate (sliding contact surface) Standard roughness 0.1 Ra or less
Swash plate (at the thrust plate) after grinding
Cylinder block (sliding contact surface) Roughness of the 0.8 Ra
Irregularity of each surface surface at the wear limit
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TRAVEL
Functions Description Refer to
HIGH SPEED High speed is obtained by changing the travel motors TRAVELLING Travel - Hydraulic
from large displacement to small displacement. schema (F.10.F - C.20.A.20)
When the pressure increases too much, the motors
automatically change to low speed.
LOW SPEED Low speed is obtained when the travel motors are TRAVELLING Travel - Hydraulic
changed to high displacement. schema (F.10.F - C.20.A.20)
STRAIGHT-LINE If you want to use the attachment or the swing during TRAVELLING Travel - Hydraulic
TRAVEL travel, the machine will continue in a straight line without schema (F.10.F - C.20.A.20)
zig-zagging.
SWING
Functions Description Refer to
BRAKING When the swing control is in the neutral position, the SWINGING Circular swing -
motor and reduction gear assembly is braked. Hydraulic schema (F.40.C -
When the swing is operated, the motor and reduction C.20.A.20)
gear assembly brake is released.
When the swing control is in the neutral position
and the boom, dipper or bucket is used, the swing
moto-reduction gear assembly brake is released.
The swing is braked 5 seconds after putting the control
into neutral or when the attachment is no longer
operated.
PRIORITY The swing torque is maintained by the priority valve SWINGING Circular swing -
incorporated in the control valve. Hydraulic schema (F.40.C -
When working in a trench, the swing variable priority C.20.A.20)
valve is activated to provide sufcient ow to the dipper.
ANTI-REBOUND This function reduces the number of rebounds when the SWINGING Circular swing -
swing is stopped. Hydraulic schema (F.40.C -
A protective valve is mounted on the swing motor. C.20.A.20)
ATTACHMENT
Functions Description Refer to
BOOM LIFTING An internal spool is used to provide two ows when BOOM Lift - Hydraulic schema
raising the boom. (H.20.B - C.20.A.20)
BOOM LOWERING, Boom lowering is made possible by unlocking the load BOOM Lift - Hydraulic schema
LOAD HOLDING holding system which is incorporated in the control valve. (H.20.B - C.20.A.20)
BOOM LOWERING, The acceleration and the ow reduction pressure BOOM Lift - Hydraulic schema
ADDITIONAL information are controlled via the additional supply in (H.20.B - C.20.A.20)
SUPPLY the boom spool and the continuous connection between
the supply and the return.
BOOM LOWERING, The pressure points are controlled by the circuit which BOOM Lift - Hydraulic schema
VIBRATION keeps part of the supply ow for the free passage. This (H.20.B - C.20.A.20)
PREVENTION is used to reduce vibration.
DIPPER OUT An internal spool provides two ows for the dipper. DIPPER Lift - Hydraulic schema
(H.25.B - C.20.A.20)
DIPPER IN, LOAD Dipper in is made possible by unlocking the load holding DIPPER Lift - Hydraulic schema
HOLDING system that is incorporated in the control valve. (H.25.B - C.20.A.20)
DIPPER IN, The additional supply cancellation valve makes DIPPER Lift - Hydraulic schema
ADDITIONAL combined movements quicker. (H.25.B - C.20.A.20)
SUPPLY
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OTHERS
Functions Description Refer to
DOZER BLADE A separate circuit (pump and control valve) supplies the LANDSCAPING Dozer blade
blade. - Hydraulic schema (J.40.F -
C.20.A.20)
PUMP FLOW Is used to reduce power consumption by decreasing the See following page
REDUCTION INFO pump ow when the machine is not under load or the
controls are in neutral.
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CRIL03J157G01 1
Controls in neutral position
(1) Low pressure pump (2) Pressure limiter
(3) Pressure limiter (4) Calibrated port
(5) Calibrated port (B26) Upper pilot pressure switch
(B27) Travel pilot pressure switch
• In neutral with the engine running, some of the ow from the low pressure pump (1) fed to (PP) is divided by a
calibrated restrictor bridge. One part passes through the two travel spools, and the other passes through all
the other spools before rejoining the general return circuit. When the spools are moved, these circuits will be
locked, which will close upper pilot (B26) and travel pilot (B27) pressure switches.
• Pump outlet (A1) enters (P2) on the control valve, while pump (A2) enters in (P1), passing through the control
valve via the free passages. They are controlled by two pressure limiters (2) and (3) set to 26,7 bar under
27 L/min and two restrictors (4) and (5). Both these pressures are sent to the HP pumps via ports (Pi1)
and (Pi2) to set them at minimum ow.
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CRIL03L043H01 1
Control valve block with options
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NOTE: Refer to the functions concerned for sections of the control valve block not described in this chapter.
CRIL03J093F01 1
Section A-A
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CRIL03J092G01 2
Section B-B
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CRIL03L045F01 3
Other sections
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CRIL03J089F01 1
(16) Valve
(17) Spring
(18) Seal
(19) Seal
(62) Main relief valve
(69) Plug
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CRIL03J088F01 1
Section I-I - Swing priority spool, negative pressure valves and dipper recycling valve.
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CRIL03J104F01 2
Section J-J - Flow re-injection spool
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CRIL03J050H01 1
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CRIL03K028G01 2
Secondary hydraulic pump coupling
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CRIL03J178H01 1
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CRIL03K145F01 1
Circuit layout
(1) Coolant temperature indicator (2) Coolant or hydraulic oil overheating indicator
lamp
(3) Audible alarm device (A2) Engine electronic control box
(B1) Coolant solution temperature sensor (B9) Coolant solution temperature sensor
(B10) Hydraulic oil temperature thermo-switch (P1) Instrument panel
CRIL03G094E03 2
Timing diagram
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DANGER
M252A - Hydraulic uid escaping under pressure can have enough force to penetrate the skin. Hydraulic
uid may also infect a minor cut or opening in the skin. If injured by escaping uid, see a doctor at
once. Serious infection or reaction can result if medical treatment is not given immediately. Make sure
all connections are tight and that hoses and lines are in good condition before applying pressure to the
system. Relieve all pressure before disconnecting the lines or performing other work on the hydraulic
system. To nd a leak under pressure use a small piece of cardboard or wood. Never use hands.
IMPORTANT: This operation must be carried out before any work is done on the hydraulic circuit.
1. Park the machine on hard, at ground.
2. Open the bucket until the cylinder rod is completely
retracted.
3. Extend the dipper until the cylinder rod is completely
retracted.
Lower the boom so that the end of the dipper is
resting on the ground.
Lower the tool to the ground.
Lower the dozer blade to the ground
4. Slow the engine speed to idle for 30 seconds, then
switch off the engine.
5. Turn the starter switch key to "ON" without starting
the engine.
6. Lower the pilot control cancellation lever.
7. Operate each control more than 10 times in both
directions to release all pressure in the circuits.
8. Press button (1) located on the hydraulic reservoir
breather to release pressure in the reservoir.
CRIL03J174A01 1
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NOTE: It is recommended to install the vacuum pump before carrying out any work on the hydraulic circuit which
requires opening the circuit.
Installing this pump prevents uid loss when the circuit is opened.
This chapter describes the procedure for installing vacuum pump CAS-10193.
1. Remove plate (A) from the top of the hydraulic
reservoir.
Do not remove the reservoir seal.
CRIL03L075A01 1
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IMPORTANT: A hydraulic component and the circuit must be bled after the component has been replaced.
It is essential to ll the pump and motor housings and hydraulic components with oil before starting the machine.
Failure to comply with these two recommendations may damage the component (overheating and seizing).
IMPORTANT: Having bled the components, stop the engine for ve minutes and check for air bubbles in the
hydraulic uid in the reservoir.
1. To ll the housing and drain the hydraulic pump,
refer to Hydraulic pump - Bleed (A.10.A.20 -
F.35.A.25)
2. To bleed the attachment cylinders, extend and
retract each cylinder rod four or ve times without
bringing them up against the stops.
Repeat the operation three or four times, this time
bringing all the cylinder rods up against the stops.
3. To ll the housing and bleed the hydraulic swing
motor, refer to Hydraulic motor - Bleed (F.40.C.28
- F.35.A.25)
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CRIL03K043F01 1
Port identication marks
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CRIL03K043F02 2
Installation of pressure test points
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CRIL03I082A 1
CAS10508-3 2
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Prior operation: To remove the side protection panels from the hydraulic control valve, refer to Side shield -
Remove (E.20.A.70 - F.10.A.10)
Prior operation: To remove the valve bank hood, the front protection panels from the hydraulic control valve and
the valve bank hood bracket, refer to Upper shield - Remove (E.20.A.71 - F.10.A.10)
Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20)
CRIL03J077B01 1
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CRIL03J088G01a 1
Output section - cross-sectional view
CRIL03L050A01 2
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CRIL03L053A01 3
CRIL03L049A01 4
CRIL03L081A01 5
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CRIL03J089F01 1
Input section - cross-sectional view
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NOTE: Clean all parts with a suitable light oil based product. Allow to air dry and place each part on a clean sheet
of paper or vinyl for inspection.
NOTE: Inspect the surface of each part for scratches, abrasion and other damage.
1. Check for scratches and dents on the check valve
seats in the control valve body and for traces of rust
and foreign matter.
2. Check for scratches and dents on the outer surface
of the spool. Remove small scratches with a piece
of cloth soaked in an abrasive product.
3. Check that all sliding surfaces move freely. Check
for the absence of foreign matter in passages and
grooves.
4. Check for deformed or worn springs.
5. Replace all seals and backup rings with new original
parts.
6. After removing the caps and plugs, make sure that
there is no trace of paint on the body ports or the
plug rims. (any trace of residual paint might lead
to contamination, which could cause the system to
malfunction and result in possible leaks).
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Prior operation: To clean and check parts before assembling, refer to Stack valve - Visual inspection (A.10.A.18
- F.40.A.10).
CRIL03J089F01 1
Input section - cross-sectional view
Torque settings
Plug (19) 103 - 113 Nm
Valve (62) 78 - 88 Nm
Plug (69) 116 - 128 Nm
1. Install plugs (69) with new seals.
2. Install springs (17) and check valves (16).
3. Install plugs (19) with new seals (18).
4. Install the main relief valve (62).
5. Tighten the plugs and the valve to the required
torque.
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Prior operation: To clean and check parts before assembling, refer to Stack valve - Visual inspection (A.10.A.18
- F.40.A.10).
CRIL03J088G01a 1
Output section - cross-sectional view
Torque settings
Plug (21) 13.5 - 16.5 Nm Plug (32) 73 - 79 Nm
Screw (45) 19 - 22 Nm Plug (49) 103 - 113 Nm
Valves (55) 103 - 113 Nm Cap screws (46) and (47) 8.8 - 10.5 Nm
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CRIL03L081A01 2
CRIL03L053A01 3
CRIL03L049A01 4
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CRIL03J077B01 1
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1. Remove the nut (1), the washer (2) and the screw
(3) and discard the seal (4).
CRIL03G175B01 1
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CRIL03G175B02 1
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CRIL03G175B03 1
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Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20)
Prior operation: Rear ballasting - Remove (F.20.B.61 - F.10.A.10)
Prior operation: Silencer - Remove (B.40.A.36 - F.10.A.10)
CRIL03J132A01 1
CRIL03J133A01 2
Next operation: To remove the secondary hydraulic pump, refer to Hydraulic pump - Remove (A.12.A.20
- F.10.A.10)
Next operation: To remove the hydraulic control pump, refer to Hydraulic pump - Remove (A.14.A.20 - F.10.A.10)
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CRIL03J055A01 1
CRIL03J056A01 2
CRIL03J057A01 3
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CRIL03J058A01 4
CRIL03J059A01 5
CRIL03J060A01 6
CRIL03J061A01 7
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CRIL03J069A01 8
CRIL03J070B01 9
CRIL03J158A01 10
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11. Remove the snap ring, push out the shaft and
remove intermediate pinion (1).
Remove the two shims.
CRIL03J159A01 11
CRIL03J160A01 12
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CRIL03J069A01 1
CRIL03J094A01 2
CRIL03J095A01 3
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CRIL03J096B01 4
CRIL03J097A01 5
CRIL03J098A01 6
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CRIL03J099A01 7
CRIL03J100A01 8
CRIL03J101A01 9
CRIL03J160A01 10
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CRIL03J159A02 11
CRIL03J158A01 12
CRIL03J055A02 13
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Prior operation: To install the secondary hydraulic pump, refer to Hydraulic pump - Install (A.12.A.20 - F.10.A.15)
Prior operation: To install the hydraulic control pump, refer to Hydraulic pump - Install (A.14.A.20 - F.10.A.15)
CRIL03J133A01 1
CRIL03J132A01 2
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IMPORTANT: After bleeding the components, shut down the engine for ve minutes, then check for the absence
of air bubbles in the hydraulic uid in the reservoir.
1. Start the engine in idle mode.
Gradually loosen hose (1) retighten it as soon as
uid ows out without air bubbles.
Check the reservoir level and top up as necessary.
CRIL03K048A02 1
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CRIL03K048A01 1
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NOTE: Cover (1) comprises regulating screws (2) and (3), pushrod (4), lock nut (5), adjusting screw (6) and nut
(7). Do not loosen these screws and nuts, failure to comply with this instruction will cause maladjustment of
pressure and ow.
CRIL03J118G01 1
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CRIL03J117G01 1
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Prior operation: To remove the protective panel from the reservoir, refer to Upper shield - Remove (E.20.A.71
- F.10.A.10)
Prior operation: To remove the electric pump for lling with fuel, refer to Fuel ller aid - Remove (B.20.A.20
- F.10.A.10)
Prior operation: To remove the right guard, refer to Side shield - Remove (E.20.A.70 - F.10.A.10)
Prior operation: To remove the lower access panel to the hydraulic reservoir, refer to Protective shield - Remove
(E.20.A.73 - F.10.A.10)
Prior operation: To release pressure from the hydraulic circuit, refer to PRIMARY HYDRAULIC POWER SYSTEM
- Depressurising (A.10.A - F.35.A.51)
CRIL03J176A01 1
CRIL03J177A01 2
CRIL03J176A02 3
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CRIL03J176A02 1
CRIL03J177A01 2
Next operation: To bleed the hydraulic circuit, refer to PRIMARY HYDRAULIC POWER SYSTEM - Bleed (A.10.A
- F.35.A.25)
Next operation: To install the lower access panel to the hydraulic reservoir, refer to Protective shield - Remove
(E.20.A.73 - F.10.A.10)
Next operation: To install the right-hand guard, refer to Side shield - Remove (E.20.A.70 - F.10.A.10)
Next operation: To install the upper guard, refer to Upper shield - Remove (E.20.A.71 - F.10.A.10)
Next operation: To install the electric pump for the fuel, refer to Fuel ller aid - Install (B.20.A.20 - F.10.A.15)
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Prior operation: To remove side guard (5) from the control valve , refer to Side shield - Remove (E.20.A.70
- F.10.A.10)
Prior operation: To remove upper guard (2) from the oil lter, refer to Upper shield - Remove (E.20.A.71
- F.10.A.10)
Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20)
CRIL03L051A01 1
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CRIL03L051A01 1
Next operation: To install side guard (5) on the control valve , refer to Side shield - Remove (E.20.A.70 - F.10.A.10)
Next operation: To install the upper guard (2) on the oil lter, refer to Upper shield - Remove (E.20.A.71
- F.10.A.10)
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CRIL03K190A01 1
CRIL03I081A01 2
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NOTE: This table summarises the main symptoms relating to the hydraulic circuit in general.
Problem Possible Cause Correction
The hydraulic system Oil level in reservoir too low Rell the tank
is not operating or is
operating incorrectly.
Insufcient pilot pressure Refer to HYDRAULIC COMMAND
SYSTEM - Troubleshooting (A.14.A -
G.40.A.10)
Pump faulty Check the pressures
Test the pump
Main relief valve faulty Refer to Relief valve - Troubleshooting
(A.10.A.16 - G.40.A.10)
Cylinder faulty Check for leaks, traces of aking or
scratches on the cylinder rods.
Pump charge pressure too high Check the pressure
Valves or control valve cracked Replace cracked components
Spool stroke incomplete Refer to Stack valve - Troubleshooting
(A.10.A.18 - G.40.A.10)
Filter clogged in the circuit Clean and replace lters
Blockage in the system Locate and remove the cause of the
blockage
NOTE: This table summarises the main symptoms relating to the control valve block in general.
Problem Possible Cause Correction
The spool does not move Abnormal rise in oil temperature (ow is Eliminate the cause of the ow resistance
encountering resistance in the lines)
Contaminated hydraulic oil Clean the circuit and replace the hydraulic
oil
Lines with over-tightened port unions Loosen and retighten the unions to the
required torque
Control valve body deformed during Loosen the xing screws and inspect
installation
Excessive pressure Check the inlet (pump side) and supply
pressures
Spool not straight Replace the control valve assembly
Return spring damaged Replace the spring
Spring or cap deformed Loosen the cap xing screws and retighten
them to the required torque
Uneven temperature distribution in the Warm up the oil by operating all the
control valve controls
Control valve obstructed by oil pollution Clean out the control valve and the
hydraulic circuit
Insufcient pilot pressure Check the pilot circuit main relief valve
Does not hold the load Oil leak in the spool Check the spool
Leak in the main relief valve Remove the valve and clean the seats of
the valve and the control valve
Leak in the load holding valve Remove the valve and clean the seats,
replacing them if necessary
Leak in the cylinder Check that the cylinder rings are not
leaking
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NOTE: This table summarises the main symptoms relating to the valve block.
Problem Possible Cause Correction
No rise in pressure Main valve, sleeve or pilot valve jammed Replace the valve
open or contamination of seat
Pressure is unstable The pilot valve seat is damaged Replace the valve
Piston or main valve seized Replace the valve
Pressure is incorrect Seat worn by contamination Replace the valve
Lock nut on adjusting device is loose Set and tighten the nut again correctly
Oil leak Damaged valve seat Replace the valve
Components seized by contamination Replace the valve
Damaged seals Replace the seals
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Index
DISTRIBUTION SYSTEMS - A
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PRIMARY HYDRAULIC POWER SYSTEM - Static description (A.10.A - C.30.A.20) 15
CX135SR
PRIMARY HYDRAULIC POWER SYSTEM - Troubleshooting (A.10.A - G.40.A.10) 75
CX135SR
PRIMARY HYDRAULIC POWER SYSTEM - Warm up (A.10.A - F.35.A.40) 33
CX135SR
Relief valve - Assemble (A.10.A.16 - F.10.A.20) 51
CX135SR
Relief valve - Disassemble (A.10.A.16 - F.10.A.25) 50
CX135SR
Relief valve - Pressure setting (A.10.A.16 - F.45.A.70) 52
CX135SR
Relief valve - Troubleshooting (A.10.A.16 - G.40.A.10) 76
CX135SR
Reservoir - Install (A.10.A.22 - F.10.A.15) 71
CX135SR
Reservoir - Remove (A.10.A.22 - F.10.A.10) 69
CX135SR
Sensing system Temperature sensor - Electrical test (A.10.A.95.90 - F.40.A.50) 74
CX135SR
Sensing system Temperature sensor - Electronic schema (A.10.A.95.90 - C.20.A.50) 32
CX135SR
Stack valve - External view (A.10.A.18 - C.10.A.40) 19
CX135SR
Stack valve - Install (A.10.A.18 - F.10.A.15) 49
CX135SR
Stack valve - Remove (A.10.A.18 - F.10.A.10) 41
CX135SR
Stack valve - Sectional view (A.10.A.18 - C.10.A.30) 21
CX135SR
Stack valve - Troubleshooting (A.10.A.18 - G.40.A.10) 75
CX135SR
Stack valve - Visual inspection (A.10.A.18 - F.40.A.10) 45
CX135SR
Stack valve Inlet section - Assemble (A.10.A.18.10 - F.10.A.20) 46
CX135SR
Stack valve Inlet section - Disassemble (A.10.A.18.10 - F.10.A.25) 44
CX135SR
Stack valve Inlet section - Sectional view (A.10.A.18.10 - C.10.A.30) 24
CX135SR
Stack valve Outlet section - Assemble (A.10.A.18.20 - F.10.A.20) 47
CX135SR
Stack valve Outlet section - Disassemble (A.10.A.18.20 - F.10.A.25) 42
CX135SR
Stack valve Outlet section - Sectional view (A.10.A.18.20 - C.10.A.30) 25
CX135SR
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CX135SR
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Contents
DISTRIBUTION SYSTEMS - A
FUNCTIONAL DATA
Stack valve
Stack valve Outlet section - Sectional view (A.12.A.18.20 - C.10.A.30) 3
CX135SR
Hydraulic pump
Hydraulic pump - Exploded view (A.12.A.20 - C.10.A.20) 5
CX135SR
SERVICE
Stack valve
Stack valve - Disassemble (A.12.A.18 - F.10.A.25) 7
CX135SR
Relief valve
Relief valve - Disassemble (A.12.A.16 - F.10.A.25) 11
CX135SR
Hydraulic pump
Hydraulic pump - Remove (A.12.A.20 - F.10.A.10) 15
CX135SR
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DISTRIBUTION SYSTEMS - SECONDARY HYDRAULIC POWER SYSTEM
CRIL03J090F01 1
(59) Seal
(60) Seal
(61) Outlet section
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DISTRIBUTION SYSTEMS - SECONDARY HYDRAULIC POWER SYSTEM
CRIL03J091F01 1
Inlet plate section
(32) Plug
(78) Inlet plate (option)
(79) Main relief valve (option)
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DISTRIBUTION SYSTEMS - SECONDARY HYDRAULIC POWER SYSTEM
CRIL03J172G01 1
Description
(1) Snap ring (2) Seal
(3) Front seal (4) Bushing
(5) Seal (6) Seal
(7) Flange (8) Drive gear
(9) Driven gear (10) Body
(11) Flange (12) Seal
(13) Seal (14) Bushing
(15) Rear cover (16) Washer
(17) Screw
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DISTRIBUTION SYSTEMS - SECONDARY HYDRAULIC POWER SYSTEM
CRIL03J173G01 1
Description
(1) Snap ring (2) Seal
(3) Seal (4) Flange
(5) Body (6) Washer
(7) Screw (8) Drive gear
(9) Front seal (10) Bushing
(11) Driven gear (12) Seal
(13) Rear cover
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DISTRIBUTION SYSTEMS - SECONDARY HYDRAULIC POWER SYSTEM
CRIL03J083B01 1
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DISTRIBUTION SYSTEMS - SECONDARY HYDRAULIC POWER SYSTEM
CRIL03J091F01 1
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DISTRIBUTION SYSTEMS - SECONDARY HYDRAULIC POWER SYSTEM
CRIL03J091F01 1
1. Install and tighten to torque 73 - 79 Nm plugs (32) complete with new seals.
2. Install and tighten to torque 49 - 59 Nm main relief valve (79) on inlet plate (78).
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DISTRIBUTION SYSTEMS - SECONDARY HYDRAULIC POWER SYSTEM
Prior operation: Clean and check parts before assembling, refer to Stack valve - Visual inspection (A.10.A.18
- F.40.A.10)
CRIL03J083B01 1
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DISTRIBUTION SYSTEMS - SECONDARY HYDRAULIC POWER SYSTEM
1. Remove the nut (1), the washer (2) and the screw
(3) and discard the seal (4).
CRIL03G175B01 1
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DISTRIBUTION SYSTEMS - SECONDARY HYDRAULIC POWER SYSTEM
CRIL03G175B02 1
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DISTRIBUTION SYSTEMS - SECONDARY HYDRAULIC POWER SYSTEM
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DISTRIBUTION SYSTEMS - SECONDARY HYDRAULIC POWER SYSTEM
CRIL03G175B03 1
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DISTRIBUTION SYSTEMS - SECONDARY HYDRAULIC POWER SYSTEM
Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20)
CRIL03J045A01 1
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DISTRIBUTION SYSTEMS - SECONDARY HYDRAULIC POWER SYSTEM
CRIL03J173G01 1
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DISTRIBUTION SYSTEMS - SECONDARY HYDRAULIC POWER SYSTEM
NOTE: Install the parts following the marks made during removal.
CRIL03J173G01 1
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DISTRIBUTION SYSTEMS - SECONDARY HYDRAULIC POWER SYSTEM
CRIL03J045A01 1
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Index
DISTRIBUTION SYSTEMS - A
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DISTRIBUTION SYSTEMS - A
CX135SR
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Contents
DISTRIBUTION SYSTEMS - A
SERVICE
Relief valve
Relief valve - Pressure test (A.14.A.16 - F.40.A.30) 3
CX135SR
Hydraulic pump
Hydraulic pump - Remove (A.14.A.20 - F.10.A.10) 5
CX135SR
Accumulator
Accumulator - Check (A.14.A.30 - F.40.A.11) 7
CX135SR
DIAGNOSTIC
HYDRAULIC COMMAND SYSTEM - Troubleshooting (A.14.A - G.40.A.10) 8
CX135SR
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DISTRIBUTION SYSTEMS - HYDRAULIC COMMAND SYSTEM
CRIL03K041A01 1
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DISTRIBUTION SYSTEMS - HYDRAULIC COMMAND SYSTEM
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DISTRIBUTION SYSTEMS - HYDRAULIC COMMAND SYSTEM
Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20)
CRIL03K044A01 1
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DISTRIBUTION SYSTEMS - HYDRAULIC COMMAND SYSTEM
CRIL03K044A01 1
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DISTRIBUTION SYSTEMS - HYDRAULIC COMMAND SYSTEM
ATTENTION: The accumulator on this machine contains highly pressurized nitrogen gas. If the accumulator system
does not work correctly, replace the accumulator. Do not try to repair the accumulator. Failure to follow these
instructions and the procedure below can cause injury or death.
1. Start the engine.
Raise the boom completely and extend the dipper.
Shut down the engine.
2. Turn the starter switch key to the "ON" position
without starting the engine.
3. Operate the boom lowering or dipper retracting
control several times in succession.
4. The pressure in the accumulator should enable the
boom lowering or dipper retracting function to be
performed about six times.
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DISTRIBUTION SYSTEMS - HYDRAULIC COMMAND SYSTEM
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Index
DISTRIBUTION SYSTEMS - A
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DISTRIBUTION SYSTEMS - A
CX135SR
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Contents
DISTRIBUTION SYSTEMS - A
TECHNICAL DATA
ELECTRICAL POWER SYSTEM - General specication (A.30.A - D.40.A.10) 4
CX135SR
Battery
Battery - General specication (A.30.A.83 - D.40.A.10) 16
CX135SR
FUNCTIONAL DATA
ELECTRICAL POWER SYSTEM - Static description (A.30.A - C.30.A.20) 18
CX135SR
Alternator
Alternator - Electronic schema (A.30.A.82 - C.20.A.50) 26
CX135SR
SERVICE
Battery
Battery - Visual inspection (A.30.A.83 - F.40.A.10) 27
CX135SR
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Battery - Overhaul (A.30.A.83 - F.10.A.40) 33
CX135SR
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
Battery
Number of batteries 2
Voltage for each battery 12 volts
Rated capacity 64 Ah
Reserve 160 min
Cold starting capacity at 17 °C 800 amps
Load for load control 400 amps
Starter motor
Voltage 24 volts
Power 4.5 kW
Alternator
Built-in voltage regulator, without adjustment
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
CRIL03G248E00 1
DESCRIPTION CODE
Test electrical connector kit CAS-30039
CRPH03I027A 2
Test electrical connector.- not used
CRPH03I028A 3
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
CRPH03I029A 4
Test electrical connector for emergency stop motor,
emergency stop motor harness side.
CRPH03I030A 5
Test electrical connector for solenoid and fuel level
sensor.
CRPH03I031A 6
Test electrical connector for hydraulic pump proportional
valve.
CRPH03I032A 7
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
CRPH03I033A 8
Test electrical connector for pressure switch, pressure
switch side.
CRPH03I034A 9
Test electrical connector for pressure switch, pressure
switch harness side.
CRPH03I035A 10
Test electrical connector for air conditioning compressor
clutch contact switch.
CRPH03I036A 11
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
CRPH03I037A 12
Test electrical connector not used.
CRPH03I038A 13
Test electrical connector not used.
CRPH03I039A 14
Test electrical connector not used.
CRPH03I040A 15
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
CRPH03I041A 16
Test electrical connector for engine rpm sensor.
CRPH03I042A 17
Test electrical connector for pressure detector.
CRPH03I043A 18
Test electrical connector for electronic acceleration
module (RED4).
CRPH03I044A 19
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
CRPH03I045A 20
Test electrical connector for electronic acceleration
module (RED4).
CRPH03I046A 21
Digital multimeter
CRIL03G249E00 22
DESCRIPTION CODE
Digital multimeter CAS-1559
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
CRIL03G248E00 1
DESCRIPTION CODE
Electrical connector test kit CAS-40041
CRPH03I027A 2
Test electrical connector-not used.
CRPH03I028A 3
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
CRPH03I029A 4
Test electrical connector for emergency stop motor,
emergency stop motor harness side.
CRPH03I030A 5
Test electrical connector for solenoid and fuel level
sensor.
CRPH03I031A 6
Test electrical connector for hydraulic pump proportional
valve.
CRPH03I032A 7
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
CRPH03I033A 8
Test electrical connector for pressure switch, pressure
switch side.
CRPH03I034A 9
Test electrical connector for pressure switch, pressure
switch harness side.
CRPH03I035A 10
Test electrical connector for air conditioning compressor
clutch contact switch.
CRPH03I036A 11
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
CRPH03I037A 12
Test electrical connector not used.
CRPH03I038A 13
Test electrical connector not used.
CRPH03I039A 14
Test electrical connector not used.
CRPH03I040A 15
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
CRPH03I041A 16
Test electrical connector for engine rpm sensor.
CRPH03I042A 17
Test electrical connector for pressure sensor.
CRPH03I043A 18
Test electrical connector for electronic acceleration
module (RED4).
CRPH03I044A 19
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
CRPH03I045A 20
Test electrical connector for electronic acceleration
module (RED4).
CRPH03I046A 21
Digital multimeter
CRIL03G249E00 22
DESCRIPTION CODE
Digital multimeter OEM-1414
Discharge test
Discharge test at -15 °C
Discharge current 300 amps
Discharge time at 6 volts 5.2 minutes
Voltage after testing for 30 seconds 10 volts
Cross-reference table between the acidimeter oat graduations and degrees Baumé at 26°C
Density of the electrolyte below Density of the electrolyte at minimum Normal density of the electrolyte
minimum
Float graduation Degrees Baumé Float graduation Degrees Baumé Float graduation Degrees Baumé
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
16 ° Baumé = 25 % of load
22 ° Baumé = 50 % of load
28 ° Baumé = 75 % of load
31 ° Baumé = 100 % of load
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
CRIL03K117H01 1
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
CRIL03G085H01 1
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
CRIL03K118F01 1
Main relays and fuses
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
CRIL03K119G01 1
Relays, fuses, electronic control box (operator’s compartment)
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
CRIL03G222F01 1
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
CRIL03G200E01 1
Circuit layout
CRIL03G201E02a 2
Timing diagram
OPERATION
• When the alternator (L) output voltage falls to 6 volts, battery charge indicator lamp (2) lights up and the
audible alarm device (3) sounds.
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
DANGER
SA046 - Before you service a battery, always wear face protection, protective gloves and protective clothing.
Battery acid or battery explosion can cause serious injuries.
DANGER
D38-14A - Batteries produce explosive gases. Keep sparks, ame and cigarettes away. Ventilate when
charging or using in enclosed space. Always shield eyes when working near batteries.
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
DANGER
SA046 - Before you service a battery, always wear face protection, protective gloves and protective clothing.
Battery acid or battery explosion can cause serious injuries.
DANGER
D38-14A - Batteries produce explosive gases. Keep sparks, ame and cigarettes away. Ventilate when
charging or using in enclosed space. Always shield eyes when working near batteries.
DANGER
M145B - When working around storage batteries,
remember that all of the exposed metal parts are
"live". Never lay a metal object across the terminals
because a spark, short circuit, explosion or personal
injury may result.
CRIL04B144A01 1
DANGER
47-55A - Disconnect the ground cable rst when the
battery cables are disconnected from the battery.
Connect the ground cable last when the battery
cables are connected to the battery.
CRIL03K003A02 2
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
CRIL03K003A01 1
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
NOTE: Use an acidimeter to check the density of the battery electrolyte. A thermometer graduated to at least 52 °C
must be used to check the temperature of the electrolyte.
NOTE: If the density of the electrolyte cannot be checked without adding water to the battery cell, after adding the
water charge the battery for 15 minutes between 15 amps and 25 amps to mix the water and the electrolyte properly.
1. Using the acidimeter, remove sufcient electrolyte
to allow the oat to move freely in the acidimeter’s
glass tube.
2. Keep the acidimeter upright and read the value
reached by the liquid, as indicated by the oat.
3. Repeat operations 1 and 2 for each battery cell.
Note the values taken from the acidimeter oat and
convert them to degrees Baumé. Refer to Battery -
General specication (A.30.A.83 - D.40.A.10).
4. The minimum density of the electrolyte should
be the 1.24 graduation 1240 on the oat, which
corresponds to 28 ° Baumé.
5. Read the electrolyte temperature on the
thermometer.
6. If the temperature of the electrolyte is above 26
°C add 1/2 ° Baumé to the gure read from the
acidimeter for every 6 °C above 26 °C.
If the temperature of the electrolyte is below 26 °C
subract 1/2 ° Baumé from the gure read from the
acidimeter for every 6 °C below 26 °C.
7. The charge level for each battery cell must be at
least 75 %, corresponding to a corrected density
of 28 ° Baumé.
8. If the difference between the high and low values
for the electrolyte density is less than 5 ° Baumé
and the charge level for each battery cell is at least
75 %, check the charge.
9. If the difference between the high and low values
for the electrolyte density is less than 5 ° Baumé
but the charge level for the battery cell is less
than 75 %, replace the battery, refer to Battery
- Remove (A.30.A.83 - F.10.A.10) and Battery -
Install (A.30.A.83 - F.10.A.15), then check again.
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
DANGER
47-83A - Never try to charge the battery if the electrolyte in the battery is frozen.
IMPORTANT: The battery must only be charged using a self-regulating charger with constant voltage and variable
current.
1. Using a charge tester or voltmeter, measure the
battery charge level. For this measurement, the
battery must not have been charged or recharged
for at least one hour.
Refer to Battery - Check (A.30.A.83 - F.40.A.11)
2. Use the following data to decide on the charging
time:
- For a charge level below 20 % or a voltage below
12 volts, the charging time is 24 hours.
- For a charge level between 20 % and 60 % or
a voltage between 12 volts and 12.3 volts, the
charging time is 12 hours.
- For a charge level above 60 % or a voltage above
12.3 volts, the charging time is 6 hours.
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
DANGER
SA046 - Before you service a battery, always wear face protection, protective gloves and protective clothing.
Battery acid or battery explosion can cause serious injuries.
DANGER
D38-14A - Batteries produce explosive gases. Keep sparks, ame and cigarettes away. Ventilate when
charging or using in enclosed space. Always shield eyes when working near batteries.
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
CRIL03K003A01 1
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
CRIL03K003A02 1
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Index
DISTRIBUTION SYSTEMS - A
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DISTRIBUTION SYSTEMS - A
CX135SR
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A.40.A / 1
Contents
DISTRIBUTION SYSTEMS - A
FUNCTIONAL DATA
Front work light
Front work light - Electronic schema (A.40.A.16 - C.20.A.50) 3
CX135SR
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DISTRIBUTION SYSTEMS - LIGHTING SYSTEM
CRIL03G205F01 1
Circuit layout
(1) Instrument panel lighting (2) Air conditioner control panel lighting
(E2) Attachment working light (E3) Working light (cab)
(K4) Working light relay (P1) Instrument panel
(P6) Air conditioner control panel (S10) Working light switch
CRIL03G206E02 2
Timing diagram
OPERATION
• Pressing working light switch (S10) once controls instrument panel lighting (1) and (2) and relay excitation (K4), which
switches on working lights (E2) and (E3).
• Pressing a second time turns off all the lit components.
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Index
DISTRIBUTION SYSTEMS - A
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27054 1 14/12/2004
A.40.A / 5
CNH France S.A.- FRANCE
SERVICE
PRINTED IN FRANCE
All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH France S.A. company reserves the right to modify without prior notice the characteristics and the design of the
machine without any obligation to carry out those modications on machines already sold.
The description of the models shown in this manual has been made using the technical specications known at the
date on which this document was designed.
27049 1 14/12/2004
REPAIR MANUAL
POWER PRODUCTION
CX135SR
27055 1 14/12/2004
B
Contents
POWER PRODUCTION - B
ENGINE B.10.A
CX135SR
27055 1 14/12/2004
B
POWER PRODUCTION - B
ENGINE - 10.A
CX135SR
27056 1 14/12/2004
B.10.A / 1
Contents
POWER PRODUCTION - B
ENGINE - 10.A
TECHNICAL DATA
ENGINE - General specication (B.10.A - D.40.A.10) 3
CX135SR
FUNCTIONAL DATA
ENGINE - Electronic schema (B.10.A - C.20.A.50) 5
CX135SR
Electronic control
Electronic control - Electronic schema (B.10.A.92 - C.20.A.50) 7
CX135SR
SERVICE
ENGINE - Remove (B.10.A - F.10.A.10) 11
CX135SR
Sensing system
Sensing system Speed sensor - Electrical test (B.10.A.95.80 - F.40.A.50) 18
CX135SR
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POWER PRODUCTION - ENGINE
Manufacturer Isuzu
Model BB-4BG1T
Type
Four-stroke, water-cooled with overhead valves, direct injection, in-line cylinders (electronic control) with
turbocharger
Number of cylinders 4 in line
Bore and stroke 105 x 125 mm
Displacement 4329 cm³
Operating conditions
Idle 1000 tr/min
Max. rpm 2100 tr/min
ECC 1289 Power 65.6 kW (88cv)
Max. torque to 322.3 Nm 1600 tr/min
Capacities
Engine oil 13.2 L
Engine cooling circuit 15.3 L
Radiator alone 6.8 L
Fuel tank 165 L
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POWER PRODUCTION - ENGINE
CRIL03K082G01 1
Power and consumption curves
(rpm) engine rpm (g/kWh) fuel consumption in grams per kilowatt hour
(kW) engine power in kilowatts (Nm) engine torque in Newton metres
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POWER PRODUCTION - ENGINE
CRIL03K121H01 1
Engine control
Circuit layout
(1) Engine (2) Rack sensor
(3) Control circuit (4) Linear motor control circuit
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POWER PRODUCTION - ENGINE
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POWER PRODUCTION - ENGINE
CRIL03K147F01 1
Circuit layout
(1) Engine electrical system fault indicator lamp (2) Audible alarm device
(3) Fault code detection connection (4) Fault code erasing connection
(5) Engine (A2) Engine electronic control box
(A3) Electronic acceleration (B1) Coolant solution temperature sender
(B41) Engine speed detector (P1) Instrument panel
(R3) Throttle control (X13) Fault code erasing connector
(X14) Fault code detection connector
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POWER PRODUCTION - ENGINE
CRIL03K148F01 2
Timing diagram with error code 41
(1) Engine electrical system fault indicator lamp (2) Audible alarm device
(3) Fault code detection connection (5A) With the engine stopped
(5B) Engine starting (5C) Engine running
OPERATION
• When connection (3) of the fault code connector (X14) is not functioning, the engine electrical system faults
are reported by the continuous lighting up of electrical system fault indicator lamp (1).
• When connection (3) of the fault code connector (X14) is functioning, the engine electrical system faults are
reported by a series of ashes of the electrical system fault indicator lamp (1).
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POWER PRODUCTION - ENGINE
CRIL03K149F01 3
Timing diagram - Error code reader
(1) Engine electrical system fault indicator lamp (3) Fault code detection connection
(5A) With the engine stopped (5C) Engine running
OPERATION
1. When connection (3) of the fault code detection connector (X14) is set up with the engine running, the
current fault code of the engine electrical system are reported by a series of ashes of the electrical system
fault indicator lamp (1).
2. When connection (3) of the fault code detection connector (X14) is set up with the engine switched off, the
current and previous fault code of the engine electrical system are reported by a series of ashes of the
electrical system fault indicator lamp (1).
3. The ashing sequence of a fault code is repeated three times before going on to the ashing sequence
of the next fault code.
CRIL03K184E00 4
The diagram above shows several simultaneous faults of the engine electrical system.
4. With the engine running or stopped, if connection (3) of fault code detection connector (X14) is set up, and if
there is no fault in the engine electrical system, the electrical system fault indicator lamp will ash at regular
intervals (once every second).
CRIL03K185E00 5
The diagram above indicates that there is no fault in the engine electrical system.
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B.10.A / 9
POWER PRODUCTION - ENGINE
27056 1 14/12/2004
B.10.A / 10
POWER PRODUCTION - ENGINE
CRIL03J106A01 1
CRIL03J107A01 2
CRIL03J108A01 3
27056 1 14/12/2004
B.10.A / 11
POWER PRODUCTION - ENGINE
CRIL03J109A01 4
CRIL03J110A01 5
CRIL03J111A01 6
CRIL03J112A01 7
27056 1 14/12/2004
B.10.A / 12
POWER PRODUCTION - ENGINE
CRIL03J113A01 8
CRIL03J114A01 9
CRIL03J115A01 10
27056 1 14/12/2004
B.10.A / 13
POWER PRODUCTION - ENGINE
CRIL03J116B01 11
Next operation: To remove the hydraulic pump, refer to Hydraulic pump - Remove (A.10.A.20 - F.10.A.10)
27056 1 14/12/2004
B.10.A / 14
POWER PRODUCTION - ENGINE
Prior operation: To connect the hydraulic pump to the engine, refer to Hydraulic pump - Install (A.10.A.20
- F.10.A.15)
CRIL03J116B01 1
CRIL03J113A01 2
27056 1 14/12/2004
B.10.A / 15
POWER PRODUCTION - ENGINE
CRIL03J112A01 3
CRIL03J111A01 4
CRIL03J110A01 5
CRIL03J108A01 6
27056 1 14/12/2004
B.10.A / 16
POWER PRODUCTION - ENGINE
CRIL03I118A01 7
CRIL03J107A01 8
CRIL03J114A01 9
27056 1 14/12/2004
B.10.A / 17
POWER PRODUCTION - ENGINE
CRIL03K191A01 1
CRIL03I078A04 2
27056 1 14/12/2004
B.10.A / 18
Index
POWER PRODUCTION - B
ENGINE - 10.A
Electronic control - Electronic schema (B.10.A.92 - C.20.A.50) 7
CX135SR
ENGINE - Electronic schema (B.10.A - C.20.A.50) 5
CX135SR
ENGINE - Engine horse power (B.10.A - D.50.A.20) 4
CX135SR
ENGINE - General specication (B.10.A - D.40.A.10) 3
CX135SR
ENGINE - Install (B.10.A - F.10.A.15) 15
CX135SR
ENGINE - Remove (B.10.A - F.10.A.10) 11
CX135SR
Sensing system Speed sensor - Electrical test (B.10.A.95.80 - F.40.A.50) 18
CX135SR
27056 1 14/12/2004
B.10.A / 19
27056 1 14/12/2004
B.10.A / 20
POWER PRODUCTION - B
CX135SR
27057 1 14/12/2004
B.20.A / 1
Contents
POWER PRODUCTION - B
FUNCTIONAL DATA
Throttle command
Throttle command Electronic throttle - Functional diagram (B.20.A.06.91 - C.20.A.70) 3
CX135SR
Fuel shut-off
Fuel shut-off Electrical shut-off - Electronic schema (B.20.A.13.81 - C.20.A.50) 8
CX135SR
Sensing system
Sensing system Level sensor - Electronic schema (B.20.A.95.90 - C.20.A.50) 10
CX135SR
SERVICE
Fuel ller aid
Fuel ller aid - Remove (B.20.A.20 - F.10.A.10) 12
CX135SR
Fuel tank
Fuel tank - Remove (B.20.A.22 - F.10.A.10) 14
CX135SR
27057 1 14/12/2004
B.20.A / 2
POWER PRODUCTION - FUEL AND INJECTION SYSTEM
THROTTLE CONTROL
CRIL03K122F01 1
Circuit layout
OPERATION
1. The engine electronic control box (A2) calculates the target position of the rack using the target rpm and
data from each sensor (actual engine rpm, actual position of the rack, fuel ow adjustment resistor), and it
transmits the signal to the electronic acceleration.
2. The electronic acceleration (A3) calculates the target position of the rack and its real position (value measured
by the rack detector) and moves the rack by turning the electric motor to adjust the quantity of fuel injected.
3. By repeating this process, the engine electronic control box (A2) controls electronic acceleration (A3) to obtain:
real number of revolutions = target number of revolutions.
27057 1 14/12/2004
B.20.A / 3
POWER PRODUCTION - FUEL AND INJECTION SYSTEM
Relationship between the throttle control position and the engine rpm
CRIL03K127E01 2
(A) Throttle control position by percentage open
(B) Engine speed in rpm.
(C) Input voltage in volts
27057 1 14/12/2004
B.20.A / 4
POWER PRODUCTION - FUEL AND INJECTION SYSTEM
CRIL03K123E01 1
Circuit layout
CRIL03K124F01 2
Timing diagram
OPERATION
1. If starter switch (S1) is in the "OFF" position when idle switch (S16) is in the "ON" position, starter switch (S16) will return to
the "OFF" position as soon as starter switch (S1) is turned to the "ON" position.
2. Every time idle switch (S16) is activated, engine idle will be alternately activated/deactivated.
27057 1 14/12/2004
B.20.A / 5
POWER PRODUCTION - FUEL AND INJECTION SYSTEM
CRIL03K146G01 1
Circuit layout
OPERATION
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B.20.A / 6
POWER PRODUCTION - FUEL AND INJECTION SYSTEM
1. To ensure low fuel consumption and optimum productivity, the calculation section (engine electronic control
box (A2) compares the information received with the stored data, then transmits a control signal to control
section (11) of linear motor (9) through connections, (5), (6), (7) and (8).
2. Control section (11) sends a signal to linear motor (9) of regulator (4) to activate rack control (10) on injection
pump (3).
27057 1 14/12/2004
B.20.A / 7
POWER PRODUCTION - FUEL AND INJECTION SYSTEM
CRIL03K141F01 1
Circuit layout
27057 1 14/12/2004
B.20.A / 8
POWER PRODUCTION - FUEL AND INJECTION SYSTEM
CRIL03K142F01 2
Timing diagram
EMERGENCY STOP CONTROL OPERATION
1. If engine emergency stop switch (S9) is activated, transistor output (OUT1) = 0 volts.
2. (OUT1) at 0 volts, emergency stop relay (K1) is activated, as is emergency stop motor (M2).
3. Stop signal input (IN1) on engine electronic control box (A2) falls to 0 volts, the engine electronic control box (A2) accepts
that as the emergency stop status and transmits the "stop engine" signal (OUT2) = 0 volts.
4. Electronic acceleration (A3) starts to control the engine shut down when it receives the signal (rack position = 0 mm).
27057 1 14/12/2004
B.20.A / 9
POWER PRODUCTION - FUEL AND INJECTION SYSTEM
CRIL03G087E01 1
Circuit layout
(1) Fuel level indicator (2) Minimum fuel level indicator lamp
(3) Audible alarm device (P1) Instrument panel
(R5) Fuel level sensor
CRIL03G088E01 2
Fuel level indicator (1)
27057 1 14/12/2004
B.20.A / 10
POWER PRODUCTION - FUEL AND INJECTION SYSTEM
CRIL03G089E02 3
Timing diagram
OPERATION
• When sensor resistance (R5) falls to 37 ohms or below, minimum fuel level indicator lamp (2) lights up.
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B.20.A / 11
POWER PRODUCTION - FUEL AND INJECTION SYSTEM
CRIL03J123A01 1
27057 1 14/12/2004
B.20.A / 12
POWER PRODUCTION - FUEL AND INJECTION SYSTEM
CRIL03J123A01 1
27057 1 14/12/2004
B.20.A / 13
POWER PRODUCTION - FUEL AND INJECTION SYSTEM
Prior operation: To remove the hydraulic reservoir protection panel, valve bank hood (1) and step (6), the protection
panels giving access to the control valve, the valve bank hood bracket, the hydraulic lter protection panel, refer
to Upper shield - Remove (E.20.A.71 - F.10.A.10)
Prior operation: To remove the right guard, refer to Side shield - Remove (E.20.A.70 - F.10.A.10)
Prior operation: To remove the access panel to the fuel tank piping and the fuel tank access panel, refer to
Protective shield - Remove (E.20.A.73 - F.10.A.10)
CRIL03J134A01 1
CRIL03J135A01 2
CRIL03J134A02 3
27057 1 14/12/2004
B.20.A / 14
POWER PRODUCTION - FUEL AND INJECTION SYSTEM
CRIL03J134A02 1
CRIL03J135A01 2
CRIL03I118A01 3
27057 1 14/12/2004
B.20.A / 15
Index
POWER PRODUCTION - B
27057 1 14/12/2004
B.20.A / 16
POWER PRODUCTION - B
CX135SR
27058 1 14/12/2004
B.30.A / 1
Contents
POWER PRODUCTION - B
SERVICE
Air cleaner
Air cleaner - Remove (B.30.A.25 - F.10.A.10) 3
CX135SR
27058 1 14/12/2004
B.30.A / 2
POWER PRODUCTION - AIR INTAKE SYSTEM
CRIL03K006A01 1
27058 1 14/12/2004
B.30.A / 3
POWER PRODUCTION - AIR INTAKE SYSTEM
CRIL03K006A01 1
27058 1 14/12/2004
B.30.A / 4
Index
POWER PRODUCTION - B
27058 1 14/12/2004
B.30.A / 5
27058 1 14/12/2004
B.30.A / 6
POWER PRODUCTION - B
CX135SR
27059 1 14/12/2004
B.40.A / 1
Contents
POWER PRODUCTION - B
SERVICE
Silencer
Silencer - Remove (B.40.A.36 - F.10.A.10) 3
CX135SR
27059 1 14/12/2004
B.40.A / 2
POWER PRODUCTION - EXHAUST SYSTEM
Prior operation: To remove the hydraulic pump protective panel, refer to Upper shield - Remove (E.20.A.71
- F.10.A.10)
CRIL03J139A01 1
CRIL03J140B01 2
27059 1 14/12/2004
B.40.A / 3
POWER PRODUCTION - EXHAUST SYSTEM
CRIL03J141A01a 3
27059 1 14/12/2004
B.40.A / 4
POWER PRODUCTION - EXHAUST SYSTEM
CRIL03J141A02a 1
CRIL03J140B01 2
CRIL03J139A01 3
27059 1 14/12/2004
B.40.A / 5
POWER PRODUCTION - EXHAUST SYSTEM
27059 1 14/12/2004
B.40.A / 6
Index
POWER PRODUCTION - B
27059 1 14/12/2004
B.40.A / 7
27059 1 14/12/2004
B.40.A / 8
POWER PRODUCTION - B
CX135SR
27060 1 14/12/2004
B.50.A / 1
Contents
POWER PRODUCTION - B
FUNCTIONAL DATA
Sensing system
Sensing system Coolant temperature - Electronic schema (B.50.A.95.90 - C.20.A.50) 3
CX135SR
SERVICE
ENGINE COOLANT SYSTEM - Drain uid (B.50.A - F.35.A.20) 7
CX135SR
Radiator
Radiator - Remove (B.50.A.32 - F.10.A.10) 10
CX135SR
Sensing system
Sensing system Coolant temperature - Electrical test (B.50.A.95.90 - F.40.A.50) 14
CX135SR
27060 1 14/12/2004
B.50.A / 2
POWER PRODUCTION - ENGINE COOLANT SYSTEM
CRIL03K145F01 1
Circuit layout
(1) Coolant temperature indicator (2) Coolant or hydraulic oil overheating indicator
lamp
(3) Audible alarm device (A2) Engine electronic control box
(B1) Coolant solution temperature sensor (B9) Coolant solution temperature sensor
(B10) Hydraulic oil temperature thermo - switch (P1) Instrument panel
27060 1 14/12/2004
B.50.A / 3
POWER PRODUCTION - ENGINE COOLANT SYSTEM
CRIL03G094E03 2
Timing diagram
CRIL03G093E01 3
27060 1 14/12/2004
B.50.A / 4
POWER PRODUCTION - ENGINE COOLANT SYSTEM
CRIL03K139F01 1
Circuit layout
OPERATION
When the idle time is too long and either the voltage supplied to the engine electronic control box (A2) drops or the
coolant temperature (B1) is low, the idling speed increases automatically.
27060 1 14/12/2004
B.50.A / 5
POWER PRODUCTION - ENGINE COOLANT SYSTEM
CRIL03K140F01 2
Adjustment to idling speed according to battery voltage and coolant temperature.
(1) Idle speed (rpm) (2) Motor electronic control box supply voltage in
volts
(3) Coolant temperature in °C
27060 1 14/12/2004
B.50.A / 6
POWER PRODUCTION - ENGINE COOLANT SYSTEM
Prior operation: To remove the access panel to the radiator and engine, refer to Protective shield Guard -
Remove (E.20.A.73.71 - F.10.A.10)
CRIL03I184A01 1
CRIL03L138A01 2
CRIL03L139A01 3
27060 1 14/12/2004
B.50.A / 7
POWER PRODUCTION - ENGINE COOLANT SYSTEM
CRIL03I184A01 1
27060 1 14/12/2004
B.50.A / 8
POWER PRODUCTION - ENGINE COOLANT SYSTEM
CRIL03I184A01 1
CRIL03K004A01 2
27060 1 14/12/2004
B.50.A / 9
POWER PRODUCTION - ENGINE COOLANT SYSTEM
CRIL03J170A01 1
CRIL03J171B01 2
27060 1 14/12/2004
B.50.A / 10
POWER PRODUCTION - ENGINE COOLANT SYSTEM
CRIL03I146A01 3
27060 1 14/12/2004
B.50.A / 11
POWER PRODUCTION - ENGINE COOLANT SYSTEM
CRIL03I146A01 1
CRIL03J171B01 2
27060 1 14/12/2004
B.50.A / 12
POWER PRODUCTION - ENGINE COOLANT SYSTEM
CRIL03J170A01 3
27060 1 14/12/2004
B.50.A / 13
POWER PRODUCTION - ENGINE COOLANT SYSTEM
CRIL03K189A01 1
CRIL03I081A03 2
27060 1 14/12/2004
B.50.A / 14
Index
POWER PRODUCTION - B
27060 1 14/12/2004
B.50.A / 15
27060 1 14/12/2004
B.50.A / 16
POWER PRODUCTION - B
CX135SR
27061 1 14/12/2004
B.60.A / 1
Contents
POWER PRODUCTION - B
FUNCTIONAL DATA
Sensing system
Sensing system Oil pressure - Electronic schema (B.60.A.95.91 - C.20.A.50) 3
CX135SR
27061 1 14/12/2004
B.60.A / 2
POWER PRODUCTION - LUBRICATION SYSTEM
CRIL03G090E01 1
Circuit layout
CRIL03G091E02 2
Timing diagram
27061 1 14/12/2004
B.60.A / 3
Index
POWER PRODUCTION - B
27061 1 14/12/2004
B.60.A / 4
POWER PRODUCTION - B
CX135SR
27062 1 14/12/2004
B.80.A / 1
Contents
POWER PRODUCTION - B
TECHNICAL DATA
Engine starter
Engine starter - General specication (B.80.A.82 - D.40.A.10) 3
CX135SR
FUNCTIONAL DATA
Cold start aid
Cold start aid Pre-heating - Electronic schema (B.80.A.30.81 - C.20.A.50) 4
CX135SR
Start control
Start control Start relay - Electronic schema (B.80.A.90.80 - C.20.A.50) 8
CX135SR
27062 1 14/12/2004
B.80.A / 2
POWER PRODUCTION - STARTING SYSTEM
Voltage 24 volts
Power 4.5 kW
27062 1 14/12/2004
B.80.A / 3
POWER PRODUCTION - STARTING SYSTEM
CRIL03K125F01 1
Circuit layout
27062 1 14/12/2004
B.80.A / 4
POWER PRODUCTION - STARTING SYSTEM
OPERATION
1. Once the starter switch is turned to "on" (IN1 = ON), main electronic control box (A1) calculates the preheating
time (Tp) based on the coolant temperatures (see graph).
2. Engine electronic control box (A2) activates pre-heating relay (K2) during preheating period (Tp) calculated
previously.
3. At the end of preheating period (Tp), preheating indicator lamp (1) goes out and preheating relay (K2) remains
activated for 2 seconds.
4. When starter switch (S1) is turned to "START" (ST, IN2 = ON), engine electronic control box (A2) reactivates
preheating relay (K2), without preheating indicator lamp (2) lighting up.
5. Engine electronic control box (A2) calculates the time after post-heating (Ta) based on the coolant temperature
(see graph).
6. When starter switch (S1) is moved from "START" to "ON" (IN1 = ON ; IN2 = OFF), engine electronic control
box (A2) activates preheating relay (K2) during the period after post-heating (Ta), without preheating indicator
lamp (2) lighting up.
7. The post-heating procedure helps stabilise the engine speed when starting, in order to reduce emission of
smoke from the exhaust.
8. The control system mentioned above starts immediately; as soon as the starter switch is turned to "on", the
preheating will begin, only if the preheating time is more than 3 seconds (coolant temperature less than - 5 °C).
CRIL03K135F01 2
Preheating and post-heating time graph
27062 1 14/12/2004
B.80.A / 5
POWER PRODUCTION - STARTING SYSTEM
TIMING DIAGRAM
1. If the engine is started within 2 seconds of the lighting up of preheating indicator lamp (2)
CRIL03K136E01 3
2. If the engine is started 2 seconds after the lighting up of preheating indicator lamp (2)
CRIL03K137E01 4
3. If the engine is started during the lighting up of preheating indicator lamp (2)
CRIL03K138E01 5
27062 1 14/12/2004
B.80.A / 6
POWER PRODUCTION - STARTING SYSTEM
Flow chart
Starter switch ON
Water Pre-heating time
temperature calculation
Calculated time
Pre-heat plug Signal active
activated
Elapsed time Signal activated
Pre-heat plug
deactivated
Engine started
Pre-heat plug
activated
Water Post-heating time
temperature calculation
Calculated time
Pre-heat plug
activated
Elapsed time
Pre-heat plug
deactivated
27062 1 14/12/2004
B.80.A / 7
POWER PRODUCTION - STARTING SYSTEM
CRIL03K143E01 1
Supply cut-off delay - Circuit conguration
CRIL03K144E01 2
Timing diagram
POWER TRANSISTOR PROTECTION
• To protect instrument panel circuits (P1) in the event of a short circuit of a solenoid valve or relay, the power transistors
turn off the electric supply.
27062 1 14/12/2004
B.80.A / 8
Index
POWER PRODUCTION - B
27062 1 14/12/2004
B.80.A / 9
27062 1 14/12/2004
B.80.A / 10
POWER PRODUCTION - B
CX135SR
27063 1 14/12/2004
B.90.A / 1
Contents
POWER PRODUCTION - B
SERVICE
Drive system
Drive system - Remove (B.90.A.42 - F.10.A.10) 3
CX135SR
27063 1 14/12/2004
B.90.A / 2
POWER PRODUCTION - PTO POWER IN
CRIL03K012A01 1
CRIL03J138B01 2
27063 1 14/12/2004
B.90.A / 3
POWER PRODUCTION - PTO POWER IN
27063 1 14/12/2004
B.90.A / 4
POWER PRODUCTION - PTO POWER IN
CRIL03J138B01 1
CRIL03K012A01 2
27063 1 14/12/2004
B.90.A / 5
Index
POWER PRODUCTION - B
27063 1 14/12/2004
B.90.A / 6
27063 1 14/12/2004
B.90.A / 7
CNH France S.A.- FRANCE
SERVICE
PRINTED IN FRANCE
All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH France S.A. company reserves the right to modify without prior notice the characteristics and the design of the
machine without any obligation to carry out those modications on machines already sold.
The description of the models shown in this manual has been made using the technical specications known at the
date on which this document was designed.
27055 1 14/12/2004
REPAIR MANUAL
TRAVELLING
CX135SR
27064 1 14/12/2004
D
Contents
TRAVELLING - D
27064 1 14/12/2004
D
TRAVELLING - D
CX135SR
27065 1 14/12/2004
D.50.B / 1
Contents
TRAVELLING - D
TECHNICAL DATA
Drive sprocket
Drive sprocket - Special tools (D.50.B.45 - D.20.A.40) 5
CX135SR
Steel track
Steel track - Service limits (D.50.B.46 - D.20.A.20) 7
CX135SR
Roller
Roller Lower roller - Special tools (D.50.B.56.10 - D.20.A.40) 8
CX135SR
Idler wheel
Idler wheel - Special tools (D.50.B.57 - D.20.A.40) 12
CX135SR
FUNCTIONAL DATA
Steel track
Steel track - Exploded view (D.50.B.46 - C.10.A.20) 14
CX135SR
Roller
Roller Lower roller - Sectional view (D.50.B.56.10 - C.10.A.30) 17
CX135SR
SERVICE
27065 1 14/12/2004
D.50.B / 2
Drive sprocket
Drive sprocket - Remove (D.50.B.45 - F.10.A.10) 19
CX135SR
Steel track
Steel track - Remove (D.50.B.46 - F.10.A.10) 22
CX135SR
Rubber track
Rubber track - Visual inspection (D.50.B.47 - F.40.A.10) 30
CX135SR
Roller
Roller - Leakage test (D.50.B.56 - F.40.A.40) 47
CX135SR
27065 1 14/12/2004
D.50.B / 3
Roller Lower roller - Install (D.50.B.56.10 - F.10.A.15) 55
CX135SR
Idler wheel
Idler wheel - Disassemble (D.50.B.57 - F.10.A.25) 64
CX135SR
27065 1 14/12/2004
D.50.B / 4
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G008F01 1
Gauge for checking sprocket wear.
27065 1 14/12/2004
D.50.B / 5
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL032G007F01 1
Sprocket
MARKING STANDARD DIMENSION WEAR LIMIT
(A) 59 mm 53 mm
(B) diameter 530.7 mm 524.7 mm
(C) diameter 594.7 mm 588.07 mm
(D) diameter 581.67 mm -
(P) 171.45 mm -
27065 1 14/12/2004
D.50.B / 6
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G011F01 1
Steel track
27065 1 14/12/2004
D.50.B / 7
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03J046F01 1
Gauge for checking wear on lower roller
27065 1 14/12/2004
D.50.B / 8
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03J048F01 1
Upper roller
27065 1 14/12/2004
D.50.B / 9
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03J051F01 1
Gauge for checking wear on upper roller
27065 1 14/12/2004
D.50.B / 10
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03J049F01 1
Upper roller
27065 1 14/12/2004
D.50.B / 11
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03J053F01 1
Gauge for checking idler wheel wear
27065 1 14/12/2004
D.50.B / 12
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03J054F01 1
Idler wheel
27065 1 14/12/2004
D.50.B / 13
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G115G01 1
27065 1 14/12/2004
D.50.B / 14
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G207F01 1
27065 1 14/12/2004
D.50.B / 15
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G208F01 1
27065 1 14/12/2004
D.50.B / 16
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03J044F01 1
Assembly dimension
(A) 261 - 259,8 mm
(B) 224 mm
Description
(1) Lower roller (2) Drain plug
(3) Retaining ring (4) Housing
(5) Seal (6) Shaft
(7) Seal (8) Bushing
27065 1 14/12/2004
D.50.B / 17
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03J043F01 1
Assembly dimension
(A) 94,3 - 94,7 mm
(B) 59 mm
Description
(1) Lower roller (2) Drain plug
(3) Screw (4) Cover
(5) Seal (6) Thrust plate
(7) Shaft (8) Seal
(9) Bushing (10) Support
(11) Screw
27065 1 14/12/2004
D.50.B / 18
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G116A00 1
CRIL03G117A00 2
CRIL03G118A01 3
27065 1 14/12/2004
D.50.B / 19
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G119A01 4
CRIL03G120A00 5
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TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G118A01 1
CRIL03G134A00 2
CRIL03G119A01 3
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D.50.B / 21
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G121A00 1
CRIL03G122A01 2
DANGER
SA024 - Hydraulic uid or grease injected into
your skin can cause severe injury or death. Keep
your hands and body away from any pressurized CRIL03G123A01 3
leak. If uid is injected into your skin, see a doctor
immediately and have the uid removed.
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TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G124A00 4
CRIL03G125A01 5
CRIL03G126A01 6
CRIL03G127A00 7
27065 1 14/12/2004
D.50.B / 23
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G128A00 8
CRIL03G129A00 9
CRIL03G130A01 10
CRIL03G131A00 11
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D.50.B / 24
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G132A00 12
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TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G136A00 1
CRIL03G137A00 2
CRIL03G138A00 3
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D.50.B / 26
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G139A00 4
6. Install the two spacers (1) in the half links where the
end of chain pin is located.
CRIL03G130A01 5
CRIL03G140A00 6
CRIL03G141A01 7
9. Install the two track shoes, the screws and the nuts.
27065 1 14/12/2004
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TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G125A01 8
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TRAVELLING - WHEELS AND TRACKS Tracks
NOTE: Measure the diameter of the pins and bushings with a micrometer or an outside calliper.
1. Measure the outside diameter of the bushing (2)
using an outside caliper (1).
CRIL03G153A01 1
27065 1 14/12/2004
D.50.B / 29
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G049A01 1
27065 1 14/12/2004
D.50.B / 30
TRAVELLING - WHEELS AND TRACKS Tracks
Prior operation: Slacken the track completely, refer to Track tensioning mechanism - Tension adjust (D.50.B.48
- F.45.A.40)
CRIL03G050A01 1
CRIL03G051A01 2
CRIL03G052A01 3
27065 1 14/12/2004
D.50.B / 31
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G053A01 4
27065 1 14/12/2004
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TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G053A02 1
CRIL03G054A01 2
CRIL03G055A01 3
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D.50.B / 33
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G052A02 4
CRIL03G056A01 5
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D.50.B / 34
TRAVELLING - WHEELS AND TRACKS Tracks
NOTE: Check the tension of the tracks as required. Adjust the tension according to the type of surface on which
the machine will be operating. Tighten the track for operation on hard surfaces and loosen the track for operation
on soft surfaces.
1. Park the machine on a hard, level surface. Rotate
the upperstructure of the machine so that the cab is
over the track to be checked.
2. Lower the attachment to raise the machine until
the track to be checked is a few centimetres off the
ground.
CRIL03G121A00 1
CRIL03G143A00 2
CRIL03G124A00 3
27065 1 14/12/2004
D.50.B / 35
TRAVELLING - WHEELS AND TRACKS Tracks
DANGER
SA024 - Hydraulic uid or grease injected into
your skin can cause severe injury or death. Keep
your hands and body away from any pressurized
leak. If uid is injected into your skin, see a doctor
immediately and have the uid removed.
CRIL03G144A00 4
CRIL03G124A00 5
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D.50.B / 36
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G189A00 1
CRIL03G190A00 2
CRIL03G191A00 3
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D.50.B / 37
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G192A00 4
27065 1 14/12/2004
D.50.B / 38
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03I148A01 1
27065 1 14/12/2004
D.50.B / 39
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03I148A01 1
(A) = 419 mm
CRIL03I147A01 2
27065 1 14/12/2004
D.50.B / 40
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G199A00 1
CRIL03G196A00 2
CRIL03G197A00 3
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D.50.B / 41
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G198A00 4
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D.50.B / 42
TRAVELLING - WHEELS AND TRACKS Tracks
IMPORTANT: Do not place any part of your body under the tension cylinder.
You could be seriously injured if the cylinder falls when the screws securing it to the machine are removed.
IMPORTANT: Do not remove the check valve.
DANGER
SA024 - Hydraulic uid or grease injected into your skin can cause severe injury or death. Keep your hands
and body away from any pressurized leak. If uid is injected into your skin, see a doctor immediately
and have the uid removed.
CRIL03G212A01 1
CRIL03G213A00 2
27065 1 14/12/2004
D.50.B / 43
TRAVELLING - WHEELS AND TRACKS Tracks
NOTE: The numbers in parentheses refer to Track tensioning mechanism Adjuster-recoil mechanism -
Exploded view (D.50.B.48.65 - C.10.A.20)
1. Remove the two screws (3) and the locking washers
(4).
Remove the bracket (5).
2. Remove the grease tting (6) from the check valve.
3. Remove the check valve from the cylinder barrel
(15).
CRIL03G220A01 1
27065 1 14/12/2004
D.50.B / 44
TRAVELLING - WHEELS AND TRACKS Tracks
NOTE: The numbers in parentheses refer to Track tensioning mechanism Adjuster-recoil mechanism -
Exploded view (D.50.B.48.65 - C.10.A.20)
1. Install the seal (14) and the ring (13) in the cylinder
barrel (15).
CRIL03G220A01 1
CRIL03G221A01a 2
27065 1 14/12/2004
D.50.B / 45
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G213A00 1
CRIL03G212A01 2
Next operation: Install the roller located under the tension cylinder, refer to Roller Lower roller - Install
(D.50.B.56.10 - F.10.A.15)
Next operation: Steel track - Install (D.50.B.46 - F.10.A.15)
27065 1 14/12/2004
D.50.B / 46
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G154A01 1
27065 1 14/12/2004
D.50.B / 47
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G050A01 1
CRIL03I176A01 2
DANGER
SA024 - Hydraulic uid or grease injected into
your skin can cause severe injury or death. Keep
your hands and body away from any pressurized
leak. If uid is injected into your skin, see a doctor
immediately and have the uid removed.
CRIL03I179A01 3
CRIL03I177A01 4
27065 1 14/12/2004
D.50.B / 48
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03I178A01 5
27065 1 14/12/2004
D.50.B / 49
TRAVELLING - WHEELS AND TRACKS Tracks
NOTE: When the lower roller is worn or leaking, it must be reconditioned or replaced with a new one. Refer to
Roller Lower roller - Service limits (D.50.B.56.10 - D.20.A.20)
1. Clean lower roller (1) using a suitable solvent.
Remove the two drain plugs (2) and drain the oil.
CRIL03G214A01 1
CRIL03G215A01 2
CRIL03G216A01 3
27065 1 14/12/2004
D.50.B / 50
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G217A01 4
CRIL03G218A01 5
CRIL03G219A01 6
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D.50.B / 51
TRAVELLING - WHEELS AND TRACKS Tracks
27065 1 14/12/2004
D.50.B / 52
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G219A02 1
CRIL03G218A01 2
CRIL03G217A02 3
CRIL03G216A01 4
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D.50.B / 53
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G215A02 5
CRIL03G214A02 6
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D.50.B / 54
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03I178A01 1
CRIL03I177A01 2
CRIL03I176A01 3
27065 1 14/12/2004
D.50.B / 55
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G121A00 1
DANGER
SA024 - Hydraulic uid or grease injected into
your skin can cause severe injury or death. Keep
your hands and body away from any pressurized
leak. If uid is injected into your skin, see a doctor
immediately and have the uid removed.
CRIL03G124A00 2
CRIL03G145A00 3
CRIL03G146A00 4
27065 1 14/12/2004
D.50.B / 56
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G147A00 5
CRIL03G148A00 6
27065 1 14/12/2004
D.50.B / 57
TRAVELLING - WHEELS AND TRACKS Tracks
NOTE: When the upper roller is worn or leaks, it should be reconditioned or replaced by a new one; for wear limits,
refer to Roller Upper roller - Service limits (D.50.B.56.20 - D.20.A.20)
1. Clean upper roller (1) using a suitable solvent.
Remove drain plug (2) and drain the oil.
CRIL03J035A01 1
CRIL03J036A01 2
CRIL03J037A01 3
27065 1 14/12/2004
D.50.B / 58
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03J038A01 4
CRIL03J039A01 5
CRIL03J040A01 6
CRIL03J041A01 7
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D.50.B / 59
TRAVELLING - WHEELS AND TRACKS Tracks
27065 1 14/12/2004
D.50.B / 60
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03J042A01 1
CRIL03J041A01 2
CRIL03J039A01 3
CRIL03J038A01 4
27065 1 14/12/2004
D.50.B / 61
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03J037A01 5
CRIL03J036A01 6
CRIL03J035A01 7
27065 1 14/12/2004
D.50.B / 62
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G152A00 1
CRIL03G147A00 2
CRIL03G145A00 3
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D.50.B / 63
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G233A01 1
CRIL03G234A01 2
CRIL03G235A01 3
CRIL03G236A01 4
27065 1 14/12/2004
D.50.B / 64
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G237A01 5
CRIL03G238A01 6
CRIL03G239A01 7
27065 1 14/12/2004
D.50.B / 65
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G240B01b 1
CRIL03G238A01 2
CRIL03G237A01 3
27065 1 14/12/2004
D.50.B / 66
TRAVELLING - WHEELS AND TRACKS Tracks
CRIL03G236A01 4
CRIL03G235A01 5
CRIL03G241A01 6
CRIL03G233A01 7
27065 1 14/12/2004
D.50.B / 67
Index
TRAVELLING - D
27065 1 14/12/2004
D.50.B / 68
Rubber track - Install (D.50.B.47 - F.10.A.15) 33
CX135SR
Rubber track - Remove (D.50.B.47 - F.10.A.10) 31
CX135SR
Rubber track - Visual inspection (D.50.B.47 - F.40.A.10) 30
CX135SR
Steel track - Exploded view (D.50.B.46 - C.10.A.20) 14
CX135SR
Steel track - Install (D.50.B.46 - F.10.A.15) 26
CX135SR
Steel track - Remove (D.50.B.46 - F.10.A.10) 22
CX135SR
Steel track - Service limits (D.50.B.46 - D.20.A.20) 7
CX135SR
Steel track Chain - Measure (D.50.B.46.20 - F.40.A.16) 29
CX135SR
Track tensioning mechanism - Tension adjust (D.50.B.48 - F.45.A.40) 35
CX135SR
Track tensioning mechanism Adjuster-recoil mechanism - Assemble (D.50.B.48.65 - F.10.A.20) 45
CX135SR
Track tensioning mechanism Adjuster-recoil mechanism - Disassemble (D.50.B.48.65 - F.10.A.25) 44
CX135SR
Track tensioning mechanism Adjuster-recoil mechanism - Exploded view (D.50.B.48.65 - 16
C.10.A.20)
CX135SR
Track tensioning mechanism Adjuster-recoil mechanism - Install (D.50.B.48.65 - F.10.A.15) 46
CX135SR
Track tensioning mechanism Adjuster-recoil mechanism - Remove (D.50.B.48.65 - F.10.A.10) 43
CX135SR
Track tensioning mechanism Shock absorber - Assemble (D.50.B.48.70 - F.10.A.20) 40
CX135SR
Track tensioning mechanism Shock absorber - Disassemble (D.50.B.48.70 - F.10.A.25) 39
CX135SR
Track tensioning mechanism Shock absorber - Exploded view (D.50.B.48.70 - C.10.A.20) 15
CX135SR
Track tensioning mechanism Shock absorber - Install (D.50.B.48.70 - F.10.A.15) 41
CX135SR
Track tensioning mechanism Shock absorber - Remove (D.50.B.48.70 - F.10.A.10) 37
CX135SR
27065 1 14/12/2004
D.50.B / 69
CNH France S.A.- FRANCE
SERVICE
PRINTED IN FRANCE
All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH France S.A. company reserves the right to modify without prior notice the characteristics and the design of the
machine without any obligation to carry out those modications on machines already sold.
The description of the models shown in this manual has been made using the technical specications known at the
date on which this document was designed.
27064 1 14/12/2004
REPAIR MANUAL
BODY AND STRUCTURE
CX135SR
27066 1 14/12/2004
E
Contents
SHIELD E.20.A
CX135SR
27066 1 14/12/2004
E
BODY AND STRUCTURE - E
SHIELD - 20.A
CX135SR
27067 1 14/12/2004
E.20.A / 1
Contents
SHIELD - 20.A
SERVICE
Side shield
Side shield - Remove (E.20.A.70 - F.10.A.10) 3
CX135SR
Upper shield
Upper shield - Remove (E.20.A.71 - F.10.A.10) 5
CX135SR
Engine hood
Engine hood - Remove (E.20.A.72 - F.10.A.10) 7
CX135SR
Protective shield
Protective shield - Remove (E.20.A.73 - F.10.A.10) 8
CX135SR
27067 1 14/12/2004
E.20.A / 2
BODY AND STRUCTURE - SHIELD
CRPH03I072A 1
2. RH REAR DOOR
This door is attached by a hinge held by hardware
(1).
CRIL03J072A01 2
3. RH FRONT DOOR
This door is attached by a hinge held by hardware
(1).
CRIL03J073A01 3
27067 1 14/12/2004
E.20.A / 3
BODY AND STRUCTURE - SHIELD
CRIL03K046A01 5
6. LH REAR DOOR
This door is attached by a hinge held by hardware
(1).
CRIL03J071A01 6
CRIL03J074A01 7
27067 1 14/12/2004
E.20.A / 4
BODY AND STRUCTURE - SHIELD
CRIL03J079A01 1
CRIL03J120A01 2
CRIL03J119A01 3
CRIL03J080A01 4
27067 1 14/12/2004
E.20.A / 5
BODY AND STRUCTURE - SHIELD
CRIL03J121B01 5
6. SAFETY RAIL.
Remove the RH tank side guard.
Remove the upper protective panel from hydraulic
reservoir.
Remove screws (1) and (2), then remove handrail
(3).
CRIL03L205A01 6
CRIL03J122A01 7
27067 1 14/12/2004
E.20.A / 6
BODY AND STRUCTURE - SHIELD
CRIL03J063A01 1
27067 1 14/12/2004
E.20.A / 7
BODY AND STRUCTURE - SHIELD
CRIL04C143A01 1
CRIL04B174B01 2
CRIL03I143A01 3
27067 1 14/12/2004
E.20.A / 8
Index
SHIELD - 20.A
Engine hood - Remove (E.20.A.72 - F.10.A.10) 7
CX135SR
Protective shield - Remove (E.20.A.73 - F.10.A.10) 8
CX135SR
Side shield - Remove (E.20.A.70 - F.10.A.10) 3
CX135SR
Upper shield - Remove (E.20.A.71 - F.10.A.10) 5
CX135SR
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E.20.A / 9
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E.20.A / 10
BODY AND STRUCTURE - E
CX135SR
27068 1 14/12/2004
E.32.A / 1
Contents
FUNCTIONAL DATA
Instrument panel
Instrument panel - Detailed view (E.32.A.81 - C.10.A.50) 3
CX135SR
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E.32.A / 2
BODY AND STRUCTURE - USER CONTROLS AND SEAT
CRIL03K120F01 1
27068 1 14/12/2004
E.32.A / 3
Index
27068 1 14/12/2004
E.32.A / 4
BODY AND STRUCTURE - E
CX135SR
27069 1 14/12/2004
E.34.A / 1
Contents
FUNCTIONAL DATA
Wiper system
Wiper system - Electronic schema (E.34.A.65 - C.20.A.50) 3
CX135SR
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E.34.A / 2
BODY AND STRUCTURE - USER PLATFORM
CRIL03G229E01 1
Circuit layout
(1) Windscreen wiper intermittent indicator lamp (2) Windscreen wiper continuous indicator lamp
(K20) Windscreen wiper motor relay (M3) Windscreen wiper motor
(P1) Instrument panel (S11) Windscreen wiper switch
CRIL03G230E02 2
Timing diagram
OPERATION
• The intermittent (1) and continuous (2) windscreen wiper indicator lamps do not light up when the windscreen
washer switch is operated.
27069 1 14/12/2004
E.34.A / 3
BODY AND STRUCTURE - USER PLATFORM
CRIL03G231E01 1
Circuit layout
(K21) Windscreen washer pump relay (M4) Windscreen washer pump motor
(P1) Instrument panel (S12) Windscreen washer switch
CRIL03G232E02 2
Timing diagram
OPERATION
• The intermittent and continuous windscreen wiper indicator lamps do not light up when windscreen washer
switch (S12) is operated.
27069 1 14/12/2004
E.34.A / 4
Index
27069 1 14/12/2004
E.34.A / 5
27069 1 14/12/2004
E.34.A / 6
BODY AND STRUCTURE - E
CX135SR
27070 1 14/12/2004
E.40.D / 1
Contents
TECHNICAL DATA
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Special tools 4
(E.40.D - D.20.A.40)
CX135SR
FUNCTIONAL DATA
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Dynamic 6
description (E.40.D - C.30.A.10)
CX135SR
Command
Command - Overview (E.40.D.05 - C.10.A.10) 8
CX135SR
SERVICE
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Evacuate 10
(E.40.D - F.35.A.35)
CX135SR
Compressor
Compressor - Remove (E.40.D.31 - F.10.A.10) 16
CX135SR
Condenser
Condenser - Remove (E.40.D.32 - F.10.A.10) 18
CX135SR
Receiver/drier
Receiver/drier - Remove (E.40.D.36 - F.10.A.10) 20
CX135SR
DIAGNOSTIC
27070 1 14/12/2004
E.40.D / 2
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Troubleshooting 22
(E.40.D - G.40.A.10)
CX135SR
Compressor
Compressor Magnetic clutch - Troubleshooting (E.40.D.31.80 - G.40.A.10) 23
CX135SR
Ventilation system
Ventilation system - Troubleshooting (E.40.D.60 - G.40.A.10) 23
CX135SR
27070 1 14/12/2004
E.40.D / 3
BODY AND STRUCTURE - ENVIRONMENT CONTROL Heating, ventilation and air-conditioning
CRPH03I021A 1
Electronic leak detector OEM-1437
CRPH03I022A 2
Thermometer 0 - 250 °C CAS-1048
CRPH03I023A 3
27070 1 14/12/2004
E.40.D / 4
BODY AND STRUCTURE - ENVIRONMENT CONTROL Heating, ventilation and air-conditioning
CRPH03I024A 4
Protective goggles CAS-10073-3
CRPH03I025A 5
27070 1 14/12/2004
E.40.D / 5
BODY AND STRUCTURE - ENVIRONMENT CONTROL Heating, ventilation and air-conditioning
The air conditioning system comprises ve major components: the condenser (5), the evaporator (3), the
compressor (4), the expansion valve (1) and the receiver-dryer (6). These components are connected by pipes and
hoses for closed circuit operation. The air-conditioning system runs on R-134a refrigerant.
The compressor receives the refrigerant in the form of gas. The compressor then compresses the refrigerant and,
still in its gaseous form, sends it to the condenser. The air circulates through the condenser and removes the
heat from the refrigerant. As the heat dissipates, the refrigerant becomes liquid. The liquid refrigerant circulates
from the condenser to the receiver-dryer. The receiver-dryer is a container lled with a material to extract the
moisture that accumulates in the air-conditioning circuit. The moisture must be eliminated to prevent the internal
components in the air-conditioning system from corroding. The receiver-dryer also acts as a refrigerant reservoir
for the air-conditioning system.
Still in liquid form, the refrigerant passes to the expansion valve. The expansion valve restricts the ow of the
refrigerant to the evaporator. Because of this restriction, the refrigerant is under less pressure at the expansion
valve outlet than at the inlet. As the refrigerant passes through the evaporator, it is warmed by the air surrounding
the evaporator. The combination of increased warmth and lower pressure causes the refrigerant to evaporate. The
evaporation cools the air circulating in the evaporation coil. The cooled air is then used to cool the driver’s cab.
The refrigerant, now in the gas phase again, returns to the compressor and the cycle is repeated.
27070 1 14/12/2004
E.40.D / 6
BODY AND STRUCTURE - ENVIRONMENT CONTROL Heating, ventilation and air-conditioning
CRIL03I010G01 1
Air-conditioning circuit components
27070 1 14/12/2004
E.40.D / 7
BODY AND STRUCTURE - ENVIRONMENT CONTROL Heating, ventilation and air-conditioning
NOTE: Refer to the Operating and Maintenance Manual for the detailed use of these controls.
CRIL03I009F01 1
Heating, ventilation and air conditioning controls.
1. System ON/OFF selector switch and indicator lamp.
2. Air conditioning ON/OFF selector switch and indicator lamp.
3. Fan speed selector switch.
4. Temperature selector switch and indicator lamp.
5. Air circulation selector switches and indicator lamps:
Top front air vent.
Top front and rear vents.
Top and bottom rear vents.
6. Windshield defroster selector switch and indicator lamp.
7. Air inlet selector switch and indicator lamp.
Outside air inlet.
Inside air inlet.
27070 1 14/12/2004
E.40.D / 8
BODY AND STRUCTURE - ENVIRONMENT CONTROL Heating, ventilation and air-conditioning
CRIL03I011G01 1
Air conditioning electrical circuit diagram
27070 1 14/12/2004
E.40.D / 9
BODY AND STRUCTURE - ENVIRONMENT CONTROL Heating, ventilation and air-conditioning
CAUTION
M143B - Never attempt to service the air conditioning system unless you are completely familiar with air
conditioning and the safety precautions which must be followed when handling liquid refrigerant. Liquid
refrigerant can cause severe and painful frostbite. Contact your Dealer, who is experienced in servicing
and handling of refrigerants.
CAUTION
SM105A - Always wear safety goggles when working with liquid refrigerant. Liquid refrigerant in your
eyes could cause blindness.
CAUTION
SM109A - When refrigerant comes in contact with an open ame, it forms phosgene gas. Never breathe
these fumes.
CAUTION
M742 - Always reclaim all refrigerant prior to opening an A/C system. A drop of liquid refrigerant on your
skin may cause frostbite. Open ttings carefully and slowly when servicing the air conditioning system.
Your skin must be treated for frostbite or a physician must be seen if you get refrigerant on your skin.
CAUTION
M743 - Keep refrigerant containers in correct upright position. Always keep refrigerant containers away
from heat and sunlight. The pressure in a container will increase with heat.
ATTENTION: Service work on air-conditioning circuits must be carried out by approved service engineers.
NOTE: If possible, run the air-conditioning system for a few minutes before starting the recovery process. Shut
down the system before proceeding.
1. Clean the external surfaces of the compressor and
hoses.
Remove the caps from low (1) and high pressure
(2) test points.
Connect hoses on the recovery station OEM-1418
on the pressure test points:
Low pressure on port (1) (suction),
High pressure on port (2) (discharge).
Start recovery.
CRIL03L159A01 1
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E.40.D / 10
BODY AND STRUCTURE - ENVIRONMENT CONTROL Heating, ventilation and air-conditioning
CRIL03L159A01 1
27070 1 14/12/2004
E.40.D / 11
BODY AND STRUCTURE - ENVIRONMENT CONTROL Heating, ventilation and air-conditioning
CRIL03L149G01 1
Air-conditioning group
CRIL03L150A01 2
27070 1 14/12/2004
E.40.D / 12
BODY AND STRUCTURE - ENVIRONMENT CONTROL Heating, ventilation and air-conditioning
CRIL03L151A01 3
CRIL03L152A01 4
CRIL03L153A01 5
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E.40.D / 13
BODY AND STRUCTURE - ENVIRONMENT CONTROL Heating, ventilation and air-conditioning
CRIL03L154B01 6
CRIL03L157A01 8
27070 1 14/12/2004
E.40.D / 14
BODY AND STRUCTURE - ENVIRONMENT CONTROL Heating, ventilation and air-conditioning
CRIL03L155B01 9
27070 1 14/12/2004
E.40.D / 15
BODY AND STRUCTURE - ENVIRONMENT CONTROL Heating, ventilation and air-conditioning
Prior operation: To discharge the air-conditioning system, refer to ENVIRONMENT CONTROL Heating,
ventilation and air-conditioning - Evacuate (E.40.D - F.35.A.35)
CRIL03L161G01 1
27070 1 14/12/2004
E.40.D / 16
BODY AND STRUCTURE - ENVIRONMENT CONTROL Heating, ventilation and air-conditioning
CRIL03L161G01 1
Torque settings
(6) Retaining screws for suction and delivery hoses 19.8 - 29.4 Nm
(7) Compressor retaining screws 19.8 - 29.4 Nm
(10) Bracket retaining screws 53.9 - 63.7 Nm
1. Install compressor bracket and tension pulley (9)
with screws (10).
2. Install compressor (8) on its bracket using screws
(7).
3. Connect suction (4) and delivery (5) hoses to the
compressor using screws (6) and new seal rings.
4. Install belt (2).
Tighten belt by adjusting screw (1) on the tension
pulley.
NOTE: By applying pressure of around 10 kg in the
middle of the belt, the tension slack should be 8 - 10 mm.
5. Connect electric wire (3).
Next operation: ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Charging (E.40.D
- F.60.A.30)
27070 1 14/12/2004
E.40.D / 17
BODY AND STRUCTURE - ENVIRONMENT CONTROL Heating, ventilation and air-conditioning
Prior operation: To discharge the air-conditioning system, refer to ENVIRONMENT CONTROL Heating,
ventilation and air-conditioning - Evacuate (E.40.D - F.35.A.35)
Prior operation: Air cleaner - Remove (B.30.A.25 - F.10.A.10)
CRIL03L158F01 1
27070 1 14/12/2004
E.40.D / 18
BODY AND STRUCTURE - ENVIRONMENT CONTROL Heating, ventilation and air-conditioning
CRIL03L158F01 1
Next operation: To charge the circuit, refer to ENVIRONMENT CONTROL Heating, ventilation and
air-conditioning - Charging (E.40.D - F.60.A.30)
Next operation: Air cleaner - Install (B.30.A.25 - F.10.A.15)
27070 1 14/12/2004
E.40.D / 19
BODY AND STRUCTURE - ENVIRONMENT CONTROL Heating, ventilation and air-conditioning
Prior operation: To discharge the air-conditioning system, refer to ENVIRONMENT CONTROL Heating,
ventilation and air-conditioning - Evacuate (E.40.D - F.35.A.35)
CRIL03L160F01 1
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E.40.D / 20
BODY AND STRUCTURE - ENVIRONMENT CONTROL Heating, ventilation and air-conditioning
CRIL03L160F01 1
Next operation: ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Charging (E.40.D
- F.60.A.30)
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E.40.D / 21
BODY AND STRUCTURE - ENVIRONMENT CONTROL Heating, ventilation and air-conditioning
27070 1 14/12/2004
E.40.D / 22
BODY AND STRUCTURE - ENVIRONMENT CONTROL Heating, ventilation and air-conditioning
27070 1 14/12/2004
E.40.D / 23
BODY AND STRUCTURE - ENVIRONMENT CONTROL Heating, ventilation and air-conditioning
27070 1 14/12/2004
E.40.D / 24
Index
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E.40.D / 25
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E.40.D / 26
BODY AND STRUCTURE - E
CX135SR
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E.50.B / 1
Contents
FUNCTIONAL DATA
Hydraulic lock-out
Hydraulic lock-out - Electrical schema (E.50.B.13 - C.20.A.40) 3
CX135SR
SERVICE
Hydraulic lock-out
Hydraulic lock-out Electrovalve - Electrical test (E.50.B.13.10 - F.40.A.50) 6
CX135SR
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E.50.B / 2
BODY AND STRUCTURE - SAFETY SECURITY ACCESSORIES Safety
CRIL03G202F02 1
Circuit layout
OPERATION
• When the engine is running and the hydraulic control cancellation lever is in the working position, contact
switch (S51) is closed and pilot pressure solenoid valve (Y2) is energised. Pilot pressure is supplied to the
servo-mechanism and the machine’s hydraulic controls are operational.
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E.50.B / 3
BODY AND STRUCTURE - SAFETY SECURITY ACCESSORIES Safety
CRIL03I136F01a 1
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E.50.B / 4
BODY AND STRUCTURE - SAFETY SECURITY ACCESSORIES Safety
CRIL03I138F01 1
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E.50.B / 5
BODY AND STRUCTURE - SAFETY SECURITY ACCESSORIES Safety
To carry out this test, use the solenoid valve electrical connector and a multimeter, refer to ELECTRICAL POWER
SYSTEM - Special tools (A.30.A - D.20.A.40).
CRIL03L141A01 1
CRIL03I078A01 2
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E.50.B / 6
BODY AND STRUCTURE - SAFETY SECURITY ACCESSORIES Safety
Prior operation: To remove the side cover plate in the cab oor, refer to Side shield - Remove (E.20.A.70 -
F.10.A.10).
Prior operation: To remove the access panel in the cab oor, refer to Protective shield Guard - Remove
(E.20.A.73.71 - F.10.A.10).
CRIL03I149A01 1
CRIL03L141A04 2
CRIL03I163A01 3
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E.50.B / 7
BODY AND STRUCTURE - SAFETY SECURITY ACCESSORIES Safety
NOTE: Mark each part of every element during disassembly to make reassembly easier.
1. Remove retaining nut (1) from the coil.
Remove the coil (2) from the solenoid.
CRIL03I157A01 1
CRIL03I153A01 2
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E.50.B / 8
BODY AND STRUCTURE - SAFETY SECURITY ACCESSORIES Safety
27071 1 14/12/2004
E.50.B / 9
BODY AND STRUCTURE - SAFETY SECURITY ACCESSORIES Safety
CRIL03I157A01 1
27071 1 14/12/2004
E.50.B / 10
BODY AND STRUCTURE - SAFETY SECURITY ACCESSORIES Safety
27071 1 14/12/2004
E.50.B / 11
Index
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E.50.B / 12
27071 1 14/12/2004
E.50.B / 13
CNH France S.A.- FRANCE
SERVICE
PRINTED IN FRANCE
All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH France S.A. company reserves the right to modify without prior notice the characteristics and the design of the
machine without any obligation to carry out those modications on machines already sold.
The description of the models shown in this manual has been made using the technical specications known at the
date on which this document was designed.
27066 1 14/12/2004
REPAIR MANUAL
FRAME POSITIONING
CX135SR
27072 1 14/12/2004
F
Contents
FRAME POSITIONING - F
27072 1 14/12/2004
F
FRAME POSITIONING - F
CX135SR
27073 1 14/12/2004
F.10.F / 1
Contents
FRAME POSITIONING - F
TECHNICAL DATA
Command valve
Command valve Foot command valve - Special tools (F.10.F.12.10 - D.20.A.40) 5
CX135SR
Hydraulic motor
Hydraulic motor - Torque (F.10.F.28 - D.20.A.10) 6
CX135SR
FUNCTIONAL DATA
TRAVELLING Travel - Electronic schema (F.10.F - C.20.A.50) 12
CX135SR
Command valve
Command valve Foot command valve - Sectional view (F.10.F.12.10 - C.10.A.30) 17
CX135SR
Control valve
Control valve - Sectional view (F.10.F.14 - C.10.A.30) 19
CX135SR
Hydraulic motor
Hydraulic motor - Exploded view (F.10.F.28 - C.10.A.20) 20
CX135SR
Sensing system
Sensing system Alarm - Electronic schema (F.10.F.95.90 - C.20.A.50) 27
CX135SR NA
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F.10.F / 2
SERVICE
Command valve
Command valve Foot command valve - Remove (F.10.F.12.10 - F.10.A.10) 28
CX135SR
Control valve
Control valve - Disassemble (F.10.F.14 - F.10.A.25) 45
CX135SR
Relief valve
Relief valve - Pressure test (F.10.F.16 - F.40.A.30) 49
CX135SR
Hydraulic motor
Hydraulic motor - Remove (F.10.F.28 - F.10.A.10) 52
CX135SR
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F.10.F / 3
Reducer, spur gear - Install (F.10.F.44 - F.10.A.15) 92
CX135SR
DIAGNOSTIC
TRAVELLING Travel - Troubleshooting (F.10.F - G.40.A.10) 93
CX135SR
Command valve
Command valve Foot command valve - Troubleshooting (F.10.F.12.10 - G.40.A.10) 93
CX135SR
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F.10.F / 4
FRAME POSITIONING - TRAVELLING Travel
CRIL03L111A01 1
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F.10.F / 5
FRAME POSITIONING - TRAVELLING Travel
CRIL03K086G01 1
Description
(1) 78 - 128 Nm (2) 78 - 118 Nm
(3) 24 - 34 Nm (4) 107 - 147 Nm
(5) 58 - 98 Nm (6) 112 - 142 Nm
(7) 313 - 393 Nm (8) 78 - 128 Nm
(9) 12 - 14 Nm (10) 5,6 - 6,1 Nm
(11) 48 - 66 Nm (12) 24 - 34 Nm
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F.10.F / 6
FRAME POSITIONING - TRAVELLING Travel
CRIL03F009E01 1
Pin diameter 2.
Used for removing ring (18).
(A) 150 mm
CRIL03F010E01 2
Lifting ring
Used for removing cover (8).
(A) PT3/8
CRIL03F011E01 3
Lifting ring
Used to lift the travel motor reduction gear, spindle (2) and housing (1).
(A) Housing M14 , spindle and motor reduction gear M16
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F.10.F / 7
FRAME POSITIONING - TRAVELLING Travel
CRIL03F013E01 4
Punch
Used to remove the outer ring from bearing (21).
(A) 150 mm
(B) 1 mm
(C) 10 mm
CRIL03F015F01 5
Support
Used to hold housing (1) on spindle (2).
Dimensions unavailable at time of publication
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F.10.F / 8
FRAME POSITIONING - TRAVELLING Travel
CRIL03F016E01 6
Guide
Used for installing bearings (22).
Dimensions unavailable at time of publication
CRIL03F018E01 7
Guide
Used for installing seal (132).
Dimensions unavailable at time of publication
CRIL03F021E01 8
Checking tool
Used to check the preloading of bearing (21).
A. Brake piston cup
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F.10.F / 9
FRAME POSITIONING - TRAVELLING Travel
CRIL03F022E01 9
CRIL03F023E01 10
CRIL03F024E01 11
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F.10.F / 10
FRAME POSITIONING - TRAVELLING Travel
CRIL03F025E01 12
CRIL03F026E01 13
(A) 21 mm (C) 10 mm
(B) 15 mm (D) M6
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F.10.F / 11
FRAME POSITIONING - TRAVELLING Travel
CRIL03G097E01 1
Circuit layout
CRIL03G098E02 2
Timing diagram
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F.10.F / 12
FRAME POSITIONING - TRAVELLING Travel
CRIL03J142G01 1
High speed travel circuit - Dynamic Description
(16) Hydraulic swivel (21) Travel motor
(C1) 2nd gear travel pilot (Pa1/A1) RH forward travel
(Pb1/B1) RH reverse travel (Pa6/A6) LH forward travel
(Pb6/B6) LH reverse travel (P1) Instrument panel
(S2) Travel gear switch (Y4) 2nd gear travel solenoid valve
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F.10.F / 13
FRAME POSITIONING - TRAVELLING Travel
• 2nd travel gear solenoid valve (red band) (Y4) must be activated to change to a high gear. The 2nd gear travel
speed pilot pressure 39 bar from 2nd gear travel solenoid valve (Y4), passes through hydraulic swivel (16) and
continues to control the displacement change spools on travel motors (21).
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F.10.F / 14
FRAME POSITIONING - TRAVELLING Travel
CRIL03J143G01 1
Low gear travel circuit - Dynamic Description
(21) Travel motor (C1) 2nd gear travel pilot
(Pa1/A1) RH forward travel (Pb1/B1) RH reverse travel
(Pa6/A6) LH forward travel (Pb6/B6) LH reverse travel
(P1) Instrument panel (S2) Travel gear switch
(Y4) 2nd gear travel solenoid valve
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F.10.F / 15
FRAME POSITIONING - TRAVELLING Travel
CRIL03J144G01 1
Straight-line travel circuit - Dynamic Description
(1) Straight-line travel valve (21) Travel motor
(Pa1/A1) RH forward travel (Pb1/B1) RH reverse travel
(Pa6/A6) LH forward travel (Pb6/B6) LH reverse travel
(Pa4) Boom spool 2 (Pa8/A8) Boom raising
(Pb8/B8) Boom lowering
STRAIGHT-LINE TRAVEL
This chapter describes the situation in which the boom is raised as the machine is travelling.
• When the boom requires raising, the boom spool is operated and the low pressure circuit coming from (PP)
and passing through all attachment and swing spools is closed. This circuit increases in pressure up to 39 bar,
which pilots the straight-line travel valve (1). The output from pump (A2) therefore supplies the two travel
systems at (P1) and the output from pump (A1) supplies the attachment at (P2). As both travel motors
(21) are supplied in parallel, their pressure is equal and the machine travels in a straight line. In addition, if
the ow is not completely expended on the attachment, the surplus from this ow is used for travel and
the loss of speed is minimal.
• If functions other than the boom are used at the same time as travel, their operation is exactly the same.
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FRAME POSITIONING - TRAVELLING Travel
CRIL03L070G01a 1
Description
(1) Lower body (2) Spool
(3) Shim (4) Washer
(5) Recoil Spring (6) Calibrated spring
(7) Spring seat (8) Seal
(9) Plug (10) Seal
(11) Push rod guide (12) Seal
(13) Pusher (14) Cover
(15) Ball (16) Screw
(17) Shaft (18) Cam
(19) Bushing (20) Boot
(21) Piston (22) Upper body
(23) Spring (24) Spring seat
(25) Ball (26) Guard
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F.10.F / 17
FRAME POSITIONING - TRAVELLING Travel
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F.10.F / 18
FRAME POSITIONING - TRAVELLING Travel
CRIL03J084F01 1
RH and straight-line travel section
CRIL03J085E01 2
LH travel section
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F.10.F / 19
FRAME POSITIONING - TRAVELLING Travel
CRIL03K029H01 1
Description
(102) Shaft (230) Spring
(103) Swash plate (236) Seal
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F.10.F / 20
FRAME POSITIONING - TRAVELLING Travel
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F.10.F / 21
FRAME POSITIONING - TRAVELLING Travel
CRIL03K129H01a 1
Description
(102) Shaft (230) Spring
(103) Swash plate (236) Seal
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F.10.F / 22
FRAME POSITIONING - TRAVELLING Travel
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F.10.F / 23
FRAME POSITIONING - TRAVELLING Travel
CRIL03K026H01 1
Description
(1) Housing (21) Bearing
(2) Knuckle (22) Bearing
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F.10.F / 24
FRAME POSITIONING - TRAVELLING Travel
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F.10.F / 25
FRAME POSITIONING - TRAVELLING Travel
CRIL03K126G01a 1
Description
(1) Housing (2) Spindle
(3) Retaining ange (4) Gear
(5) Gear (6) Sun pinion
(7) Planetary pinion (8) Cover
(9) Pin (12) Spacer
(15) Coupling (17) Roller
(18) Screw (19) Screw
(20) Snap ring (21) Bearing
(22) Bearing (23) Bearing
(25) Snap ring (28) Seal
(29) Seal (30) Seal
(31) Face seal (33) Plug
(36) Ball (43) Centring stud
(132) Seal
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F.10.F / 26
FRAME POSITIONING - TRAVELLING Travel
CRIL03G225E02 1
Travel audible alarm device - Circuit layout
(B27) Travel pilot pressure switch (H2) TRAVEL AUDIBLE ALARM DEVICE
(P1) Instrument panel
CRIL03G226E02 2
Timing diagram
OPERATION
• When the travel mode is active, the travel pilot pressure closes the contact with pressure switch (B27), a signal is sent to
instrument panel (P1) and travel audible alarm device (H2) sounds.
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F.10.F / 27
FRAME POSITIONING - TRAVELLING Travel
Prior operation: To remove the side guard from under the cab oor, refer to Side shield - Remove (E.20.A.70
- F.10.A.10)
Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20)
CRIL03L107A00 1
CRIL03I083A01 2
CRIL03I083A02 3
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F.10.F / 28
FRAME POSITIONING - TRAVELLING Travel
NOTE: Always handle high precision parts with the greatest care to prevent them being damaged by being knocked
or dropped.
The control pedal components may rust due to contamination and humidity if they are left without protection
after disassembly.
If work has to be interrupted, the components must be protected from contamination or corrosion.
NOTE: Mark the position and bore of all parts.
1. Tighten the control pedal in a vice with soft jaws.
CRPH03I047A 1
CRPH03I048A 2
CRPH03I049A 3
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FRAME POSITIONING - TRAVELLING Travel
CRPH03I050A 4
CRPH03I051A 5
CRPH03I052A 6
CRIL03L095A00 7
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FRAME POSITIONING - TRAVELLING Travel
CRIL03L096A00 8
CRIL03L092A00 9
CRIL03L093A00 10
CRIL03L094A00 11
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FRAME POSITIONING - TRAVELLING Travel
CRPH03I060A 12
CRIL03L106A00 13
CRIL03L097A00 14
CRPH03I061A 15
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FRAME POSITIONING - TRAVELLING Travel
CRPH03I062A 16
CRIL03L098A00 17
CRPH03I064A 18
CRPH03I065A 19
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F.10.F / 33
FRAME POSITIONING - TRAVELLING Travel
CRIL03L099A00 20
CRIL03L100A00 21
CRIL03L101A00 22
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F.10.F / 34
FRAME POSITIONING - TRAVELLING Travel
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FRAME POSITIONING - TRAVELLING Travel
NOTE: Immerse all components in clean hydraulic uid to guarantee proper lubrication when assembling and
resuming operation.
NOTE: Assemble following the markings made during removal.
1. Install washer, shim, calibrated spring and spring
seat on the spool.
CRPH03I065A 1
CRPH03I064A 2
CRPH03I062A 3
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F.10.F / 36
FRAME POSITIONING - TRAVELLING Travel
CRPH03I061A 4
CRIL03L097A00 5
CRIL03L106A00 6
CRIL03L102A00 7
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FRAME POSITIONING - TRAVELLING Travel
CRIL03L094A00 8
CRIL03L093A00 9
CRIL03L100A00 10
CRIL03L099A00 11
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FRAME POSITIONING - TRAVELLING Travel
CRIL03L103A00 12
CRIL03L104A00 13
CRIL03L098A00 14
CRIL03L095A00 15
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F.10.F / 39
FRAME POSITIONING - TRAVELLING Travel
CRPH03I052A 16
CRPH03I068A 17
CRPH03I050A 18
CRPH03I069A 19
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F.10.F / 40
FRAME POSITIONING - TRAVELLING Travel
20. Tilt the cam and apply grease at the ends of the
push-rods and inject grease in the tappet guide
bushings.
CRIL03I073A01 20
CRPH03I070A 21
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F.10.F / 41
FRAME POSITIONING - TRAVELLING Travel
CRIL03I083A02 1
CRIL03I083A01 2
CRIL03L107A00 3
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F.10.F / 42
FRAME POSITIONING - TRAVELLING Travel
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FRAME POSITIONING - TRAVELLING Travel
To carry out this test, use the solenoid valve electrical connector and a multimeter, refer to ELECTRICAL POWER
SYSTEM - Special tools (A.30.A - D.20.A.40)
CRIL03L141A03 1
CRIL03I078A03 2
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FRAME POSITIONING - TRAVELLING Travel
CRIL03J084F01 1
RH and straight-line travel spools
CRIL03J085E01 2
LH travel spool
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F.10.F / 45
FRAME POSITIONING - TRAVELLING Travel
CRIL03L053A01 3
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F.10.F / 46
FRAME POSITIONING - TRAVELLING Travel
Prior operation: To clean and check parts before assembling, refer to Stack valve - Visual inspection (A.10.A.18
- F.40.A.10)
CRIL03J084F01 1
RH and straight-line travel spools
CRIL03J085E01 2
LH travel spool
Torque settings
Fixing screws for return springs on spools (2), (10) and (40) 9.8 - 11.8 Nm
Cap screws (11) and (13) 20 - 25 Nm
Plugs (19) and (22) 103 - 113 Nm
Union (20) 49 - 59 Nm
Plug (21) 13.5 - 16.5 Nm
1. Install check valves (16) and (26) and springs (17).
2. Install plugs (19) and (22) complete with new seals
(18) and tighten to the required torque.
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FRAME POSITIONING - TRAVELLING Travel
CRIL03L053A01 3
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F.10.F / 48
FRAME POSITIONING - TRAVELLING Travel
NOTE: Travel secondary relief valves (K) and (L) are calibrated to a higher pressure than the main relief valve (A).
To check or calibrate the travel secondary relief valves, main relief valve (A) must be overcalibrated.
1. Overcalibrate main relief valve (A) by tightening the
adjusting screw by 180 °, refer to Relief valve -
Pressure setting (A.10.A.16 - F.45.A.70).
2. Connect a 0-600 bar (0-60 MPa) pressure gauge to
the pressure test point (M2) for right-hand travel and
to (M1) for left-hand travel.
3. Have a locking pin produced locally:
(A) = 35 mm
(B) = 68 mm
(C) = 250 mm
(D) = 70 mm
CRIL03I164A01 1
CRIL03I165A01 2
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F.10.F / 49
FRAME POSITIONING - TRAVELLING Travel
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FRAME POSITIONING - TRAVELLING Travel
CRIL03K063A01 1
CRIL03K061A01 2
Next operation: Reset main relief valve (A), refer to Relief valve - Pressure setting (A.10.A.16 - F.45.A.70)
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FRAME POSITIONING - TRAVELLING Travel
CRIL03K049A01 1
CRIL03K050A01 2
CRIL03K051A01 3
CRIL03K052A01 4
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F.10.F / 52
FRAME POSITIONING - TRAVELLING Travel
CRIL03K053A01 5
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FRAME POSITIONING - TRAVELLING Travel
NOTE: The numbers in brackets refer to the hydraulic motor exploded view Hydraulic motor - Exploded view
(F.10.F.28 - C.10.A.20)
1. Remove springs (113) and valve plate (109).
CRIL03F165A00 1
CRIL03F166A00 2
CRIL03F167A00 3
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FRAME POSITIONING - TRAVELLING Travel
CRIL03K066A01 4
CRIL03K067A01 5
CRIL03K068A01 6
CRIL03K069A01 7
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FRAME POSITIONING - TRAVELLING Travel
CRIL03K070A01 8
CRIL03K071A01 9
CRIL03K072A01 10
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FRAME POSITIONING - TRAVELLING Travel
CRIL03K073A01 11
CRIL03K074A01 12
CRIL03K075A01 13
CRIL03F176A00 14
27073 1 14/12/2004
F.10.F / 57
FRAME POSITIONING - TRAVELLING Travel
CRIL03F177A00 15
CRIL03F220A00 16
CRIL03F179A00 17
CRIL03F180A00 18
27073 1 14/12/2004
F.10.F / 58
FRAME POSITIONING - TRAVELLING Travel
CRIL03F181A00 19
CRIL03F182A00 20
CRIL03F183B01 21
27073 1 14/12/2004
F.10.F / 59
FRAME POSITIONING - TRAVELLING Travel
CRIL03F185A00 22
CRIL03F186A00 23
CRIL03F187A00a 24
CRIL03F188A00 25
27073 1 14/12/2004
F.10.F / 60
FRAME POSITIONING - TRAVELLING Travel
CRIL03G113A01 26
27073 1 14/12/2004
F.10.F / 61
FRAME POSITIONING - TRAVELLING Travel
27073 1 14/12/2004
F.10.F / 62
FRAME POSITIONING - TRAVELLING Travel
NOTE: Numbers in parentheses refer to Hydraulic motor - Exploded view (F.40.C.28 - C.10.A.20)Hydraulic
motor - Exploded view (F.10.F.28 - C.10.A.20)
1. Place bearing (149) into a bearing oven and heat it
to 100 °C for 10 minutes.
Install bushing (229) on shaft (102) and install the
bearing.
DANGER
SM121A - Always wear heat protective gloves to
prevent burning your hands when handling heated
parts.
CRIL03F208A00 1
CRIL03F209A00 2
CRIL03F187A00a 3
27073 1 14/12/2004
F.10.F / 63
FRAME POSITIONING - TRAVELLING Travel
CRIL03F186A00 4
CRIL03F183B01 5
CRIL03F182A00 6
27073 1 14/12/2004
F.10.F / 64
FRAME POSITIONING - TRAVELLING Travel
CRIL03F181A00 7
CRIL03F180A00 8
CRIL03G006A00 9
CRIL03F220A00 10
27073 1 14/12/2004
F.10.F / 65
FRAME POSITIONING - TRAVELLING Travel
CRIL03F177A00 11
CRIL03K075A01 12
CRIL03K074A01 13
CRIL03K072A01 14
27073 1 14/12/2004
F.10.F / 66
FRAME POSITIONING - TRAVELLING Travel
CRIL03K073A01 15
CRIL03K071A01 16
CRIL03K070A01 17
27073 1 14/12/2004
F.10.F / 67
FRAME POSITIONING - TRAVELLING Travel
CRIL03K069A01 18
CRIL03K068A01 19
CRIL03K067A01 20
CRIL03K066A01 21
27073 1 14/12/2004
F.10.F / 68
FRAME POSITIONING - TRAVELLING Travel
CRIL03F229A 22
CRIL03F166A00 23
CRIL03F165A00 24
Next operation: To install the hydraulic motor cover on the reduction gear housing, refer to Hydraulic motor -
Install (F.10.F.28 - F.10.A.15)
27073 1 14/12/2004
F.10.F / 69
FRAME POSITIONING - TRAVELLING Travel
CRIL03K053A01 1
CRIL03K052A01 2
CRIL03K051A01 3
CRIL03K050A01 4
27073 1 14/12/2004
F.10.F / 70
FRAME POSITIONING - TRAVELLING Travel
CRIL03K049A01 5
27073 1 14/12/2004
F.10.F / 71
FRAME POSITIONING - TRAVELLING Travel
CRIL03I164A01 1
CRIL03I165A01 2
27073 1 14/12/2004
F.10.F / 72
FRAME POSITIONING - TRAVELLING Travel
CRIL03I168A00 3
27073 1 14/12/2004
F.10.F / 73
FRAME POSITIONING - TRAVELLING Travel
CRIL03F153A01a 1
CRIL03F154A01a 2
27073 1 14/12/2004
F.10.F / 74
FRAME POSITIONING - TRAVELLING Travel
NOTE: numbers in brackets refer to Reducer, spur gear - Exploded view (F.10.F.44 - C.10.A.20)
1. Make identication markings on housing (1) and
cover (8).
Remove screws (18).
CRIL03K013A00 1
CRIL03K014A01 2
CRIL03K015A00 3
27073 1 14/12/2004
F.10.F / 75
FRAME POSITIONING - TRAVELLING Travel
CRIL03K016A01 4
CRIL03K017A00 5
CRIL03K018A00 6
CRIL03F045A00 7
27073 1 14/12/2004
F.10.F / 76
FRAME POSITIONING - TRAVELLING Travel
CRIL03F046A00 8
CRIL03F047A00 9
CRIL03F048A00 10
CRIL03F049A00 11
27073 1 14/12/2004
F.10.F / 77
FRAME POSITIONING - TRAVELLING Travel
CRIL03F050A00 12
CRIL03F051A00 13
CRIL03F052A00 14
CRIL03F053A00 15
27073 1 14/12/2004
F.10.F / 78
FRAME POSITIONING - TRAVELLING Travel
CRIL03F054A00 16
CRIL03F056A00 17
CRIL03F057A01 18
19. Remove gears (4) and (5) shafts (9) only if replacing
bearings (22) and (23) proves necessary.
20. Turn the housing over.
Using a punch, remove bearing (21).
CRIL03F058A01a 19
27073 1 14/12/2004
F.10.F / 79
FRAME POSITIONING - TRAVELLING Travel
CRIL03F059A01 20
CRIL03F060A00 21
CRIL03F061A00 22
CRIL03F062A00 23
27073 1 14/12/2004
F.10.F / 80
FRAME POSITIONING - TRAVELLING Travel
27073 1 14/12/2004
F.10.F / 81
FRAME POSITIONING - TRAVELLING Travel
NOTE: If any of the following parts are replaced, the axial play of bearing (22) will require adjusting to the
recommended value, as will the thickness of snap ring (20).
Parts affected by the adjustment of axial play on bearing (22):
spindle (2),
retaining ange (3),
crankshaft (9),
spacer (12),
snap ring (20)
and bearing (22).
NOTE: Numbers in brackets refer to Reducer, spur gear - Exploded view (F.10.F.44 - C.10.A.20).
1. Using a hammer and suitable tool, lightly tap
the outside rings of bearings (22) tted to the
crankshafts (9).
CRIL03F072A00 1
CRIL03F049A00 2
CRIL03F073A00 3
27073 1 14/12/2004
F.10.F / 82
FRAME POSITIONING - TRAVELLING Travel
CRIL03F149A00 4
CRIL03F049A00 6
27073 1 14/12/2004
F.10.F / 83
FRAME POSITIONING - TRAVELLING Travel
NOTE: Numbers in parentheses refer to Reducer, spur gear - Exploded view (F.10.F.44 - C.10.A.20)
1. Install the main bearing preload adjustment tool,
refer to Reducer, spur gear - Special tools
(F.10.F.44 - D.20.A.40).
Push bearing (21) into the housing.
Tighten special nut (1) to a torque of 40 Nm.
CRIL03F069A00a 1
CRIL03F199B01a 2
27073 1 14/12/2004
F.10.F / 84
FRAME POSITIONING - TRAVELLING Travel
CRIL03F150A01a 3
27073 1 14/12/2004
F.10.F / 85
FRAME POSITIONING - TRAVELLING Travel
NOTE: Numbers in brackets refer to Reducer, spur gear - Exploded view (F.10.F.44 - C.10.A.20)
1. Using a punch, install bearing (21) in the housing.
CRIL03F079A01 1
CRIL03F060A00 2
CRIL03F054A00 3
27073 1 14/12/2004
F.10.F / 86
FRAME POSITIONING - TRAVELLING Travel
CRIL03F053A00 4
CRIL03F074A00 5
CRIL03F075A00 6
CRIL03F076A00 7
27073 1 14/12/2004
F.10.F / 87
FRAME POSITIONING - TRAVELLING Travel
CRIL03F078A00 8
12. Using a punch, install bearing (21) and tap all the
way round to drive it gradually into position.
CRIL03G251A00 9
CRIL03F080A00 10
15. Coat screws (19) with locking uid and tighten them
to torque 637 - 735 Nm.
Check that retaining ange (3) is correctly inserted
in the bearing.
CRIL03F051A00 11
27073 1 14/12/2004
F.10.F / 88
FRAME POSITIONING - TRAVELLING Travel
CRIL03G005A00 12
CRIL03F049A00 13
CRIL03F047A00 14
CRIL03F046A00 15
27073 1 14/12/2004
F.10.F / 89
FRAME POSITIONING - TRAVELLING Travel
CRIL03F045A00 16
CRIL03K018A00 17
CRIL03K016A01 18
CRIL03K015A00 19
27073 1 14/12/2004
F.10.F / 90
FRAME POSITIONING - TRAVELLING Travel
CRIL03K013A00 20
CRIL03K014A01 21
27073 1 14/12/2004
F.10.F / 91
FRAME POSITIONING - TRAVELLING Travel
CRIL03F159A01a 1
CRIL03F158A00a 2
CRIL03F153A01a 3
27073 1 14/12/2004
F.10.F / 92
FRAME POSITIONING - TRAVELLING Travel
NOTE: The table below shows a list of common problems. This list is not exhaustive.
Problem Possible Cause Correction
External oil leaks O-ring bearing surfaces scratched Repair or replace the parts
Defective seals Replace the seals
The secondary pressure Worn or broken spool return spring Replace the spring
does not increase
gradually or is out of
tolerance.
Dirt on the spool. Disassemble, clean and repair. Replace
the assembly if necessary
The lever does not move Dirt in the piston Disassemble, clean and repair. Replace
freely or does not return the assembly if necessary
to the neutral position
Dirt in the pushrod Disassemble, clean and repair. Replace
the assembly if necessary
Dirt on the pivot pin and cam Disassemble, clean and repair. Replace
the assembly if necessary
Worn or broken piston return spring Replace the spring
Damping force too weak Broken damper pin Replace the pin.
27073 1 14/12/2004
F.10.F / 93
FRAME POSITIONING - TRAVELLING Travel
27073 1 14/12/2004
F.10.F / 94
Index
FRAME POSITIONING - F
27073 1 14/12/2004
F.10.F / 95
Reducer, spur gear - Exploded view (F.10.F.44 - C.10.A.20) 24
CX135SR
Reducer, spur gear - Install (F.10.F.44 - F.10.A.15) 92
CX135SR
Reducer, spur gear - Measure (F.10.F.44 - F.40.A.16) 82
CX135SR
Reducer, spur gear - Remove (F.10.F.44 - F.10.A.10) 74
CX135SR
Reducer, spur gear - Sectional view (F.10.F.44 - C.10.A.30) 26
CX135SR
Reducer, spur gear - Special tools (F.10.F.44 - D.20.A.40) 6
CX135SR
Reducer, spur gear - Visual inspection (F.10.F.44 - F.40.A.10) 81
CX135SR
Reducer, spur gear Bearing - Preload (F.10.F.44.10 - F.45.A.30) 84
CX135SR
Relief valve - Pressure setting (F.10.F.16 - F.45.A.70) 51
CX135SR
Relief valve - Pressure test (F.10.F.16 - F.40.A.30) 49
CX135SR
Sensing system Alarm - Electronic schema (F.10.F.95.90 - C.20.A.50) 27
CX135SR NA
TRAVELLING Travel - Electronic schema (F.10.F - C.20.A.50) 12
CX135SR
TRAVELLING Travel - Hydraulic schema (F.10.F - C.20.A.20) 13
CX135SR
TRAVELLING Travel - Hydraulic schema (F.10.F - C.20.A.20) 15
CX135SR
TRAVELLING Travel - Hydraulic schema (F.10.F - C.20.A.20) 16
CX135SR
TRAVELLING Travel - Troubleshooting (F.10.F - G.40.A.10) 93
CX135SR
27073 1 14/12/2004
F.10.F / 96
FRAME POSITIONING - F
CX135SR
27074 1 14/12/2004
F.20.B / 1
Contents
FRAME POSITIONING - F
SERVICE
Rear ballasting
Rear ballasting - Remove (F.20.B.61 - F.10.A.10) 3
CX135SR
27074 1 14/12/2004
F.20.B / 2
FRAME POSITIONING - STABILISING Ballasting
Prior operation: To remove the rear protective panels, refer to Upper shield - Remove (E.20.A.71 - F.10.A.10)
Prior operation: To remove the rear RH and LH doors, refer to Side shield - Remove (E.20.A.70 - F.10.A.10)
CRIL03K042A01 1
CRIL03K094A01 2
27074 1 14/12/2004
F.20.B / 3
FRAME POSITIONING - STABILISING Ballasting
CRIL03K094A01 1
27074 1 14/12/2004
F.20.B / 4
Index
FRAME POSITIONING - F
27074 1 14/12/2004
F.20.B / 5
27074 1 14/12/2004
F.20.B / 6
FRAME POSITIONING - F
CX135SR
27075 1 14/12/2004
F.40.C / 1
Contents
FRAME POSITIONING - F
TECHNICAL DATA
Command valve
Command valve Hand command valve - Torque (F.40.C.12.10 - D.20.A.10) 5
CX135SR
Hydraulic motor
Hydraulic motor - Service limits (F.40.C.28 - D.20.A.20) 5
CX135SR
Swivel
Swivel - General specication (F.40.C.69 - D.40.A.10) 9
CX135SR
FUNCTIONAL DATA
SWINGING Circular swing - Hydraulic schema (F.40.C - C.20.A.20) 10
CX135SR
Command valve
Command valve Hand command valve - Sectional view (F.40.C.12.10 - C.10.A.30) 14
CX135SR
Control valve
Control valve - Sectional view (F.40.C.14 - C.10.A.30) 15
CX135SR
Hydraulic motor
Hydraulic motor - Sectional view (F.40.C.28 - C.10.A.30) 16
CX135SR
Hydraulic brake
Hydraulic brake - Electronic schema (F.40.C.59 - C.20.A.50) 19
CX135SR
Swivel
Swivel - Exploded view (F.40.C.69 - C.10.A.20) 21
CX135SR
27075 1 14/12/2004
F.40.C / 2
SERVICE
Command valve
Command valve Hand command valve - Remove (F.40.C.12.10 - F.10.A.10) 22
CX135SR
Control valve
Control valve - Disassemble (F.40.C.14 - F.10.A.25) 36
CX135SR
Relief valve
Relief valve - Pressure test (F.40.C.16 - F.40.A.30) 38
CX135SR
Hydraulic motor
Hydraulic motor - Leakage test (F.40.C.28 - F.40.A.40) 40
CX135SR
27075 1 14/12/2004
F.40.C / 3
Bearing and ring gear - Remove (F.40.C.45 - F.10.A.10) 65
CX135SR
Hydraulic brake
Hydraulic brake - Pressure test (F.40.C.59 - F.40.A.30) 68
CX135SR
Swivel
Swivel - Remove (F.40.C.69 - F.10.A.10) 70
CX135SR
DIAGNOSTIC
SWINGING Circular swing - Troubleshooting (F.40.C - G.40.A.10) 77
CX135SR
27075 1 14/12/2004
F.40.C / 4
FRAME POSITIONING - SWINGING Circular swing
Wear Limit
Description Standard Minimum Solution
dimensions dimensions
(mm) (mm)
Play between piston and barrel bore 0,016 0,046 Replace the barrel and the pistons
Play between piston and shoe (A) 0 0,3 Change the pistons and the pads
Thickness of shoes (B) 4 3,8 Change the pistons and the pads
Assembled height of thrust plate and 5,5 5,0 Replace the thrust pad and the spherical
spherical bearing (H - h) bearing
Thickness of the friction plate 3,5 3,1 Replace the plate
CRIL03K157E01 1
Wear limits
Surface roughness
Description Surface roughness Surface roughness (RA)
(RA) STANDARD WEAR LIMIT
Shoe 0,2 0,8
Piston wear plate 0,1 0,8
Cylinder barrel 0,4 3,2
Valve plate 0,2 1,6
NOTE: If the roughness of the sliding surfaces exceeds the tolerance limit, repair or replace the defective parts.
27075 1 14/12/2004
F.40.C / 5
FRAME POSITIONING - SWINGING Circular swing
CRIL03K160F01 1
27075 1 14/12/2004
F.40.C / 6
FRAME POSITIONING - SWINGING Circular swing
CRIL03K088H02 1
Description
(1) Plug 36 Nm
(2) Plug 4,4 Nm
(3) Plug 1,7 Nm
27075 1 14/12/2004
F.40.C / 7
FRAME POSITIONING - SWINGING Circular swing
CRIL03L007A01 1
CRIL03L008A01 2
CRIL03L009E01 3
27075 1 14/12/2004
F.40.C / 8
FRAME POSITIONING - SWINGING Circular swing
(A) 10 mm
(B) 128 mm
(C) 118 mm
(D) 138 mm
(E) 125 mm
Use of ports
Port A LH forward travel
Port B RH forward travel
Port C LH reverse travel
Port D RH reverse travel
Port E Raising the dozer blade
Port F Lowering the dozer blade
Port P Pilot
Port T Leak -off return
27075 1 14/12/2004
F.40.C / 9
FRAME POSITIONING - SWINGING Circular swing
CRIL03J145G01 1
Swing circuit - Dynamic description
(22) Swing motor (B22) Swing pilot pressure switch
(B26) Upper pilot pressure switch (C2) Swing brake pilot
(Pa3/A3) Swing left (Pb3/B3) Swing right
(P1) Instrument panel (Y3) Swing brake solenoid valve (pink band)
BRAKING
• Swing motor (22) is supplied by a ow.
• On starting the engine, if the swing control is in the neutral position, swing brake solenoid valve (Y3) is
activated and the swing motor is braked.
• When the swing is operated, swing pilot pressure switch (B22) closes. The swing brake solenoid valve (pink
band) (Y3) is deactivated and the swing motor (22) brake is released. The upperstructure can then turn.
• When the attachment is operated within the 5 seconds following the return of the swing control to the neutral
position, lateral forces are generated on the attachment. To avoid these twisting forces, swing motor (22)
brake is released.
27075 1 14/12/2004
F.40.C / 10
FRAME POSITIONING - SWINGING Circular swing
• Five seconds after the attachment or swing control has returned to neutral, the swing brake solenoid valve
(Y3) is activated and swing motor (22) is braked.
Starter switch Functions Swing pilot Upper pilot Swing brake Swing motor
pressure switch pressure switch solenoid valve
Open none Open Open De-activated Braked
Closed none Open Open Activated Braked
Attachment Open Closed Activated Braked
Swing Closed Closed De-activated Brake is released
Attachment Closed Closed De-activated Brake is released
+ Swing
Stop Open Open Activated after Braked
Attachment 5 secondes
27075 1 14/12/2004
F.40.C / 11
FRAME POSITIONING - SWINGING Circular swing
CRIL03J146G01 1
Swing variable priority circuit - Dynamic description
(1) Swing priority valve (15) Main control valve
(22) Swing motor (81) Swing shuttle block
(Pa3/A3) Swing left (Pb3/B3) Swing right
(Pa5/A5) Dipper out (Pb5/B5) Dipper return
(Pa9/Pb9) Dipper valve spool 2 (Pc3) Priority to swing
(Pb4) Boom valve spool 2 (Pc3) Swing priority valve piloting
VARIABLE PRIORITY
• The swing pilot pressure arrives in the main control valve (15) via port (Pc3) after passing through swing
shuttle block (81) and pilots swing priority valve (1). This provides the maximum possible torque to swing
motor (22) with high swing pressure, even the dipper is used at the same time.
• When digging, the pilot pressure for raising the boom actuates the swing priority valve (1) via orice (Pbu).
The swing ow is therefore in parallel with the dipper via swing priority valve (1). This has the effect of
improving the speed of the dipper.
• The trench is dug more uniformly even if the free passage is closed by the valve spool on boom 2.
27075 1 14/12/2004
F.40.C / 12
FRAME POSITIONING - SWINGING Circular swing
• When the upperstructure is rotated and the dipper is retracted or the boom is raised at the same time, the
parallel arrangement is reduced and the swing pressure is maintained.
27075 1 14/12/2004
F.40.C / 13
FRAME POSITIONING - SWINGING Circular swing
CRIL03I001G01 1
Description
(1) Lock nut (2) Boot
(3) Disc (4) Pusher
(5) Plate (6) Guide
(7) Seal (8) Spring seat
(9) Spring (10) Spring
(11) Spool (12) Body
(13) Port plate (14) Screw
(15) Seal (16) Bushing
(17) Spool (18) Spring
(19) Seal (20) Universal joint
(21) Retaining pin (22) Washer
27075 1 14/12/2004
F.40.C / 14
FRAME POSITIONING - SWINGING Circular swing
CRIL03J102E01 1
(4) Spool
(11) Large cap
(12) Seal
(13) Small cap
(16) Valve
(17) Spring
(18) Seal
(19) Plug
(65) Screw
27075 1 14/12/2004
F.40.C / 15
FRAME POSITIONING - SWINGING Circular swing
CRIL03K088H01 1
27075 1 14/12/2004
F.40.C / 16
FRAME POSITIONING - SWINGING Circular swing
27075 1 14/12/2004
F.40.C / 17
FRAME POSITIONING - SWINGING Circular swing
CRIL03K183G01 1
27075 1 14/12/2004
F.40.C / 18
FRAME POSITIONING - SWINGING Circular swing
CRIL03G187F01 1
Circuit layout
27075 1 14/12/2004
F.40.C / 19
FRAME POSITIONING - SWINGING Circular swing
CRIL03G188F02 2
Timing diagram
OPERATION OF THE SWING BRAKE CONTROL
1. Swing brake (1) will be activated 5 seconds after upper pilot pressure switch (B26) is in the open position.
2. Swing brake (1) will be activated 3 seconds after the supply cut-off delay.
27075 1 14/12/2004
F.40.C / 20
FRAME POSITIONING - SWINGING Circular swing
CRIL03K081G01 1
27075 1 14/12/2004
F.40.C / 21
FRAME POSITIONING - SWINGING Circular swing
Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20)
CRIL03I107B01 1
CRIL03I119A01 2
27075 1 14/12/2004
F.40.C / 22
FRAME POSITIONING - SWINGING Circular swing
NOTE: Always handle high precision parts with the greatest care to prevent them being damaged by being knocked
or dropped.
The components of the control lever may rust due to dirt and moisture if they are left unprotected after dismantling.
If work has to be interrupted, the components must be protected from contamination or corrosion.
1. Install the control lever in a soft-jawed vice.
Remove the boot.
CRPH03I001A 1
CRPH03I002A 2
CRPH03I003A 3
27075 1 14/12/2004
F.40.C / 23
FRAME POSITIONING - SWINGING Circular swing
CRPH03I004A 4
CRPH03I005A 5
CRPH03I006A 6
CRPH03I007A 7
27075 1 14/12/2004
F.40.C / 24
FRAME POSITIONING - SWINGING Circular swing
CRPH03I008A 8
CRPH03I009A 9
CRPH03I010A 10
27075 1 14/12/2004
F.40.C / 25
FRAME POSITIONING - SWINGING Circular swing
CRIL03I002B01 11
12. Remove the spool (17) and the spring (18) from the
guide.
CRIL03I003A01 12
13. Remove the push rod (4) from the guide (6).
CRIL03I004A01 13
27075 1 14/12/2004
F.40.C / 26
FRAME POSITIONING - SWINGING Circular swing
CRPH03I011A 14
CRPH03I012A 15
27075 1 14/12/2004
F.40.C / 27
FRAME POSITIONING - SWINGING Circular swing
27075 1 14/12/2004
F.40.C / 28
FRAME POSITIONING - SWINGING Circular swing
CRIL03I005A01 1
27075 1 14/12/2004
F.40.C / 29
FRAME POSITIONING - SWINGING Circular swing
CRPH03I010A 1
CRPH03I013A 2
3. Install the port plate (13) with the plastic pin (21) in
port (A) of the body.
CRIL03I006A01 3
27075 1 14/12/2004
F.40.C / 30
FRAME POSITIONING - SWINGING Circular swing
CRPH03I014A 4
CRIL03I007A01 5
CRPH03I015A 6
CRPH03I016A 7
27075 1 14/12/2004
F.40.C / 31
FRAME POSITIONING - SWINGING Circular swing
CRIL03I008B01 8
CRIL03I004A01 9
10. Install the spool (17) and the spring (18) in the guide
(6).
CRIL03I003A01 10
27075 1 14/12/2004
F.40.C / 32
FRAME POSITIONING - SWINGING Circular swing
CRPH03I017A 11
CRPH03I018A 12
CRPH03I003A 13
CRPH03I019A 14
27075 1 14/12/2004
F.40.C / 33
FRAME POSITIONING - SWINGING Circular swing
CRPH03I020A 15
CRPH03I001A 16
27075 1 14/12/2004
F.40.C / 34
FRAME POSITIONING - SWINGING Circular swing
CRIL03I119A01 1
CRIL03I107B01 2
27075 1 14/12/2004
F.40.C / 35
FRAME POSITIONING - SWINGING Circular swing
CRIL03J102E01 1
CRIL03L053A01 2
27075 1 14/12/2004
F.40.C / 36
FRAME POSITIONING - SWINGING Circular swing
CRIL03J102E01 1
Torque settings
Fixing screws for spool return spring (4) 9.8 - 11.8 Nm
Plug (19) 103 - 113 Nm
Main relief valve (63) 78 - 88 Nm
Cap xing screws (65) 20 - 25 Nm
1. Install check valve (16) and spring (17).
Install plug (19) tted with a new seal and tighten to
the required torque (18).
2. Install valves (63) and tighten to the required torque.
3. Coat the threaded part of spool (A) with locking uid.
Clamp the end of the spool in a soft-jawed vice.
Install spring (44) and seats (43) on screw (45).
Install and tighten the screws to the required torque.
Install spool (4) in its housing.
CRIL03L053A01 2
4. Install caps (11) and (13) tted with new seals (12).
Install and tighten screws (65) to the required
torque.
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FRAME POSITIONING - SWINGING Circular swing
CRIL03K062A02 1
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FRAME POSITIONING - SWINGING Circular swing
CRIL03K062A01 1
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FRAME POSITIONING - SWINGING Circular swing
CRIL03I156A01 1
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FRAME POSITIONING - SWINGING Circular swing
CRIL03K083A01 1
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FRAME POSITIONING - SWINGING Circular swing
CRIL03K095A01 1
CRIL03K096A01 2
CRIL03K097A00 3
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FRAME POSITIONING - SWINGING Circular swing
CRIL03K098A00 4
CRIL03K099A01 5
CRIL03K100A01 6
CRIL03K101A00 7
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FRAME POSITIONING - SWINGING Circular swing
CRIL03K102A01 8
CRIL03K103A01 9
13. Mark and remove friction plates (1) and steel plates
(2) from housing (3).
CRIL03K105A01 11
14. Remove the snap ring from the tip of the drive shaft
and remove the inner ring from the bearing.
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FRAME POSITIONING - SWINGING Circular swing
CRIL03K109A01 12
CRIL03K108A01 13
CRIL03K106A01 14
CRIL03K107B01 15
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FRAME POSITIONING - SWINGING Circular swing
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FRAME POSITIONING - SWINGING Circular swing
Install the other spacer (2) and the other snap ring
(3).
CRIL03K110A01 1
CRIL03K111A01 2
CRIL03K112A01 3
CRIL03K113A01 4
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FRAME POSITIONING - SWINGING Circular swing
CRIL03K114A01 5
CRIL03K115A01 6
CRIL03K103A01 7
CRIL03K105A01 8
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FRAME POSITIONING - SWINGING Circular swing
CRIL03K116A00 9
CRIL03K132A01 10
CRIL03K101A00 11
CRIL03K133A01 12
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FRAME POSITIONING - SWINGING Circular swing
CRIL03K134A01 13
CRIL03K100A02 14
CRIL03K099A02 15
CRIL03K098A00 16
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FRAME POSITIONING - SWINGING Circular swing
CRIL03K097A00 17
20. Install plug (1) complete with seal (2) on the cover
and tighten to torque .
NOTE: Turn the cover 180 degrees and repeat steps 23
to 25 to install the other check valve.
CRIL03K096A01 18
CRIL03K095A01 19
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FRAME POSITIONING - SWINGING Circular swing
CRIL03K083A02 1
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FRAME POSITIONING - SWINGING Circular swing
CRIL03K174A01 1
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FRAME POSITIONING - SWINGING Circular swing
CRIL03L046A01 1
CRIL03K083A00 2
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FRAME POSITIONING - SWINGING Circular swing
CRIL03I051B01 3
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FRAME POSITIONING - SWINGING Circular swing
CRIL03L016A00 1
CRIL03L017A01a 2
CRIL03L018A01 3
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FRAME POSITIONING - SWINGING Circular swing
CRIL03L019A01 4
CRIL03L020A01 5
CRIL03L021B01 6
CRIL03L022A01 7
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FRAME POSITIONING - SWINGING Circular swing
CRIL03L023B01 8
CRIL03L024A01 9
CRIL03L025A01 10
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FRAME POSITIONING - SWINGING Circular swing
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FRAME POSITIONING - SWINGING Circular swing
CRIL03L026A00 1
CRIL03L027A01 2
CRIL03L029A01 3
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FRAME POSITIONING - SWINGING Circular swing
CRIL03L030A01 4
CRIL03L028B01 5
CRIL03L019A01 6
CRIL03L034A00 7
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FRAME POSITIONING - SWINGING Circular swing
11. Install the ring gear following the marks made during
removal.
NOTE: Install it provisionally using motor xing screws.
CRIL03L036A00 8
CRIL03L037A00 9
CRIL03L038A00 10
CRIL03L039A01 11
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FRAME POSITIONING - SWINGING Circular swing
CRIL03L042A01 12
CRIL03L040A00 13
17. Install the rst stage sun gear. Mesh the teeth
of the sun gear with the teeth of the planetary
gear assembly. Turn the rst stage planetary gear
assembly by hand to check that the output shaft
rotates smoothly.
CRIL03L016A00 14
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FRAME POSITIONING - SWINGING Circular swing
CRIL03I051B01 1
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FRAME POSITIONING - SWINGING Circular swing
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FRAME POSITIONING - SWINGING Circular swing
If the upperstructure squeals, does not revolve properly or pauses before revolving, this indicates that the turntable
is worn or damaged. When an operator is working with the machine, he must pay attention to any unusual noises
that may indicate turntable wear. If the operator hears unusual noises and if the upperstructure pauses before
revolving, he must carry out the following inspection.
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FRAME POSITIONING - SWINGING Circular swing
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FRAME POSITIONING - SWINGING Circular swing
CRIL03K062A02 1
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FRAME POSITIONING - SWINGING Circular swing
To carry out this test, use the solenoid valve electrical connector and a multimeter, refer to ELECTRICAL POWER
SYSTEM - Special tools (A.30.A - D.20.A.40)
CRIL03L141A02 1
CRIL03I078A02 2
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FRAME POSITIONING - SWINGING Circular swing
Prior operation: To remove the protective panel, refer to Upper shield - Remove (E.20.A.71 - F.10.A.10)
Prior operation: To remove hydraulic swivel lower protective panel, refer to Protective shield - Remove
(E.20.A.73 - F.10.A.10)
Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20)
CRIL03K058A00 1
CRIL03K059A00 2
CRIL03K060A01 3
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FRAME POSITIONING - SWINGING Circular swing
CRIL03K076A01 1
CRIL03K077A01 2
CRIL03K078A01 3
CRIL03F004A03 4
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FRAME POSITIONING - SWINGING Circular swing
CRIL03F005A01 5
CRIL03K079A01 6
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FRAME POSITIONING - SWINGING Circular swing
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FRAME POSITIONING - SWINGING Circular swing
CRIL03K079A01 1
CRIL03F008A01a 2
CRIL03F005A01 3
CRIL03K080A01 4
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FRAME POSITIONING - SWINGING Circular swing
CRIL03K078A01 5
CRIL03K077A01 6
CRIL03K076A01 7
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FRAME POSITIONING - SWINGING Circular swing
CRIL03K060A01 1
CRIL03K059A00 2
CRIL03K058A00 3
Next operation: To install the protective panel, refer to Upper shield - Remove (E.20.A.71 - F.10.A.10)
Next operation: To install hydraulic swivel lower protective panel, refer to Protective shield - Remove (E.20.A.73
- F.10.A.10)
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FRAME POSITIONING - SWINGING Circular swing
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Index
FRAME POSITIONING - F
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Hydraulic motor - Special tools (F.40.C.28 - D.20.A.40) 5
CX135SR
Hydraulic motor - Torque (F.40.C.28 - D.20.A.10) 7
CX135SR
Hydraulic motor - Visual inspection (F.40.C.28 - F.40.A.10) 46
CX135SR
Reducer, spur gear - Assemble (F.40.C.44 - F.10.A.20) 60
CX135SR
Reducer, spur gear - Disassemble (F.40.C.44 - F.10.A.25) 56
CX135SR
Reducer, spur gear - Install (F.40.C.44 - F.10.A.15) 64
CX135SR
Reducer, spur gear - Remove (F.40.C.44 - F.10.A.10) 54
CX135SR
Reducer, spur gear - Sectional view (F.40.C.44 - C.10.A.30) 18
CX135SR
Reducer, spur gear - Special tools (F.40.C.44 - D.20.A.40) 8
CX135SR
Reducer, spur gear - Visual inspection (F.40.C.44 - F.40.A.10) 59
CX135SR
Relief valve - Pressure setting (F.40.C.16 - F.45.A.70) 39
CX135SR
Relief valve - Pressure test (F.40.C.16 - F.40.A.30) 38
CX135SR
SWINGING Circular swing - Hydraulic schema (F.40.C - C.20.A.20) 10
CX135SR
SWINGING Circular swing - Hydraulic schema (F.40.C - C.20.A.20) 12
CX135SR
SWINGING Circular swing - Troubleshooting (F.40.C - G.40.A.10) 77
CX135SR
Swivel - Assemble (F.40.C.69 - F.10.A.20) 74
CX135SR
Swivel - Cleaning (F.40.C.69 - F.30.A.10) 73
CX135SR
Swivel - Disassemble (F.40.C.69 - F.10.A.25) 71
CX135SR
Swivel - Exploded view (F.40.C.69 - C.10.A.20) 21
CX135SR
Swivel - General specication (F.40.C.69 - D.40.A.10) 9
CX135SR
Swivel - Install (F.40.C.69 - F.10.A.15) 76
CX135SR
Swivel - Remove (F.40.C.69 - F.10.A.10) 70
CX135SR
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CNH France S.A.- FRANCE
SERVICE
PRINTED IN FRANCE
All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH France S.A. company reserves the right to modify without prior notice the characteristics and the design of the
machine without any obligation to carry out those modications on machines already sold.
The description of the models shown in this manual has been made using the technical specications known at the
date on which this document was designed.
27072 1 14/12/2004
REPAIR MANUAL
WORKING ARM
CX135SR
27076 1 14/12/2004
H
Contents
WORKING ARM - H
27076 1 14/12/2004
H
WORKING ARM - H
CX135SR
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H.20.B / 1
Contents
WORKING ARM - H
TECHNICAL DATA
BOOM Lift - Service limits (H.20.B - D.20.A.20) 4
CX135SR
Command valve
Command valve Hand control valve - Torque (H.20.B.12.10 - D.20.A.10) 5
CX135SR
Cylinder
Cylinder - Torque (H.20.B.26 - D.20.A.10) 6
CX135SR
FUNCTIONAL DATA
BOOM Lift - Hydraulic schema (H.20.B - C.20.A.20) 8
CX135SR
Command valve
Command valve Hand control valve - Sectional view (H.20.B.12.10 - C.10.A.30) 11
CX135SR
Control valve
Control valve - Sectional view (H.20.B.14 - C.10.A.30) 12
CX135SR
Cylinder
Cylinder - Sectional view (H.20.B.26 - C.10.A.30) 13
CX135SR
Arm
Arm - Exploded view (H.20.B.50 - C.10.A.20) 14
CX135SR
Sensing system
Sensing system - Electronic schema (H.20.B.95 - C.20.A.50) 15
CX135SR
SERVICE
Command valve
Command valve Hand control valve - Overhaul (H.20.B.12.10 - F.10.A.40) 16
CX135SR
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Command valve Cushion valve - Assemble (H.20.B.12.20 - F.10.A.20) 19
CX135SR
Control valve
Control valve - Disassemble (H.20.B.14 - F.10.A.25) 21
CX135SR
Safety valve
Safety valve - Remove (H.20.B.15 - F.10.A.10) 25
CX135SR
Relief valve
Relief valve - Disassemble (H.20.B.16 - F.10.A.25) 31
CX135SR
Arm
Arm - Remove (H.20.B.50 - F.10.A.10) 37
CX135SR
Cylinder
Cylinder - Remove (H.20.B.26 - F.10.A.10) 39
CX135SR
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WORKING ARM - BOOM Lift
CRIL03G012E01 1
Linkage points
1. Foot of boom on chassis
CRIL03G015E01 2
MARKING STANDARD DIMENSION WEAR LIMIT
(A) 589 mm 599 mm
(B) 568 mm 566 mm
(C) (a-b) 1 - 3.5 mm Shims
(D) pin diameter 75 mm 74 mm
(D) bushing diameter 75 mm 76,5 mm
CRIL03L133E01 3
MARKING STANDARD DIMENSION WEAR LIMIT
(A) 83,5 mm 89,5 mm
(B) 82,5 mm 80,5 mm
(C) play 1 - 2.5 mm Shims
(D) pin diameter 70 mm 69 mm
(D) bushing diameter 70 mm 71,5 mm
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WORKING ARM - BOOM Lift
CRIL03L134E01 4
MARKING STANDARD DIMENSION WEAR LIMIT
(A) 92 mm 90 mm
(B) 437 mm 431 mm
(C) play 1 - 2.5 mm Shims
(D) pin diameter 70 mm 69 mm
(D) bushing diameter 70 mm 71,5 mm
NOTE: Refer to Command valve Hand command valve - Torque (F.40.C.12.10 - D.20.A.10)
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WORKING ARM - BOOM Lift
CRIL03L044G02 1
Description
(1) Screw 171 Nm
(2) Plug 97,5 - 102,8 Nm
(3) Screw 25,62 - 37,88 Nm
(4) Screw 46,2 - 67,6 Nm
(5) Nut (M 52) 3180 Nm
(6) Screw 21,4 - 31,2 Nm
(7) Screw 46,2 - 67,6 Nm
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WORKING ARM - BOOM Lift
CRIL03J014E 1
Repair bench 380000812.
Used for repairing cylinders.
CRPH03J001E 2
Gland wrench.
Used for removing and retting glands.
OEM6210: opening capacity 50 - 120 mm
OEM6203: opening capacity 120 - 320 mm
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WORKING ARM - BOOM Lift
CRIL03J147G01 1
Boom raising circuit - Dynamic Description
(1) Straight-line travel valve (2) RH travel spool
(3) Boom valve spool 2 (4) Boom spool 1
(25) Boom cylinder (26) Boom cylinder
(32) Boom load holding valve (P1) Flow at pump outlet A2
(P2) Flow at pump outlet A1 (Pa8/A8) Boom raising
(Pb8/B8) Boom lowering
BOOM LIFTING
• Boom raising (large cylinder chamber) (25) and (26) is supplied by outputs from pumps (P1) and (P2).
• The ow from pump (P1) passes through the straight-line travel valve (1) or the RH travel spool (2), then the
parallel feed passage to pass through boom spool 2 (3) and arrive at the outlet of the boom 1 spool (4).
• The ow from pump (P2) passes through the 2nd parallel feed passage and the boom spool 1 (4) and joins
the ow from pump (P1).
• The outputs from pumps (P1) and (P2) supply the large boom cylinder chambers (25) and (26) by passing
through the boom load holding valve (32).
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WORKING ARM - BOOM Lift
CRIL03J148G01 1
Boom lowering circuit - Dynamic Description
(1) Boom spool 1 (25) Boom cylinder
(32) Boom load holding valve (P2) Flow at pump outlet A2
(Pa8/A8) Boom raising (Pb8/B8) Boom lowering
(Pc2) Boom load holding
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H.20.B / 9
WORKING ARM - BOOM Lift
(25) and (26), passing via non-return valve (2). The lower the pressure in the boom cylinder small chambers
(25) and (26), the greater the ow of reinjected oil.
Even if boom spool 1 (1) is completely piloted, a connection still exists with the free passage via a jet (4) that
generates ow reduction information pressure towards the pump. This ow reduction is compensated by the
re-injection circuit. In addition, the engine power can be used more efciently.
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H.20.B / 10
WORKING ARM - BOOM Lift
NOTE: Refer to Command valve Hand command valve - Sectional view (F.40.C.12.10 - C.10.A.30)
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WORKING ARM - BOOM Lift
CRIL03J087F01 1
Cross-sectional view - Boom section 1 and 2
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WORKING ARM - BOOM Lift
CRIL03L044G01 1
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WORKING ARM - BOOM Lift
CRIL03L137F01 1
(1) Screw
(2) Nut
(3) Pin
(4) Shim
(5) Bushing
(6) Seal
(7) Grease tting
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WORKING ARM - BOOM Lift
OVERLOAD INDICATOR
CRIL03G223E01 1
Circuit layout
(A7) Overload indicator electronic control box (B45) Overload indicator pressure sensor
(H3) Overload indicator audible alarm device (S13) Overload indicator switch
CRIL03G224E02 2
Timing diagram
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WORKING ARM - BOOM Lift
1. Refer to:
Command valve Hand command valve - Remove
(F.40.C.12.10 - F.10.A.10)
Command valve Hand command valve -
Disassemble (F.40.C.12.10 - F.10.A.25)
Command valve Hand command valve -
Cleaning (F.40.C.12.10 - F.30.A.10)
Command valve Hand command valve - Visual
inspection (F.40.C.12.10 - F.40.A.10)
Command valve Hand command valve -
Assemble (F.40.C.12.10 - F.10.A.20)
Command valve Hand command valve - Install
(F.40.C.12.10 - F.10.A.15)
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WORKING ARM - BOOM Lift
Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20)
Prior operation: Remove the side guard from under the oor, refer to Side shield - Remove (E.20.A.70 -
F.10.A.10).
CRIL03L109A01 1
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WORKING ARM - BOOM Lift
CRIL03L110F01 1
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WORKING ARM - BOOM Lift
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WORKING ARM - BOOM Lift
CRIL03L109A01 1
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WORKING ARM - BOOM Lift
CRIL03J087F01 1
Boom section spools 1 and 2
CRIL03L053A01 2
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WORKING ARM - BOOM Lift
CRIL03L076A01 3
CRIL03L078A01 4
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WORKING ARM - BOOM Lift
Prior operation: To clean and check parts before assembling, refer to Stack valve - Visual inspection (A.10.A.18
- F.40.A.10)
CRIL03J087F01 1
Boom section spools 1 and 2
Torque settings
Fixing screws (45) for return springs on spools (5) and (8) 9.8 - 11.8 Nm
Plug (A) of spool (8) 9.8 - 11.8 Nm
Plug (19) 103 - 113 Nm
Plug (21) 13.5 - 16.5 Nm
Plug (32) 73 - 79 Nm
Valves (63) 78 - 88 Nm
Screws (65) and (67) 20 - 25 Nm
1. Install plugs (21) and (32) complete with new seals
and tighten them to the required torque.
2. Install valves (63) and tighten them to the required
torque.
3. Install check valves (16) and springs (17).
Install plugs (19) complete with new seals (18) and
tighten them to the required torque.
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WORKING ARM - BOOM Lift
CRIL03L078A01 2
CRIL03L053A01 3
CRIL03L076A01 4
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WORKING ARM - BOOM Lift
Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20)
CRIL03K055A03 1
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WORKING ARM - BOOM Lift
CRIL03L119G01 1
Description of components
(1) Spool stop plug (2) Seal
(3) Spool cap (4) Seal
(5) Spring (6) Spring
(7) Spring seat (8) Spool
(9) Seal (10) Valve
(11) Plug (12) Seal
(13) Spring (14) Check valve
(15) Plug (16) Seal
(17) Spring (18) Piloted check valve
1. Remove plug (1).
Discard seal (2).
2. Remove cap (3).
Discard seal (4)
Remove the springs (5) and (6).
Remove seat (7).
Remove spool (8).
3. Remove plug (11).
Discard seal (12).
Remove spring (13) and check valve (14) after
marking their positions.
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WORKING ARM - BOOM Lift
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WORKING ARM - BOOM Lift
CRIL03L119G01 1
Tightening torque
(1) Spool stop plug 77.8 - 79.2 Nm
(3) Spool cap 271.6 - 277.6 Nm
(10) Valve 58.2 - 59.4 Nm
(11) Plug 213.8 - 217.8 Nm
(15) Plug 77.8 - 79.2 Nm
1. Install plug (1) complete with a new seal (2) and
tighten to the required torque.
2. Oil and install spool (8).
Install seat (7).
Install springs (5) and (6).
Install spool cap (3) complete with a new seal (4)
and tighten to the required torque.
3. Oil and install check valve (14) and spring (13) in
their original positions.
Install plug (11) complete with a new seal (12) and
tighten to the required torque.
4. Oil and install check valve (18) and spring (17) in
their original positions.
Install plug (15) complete with a new seal (16) and
tighten to the required torque.
5. Install valve (10) complete with a new seal (9) and
tighten to the required torque.
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WORKING ARM - BOOM Lift
CRIL03K055A03 1
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WORKING ARM - BOOM Lift
CRIL03K055A02 2
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WORKING ARM - BOOM Lift
CRIL03L105B01 1
2. Remove plug (3) from body (2) and discard seal (4).
3. Remove the springs (5) and (6).
4. Remove the valve (7).
5. Remove nut (8) screw (9), washer (10), and discard
the seal (11).
6. Remove the tip of valve (12) from the body (2).
7. Extract the valve seat (13) and discard seals (14)
and (15).
8. Remove the spring (16) and valve seat (17).
9. Remove valve (18) and discard seals (19) and (20).
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WORKING ARM - BOOM Lift
CRIL03L105B01 1
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WORKING ARM - BOOM Lift
NOTE: The secondary relief valves on the boom (B) and (C) are calibrated to a higher pressure than the main relief
valve (A). To check or calibrate the secondary relief valves, main relief valve (A) must be overcalibrated.
NOTE: If the excavator is equipped with safety valves on the boom, the secondary relief valves are not tted on
the valve block, or they are overcalibrated. In this case, the secondary relief valves mounted on the safety valves
must be calibrated.
1. Overcalibrate main relief valve (A) by tightening the
adjusting screw by 180 °, refer to Relief valve -
Pressure setting (A.10.A.16 - F.45.A.70).
2. Connect a 0-600 bar (0-60 MPa) pressure gauge to
the pressure test point M1.
3. Start the engine and run it at maximum speed.
4. Operate the control for the function to be checked
and hold it against the stop.
5. The raising and lowering pressures of the boom as
displayed on the pressure gauge should be 395 ±
10 bar (39.5 ± 1 MPa)
6. If the pressures are incorrect, calibrate boom relief
valves (B) and (C), refer to Relief valve - Pressure
setting (H.20.B.16 - F.45.A.70)
Next operation: To recalibrate main relief valve (A), refer to Relief valve - Pressure setting (A.10.A.16 - F.45.A.70)
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H.20.B / 33
WORKING ARM - BOOM Lift
CRIL03K054A01 1
Next operation: Reset main relief valve (A), refer to Relief valve - Pressure setting (A.10.A.16 - F.45.A.70).
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H.20.B / 34
WORKING ARM - BOOM Lift
NOTE: Take care when disassembling the load holding valve, some parts are under pressure from the springs.
1. Place the load holding valve assembly (30) in a
soft-jawed vice.
2. Remove the plug (P).
Remove piston (D), spool (E) and spring (G).
Unscrew and remove plug (C) then remove seal (N).
CRIL03L080B01 1
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H.20.B / 35
WORKING ARM - BOOM Lift
1. Fit seals (K) and (J) back-up rings (L) and (M) into
the grooves of the sleeve (F).
NOTE: Follow the positions of the seals and backup rings.
CRIL03L080B01 1
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H.20.B / 36
WORKING ARM - BOOM Lift
Prior operation: To remove the side protective panel from the control valve , refer to Side shield - Remove
(E.20.A.70 - F.10.A.10)
CRIL03L140A00 1
27077 1 14/12/2004
H.20.B / 37
WORKING ARM - BOOM Lift
7. Install the rst nut on the screw (2) and tighten until
the nut touches the boss.
Loosen the nut a quarter of a turn.
Fit the second nut (2) to keep the rst in position.
8. To connect the boom cylinder rods, refer to Cylinder
- Install (H.20.B.26 - F.10.A.15).
9. Start the vacuum pump.
Remove the plugs.
Connect the boom foot/chassis hoses, following the
markings made during removal.
Stop and remove the vacuum pump.
CRIL03L140A00 1
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H.20.B / 38
WORKING ARM - BOOM Lift
Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20)
CRIL03K175A00 1
CRIL03K176A01 2
CRIL03K177A01 3
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H.20.B / 39
WORKING ARM - BOOM Lift
CRIL03K178A01 4
CRIL03K179A00 5
CRIL03K180A01 6
CRIL03K181A01 7
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H.20.B / 40
WORKING ARM - BOOM Lift
CRIL03K182A01 8
10. Remove the sling that holds the rod together with
the cylinder barrel.
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H.20.B / 41
WORKING ARM - BOOM Lift
To use a cylinder bench for removal operations, refer to Cylinder - Special tools (H.20.B.26 - D.20.A.40)
CRPH03J002A 1
CRIL03K193A01 2
CRIL03K194A01 3
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H.20.B / 42
WORKING ARM - BOOM Lift
CRIL03K195A01 4
CRPH03J005A 5
CRIL03K196A01 6
CRIL03K197A01 7
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H.20.B / 43
WORKING ARM - BOOM Lift
CRIL03K198A01 8
CRIL03J023A01 9
CRPH03J006A 10
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H.20.B / 44
WORKING ARM - BOOM Lift
NOTE: Clean each part with a suitable detergent and inspect the parts listed below. Replace all seals with new
seals from the manufacturer.
1. INSPECTING THE ROD
If the rod is cracked, replace it.
If the thread is damaged, re-thread it or replace the
rod.
If the chrome surface is cracked, rusty or defective,
replace the rod.
If the bushing bore is poorly dened or worn, replace
the rod.
If the eye ring is worn, replace the ring.
If the rod has run-out deection greater than 1 mm
per 1 m, replace the rod.
2. ROD RUN OUT MEASUREMENT
Place the rod horizontally on V-shaped blocks, at
each end of the sliding surface.
Place a dial gauge in contact with the rod, positioned
halfway between the two supports.
Rotate the rod about its own axis and note the
differences displayed on the dial gauge between the
minimum and maximum.
This difference will correspond to the amount of rod
run out.
CRPH03J008A 1
3. BARREL INSPECTION
If cracks appear around the weld joints, replace the
tube.
If there are scratches in the tube bore, replace the
tube.
If the tube eye ring is worn, replace the ring.
4. INSPECTING THE GLAND
If the surface is worn and the clearance between
the rod and the gland exceeds 0.25 mm, replace
the ring.
If excessively deep scratches appear on the ring,
replace the ring.
5. INSPECTING SLIDING PARTS
Check sliding parts for wear or damage such as
scratches, dents, or bent components.
Small scratches can be removed with a hone or
crocus cloth.
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H.20.B / 45
WORKING ARM - BOOM Lift
CRPH03J006A 1
CRIL03J023A01 2
CRIL03K198A01 3
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H.20.B / 46
WORKING ARM - BOOM Lift
CRIL03K197A01 4
CRIL03K196A01 5
CRPH03J005A 6
CRIL03L032A01 7
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H.20.B / 47
WORKING ARM - BOOM Lift
CRIL03J02601A 8
CRIL03K194A01 9
CRIL03L033A01 10
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H.20.B / 48
WORKING ARM - BOOM Lift
CRIL03K179A00 1
CRIL03K178A01 2
CRIL03K182A01 3
CRIL03K180A01 4
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H.20.B / 49
WORKING ARM - BOOM Lift
CRIL03K181A01 5
27077 1 14/12/2004
H.20.B / 50
Index
WORKING ARM - H
27077 1 14/12/2004
H.20.B / 51
Load holding valve - Disassemble (H.20.B.19 - F.10.A.25) 35
CX135SR
Relief valve - Assemble (H.20.B.16 - F.10.A.20) 32
CX135SR
Relief valve - Disassemble (H.20.B.16 - F.10.A.25) 31
CX135SR
Relief valve - Pressure setting (H.20.B.16 - F.45.A.70) 34
CX135SR
Relief valve - Pressure test (H.20.B.16 - F.40.A.30) 33
CX135SR
Safety valve - Assemble (H.20.B.15 - F.10.A.20) 28
CX135SR
Safety valve - Disassemble (H.20.B.15 - F.10.A.25) 26
CX135SR
Safety valve - Install (H.20.B.15 - F.10.A.15) 29
CX135SR
Safety valve - Pressure setting (H.20.B.15 - F.45.A.70) 30
CX135SR
Safety valve - Remove (H.20.B.15 - F.10.A.10) 25
CX135SR
Sensing system - Electronic schema (H.20.B.95 - C.20.A.50) 15
CX135SR
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H.20.B / 52
WORKING ARM - H
CX135SR
27078 1 14/12/2004
H.20.D / 1
Contents
WORKING ARM - H
TECHNICAL DATA
Cylinder
Cylinder - Torque (H.20.D.26 - D.20.A.10) 4
CX135SR
Boom
Boom - Service limits (H.20.D.50 - D.20.A.20) 5
CX135SR
FUNCTIONAL DATA
BOOM Swing - Hydraulic schema (H.20.D - C.20.A.20) 10
CX135SR
Control valve
Control valve - Sectional view (H.20.D.14 - C.10.A.30) 11
CX135SR
Cylinder
Cylinder - Sectional view (H.20.D.26 - C.10.A.30) 12
CX135SR
SERVICE
Command valve
Command valve Foot command valve - Remove (H.20.D.12.10 - F.10.A.10) 13
CX135SR
Control valve
Control valve - Disassemble (H.20.D.14 - F.10.A.25) 16
CX135SR
Relief valve
Relief valve - Overhaul (H.20.D.16 - F.10.A.40) 19
CX135SR
Cylinder
Cylinder - Remove (H.20.D.26 - F.10.A.10) 22
CX135SR
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Cylinder - Disassemble (H.20.D.26 - F.10.A.25) 24
CX135SR
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H.20.D / 3
WORKING ARM - BOOM Swing
CRIL03L112G01 1
Description
(1) Screw 21.4 - 31.2 Nm
(2) Gland 834 Nm
(3) Nut (M 52) 2620 Nm
(4) Screw 46.2 - 67.6 Nm
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H.20.D / 4
WORKING ARM - BOOM Swing
CRIL03G026F01 1
Articulation points
1. Foot of backhoe-offset boom on pre-boom head
CRIL03G027E01 2
MARKING STANDARD DIMENSION WEAR LIMIT
(A) frame 485 mm 491 mm
(B) boom foot 484.5 mm 482.5 mm
(C) play 1 - 1.5 mm shims
(D) pin diameter 110 mm 109 mm
(E) bushing diameter 110 mm 111.5 mm
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H.20.D / 5
WORKING ARM - BOOM Swing
CRIL03G028E01 3
MARKING STANDARD DIMENSION WEAR LIMIT
(A) pre-boom 98 mm 104 mm
(B) cylinder foot 97 mm 95 mm
(C) (play) 0.5 - 0.3 mm shims
(D) 201 mm 207 mm
(E) bushing diameter 200 mm 198 mm
(F) play 0.5 - 3 mm shims
(G) pin diameter 65 mm 64 mm
(H) cylinder foot bushing diameter 65 mm 66.5 mm
(I) tie rod bushing diameter 65 mm 66.5 mm
CRIL03G029E01 4
MARKING STANDARD DIMENSION WEAR LIMIT
(A) pre-boom 98 mm 104 mm
(B) cylinder head 97 mm 95 mm
(C) play 0.5 - 3.0 mm shims
(D) pin diameter 65 mm 64 mm
(E) bushing diameter 65 mm 66.5 mm
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H.20.D / 6
WORKING ARM - BOOM Swing
CRIL03G030E01 5
MARKING STANDARD DIMENSION WEAR LIMIT
(A) dipper 201 mm 207 mm
(B) tie rod 200 mm 198 mm
(C) play 0.5 - 3 mm shims
(D) pin diameter 65 mm 64 mm
(E) bushing diameter 65 mm 66.5 mm
CRIL03G031E01 6
MARKING STANDARD DIMENSION WEAR LIMIT
(A) boom 400 mm 406 mm
(B) dipper 399.5 mm 397.5 mm
(C) play 0.5 - 1.5 mm shims
(D) pin diameter 110 mm 109 mm
(E) pin diameter 110 mm 111.5 mm
CRIL03G032E01 7
MARKING STANDARD DIMENSION WEAR LIMIT
(A) dipper 291 mm 297 mm
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H.20.D / 7
WORKING ARM - BOOM Swing
CRIL03G033E01 8
MARKING STANDARD DIMENSION WEAR LIMIT
(A) backhoe-offset dipper 231 mm 237 mm
(B) dipper foot 230.5 mm 228.5 mm
(C) play 0.5 - 1.1 mm shims
(D) pin diameter 75 mm 74 mm
(E) bushing diameter 75 mm 76.5 mm
CRIL03G034E01 9
MARKING STANDARD DIMENSION WEAR LIMIT
(A) dipper 97 mm 103 mm
(B) cylinder 96 mm 94 mm
(C) play 0.5 - 3 mm shims
(D) pin diameter 70 mm 69 mm
(E) bushing diameter 70 mm 71.5 mm
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H.20.D / 8
WORKING ARM - BOOM Swing
CRIL03G035E01 10
MARKING STANDARD DIMENSION WEAR LIMIT
(A) dipper 88 mm 94 mm
(B) backhoe-offset dipper 87 mm 85 mm
(C) play 0.5 - 3 mm shims
(D) pin diameter 65 mm 64 mm
(E) bushing diameter 65 mm 66.5 mm
27078 1 14/12/2004
H.20.D / 9
WORKING ARM - BOOM Swing
CRIL03J156G01 1
Backhoe-offset circuit - Dynamic description
(1) Backhoe-offset control pedal (optional) (2) Backhoe-offset cylinder
(pr) Flow at pump outlet A3 (Pra2/AR2) RH backhoe-offset
(Prb2/BR2) LH backhoe-offset
BACKHOE-OFFSET
• The backhoe-offset cylinder is supplied by the ow from pump (pr). When backhoe-offset control pedal (1)
is activated, the corresponding spool is piloted by port (pra2) or (prb2), which feeds the backhoe-offset
cylinder (2) via port (AR2) or (BR2).
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H.20.D / 10
WORKING ARM - BOOM Swing
CRIL03J105F01a 1
27078 1 14/12/2004
H.20.D / 11
WORKING ARM - BOOM Swing
CRIL03L112G02 1
Description
(1) Screw (2) Pipe
(3) Seal (4) Seal
(5) Bushing (6) Grease tting
(7) Barrel (8) Gland
(9) Seal (10) Seal
(11) Seal (12) Seal
(13) Bushing (14) Snap ring
(15) Seal (16) Seal
(17) Screw (18) Ball
(19) Piston (20) Seal
(21) Seal (22) Nut
(23) Rod
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WORKING ARM - BOOM Swing
Prior operation: To remove the side guard from under the cab oor, refer to Side shield - Remove (E.20.A.70
- F.10.A.10)
Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20)
CRIL03L135A01 1
CRIL03L136A01 2
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H.20.D / 13
WORKING ARM - BOOM Swing
CRIL03L136A01 1
CRIL03L135A01 2
Next operation: To install the side guard under the cab oor, refer to Side shield - Remove (E.20.A.70 - F.10.A.10).
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H.20.D / 14
WORKING ARM - BOOM Swing
27078 1 14/12/2004
H.20.D / 15
WORKING ARM - BOOM Swing
CRIL03J105F03a 1
CRIL03L053A01 2
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H.20.D / 16
WORKING ARM - BOOM Swing
CRIL03J105F03a 1
Torque settings
Fixing screws for spool return spring (A) 9.8 - 11.8 Nm
Main relief valve (63) 78 - 88 Nm
Cap xing screws (65) 20 - 25 Nm
Plug (81) 89 - 97 Nm
1. Install check valve (24) and spring (25).
Install plug (81) complete with a new seal (18) and
tighten to the required torque.
2. Install valves (63) and tighten to the required torque.
3. Coat the threaded part of spool (A) with locking uid.
Clamp the end of the spool in a soft-jawed vice.
Install spring (44) and seats (43) on screw (45).
Install and tighten the screws to the required torque.
Install spool (A) in its housing.
CRIL03L053A01 2
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H.20.D / 17
WORKING ARM - BOOM Swing
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H.20.D / 18
WORKING ARM - BOOM Swing
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H.20.D / 19
WORKING ARM - BOOM Swing
NOTE: The secondary relief valves on the backhoe-offset (O) and (P) are calibrated to a higher pressure than the
main relief valve (S). To check or calibrate the secondary relief valves, main relief valve (S) must be overcalibrated.
1. Overcalibrate main relief valve (S) by tightening the
adjusting screw by 180 °, refer to Relief valve -
Pressure setting (A.12.A.16 - F.45.A.70).
2. Connect a 0-600 bar (0-60 MPa) pressure gauge to
pressure test point M4.
3. Start the engine and run it at maximum speed.
4. Operate the control for the function to be checked
and hold it up against the stop.
5. The pressure readings on the pressure gauge
should be 185 ± 10 bar (18.5 ± 1 MPa) for the boom
to the right. And 230 ± 10 bar (23 ± 1 MPa) for the
boom to the left.
6. If the pressures are incorrect, calibrate
backhoe-offset boom relief valves (0) and (P), refer
to Relief valve - Pressure setting (H.20.D.16 -
F.45.A.70)
Next operation: To reset main relief valve (S), refer to Relief valve - Pressure setting (A.12.A.16 - F.45.A.70).
27078 1 14/12/2004
H.20.D / 20
WORKING ARM - BOOM Swing
CRIL03K054A01 1
Next operation: Reset main relief valve (S), refer to Relief valve - Pressure setting (A.12.A.16 - F.45.A.70).
27078 1 14/12/2004
H.20.D / 21
WORKING ARM - BOOM Swing
Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20)
CRIL03G107A00 1
CRIL03G108A01 2
CRIL03G061A00 3
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H.20.D / 22
WORKING ARM - BOOM Swing
CRIL03G108A02 4
CRIL03G108A03 5
27078 1 14/12/2004
H.20.D / 23
WORKING ARM - BOOM Swing
To use a cylinder bench and bearing wrench for removal operations, refer to Cylinder - Special tools (H.20.B.26 -
D.20.A.40)
CRPH03J002A 1
CRPH03J003A 2
CRPH03J004A 3
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H.20.D / 24
WORKING ARM - BOOM Swing
CRIL03K195A01 4
CRPH03J005A 5
CRIL03J019A01 6
CRIL03J022A01 7
27078 1 14/12/2004
H.20.D / 25
WORKING ARM - BOOM Swing
CRIL03J023A01 8
CRPH03J006A 9
27078 1 14/12/2004
H.20.D / 26
WORKING ARM - BOOM Swing
To use a cylinder bench and bearing wrench for assembly operations, refer to Cylinder - Special tools (H.20.B.26 -
D.20.A.40)
CRPH03J006A 1
CRIL03J023A01 2
CRIL03J022A01 3
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H.20.D / 27
WORKING ARM - BOOM Swing
4. Install carrier seals (1) and joints (2) and (3) on the
piston.
CRIL03J019A01 4
CRPH03J005A 5
CRIL03J032A01 6
CRIL03J02601A 7
27078 1 14/12/2004
H.20.D / 28
WORKING ARM - BOOM Swing
CRPH03J007A 8
CRPH03J004A 9
CRPH03J003A 10
27078 1 14/12/2004
H.20.D / 29
WORKING ARM - BOOM Swing
CRIL03G061A00 1
CRIL03G108A03 2
CRIL03G108A02 3
27078 1 14/12/2004
H.20.D / 30
WORKING ARM - BOOM Swing
27078 1 14/12/2004
H.20.D / 31
Index
WORKING ARM - H
27078 1 14/12/2004
H.20.D / 32
WORKING ARM - H
CX135SR
27079 1 14/12/2004
H.25.B / 1
Contents
WORKING ARM - H
TECHNICAL DATA
DIPPER Lift - Service limits (H.25.B - D.20.A.20) 4
CX135SR
Command valve
Command valve Hand control valve - Torque (H.25.B.12.10 - D.20.A.10) 5
CX135SR
Cylinder
Cylinder - Torque (H.25.B.26 - D.20.A.10) 6
CX135SR
FUNCTIONAL DATA
DIPPER Lift - Hydraulic schema (H.25.B - C.20.A.20) 7
CX135SR
Command valve
Command valve Hand control valve - Sectional view (H.25.B.12.10 - C.10.A.30) 10
CX135SR
Control valve
Control valve - Sectional view (H.25.B.14 - C.10.A.30) 11
CX135SR
Cylinder
Cylinder - Sectional view (H.25.B.26 - C.10.A.30) 12
CX135SR OFFSET BOOM
SERVICE
Command valve
Command valve Hand control valve - Overhaul (H.25.B.12.10 - F.10.A.40) 13
CX135SR
Control valve
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H.25.B / 2
Control valve - Disassemble (H.25.B.14 - F.10.A.25) 21
CX135SR
Safety valve
Safety valve - Remove (H.25.B.15 - F.10.A.10) 25
CX135SR
Relief valve
Relief valve - Overhaul (H.25.B.16 - F.10.A.40) 31
CX135SR
Cylinder
Cylinder - Remove (H.25.B.26 - F.10.A.10) 36
CX135SR MONOBLOC BOOM
Cylinder
Cylinder - Remove (H.25.B.26 - F.10.A.10) 47
CX135SR OFFSET BOOM
Arm
Arm - Remove (H.25.B.50 - F.10.A.10) 59
CX135SR
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H.25.B / 3
WORKING ARM - DIPPER Lift
CRIL03G012E02 1
Linkage points
1. Dipper cylinder foot on boom
CRIL03G018E01 2
MARKING STANDARD DIMENSION WEAR LIMIT
(A) frame 99 mm 105 mm
(B) cylinder 98 mm 96 mm
(C) (A-B) 0.5 - 3 mm shims
(D) pin diameter 70 mm 69 mm
(D) bushing diameter 70 mm 71.5 mm
CRIL03G019E01 3
MARKING STANDARD DIMENSION WEAR LIMIT
(A) boom 259 mm 262 mm
(B) dipper 258.5 mm 256.5 mm
(C) play 0.5 - 1.3 mm shims
(D) pin diameter 75 mm 74 mm
(D) bushing diameter 75 mm 76.5 mm
27079 1 14/12/2004
H.25.B / 4
WORKING ARM - DIPPER Lift
CRIL03G020E01 4
MARKING STANDARD DIMENSION WEAR LIMIT
(A) frame 96.5 mm 102.5 mm
(B) cylinder 95.5 mm 93.5 mm
(C) play (A-B) 0.5 - 3.0 mm shims
(D) pin diameter 70 mm 69 mm
(D) bushing diameter 70 mm 71.5 mm
NOTE: Refer to Command valve Hand command valve - Torque (F.40.C.12.10 - D.20.A.10)
27079 1 14/12/2004
H.25.B / 5
WORKING ARM - DIPPER Lift
CRIL03L069G02 1
Description
(1) Screw 171 Nm
(2) Plug 191,7 - 260,3 Nm
(3) Screw 25,62 - 37,88 Nm
(4) Screw 51,21 - 62,59 Nm
(5) Nut (M52) 4780 Nm
(6) Screw 41,59 - 60,81 Nm
(7) Screw 46,2 - 67,6 Nm
27079 1 14/12/2004
H.25.B / 6
WORKING ARM - DIPPER Lift
CRIL03J149G01 1
Dipper out circuit, load holding valve - Dynamic Description
(1) Dipper spool 1 (2) Straight-line travel valve
(3) Dipper spool 2 (27) Dipper cylinder
(31) Load holding valve (P1) Flow at pump outlet A2
(P2) Flow at pump outlet A1 (Pa5/A5) Dipper out
(Pb5/B5) Dipper in
DIPPER OUT
Dipper cylinder (27) is fed by the ow from pumps (A1) and (A2) via ports (P1) and (P2).
• When the dipper out is not activated, the oil from the small chamber on dipper cylinder (27) is retained by
load holding valve (31). This minimises leakage from dipper 1 spool (1)
• When the dipper out control is activated, the spools on dipper 1 (1) and dipper 2 (3) are piloted via the
ports (Pa5) and (Pa9).
At the same time, the pilot pressure reaches (Pc1) and unlocks the load holding valve (31). This means that
the oil in the large chamber on dipper cylinder (27) can return to the reservoir.
27079 1 14/12/2004
H.25.B / 7
WORKING ARM - DIPPER Lift
CRIL03J150G01 1
Dipper in circuit - Dynamic description.
(1) Dipper spool 1 (2) Straight-line travel valve
(3) Dipper spool 2 (4) Recycling valve
(5) Check valve (27) Dipper cylinder
(31) Load holding valve (P1) Flow at pump outlet A2
(P2) Flow at pump outlet A1 (Pa5/A5) Dipper out
(Pb5/B5) Dipper in (Pa9/pb9) Dipper spool pilot
DIPPER IN
• Dipper cylinder (27) is fed by ows from pumps (A1) and (A2) via ports (P1) and (P2).
• When the dipper in control is activated, the spools on dipper 1 (1) and dipper 2 (3) are piloted via ports
(Pa5) and (Pa9).
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H.25.B / 8
WORKING ARM - DIPPER Lift
This means that the oil from the small chamber on dipper cylinder (27) is reinjected into the large chamber on
dipper cylinder (27) passing through the small restriction in recycling valve (4) and check valve (5).
• When the pressure in the large chamber on the dipper cylinder (27) increases, recycling valve (4) is activated
and placed in restriction position.
This stops the reinjection from the small chamber to the large chamber on dipper cylinder (27).
27079 1 14/12/2004
H.25.B / 9
WORKING ARM - DIPPER Lift
NOTE: Refer to Command valve Hand command valve - Sectional view (F.40.C.12.10 - C.10.A.30)
27079 1 14/12/2004
H.25.B / 10
WORKING ARM - DIPPER Lift
CRIL03J086F01 1
Cross-sectional view - Dipper section 1 and 2
27079 1 14/12/2004
H.25.B / 11
WORKING ARM - DIPPER Lift
CRIL03L069G01a 1
27079 1 14/12/2004
H.25.B / 12
WORKING ARM - DIPPER Lift
1. Refer to:
Command valve Hand command valve - Remove
(F.40.C.12.10 - F.10.A.10)
Command valve Hand command valve -
Disassemble (F.40.C.12.10 - F.10.A.25)
Command valve Hand command valve -
Cleaning (F.40.C.12.10 - F.30.A.10)
Command valve Hand command valve - Visual
inspection (F.40.C.12.10 - F.40.A.10)
Command valve Hand command valve -
Assemble (F.40.C.12.10 - F.10.A.20)
Command valve Hand command valve - Install
(F.40.C.12.10 - F.10.A.15)
27079 1 14/12/2004
H.25.B / 13
WORKING ARM - DIPPER Lift
Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20)
Prior operation: Remove the side guard from under the oor, refer to Side shield - Remove (E.20.A.70 -
F.10.A.10).
CRIL03L109A01 1
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WORKING ARM - DIPPER Lift
CRIL03L110F01 1
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WORKING ARM - DIPPER Lift
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WORKING ARM - DIPPER Lift
CRIL03L109A01 1
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WORKING ARM - DIPPER Lift
CRIL03F201E01 1
Dipper pilot outlet 2
(1) Spring (7) Ring
(2) Calibrated port (8) Snap ring
(3) Body (9) Seal
(4) Connector (10) Seal
(5) Sleeve (11) Seal
(6) Plunger (12) Plunger sub-assembly
CRIL03L114A01a 2
CRIL03F202E01 3
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WORKING ARM - DIPPER Lift
CRIL03F203A01 4
CRIL03F204A01 5
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WORKING ARM - DIPPER Lift
CRIL03F204A01 1
CRIL03F203A01 2
CRIL03F202E01 3
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WORKING ARM - DIPPER Lift
CRIL03J086F01 1
Dipper section 1 and 2
CRIL03L053A01 2
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WORKING ARM - DIPPER Lift
CRIL03L077A01 3
CRIL03L078A01 4
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WORKING ARM - DIPPER Lift
Prior operation: To clean and check parts before assembling, refer to Stack valve - Visual inspection (A.10.A.18
- F.40.A.10)
CRIL03J086F01 1
Dipper section 1 and 2
Torque settings
Fixing screws (45) for return springs on spools (6) and (7) 9.8 - 11.8 Nm
Plug (A) of spool (6) 9.8 - 11.8 Nm
Plug (19) 103 - 113 Nm
Plug (21) 13.5 - 16.5 Nm
Plug (32) 73 - 79 Nm
Fixing screws for ange (39) 39 - 44 Nm
Valves (63) 78 - 88 Nm
Screws (65) and (67) 20 - 25 Nm
1. Install plugs (21) and (32) complete with new seals
and tighten them to the required torque.
2. Install valves (63) and tighten them to the required
torque.
3. Install check valve (16) and spring (17).
Install plug (19) complete with a new seal (18) and
tighten to the required torque.
4. Install sleeve (33).
Install springs (37) and (35) and check valves (36)
and (34).
Install ange (39) complete with new seal (38).
Tighten the screws to the required torque.
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WORKING ARM - DIPPER Lift
CRIL03L078A01 2
CRIL03L053A01 3
CRIL03L077A01 4
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WORKING ARM - DIPPER Lift
Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20)
CRIL03L131A01 1
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WORKING ARM - DIPPER Lift
CRIL03L120G01 1
Description of components
(1) Spool stop cap (2) Seal
(3) Spool cap (4) Seal
(5) Spring (6) Spring seat
(7) Spring seat (8) Spool
(9) Seal (10) Valve
(11) Plug (12) Seal
(13) Spring (14) Check valve
(15) Plug (16) Seal
(17) Spring (18) Piloted check valve
1. Remove cap (1).
Discard seal (2).
2. Remove cap (3).
Discard seal (4)
Remove springs (5).
Remove seats (6) and (7).
Remove spool (8).
3. Remove plug (11).
Discard seal (12).
Remove spring (13) and check valve (14) after
marking their positions.
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WORKING ARM - DIPPER Lift
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WORKING ARM - DIPPER Lift
CRIL03L120G01 1
Tightening torque
Cap screws on spool (1) and (3) 38.8 - 39.6 Nm
Valve (10) 58.2 - 59.4 Nm
Plugs (11) and (15) 213.8 - 217.8 Nm
1. Install cap (1) complete with new seal (2).
Install cap xing screws and tighten to the required
torque.
2. Oil and install spool (8).
Install springs (5) and check valves (6) and (7).
Install spool cap (3) complete with new seal (4).
Install cap xing screws and tighten to the required
torque.
3. Oil and install check valve (14) and spring (13) in
their original positions.
Install plug (11) complete with a new seal (12) and
tighten to the required torque.
4. Oil and install check valve (18) and spring (17) in
their original positions.
Install plug (15) complete with a new seal (16) and
tighten to the required torque.
5. Install valve (10) complete with a new seal (9) and
tighten to the required torque.
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WORKING ARM - DIPPER Lift
CRIL03L131A01 1
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WORKING ARM - DIPPER Lift
CRIL03K057A01 2
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WORKING ARM - DIPPER Lift
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WORKING ARM - DIPPER Lift
NOTE: The dipper secondary relief valves (D) and (E) are calibrated to a higher pressure than the main relief valve
(A). To check or calibrate the secondary relief valves, main relief valve (A) must be overcalibrated.
NOTE: If the excavator is equipped with a safety valve on the dipper, secondary relief valve (D) is not tted on the
valve block, or it is overcalibrated. In this case, valve (D1) mounted on the safety valve must be calibrated.
1. Overcalibrate main relief valve (A) by tightening the
adjusting screw by 180 °, refer to Relief valve -
Pressure setting (A.10.A.16 - F.45.A.70).
2. Connect a 0-600 bar (0-60 MPa) pressure gauge to
the pressure test point .
3. Start the engine and run it at maximum speed.
4. Operate the control for the function to be checked
and hold it against the stop.
5. The pressure readings on the pressure gauge
should be 395 ± 10 bar (39.5 ± 1 MPa).
6. If the pressures are incorrect, calibrate dipper relief
valves (D) and (E), refer to Relief valve - Pressure
setting (H.25.B.16 - F.45.A.70)
Next operation: Reset main relief valve (A), refer to Relief valve - Pressure setting (A.10.A.16 - F.45.A.70).
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WORKING ARM - DIPPER Lift
CRIL03K054A01 1
Next operation: To re-calibrate main relief valve (A), refer to Relief valve - Pressure setting (A.10.A.16
- F.45.A.70)
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WORKING ARM - DIPPER Lift
NOTE: Take care when disassembling the load holding valve, some parts are under pressure from the springs.
1. Place the load holding valve assembly (30) in a
soft-jawed vice.
2. Remove the plug (P).
Remove piston (D), spool (E) and spring (G).
Unscrew and remove plug (C) then remove seal (N).
CRIL03L080B01 1
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WORKING ARM - DIPPER Lift
1. Fit seals (K) and (J) back-up rings (L) and (M) into
the grooves of the sleeve (F).
NOTE: Follow the positions of the seals and backup rings.
CRIL03L080B01 1
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WORKING ARM - DIPPER Lift
Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20)
CRIL03G066A00 1
CRIL03G067A01 2
CRIL03G061A00 3
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WORKING ARM - DIPPER Lift
CRIL03G068A01 4
CRIL03L047A01 5
CRIL03G069A01 6
CRIL03G071A00 7
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WORKING ARM - DIPPER Lift
CRIL03L048A01 8
10. Remove the sling that holds the rod together with
the cylinder barrel.
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WORKING ARM - DIPPER Lift
To use a cylinder bench for removal operations, refer to Cylinder - Special tools (H.20.B.26 - D.20.A.40)
CRPH03J002A 1
CRIL03K193A01 2
CRIL03K194A01 3
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WORKING ARM - DIPPER Lift
CRIL03K195A01 4
CRPH03J005A 5
CRIL03K196A01 6
8. Discard carrier seals (1), seals (2), (3) and (4), and
back-up rings (5).
CRIL03K197A01 7
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WORKING ARM - DIPPER Lift
CRIL03K198A01 8
CRIL03J023A01 9
CRPH03J006A 10
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WORKING ARM - DIPPER Lift
CRPH03J006A 1
CRIL03J023A01 2
CRIL03K198A01 3
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WORKING ARM - DIPPER Lift
CRIL03K197A01 4
CRIL03K196A01 5
CRPH03J005A 6
CRIL03L032A01 7
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WORKING ARM - DIPPER Lift
CRIL03J02601A 8
CRIL03K194A01 9
CRIL03L033A01 10
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WORKING ARM - DIPPER Lift
CRIL03G061A00 1
CRIL03G069A01 3
CRIL03G068A01 4
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WORKING ARM - DIPPER Lift
CRIL03L047A01 5
CRIL03G067A01 6
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WORKING ARM - DIPPER Lift
CRIL03L052A00 1
CRIL03L054B01 2
CRIL03G061A00 3
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WORKING ARM - DIPPER Lift
CRIL03G111A01 4
CRIL03L055B01 5
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WORKING ARM - DIPPER Lift
CRIL03L054B02 6
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WORKING ARM - DIPPER Lift
To use a cylinder bench for removal operations, refer to Cylinder - Special tools (H.20.B.26 - D.20.A.40)
CRPH03J002A 1
CRIL03K193A01 2
CRIL03K194A01 3
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WORKING ARM - DIPPER Lift
CRIL03K195A01 4
CRPH03J005A 5
CRIL03L072A01 6
8. Discard carrier seals (1), seals (2), (3) and (4), and
back-up rings (5).
CRIL03K197A01 7
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WORKING ARM - DIPPER Lift
CRIL03K198A01 8
CRIL03J023A01 9
CRPH03J006A 10
CRIL03L073A01 11
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WORKING ARM - DIPPER Lift
CRPH03J006A 1
CRIL03J023A01 2
CRIL03L073A01 3
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WORKING ARM - DIPPER Lift
CRIL03K198A01 4
5. Install seal (1), seals (2), (3) and (4) and back-up
rings (5) on the piston.
CRIL03K197A01 5
CRIL03L072A01 6
CRPH03J005A 7
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WORKING ARM - DIPPER Lift
CRIL03L032A01 8
CRIL03J02601A 9
CRIL03K194A01 10
CRIL03L033A01 11
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WORKING ARM - DIPPER Lift
CRIL03G061A00 1
CRIL03L054B02 2
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WORKING ARM - DIPPER Lift
CRIL03G111A01 3
CRIL03L055B01 4
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WORKING ARM - DIPPER Lift
CRIL03L054B01 5
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WORKING ARM - DIPPER Lift
Prior operation: To remove the bucket, refer to Arm - Remove (H.30.C.50 - F.10.A.10).
CRIL03L142G01 1
Description of components
(1) Screw (2) Nut
(3) Pin (4) Bushing
(5) Seal (6) Bushing
(7) Bushing (8) Grease tting
(9) Seal (10) Seal
1. To disconnect the dipper cylinder rod, refer to
Cylinder - Remove (H.25.B.26 - F.10.A.10).
Attach the dipper cylinder to the boom.
2. To install a vacuum pump, refer to PRIMARY
HYDRAULIC POWER SYSTEM - Drain uid
(A.10.A - F.35.A.20).
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WORKING ARM - DIPPER Lift
CRIL03H006A00 2
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WORKING ARM - DIPPER Lift
CRIL03L142G01 1
Description of components
(1) Screw (2) Nut
(3) Pin (4) Bushing
(5) Seal (6) Bushing
(7) Bushing (8) Grease tting
(9) Seal (10) Seal
1. Install bushings (4), (6) and (7).
2. Install seals (5).
3. Install grease ttings (8).
4. Attach a suitable lifting device to the dipper.
Bring the dipper close to the machine.
Start the engine.
Align the dipper orices with the orices on the
boom.
Shut down the engine.
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WORKING ARM - DIPPER Lift
7. Install the rst nut on the screw (2) and tighten until
the nut touches the boss.
Loosen the nut a quarter of a turn.
Fit the second nut (2) to keep the rst in position.
8. To connect the boom cylinder rod, refer to Cylinder
- Install (H.25.B.26 - F.10.A.15).
9. Start the vacuum pump.
Remove the plugs.
Connect the hoses between the boom and the
dipper, following the markings made during removal.
Stop and remove the vacuum pump.
CRIL03H006A00 2
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Index
WORKING ARM - H
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DIPPER Lift - Hydraulic schema (H.25.B - C.20.A.20) 8
CX135SR
DIPPER Lift - Service limits (H.25.B - D.20.A.20) 4
CX135SR
Load holding valve - Assemble (H.25.B.19 - F.10.A.20) 35
CX135SR
Load holding valve - Disassemble (H.25.B.19 - F.10.A.25) 34
CX135SR
Relief valve - Overhaul (H.25.B.16 - F.10.A.40) 31
CX135SR
Relief valve - Pressure setting (H.25.B.16 - F.45.A.70) 33
CX135SR
Relief valve - Pressure test (H.25.B.16 - F.40.A.30) 32
CX135SR
Safety valve - Assemble (H.25.B.15 - F.10.A.20) 28
CX135SR
Safety valve - Disassemble (H.25.B.15 - F.10.A.25) 26
CX135SR
Safety valve - Install (H.25.B.15 - F.10.A.15) 29
CX135SR
Safety valve - Pressure setting (H.25.B.15 - F.45.A.70) 30
CX135SR
Safety valve - Remove (H.25.B.15 - F.10.A.10) 25
CX135SR
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WORKING ARM - H
CX135SR
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H.30.C / 1
Contents
WORKING ARM - H
TECHNICAL DATA
ARM TOOL ATTACHMENT Tilt - Service limits (H.30.C - D.20.A.20) 4
CX135SR
Command valve
Command valve Hand control valve - Torque (H.30.C.12.10 - D.20.A.10) 6
CX135SR
Cylinder
Cylinder - Torque (H.30.C.26 - D.20.A.10) 7
CX135SR
FUNCTIONAL DATA
ARM TOOL ATTACHMENT Tilt - Hydraulic schema (H.30.C - C.20.A.20) 8
CX135SR
Command valve
Command valve Hand control valve - Sectional view (H.30.C.12.10 - C.10.A.30) 10
CX135SR
Control valve
Control valve - Sectional view (H.30.C.13 - C.10.A.30) 11
CX135SR
Cylinder
Cylinder - Sectional view (H.30.C.26 - C.10.A.30) 12
CX135SR
SERVICE
Command valve
Command valve Hand control valve - Overhaul (H.30.C.12.10 - F.10.A.40) 13
CX135SR
Control valve
Control valve - Disassemble (H.30.C.13 - F.10.A.25) 14
CX135SR
Relief valve
Relief valve - Overhaul (H.30.C.16 - F.10.A.40) 16
CX135SR
Cylinder
Cylinder - Remove (H.30.C.26 - F.10.A.10) 19
CX135SR
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Cylinder - Disassemble (H.30.C.26 - F.10.A.25) 21
CX135SR
Arm
Arm - Remove (H.30.C.50 - F.10.A.10) 29
CX135SR
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WORKING ARM - ARM TOOL ATTACHMENT Tilt
CRIL03G012E03 1
Linkage points
1. Bucket cylinder foot on dipper
CRIL03G021E01 2
MARKING STANDARD DIMENSION WEAR LIMIT
(A) frame 88 mm 94 mm
(B) cylinder 87 mm 85 mm
(C) (a-b) 0.5 - 3 mm shims
(D) pin diameter 65 mm 64 mm
(D) bushing diameter 65 mm 66.5 mm
2. Yoke on dipper
CRIL03G022E01 3
MARKING STANDARD DIMENSION WEAR LIMIT
(A) 32 mm 29 mm
(B) 254 mm 252 mm
(C) play 1 - 1.5 mm shims
(D) pin diameter 65 mm 64 mm
(D) bushing diameter 65 mm 66.5 mm
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WORKING ARM - ARM TOOL ATTACHMENT Tilt
CRIL03G023E01 4
MARKING STANDARD DIMENSION WEAR LIMIT
(A) bucket 255 mm 261 mm
(B) connecting rod 254 mm 252 mm
(C) play 1 - 1.5 mm shims
(D) pin diameter 65 mm 64 mm
(D) bushing diameter 65 mm 66.5 mm
4. Connecting rod, yoke and bucket cylinder head
CRIL03G024E01 5
MARKING STANDARD DIMENSION WEAR LIMIT
(A) yoke 32 mm 29 mm
(B) cylinder 254 mm 252 mm
(C) play 1 - 1.5 mm shims
(D) 92 mm 94 mm
(E) 91 mm 89 mm
(F) play 1 - 2 mm shims
(G) pin diameter 70 mm 69 mm
(G) yoke bushing diameter 70 mm 71.5 mm
(G) bucket cylinder head bushing 70 mm 71.5 mm
diameter
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WORKING ARM - ARM TOOL ATTACHMENT Tilt
CRIL03G025E01 6
MARKING STANDARD DIMENSION WEAR LIMIT
(A) bucket 255 mm 261 mm
(B) bucket head 254 mm 252 mm
(C) (a-b) 1 - 3.5 mm shims
(D) 16 mm 8 mm
(E) pin diameter 65 mm 64 mm
(E) dipper head bushing diameter 65 mm 66.5 mm
(E) bucket bushing diameter 65 mm 66.5 mm
NOTE: Refer to Command valve Hand command valve - Torque (F.40.C.12.10 - D.20.A.10)
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WORKING ARM - ARM TOOL ATTACHMENT Tilt
CRIL03L108G01 1
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WORKING ARM - ARM TOOL ATTACHMENT Tilt
CRIL03I029G01 1
Bucket opening circuit - Dynamic Description
Bucket opening (small cylinder chamber) (28) is supplied by the output from pump (P2).
(28) Bucket cylinder (P2) Pump outlet ow
(Pa7/A7) Bucket closing (Pb7/B7) Bucket opening
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WORKING ARM - ARM TOOL ATTACHMENT Tilt
CRIL03I030G01 2
Bucket closing circuit - Dynamic Description
Bucket closing (large cylinder chamber) (28) is supplied by the output from pump (P2).
(28) Bucket cylinder (P2) Pump outlet ow
(Pa7/A7) Bucket closing (Pb7/B7) Bucket opening
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WORKING ARM - ARM TOOL ATTACHMENT Tilt
NOTE: Refer to Command valve Hand command valve - Sectional view (F.40.C.12.10 - C.10.A.30)
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WORKING ARM - ARM TOOL ATTACHMENT Tilt
CRIL03J103E01 1
Bucket section
(9) Spool
(11) Large cap
(12) Seal
(13) Small cap
(16) Valve
(17) Spring
(18) Seal
(19) Plug
(63) Relief valve
(65) Screw
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WORKING ARM - ARM TOOL ATTACHMENT Tilt
CRIL03L108G02 1
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WORKING ARM - ARM TOOL ATTACHMENT Tilt
1. Refer to:
Command valve Hand command valve - Remove
(F.40.C.12.10 - F.10.A.10)
Command valve Hand command valve -
Disassemble (F.40.C.12.10 - F.10.A.25)
Command valve Hand command valve -
Cleaning (F.40.C.12.10 - F.30.A.10)
Command valve Hand command valve - Visual
inspection (F.40.C.12.10 - F.40.A.10)
Command valve Hand command valve -
Assemble (F.40.C.12.10 - F.10.A.20)
Command valve Hand command valve - Install
(F.40.C.12.10 - F.10.A.15)
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WORKING ARM - ARM TOOL ATTACHMENT Tilt
CRIL03J103E01 1
CRIL03L053A01 2
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WORKING ARM - ARM TOOL ATTACHMENT Tilt
CRIL03J103E01 1
Torque settings
Fixing screws for spool return spring (9) 9.8 - 11.8 Nm
Plug (19) 103 - 113 Nm
Main relief valve (63) 78 - 88 Nm
Cap xing screws (65) 20 - 25 Nm
1. Install check valve (16) and spring (17).
Install plug (19) complete with a new seal (18) and
tighten to the required torque.
2. Install valves (63) and tighten to the required torque.
3. Coat the threaded part of spool (A) with locking uid.
Clamp the end of the spool in a soft-jawed vice.
Install spring (44) and seats (43) on screw (45).
Install and tighten the screws to the required torque.
Install spool (9) in its housing.
CRIL03L053A01 2
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WORKING ARM - ARM TOOL ATTACHMENT Tilt
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WORKING ARM - ARM TOOL ATTACHMENT Tilt
NOTE: The secondary relief valves on the bucket, (F) and (G) are calibrated to a higher pressure than the main
relief valve (A). To check or calibrate the secondary relief valves, main relief valve (A) must be overcalibrated.
1. Overcalibrate main relief valve (A) by tightening the
adjusting screw by 180 °, refer to Relief valve -
Pressure setting (A.10.A.16 - F.45.A.70).
2. Connect a 0-600 bar (0-60 MPa) pressure gauge to
the pressure test point .
3. Start the engine and run it at maximum speed.
4. Operate the control for the function to be checked
and hold it against the stop.
5. The pressure readings on the pressure gauge
should be 395 ± 10 bar (39.5 ± 1 MPa)
6. If the pressures are incorrect, calibrate bucket relief
valves (F) and (G), refer to Relief valve - Pressure
setting (H.30.C.16 - F.45.A.70)
Next operation: Reset main relief valve (A), refer to Relief valve - Pressure setting (A.10.A.16 - F.45.A.70).
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WORKING ARM - ARM TOOL ATTACHMENT Tilt
CRIL03K054A01 1
Next operation: Reset main relief valve (A), refer to Relief valve - Pressure setting (A.10.A.16 - F.45.A.70)
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WORKING ARM - ARM TOOL ATTACHMENT Tilt
Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20)
CRIL03G073A00 1
CRIL03G074A01 2
CRIL03G075A01 3
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WORKING ARM - ARM TOOL ATTACHMENT Tilt
CRIL03G076A01 4
CRIL03G077A01 5
CRIL03G078A01 6
CRIL03G079A01 7
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WORKING ARM - ARM TOOL ATTACHMENT Tilt
To use a cylinder bench for removal operations, refer to Cylinder - Special tools (H.20.B.26 - D.20.A.40)
CRPH03J002A 1
CRIL03K193A01 2
CRIL03K194A01 3
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WORKING ARM - ARM TOOL ATTACHMENT Tilt
CRIL03K195A01 4
CRPH03J005A 5
CRIL03L079A01 6
CRIL03K197A01 7
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WORKING ARM - ARM TOOL ATTACHMENT Tilt
CRIL03K198A01 8
CRIL03J023A01 9
CRPH03J006A 10
27080 1 14/12/2004
H.30.C / 23
WORKING ARM - ARM TOOL ATTACHMENT Tilt
CRPH03J006A 1
CRIL03J023A01 2
CRIL03K198A01 3
27080 1 14/12/2004
H.30.C / 24
WORKING ARM - ARM TOOL ATTACHMENT Tilt
CRIL03K197A01 4
CRIL03L079A01 5
CRPH03J005A 6
CRIL03L032A01 7
27080 1 14/12/2004
H.30.C / 25
WORKING ARM - ARM TOOL ATTACHMENT Tilt
CRIL03J02601A 8
CRIL03K194A01 9
CRIL03L033A01 10
27080 1 14/12/2004
H.30.C / 26
WORKING ARM - ARM TOOL ATTACHMENT Tilt
CRIL03G061A00 1
CRIL03G079A01 2
CRIL03G077A01 4
27080 1 14/12/2004
H.30.C / 27
WORKING ARM - ARM TOOL ATTACHMENT Tilt
CRIL03G080A00 5
CRIL03G081A01 6
27080 1 14/12/2004
H.30.C / 28
WORKING ARM - ARM TOOL ATTACHMENT Tilt
CRIL03L143G01 1
Description of components
(1) Pin (2) Retaining pin
(3) Pin (4) Snap ring
(5) Seal (6) Yoke
(7) Connecting rod (8) Grease tting
(9) Nut (10) Screw
(11) Pin (12) Shim
(13) Seal (14) Pin
(15) Bushing
1. Place the bucket at on at, level ground.
Operate the attachment controls so that pin (1) is
not under stress from the dipper load.
2. Remove snap rings (4) and retaining pins (2).
3. Remove pins (1) and (3).
27080 1 14/12/2004
H.30.C / 29
WORKING ARM - ARM TOOL ATTACHMENT Tilt
27080 1 14/12/2004
H.30.C / 30
WORKING ARM - ARM TOOL ATTACHMENT Tilt
CRIL03L143G01 1
Description of components
(1) Pin (2) Retaining pin
(3) Pin (4) Snap ring
(5) Seal (6) Yoke
(7) Connecting rod (8) Grease tting
(9) Nut (10) Screw
(11) Pin (12) Shim
(13) Seal (14) Pin
(15) Bushing
1. Install bushings (15) in yoke (6).
2. Install pin (11), connecting rods (7), shims (12) and
screws (10).
27080 1 14/12/2004
H.30.C / 31
WORKING ARM - ARM TOOL ATTACHMENT Tilt
27080 1 14/12/2004
H.30.C / 32
Index
WORKING ARM - H
27080 1 14/12/2004
H.30.C / 33
CNH France S.A.- FRANCE
SERVICE
PRINTED IN FRANCE
All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH France S.A. company reserves the right to modify without prior notice the characteristics and the design of the
machine without any obligation to carry out those modications on machines already sold.
The description of the models shown in this manual has been made using the technical specications known at the
date on which this document was designed.
27076 1 14/12/2004
REPAIR MANUAL
TOOLS AND COUPLERS
CX135SR
27081 1 14/12/2004
J
Contents
27081 1 14/12/2004
J
TOOLS AND COUPLERS - J
CX135SR
27082 1 14/12/2004
J.20.E / 1
Contents
FUNCTIONAL DATA
DIGGING Hammer - Hydraulic schema (J.20.E - C.20.A.20) 3
CX135SR
Control valve
Control valve - Sectional view (J.20.E.14 - C.10.A.30) 6
CX135SR
SERVICE
Command valve
Command valve Foot command valve - Overhaul (J.20.E.12.10 - F.10.A.40) 7
CX135SR
Control valve
Control valve - Disassemble (J.20.E.14 - F.10.A.25) 8
CX135SR
27082 1 14/12/2004
J.20.E / 2
TOOLS AND COUPLERS - DIGGING Hammer
CRIL03J154G01 1
Hammer circuit - dynamic description
(72) Control pedal (76) 3-way selector
(P1) Flow at outlet A2 (Pa2/A2) Option circuit
(Pb2/B2) Option circuit (Y9) Dual ow hammer/grab option solenoid valve .
HAMMER
• 3-way selector (76) must be positioned for the hammer function.
The hammer is supplied by the ow from pump (P1).
• When hammer/grab switch (S14) is in the hammer position and control pedal (72) is moved towards the front
of the machine, the option spool is piloted by port (Pb2) which allows the hammer to be supplied via port (B2).
• As soon as the hammer return pressure is higher than the regulating pressure for the safety valve for the
3-way selector (76), the oil returns to the reservoir via this same safety valve.
27082 1 14/12/2004
J.20.E / 3
TOOLS AND COUPLERS - DIGGING Hammer
CRIL03J153G01 2
Grab circuit - dynamic description
(61) Flow reinjection spool (72) Control pedal
(75) Flow reinjection valve (76) 3-way selector
(79) Control shuttle block (P1) Flow at pump outlet A2
(P2) Flow at pump outlet A1 (Pa2/A2) Option circuit
(Pb2/B2) Option circuit (S14) Hammer/grab switch
(Y9) Dual output hammer/grab option solenoid
valve .
SHEARS
• 3-way selector (76) must be positioned for the grab function.
• The grab can be supplied by the outputs from pumps (P1) and (P2).
• The output from pump (P1) directly supplies the option spool. The output from pump (P2) is forced towards the
ow reinjection valve (75) and joins the output from pump (P1) at the option spool inlet.
• When hammer/grab switch (S14) is in the grab position, the hammer/grab dual output solenoid valve option
(Y9) is activated.
• When control pedal (72) is moved forwards or backwards, the pilot pressure, after passing through control
shuttle block (79) and hammer/grab dual ow option solenoid valve (Y9), unlocks ow reinjection valve (75)
27082 1 14/12/2004
J.20.E / 4
TOOLS AND COUPLERS - DIGGING Hammer
and pilots ow reinjection valve spool (61). This closes the free passage of the ow reinjection spool (61) and
allows the ow from pump (P2) to be reinjected into ow reinjection valve (75) via port (P3).
• The pilot pressure from hammer/grab dual ow option solenoid valve (Y9) reaches port (P) of the ow
reinjection valve (75) and activates the unlocking spool on the load holding check valve of ow reinjection
valve (75). The oil reaching port (B), therefore, is reinjected via port (A) on ow reinjection valve (75) towards
port (P4) on main control valve (15) to join pump ow (P1) at the option spool inlet.
• When the dipper out control is operated at the same time as the grab, the ow from pump (P1) supplies the
grab and the ow from pump (P2) supplies the dipper.
27082 1 14/12/2004
J.20.E / 5
TOOLS AND COUPLERS - DIGGING Hammer
CRIL03J078E01 1
Section E-E _ Hydraulic breaker or shears (high ow option)
27082 1 14/12/2004
J.20.E / 6
TOOLS AND COUPLERS - DIGGING Hammer
NOTE: This control pedal is identical to the one operating the dozer blade.
Refer to the following locations to service this component.
1. Command valve Foot command valve - Special
tools (F.10.F.12.10 - D.20.A.40)
2. Command valve Foot command valve - General
specication (J.40.F.12.10 - D.40.A.10)
3. Command valve Foot command valve - Remove
(H.20.D.12.10 - F.10.A.10)
4. Command valve Foot command valve -
Disassemble (J.40.F.12.10 - F.10.A.25)
5. Command valve Foot command valve - Visual
inspection (F.10.F.12.10 - F.40.A.10)
6. Command valve Foot command valve -
Assemble (J.40.F.12.10 - F.10.A.20)
7. Command valve Foot command valve - Install
(H.20.D.12.10 - F.20.A.20)
8. Command valve Foot command valve -
Troubleshooting (F.10.F.12.10 - G.40.A.10)
27082 1 14/12/2004
J.20.E / 7
TOOLS AND COUPLERS - DIGGING Hammer
CRIL03J078E01 1
CRIL03L053A01 2
27082 1 14/12/2004
J.20.E / 8
TOOLS AND COUPLERS - DIGGING Hammer
CRIL03J078E01 1
CRIL03L053A01 2
27082 1 14/12/2004
J.20.E / 9
Index
27082 1 14/12/2004
J.20.E / 10
TOOLS AND COUPLERS - J
CX135SR
27083 1 14/12/2004
J.40.F / 1
Contents
TECHNICAL DATA
LANDSCAPING Dozer blade - Service limits (J.40.F - D.20.A.20) 4
CX135SR
Command valve
Command valve Foot command valve - Special tools (J.40.F.12.10 - D.20.A.40) 5
CX135SR
Cylinder
Cylinder - Torque (J.40.F.26 - D.20.A.10) 6
CX135SR
FUNCTIONAL DATA
LANDSCAPING Dozer blade - Hydraulic schema (J.40.F - C.20.A.20) 7
CX135SR
Control valve
Control valve - Sectional view (J.40.F.14 - C.10.A.30) 8
CX135SR
Cylinder
Cylinder - Sectional view (J.40.F.26 - C.10.A.30) 9
CX135SR
SERVICE
Command valve
Command valve Foot command valve - Remove (J.40.F.12.10 - F.10.A.10) 10
CX135SR
Control valve
Control valve - Disassemble (J.40.F.14 - F.10.A.25) 16
CX135SR
Relief valve
Relief valve - Overhaul (J.40.F.16 - F.10.A.40) 19
CX135SR
27083 1 14/12/2004
J.40.F / 2
Relief valve - Pressure test (J.40.F.16 - F.40.A.30) 20
CX135SR
Cylinder
Cylinder - Remove (J.40.F.26 - F.10.A.10) 22
CX135SR
DIAGNOSTIC
Command valve
Command valve Foot command valve - Troubleshooting (J.40.F.12.10 - G.40.A.10) 31
CX135SR
27083 1 14/12/2004
J.40.F / 3
TOOLS AND COUPLERS - LANDSCAPING Dozer blade
CRIL03G036F01 1
Linkage points
1. Foot of dozer blade cylinder on dozer blade
CRIL03G037E01 2
MARKING STANDARD DIMENSION WEAR LIMIT
(A) 76 mm 82 mm
(B) 75 mm 73 mm
(C) (a-b) 1 - 2.5 mm shims
(D) pin diameter 55 mm 54 mm
(E) bushing diameter 55 mm 56,5 mm
27083 1 14/12/2004
J.40.F / 4
TOOLS AND COUPLERS - LANDSCAPING Dozer blade
CRIL03G038E01 3
MARKING STANDARD DIMENSION WEAR LIMIT
(A) 79 mm 85 mm
(B) 75 mm 73 mm
(C) 3 - 4.5 mm shims
(D) pin diameter 55 mm 54 mm
(E) bushing diameter 55 mm 56,5 mm
CRIL03G039E01 4
MARKING STANDARD DIMENSION WEAR LIMIT
(A) 79 mm 85 mm
(B) 75 mm 73 mm
(C) play 3 - 6 mm shims
(D) pin diameter 65 mm 64 mm
(E) bushing diameter 65 mm 66.5 mm
NOTE: Refer to Command valve Foot command valve - Special tools (F.10.F.12.10 - D.20.A.40)
27083 1 14/12/2004
J.40.F / 5
TOOLS AND COUPLERS - LANDSCAPING Dozer blade
CRIL03L115G01 1
27083 1 14/12/2004
J.40.F / 6
TOOLS AND COUPLERS - LANDSCAPING Dozer blade
CRIL03J155G01 1
Dozer blade circuit - dynamic description
Dozer blade cylinder (2) is supplied by the ow from pump (Pr).
When the dozer blade control lever (1) is activated, the corresponding spool is piloted by port (pra1) or (prb1), which allows the
dozer blade cylinder to be supplied via port (AR1) or (BR1).
(1) Dozer blade control lever
(2) Dozer blade cylinder
(Pr) Flow at pump outlet A4
(Pra1/AR1) Dozer blade raising
(Prb1/BR1) Dozer blade lowering
27083 1 14/12/2004
J.40.F / 7
TOOLS AND COUPLERS - LANDSCAPING Dozer blade
CRIL03J105F02a 1
27083 1 14/12/2004
J.40.F / 8
TOOLS AND COUPLERS - LANDSCAPING Dozer blade
CRIL03L115G02 1
Description
(1) Screw (2) Clamp
(3) Pipe (4) Screw
(5) Seal (6) Seal
(7) Bushing (8) Grease tting
(9) Cylinder rod (10) Barrel
(11) Seal (12) Gland
(13) Seal (14) Seal
(15) Bushing (16) seal
(17) Seal (18) Screw
(19) Ball (20) Piston
(21) Seal (22) Seal
(23) Snap ring (24) Seal
27083 1 14/12/2004
J.40.F / 9
TOOLS AND COUPLERS - LANDSCAPING Dozer blade
Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20)
CRIL03L132A01 1
27083 1 14/12/2004
J.40.F / 10
TOOLS AND COUPLERS - LANDSCAPING Dozer blade
NOTE: Always handle high precision parts with the greatest care to prevent them being damaged by being knocked
or dropped.
The control pedal components may rust due to contamination and humidity if they are left
without protection after disassembly.If work has to be interrupted, the components must be protected from
contamination or corrosion.
NOTE: Mark the position and bore of all parts.
CRIL03L116G01 1
Cross-sectional view
27083 1 14/12/2004
J.40.F / 11
TOOLS AND COUPLERS - LANDSCAPING Dozer blade
27083 1 14/12/2004
J.40.F / 12
TOOLS AND COUPLERS - LANDSCAPING Dozer blade
27083 1 14/12/2004
J.40.F / 13
TOOLS AND COUPLERS - LANDSCAPING Dozer blade
CRIL03L116G02 1
Torque settings
Plug (4) 25.4 - 33.4 Nm
Fixing screws (13) on cover (11) 27.4 - 31.11 Nm
Locking screw (18) on the cam pin (21) 5.9 - 7.9 Nm (to be installed with thread lock uid)
1. The parts are assembled in the reverse order
of disassembly, refer to Command valve Foot
command valve - Disassemble (J.40.F.12.10 -
F.10.A.25)
27083 1 14/12/2004
J.40.F / 14
TOOLS AND COUPLERS - LANDSCAPING Dozer blade
CRIL03L132A01 1
27083 1 14/12/2004
J.40.F / 15
TOOLS AND COUPLERS - LANDSCAPING Dozer blade
CRIL03J105F03a 1
CRIL03L053A01 2
27083 1 14/12/2004
J.40.F / 16
TOOLS AND COUPLERS - LANDSCAPING Dozer blade
CRIL03J105F03a 1
Torque settings
Fixing screws for spool return spring (A) 9.8 - 11.8 Nm
Main relief valve (63) 78 - 88 Nm
Cap xing screws (65) 20 - 25 Nm
Plug (81) 89 - 97 Nm
1. Install check valve (24) and spring (25).
Install plug (81) complete with a new seal (18) and
tighten to the required torque.
2. Install valves (63) and tighten to the required torque.
3. Coat the threaded part of spool (A) with locking uid.
Clamp the end of the spool in a soft-jawed vice.
Install spring (44) and seats (43) on screw (45).
Install and tighten the screws to the required torque.
Install spool (A) in its housing.
CRIL03L053A01 2
27083 1 14/12/2004
J.40.F / 17
TOOLS AND COUPLERS - LANDSCAPING Dozer blade
27083 1 14/12/2004
J.40.F / 18
TOOLS AND COUPLERS - LANDSCAPING Dozer blade
27083 1 14/12/2004
J.40.F / 19
TOOLS AND COUPLERS - LANDSCAPING Dozer blade
NOTE: Dozer blade secondary relief valves (T) and (U) are calibrated to a higher pressure than the main relief valve
(S). To check or calibrate the secondary relief valves, main relief valve (S) must be overcalibrated.
1. Overcalibrate main relief valve (S) by tightening the
adjusting screw by 180 °, refer to Relief valve -
Pressure setting (A.12.A.16 - F.45.A.70).
2. Connect a 0-600 bar (0-60 MPa) pressure gauge to
pressure test point M4.
3. Start the engine and run it at maximum speed.
4. Activate the control for the blade to be checked and
maintain against the stops.
5. The pressure reading on the pressure gauge should
be: 250 ± 10 bar (25 ± 1 MPa)
6. If the pressures are incorrect, calibrate dozer blade
relief valves (T) and (U), refer to Relief valve -
Pressure setting (J.40.F.16 - F.45.A.70)
Next operation: To reset main relief valve (S), refer to Relief valve - Pressure setting (A.12.A.16 - F.45.A.70).
27083 1 14/12/2004
J.40.F / 20
TOOLS AND COUPLERS - LANDSCAPING Dozer blade
CRIL03K054A01 1
Next operation: To reset main relief valve (S), refer to Relief valve - Pressure setting (A.12.A.16 - F.45.A.70).
27083 1 14/12/2004
J.40.F / 21
TOOLS AND COUPLERS - LANDSCAPING Dozer blade
Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20)
CRIL03G193A00 1
CRIL03L117A01 2
CRIL03L130A01 3
27083 1 14/12/2004
J.40.F / 22
TOOLS AND COUPLERS - LANDSCAPING Dozer blade
CRIL03L118A01 4
27083 1 14/12/2004
J.40.F / 23
TOOLS AND COUPLERS - LANDSCAPING Dozer blade
To use a cylinder bench and bearing wrench for removal operations, refer to Cylinder - Special tools (H.20.B.26 -
D.20.A.40)
CRPH03J002A 1
CRPH03J003A 2
CRPH03J004A 3
27083 1 14/12/2004
J.40.F / 24
TOOLS AND COUPLERS - LANDSCAPING Dozer blade
CRIL03K195A01 4
CRPH03J005A 5
CRIL03J019A01 6
CRIL03J022A01 7
27083 1 14/12/2004
J.40.F / 25
TOOLS AND COUPLERS - LANDSCAPING Dozer blade
CRIL03J023A01 8
CRPH03J006A 9
27083 1 14/12/2004
J.40.F / 26
TOOLS AND COUPLERS - LANDSCAPING Dozer blade
To use a cylinder bench and bearing wrench for assembly operations, refer to Cylinder - Special tools (H.20.B.26 -
D.20.A.40)
CRPH03J006A 1
CRIL03J023A01 2
CRIL03J022A01 3
27083 1 14/12/2004
J.40.F / 27
TOOLS AND COUPLERS - LANDSCAPING Dozer blade
4. Install carrier seals (1) and joints (2) and (3) on the
piston.
CRIL03J019A01 4
CRPH03J005A 5
CRIL03J032A01 6
CRIL03J02601A 7
27083 1 14/12/2004
J.40.F / 28
TOOLS AND COUPLERS - LANDSCAPING Dozer blade
CRPH03J007A 8
CRPH03J004A 9
CRPH03J003A 10
27083 1 14/12/2004
J.40.F / 29
TOOLS AND COUPLERS - LANDSCAPING Dozer blade
CRIL03L117A01 2
CRIL03L130A01 3
27083 1 14/12/2004
J.40.F / 30
TOOLS AND COUPLERS - LANDSCAPING Dozer blade
NOTE: The table below shows a list of common problems. This list is not exhaustive.
Problem Possible Cause Correction
External oil leaks O-ring bearing surfaces scratched Repair or replace the parts
Defective seals Replace the seals
The secondary pressure Worn or broken spool return spring Replace the spring
does not increase
gradually or is out of
tolerance.
Dirt on the spool. Disassemble, clean and repair. Replace
the assembly if necessary
The lever does not move Dirt in the piston Disassemble, clean and repair. Replace
freely or does not return the assembly if necessary
to the neutral position
Dirt in the pushrod Disassemble, clean and repair. Replace
the assembly if necessary
Dirt on the pivot pin and cam Disassemble, clean and repair. Replace
the assembly if necessary
Worn or broken piston return spring Replace the spring
Damping force too weak Broken damper pin Replace the pin.
Dirt in the piston Disassemble, clean and repair. Replace
the assembly if necessary
Damping force too strong Piston restrictor port blocked Disassemble, clean and repair. Replace
the assembly if necessary
27083 1 14/12/2004
J.40.F / 31
Index
27083 1 14/12/2004
J.40.F / 32
27083 1 14/12/2004
J.40.F / 33
CNH France S.A.- FRANCE
SERVICE
PRINTED IN FRANCE
All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH France S.A. company reserves the right to modify without prior notice the characteristics and the design of the
machine without any obligation to carry out those modications on machines already sold.
The description of the models shown in this manual has been made using the technical specications known at the
date on which this document was designed.
27081 1 14/12/2004
27081 1 14/12/2004
CNH France S.A.- FRANCE
SERVICE
PRINTED IN FRANCE
All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH France S.A. company reserves the right to modify without prior notice the characteristics and the design of the
machine without any obligation to carry out those modications on machines already sold.
The description of the models shown in this manual has been made using the technical specications known at the
date on which this document was designed.
9-40641 1 14/12/2004
22 27 D2 P3 P P P3 D2 * 101 28 26 25
* 100 ITEM DESCRIPTION PRESSURE SETTING
*B45 A= MAIN RELIEF (STANDARD) 34.3 MPa / 343 bar / 4977 psi
ITEM
1.
DESCRIPTION
HYDRAULIC RESERVOIR
2. BREATHER
100 B= BOOM RAISING PORT SECONDARY RELIEF 37.8 MPa / 378 bar / 5729 psi
G * 29 * 29
4.
5.
BY-PASS VALVE
SCREEN FILTER
30 *
B1/B2 = RELIEF ON BOOM HBCV 37.3 MPa / 373 bar / 5410 psi
6. RETURN FILTER
C= BOOM LOWERING PORT SECONDARY RELIEF 37.8 MPa / 378 bar / 5482 psi
100 10. MAIN HYDRAULIC PUMP
P P D= DIPPER OUT PORT SECONDARY RELIEF 37.8 MPa / 378 bar / 5482 psi 15. MAIN CONTROL VALVE
16. HYDRAULIC SWIVEL
D1 = RELIEF ON DIPPER HBCV 36.3 MPa / 363 bar / 5265 psi 21. TRAVEL MOTOR
B B E= DIPPER IN PORT SECONDARY RELIEF 37.8 MPa / 378 bar / 5482 psi
22. SWING MOTOR
P2 P3 P3 P2 23. TRAVEL MOTOR BRAKE
RED
RED
L1 K1 A A
K2 L2 F= BUCKET OPEN PORT SECONDARY RELIEF 37.8 MPa / 378 bar / 5482 psi 25.
26.
RIGHT BOOM CYLINDER
LEFT BOOM CYLINDER
G= BUCKET CLOSE PORT SECONDARY RELIEF 37.8 MPa / 378 bar / 5482 psi
Dr 27. DIPPER CYLINDER
T2 H= PILOT PRESSURE RELIEF 3.9 MPa / 39 bar / 566 psi 28. BUCKET CYLINDER
29. BOOM SAFETY VALVE
I= RIGHT-HAND SWING PORT SECONDARY RELIEF 28.5 MPa / 285 bar / 4133 psi
30. DIPPER SAFETY VALVE
J I Pi Pi J= LEFT-HAND SWING PORT SECONDARY RELIEF 28.5 MPa / 285 bar / 4133 psi 31. DIPPER LOAD HOLDING VALVE
PA PB Pi 32. BOOM LOAD HOLDING VALVE
K1/K2 = TRAVEL REVERSE PORT SECONDARY RELIEF 34.8 MPa / 348 bar / 5047 psi 41. FILTER (ULTRA-CLEAN)
L1/L2 = TRAVEL FORWARD PORT SECONDARY RELIEF 34.8 MPa / 348 bar / 5047 psi 42. OIL COOLER
43. RETURN MANIFOLD
N1/N2 = NEGATIVE CONTROL RELIEF 2.7 MPa / 27 bar / 392 psi 44. OIL COOLER BY-PASS VALVE
T1 P1 D1 P2 P2 D1
C P1 T T P1 O= OFFSET BACKHOE SECONDARY RELIEF VALVE, RIGHT-HAND 23.5 MPa / 235 bar / 3408 psi
51. ACCUMULATOR
53. BOOM & BUCKET CONTROL LEVER
A 83 83 P G P= OFFSET BACKHOE SECONDARY RELIEF VALVE, LEFT-HAND 23.5 MPa / 235 bar / 3408 psi 54. SWING & DIPPER CONTROL LEVER
B
D1 23 21 21 23 3 2 55. TRAVEL CONTROL PEDAL
15 83
S= DOZER BLADE + OFFSET BACKHOE MAIN RELIEF 20.6 MPa / 206 bar / 2988 psi
56. DIPPER CONTROL SHOCK ABSORBER
pb5 1
16
15
Pa8 B2 43
B1 * 98
16
E
16
F
T=
U=
DOZER BLADE LOWERING SECONDARY RELIEF
T
Prb1 99 Y4.
Y9.
2 STAGE TRAVEL SOLENOID VALVE (RED BAND)
CRUSHER/BREAKER OPTION TWO FLOW SOLENOID VALVE
COMPONENT BOUNDARY
A Pra1 72 55 55 72
10µ
44 DOZER P P
5a4 T
5a4 T
BLADE 97 97
2 Pr
P T
PIPING CONNECTION
15 Tr6
1 T 2
0.02 MPa 0.004 MPa Pcc
PIPING CROSS-OVER
Dr T1 T2
3 psi 0.58 psi
Ps1 Ps2
0.2 bar 0,04 bar
41 COMPONENT ITEM NO.
15 Y9
P 85
S N2 DR A
COMPONENT NUMBER
B A
N1 Pcc
C
15 15 9
Pc1 al1
15 31 RETRACTED Pb5
93 94
43 Pb9
Pc1 DIPPER (2)
4
5a4 4
5a4 CONNECTION ITEM NO.
Pb9 15
0.1 MPa 10µ A5 Pa5
Pa9 OPTIONAL ITEM NO.
150 MESH
14.5 psi
1 bar B5
DIPPER (1) EXTENDED *
RETRACTED
15 Pb5
56
Pb9 Pa5
B Pc2
30
Pi EXTENDED
5 1 4 6 56 15
C 32 A8
6 B2
B8 102
29
WITHOUT DUAL
FLOW OPTION
D E
BOOM (1)
LOWER * 83 T 1
T
81 Pc3 B T A
Pb8 15
S3
Pbu
BOOM (2)
RAISE Pa8 Pa4
C1
51 82 M3 * 78
10µ
Pb4
HYDRAULIC / ELECTRIC
B7
CX135SR EXCAVATOR
15 Pa4 Y4 Y2 P3 15
OPEN A7 10 µ 5 B2
Pb8 BUCKET
B3 P P0 P
A3 RIGHT SWING F
Pb7 53
3 29 0.2 MPa
* 83 15
T Pi C2 29 psi
CLOSED Pa7 4 A2
Pb3 53 2 bar
Pa3 W1 W2 1
P
B6 Y3
SCHEMATIC
LEFT
83 83 76 TRAVEL 0.103 MPa
86
6 5 A B2 A6 15 psi 15
1.03 bar 3 BR2
Pb6 55
83 76 A2 HAMMER (H) G
* 75 A
4 D Pb2
REAR 1
P2 P1
* 83 15
FRONT Pa6
97 79 55 2 AR2
1 97 79 Pa2 ON
2
B1
2 B2 60
B 15 P4
16
P3
1 T
B1
TRAVEL
B A 15 A1 REAR
B2 55
3
Pb1
83 55 Pa1 FRONT
4
C D 15 Ts3
A PH1 PH2
* 78
A2
Ts5 A1 A2
P1 P2
PT PP PA P3 10
* 76 75
a1 a2
99 99
P T
3 4 3 4
* * 97
2 1 P 2 1 T 72 Pi1 Pi2
96 A
55
93 94 OPTION HAMMER
B 2
T D
LOWER
T T M
1 T 2 1 T 2
ISUZU
B
4BG1T H
65,6 Kw
A 1 T R P 85 P 85 à 2100 tr/mn
F Dr A3
HYDRAULIC SCHEMATIC
Number 9-43660
F21
5 R 207 5 R 207 1 5 R 207 5 R 207 2 ITEM DESCRIPTION
2 LR 261 2 LR 061 2 2 LR 061 2 LR 061 5 R 204 1 F23
A2. ENGINE CONTROLLER
RW 206 206, 484, 540, 544, 546, 013
CN C1
5 R 100
5 R 204
0.85 GR 312, OW 355 A3. ELECTRONIC ACCELERATION
CN 22
2
013, 418, 419, 430, 431, 436, 439, 451, 455, 514, 540, 544, 546, 820 A7. OVER LOAD WARNING CONTROLLER
1
2
F22
1
484, 506, 830, 890, 899, 900, 902, 903, 930, 980 1
B1. COOLANT TEMPERATURE SENSOR
2
2
1
15A 10A 20A 10A 30A 10A 10A 10A 15A 15A 15A 10A 15A 10A 10A 15A 10A 20A 10A 10A CN C2
K7 B21. ENGINE OIL PRESSURE SWITCH
RW 203
R 206
CONNECTION
0.85 LR 380
RG 243
LR 250
VW 280
LgR 305
2 WR 052
0.85 W 323
0.85 YR 278
0.85 GR 310
0.85 OR 379
L 290
OW 355
BrW 232
0.85 WR 370
R 295
1.25 LW 340
R 222
RY 220
4
OFF ACC B22. SWING PILOT PRESSURE SWITCH
20
HEAT B G1 G2 Acc M ST
5R
ON B26. UPPER PILOT PRESSURE SWITCH (YELLOW BAND)
ST HEAT
R 206 RW 203
OFF B27. TRAVEL PILOT PRESSURE SWITCH
ACC 60 R 200 60 R 201 60 R 001
M8 24V 40A B41. ENGINE RPM SENSOR
60 B 799
M8 5 B 797 M5 E
R3 ON
S16
W 328
0.85 GR 312
R 279
START M10 M10 M10 M10
LgR 540 G2 B45. OVERLOAD INDICATOR PRESSURE SWITCH
R 225
M4
3
2
1
- + - + WR 546 B81. HORN
M8
0.85 B
0.85 Y
0.85 L
1 2 3
4 5 6 12V 12V E2. WORKING LIGHT (ATTACHMENT)
6
2
1
4
5
0.85 W 323
3 2 1 E3. WORKING LIGHT (CAB)
WR 391
LgR 542
GrR 010
RY 220
CN A
1
2
3
G1 M5
1
2
3
4
1 2 3 4 B E4. CAB LIGHT
CN 50 1 5 R 100
1
G 450
BG 603
E52. AIR CONDITIONER
0.85 L 480
0.85 BL 490
0.85 LY 470
CN C0
CN C9
F1. FUSE 20A; ENGINE CONTROLLER
1
B 750
2
F10. FUSE 10A; OVER LOAD WARNING CONTROLLER
SG
60 B 799
0.85 BrR 544
F11. FUSE 10A; BACK-UP
WR 546
602, 606
M8 F12. FUSE 10A; KEY SWITCH
RY 220 2 B 600 0.85 BrR 544 2 L
2 BrR 547 2 B 700 F13. FUSE 20A; HEATER / AIR CONDITIONER
010, 450, 542 0.85 LgR 020 1 R
9 10 11 12 13 14 15 16 17 18
2
1 WR 548 RW 206 RW 206 F14. FUSE 10A; NOT USED
M8
BrR 030
603, 607 GND
P1
CN 9
7
2
1
LgR 540 LgR 540
F15. FUSE 15A; WORKING LIGHT
R
WR 391
6
WR 546 3 WR 546
F16. FUSE 15A; CRUSHER/BREAKER OPTION TWO FLOW
5
470, 480, 490 YR 830 4 YR 830
GrR 504
WR 390 0.85 BrR 544 5 0.85 BrR 544 F17. FUSE 10A; DC-DC (24V-12V) CONVERTER
LgR 502
1 1 GrR 013 6 GrR 013
GrR 013 F18. FUSE 15A; WIPER AND WASHER
1
2
1
2
7 0.85 GR 312
3 4
2 2 0.85 GR 312
24V STARTER 1 GrR 010 OR 506
OR 506 8 F19. FUSE 10A; HORN
2 LgR 542
OG 514 9 OG 514
2
3 60 R 001 M10 B F2. FUSE 10A;
CONTROL 24V LgR 540 CN P6 CN P5 0.85 PL 484 10 0.85 PL 484 M
1
POWER 24V 4 0.85 W 324 F20. FUSE 15A; CIGARETTE LIGHTER AND CAB SEAT COMPRESSOR ADJUSTMENT
S51 S15 YW 899 11 YW 899
11 12 13 14 15 16 17 18 19 20
9 10
8 F23. FUSE 65A; MAIN FUSE FOR F1 TO F10 AND F13 TO F20 CIRCUITS
CN M1A
CN B4
2 YW 970 GrR 013 S
5
R 770
B 771
1
2
3 BL 973 OW 355 17 OW 355
0.85 Y 419 F4. FUSE 10A; HYDRAULIC FUNCTION CANCELLATION LEVER SWITCH
3 4
FUEL SENSOR 11
1
2
1
2
3
4
LW 972 18
1
4
2
3
WATER TEMP SENSOR 12 1 2 1 2 3 4 BrR 030 R
0.85 YB 418 F5. FUSE 10A; SWING BRAKE RELAY
1
18 17 16 15 14 13 12 11 10 9
5 0.85 B 724 1
1
2
ILLUMINATION POWER 13
2
YR 830
RG 243
VR 900
L 290
0.85 W 323
0.85 LW 914
OR 379
2 3 1 2 F6. FUSE 10A; ROTARY LIGHT
2
6 WR 390 WR 390
14
1
WL 587
7 0.85 LR 836
3
GND ILLUMINATION 15 WL 808 F7. FUSE 20A; FUEL FILLER PUMP
8 0.85 L 835 CN A
4
16 M F8. FUSE 15A; ENGINE STOP MOTOR
CN 4
9 0.85 B 711
BATTERY RELAY 17 WR 546
10 0.85 BrR 304 BrR 304 H2 2 LR 061 M4
F9. FUSE 30A; GLOW PLUG
18 835, 836, 892
11 0.85 GR 892
5
243, 900 G1. BATTERY
19 12 0.85 B 742 0.85 B 742
6
20 830, 290 WG 820 G2. ALTERNATOR
13
R1
7
14 OW 355 H3. OVER LOAD WARNING AUDIBLE ALARM
8
M3
R 766
B 767
K18. RELAY-TRAVEL MODE
CN D7
1
K19. RELAY-SWING BRAKE
2
K2 K18 K19 K4
1
2
BG 640 K2. RELAY-GLOW PLUG
0.85 GR 890 1 0.85 GR 890 1 1
24V
LgY 436 B21 K20. RELAY-WIPER MOTOR
CN A5
OIL PRESSURE SWITCH VW 2 LgY 436
E2
1
3
K23. RELAY-LOW BLOWER
SWING PRESSURE SWITCH VR BrY 451
E3
2
1 2 1 4 2 1 4 2 1 4 2 1 4 2
4 K24. RELAY-MEDIUM BLOWER
1
2
2
5 5 5 5
0.85 BP 494 1 t C
5
2
2
4
4
TRAVEL SW
3
1
3
1
3
1
3
1
BW 5 YG 431 3 3 3 3
B1 K25. RELAY-HIGHT BLOWER
BG 607
BG 606
BG 603
BG 602
UPPER SW 0.85 BrR 6 LG 430 0.85 BW 520 0.85 PL 484 2
2 WR 052
1.25 WR 051
OR 506
2 LR 061
LgR 306
LgR 305
Lg 805
YW 899
BrW 232
BrW 233
VW 809
VW 902
0.85 WR 370
0.85 WR 371
WL 808
0.85 GR 890
K4. RELAY-WORKING LIGHT
9 10 11 12 13 14 15 16
8
GrR 9
K7. RELAY BATTERY
5
10
CN A7
M1. STARTER MOTOR
3 4
1
WR 391
YW 970
LW 972
2 B 600
BY 971
12
BL 973
2
R 222
1
BrW 14
1
2
15
1
2
3
4
5
6
7
8
9
16
052, 232, 305, 370
061, 506, 890, 899, 902, 903 0.85 LW 914 1 Y9
R2 M5. MOTOR (AIR CHANGING)
M6. AIR VENT DIRECTION CONTROL MOTOR
CN A8
B 700 B 700 2
1
M7. MOTOR ACT (AIR-MIX)
2
1
M8. BLOWER MOTOR
0.85 LW 379
CN A W 497 2
K20 K21 K1 K5 P6. AIR CONDITIONER CONTROL PANEL
3 2 1
TRAVEL MODE WR 1 Lg 805
X12 P8. HEATER CONTROL PANEL
1
1
2
WIPER 2
CN 27 R1. GLOW PLUG
VW YL 804
1
5 6
2
CN A2
WASHER 3
2B 700
VR YG 803
0.85 OR 379
2
A3
9 10 11 12
6
4
WORKING LIGHT WV WL 806 VW 902 Y3
7 8
3
1
0.85 TR 278
0.85 B 742
SWING BRAKE
CN M2
BW 5 VW 809
4
B 762 2
3 4
5
X13 X14
2
4
4
3
1
3
1
3
1
3
1
2
3 3 3 3
8
0.85 LR 836
0.85 BrR 361
YL 804
0.85 B 722
0.85 L 835
0.85 L 910
0.85 LR 381
0.85 BrR 530
0.85 LY 912
0.85 LW 911
LR 250
LR 251
GR 533
GrR 893
YW 899 0.85 GR 954 3 PWM
Y4
1
2
3
1
10 X4 S1. KEY SWITCH
ONE TOUCH IDLE LW 11 GR 511 278, 379
B 761 2 0.85 WL 482 4 RACK 1ST
E
BP 633
P 588
BP 632
VCC
BG 620
VY 577
9 10
4
0.85 B 722
1
4
S52. AIR CONDITIONING COMPRESSOR CLUTCH SWITCH
CN A3
830, 804, 835, 836
2
5
CN 5
250, 360 330, 380 S6. ROTARY LIGHT SWITCH
3
6
0.85 WL 930 381, 530, 893, 910, 911, 912
6 7
S9. ENGINE EMERGENCY STOP SWITCH
2
1.25 LG 952 1 VB
U1. DC-DC (24V-12V) CONVERTER
5
1
1.25 GrB 953 4 POWER GND
1
5 6
W1. ANTENNA
U1 B 760 2
2
PA
1
L 455 L 455
2
3
2
3
2
3
7 2 X13. FAULT DIAGNOSTIS CONNECTOR
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 9 10 11 12 13 14 15 16 17 18 12V 0.85 RW 282 3 1 1 1 0.85 Y 419 8 0.85 Y 419 0.85 LG 507 3 LIMP HOME
0.85 BY 729 4 X14. CLEAR MEMORY CONNECTOR
W 833
L 834
GR 533
B 723
2 3 2 3 2 3 VR 900 9 VR 900 VR 900
7 Y2. PILOT PRESSURE SOLENOID VALVE (BLUE BAND)
CN AC1 CN AC2 0.85 WR 980 10 0.85 WR 980 B 753 B81
80 B 798
1
CN A4
CN A CN A CN A Y3. SWING BRAKE SOLENOID VALVE (PINK BAND)
2
24V. 95 105dB
3
Y4. 2 STAGE TRAVEL SOLENOID VALVE (RED BAND)
CN H1
1
B 753
1
2
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
1
2
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
2
0.85 WR 530 Y9. CRUSHER/BREAKER OPTION TWO FLOW SOLENOID VALVE
YR 1409
R 225
GY 1400
YB 1413
R 346
Y 1433
RY 1407
WL 1405
WR 1408
WB 1434
LR 528
OL 529
WG 527
O 1410
B 701
L 1414
L BG 1411
G 1404
L gB 1406
LR 1432
YW 1403
GR 526
LR 1427
RY 1422
WR 1430
RW 1423
GW 1421
LgR 1425
OR 1424
BW 1429
WG 1431
BrR 1426
LW 1420
GR 1428
0.85 LR 381
0.85 B 720
BG 643 2
1.25 B 743
BG 643 LEGEND
GrR 893 1 GrR 893
1.25 GrR 330 2 1.25 GrR 330
WL 449
NOT CONNECTED
H3 0.85 LR 380 3 0.85 LR 380 CONNECTED
0.85 L 910 4 0.85 L 910 0.85 YB 418
B 701 W 833 0.85 LW 911 5 0.85 LW 911 M4 B9 M14
1
1 1.25 LW 340 1.25LW 340 24V. 71 83dB R 818 0.85 LY 912 6 0.85 LY 912
2
M8 M 2 1.25 LB 1415 R 225 7 BOOT GROUND CABLE GROUND
0.85 LR 407 0.85 LR 407
1.25 LW 345
8
0.85 WR 417 9 0.85 WR 417
1.25 GrR 330 1 1.25 GrR 330
0.85 BL 427 10 0.85 BL 427 M
1.25 B 743 2 1.25 B 743 SINGLE WIRE CONNECTOR HARNESS
CN A
R 295 11
2
1
B 710 12 M5
L 455 1 24V
13
2
X11 1.25 B 743 14 1.25 B 743 BG 660
R5
0.85 WR 417
0.85 RL 407
0.85 BL 427
Y 573
L 834
1 0.85 LY 905
2 1 W 328 W 328
CN B3
1
1 2 3 4
R7
6
7
3 1.25 LB 904 2 WL 567 WL 567
2
1
2
3
4
5
6
7
8
5 6 7 8
INSULATION AGAINST MAGNETISM
5
8
3
4 0.85 LW 906 3 BrR 1426
GrR 893
B
R
L
RL
WR
BL
G
Y
14 13 12 11 10 9
4
SWP
CN 13
4 BW 1429 B 755 X2 INDICATES CONSTANT POWER
5 WR 1430
9 10 11 12 13 14 15 16 17 18
8
BrY 451 2
6 1
CN A
RY 1422
3
2
4
7
BG 652 1 B22 INDICATES POWER WHEN KEY SWITCH IS ON
6
2
1
3
GW 1421
5
1
8 LW 1420
WB 1434
YW 1403
WL 1405
GY 1400
4 5 6
LY 1432
1 2 3
CN12 (R)
O 1401
G 1404
Y 1433
B 1402
9
A7 K22 K23 K24 K25
M6 1 2 3
10
1 2
M2
4
4 5 6
11 CONNECTOR NUMBER COLOR OF CONNECTOR
3
2
1
3
6
5
4
5 O 1410 CN A 12
2
M
2 RY 1407 15 RW 1423 1 4 2 1 4 2 1 4 2 1 4 2
0.85 LY 912 5 LY 60 B 001
5 5 5 5
WR 1408 1 2 0.85 B 748 6 B AREA
5
CIRCUIT NUMBER
2
2
4
4
3
1
3
1
3
1
3
1
3 16 OR 1424 3 3 3 3
M 3
1 LgB 1406 17 GR 1428 COLOR
1.25 LW 341
1.25 LW 342
GR 526
0.85 WR 980
0.85 LW 906
1.25 LW 343
WG 527
1.25 B 691
0.85 LW 905
1.25 LW 344
LR 528
1.25 B 692
1.25 LB 904
1.25 LW 345
OL 529
1.25 B 693
18 LR 1427
TABLE OF COLOR SYMBOLS
LG 430 2
M5 M7 BG 650 1 B26 SYMBOL COLOR
CN D6
4
1
B BLACK
5
2
0.85 B 749
0.85 L 913
6
0.85 WR 980
6
3
W WHITE
5
1.25 B 693 1 2
M
P6 P8
4
1
2
P PINK
2
1
1 2 VIOLET
1 2 V
2
CN 21
0.85 WR 980
S52 G GREEN
1
2
1.25 W 981 1
O ORANGE
1 OB 1412 CN B9
R4 2 YB 1413 R RED
2B 700 2 2B 700 1
CN A0 CN A1 CN 7 CN 8 0.85 BL 427 3 0.85 BL 427 Y YELLOW
2B 600 1 2B 600 1
0.85 RL 407 1 0.85 RL 407 2
B45 Lg LIGHT GREEN
CN A
1 2 3 4 5 6 7 8 9 10 11 33 34 35 36 37 38 39 40 58 59 60 61 62 63 64 65 66 67 89 90 91 92 93 BW 505
Sb SKY BLUE
12 13 14 15 16 17 18 19 20 21 22 23 24 41 42 43 44 45 46 47 48 49 50 68 69 70 71 72 73 74 75 76 77 78 79 94 95 96 97 98 99 100 484, 501
1.25 B 730
1
25 26 27 28 29 30 31 32 51 52 53 54 55 56 57 80 81 82 83 84 85 86 87 88 101 102 103 104 1.25 W 981 1 L BLUE
0.85 GR 310
2
Gr GRAY
1
3
3
2
470, 480, 490, 502, 504, 511, 512, 513, 575, 576, 577, 588
NOTE :
Y8 1. "BR" INDICATES BLACK CABLE WITH RED STRIPE.
1.25 GrB 953
0.85 WG 473
1.25 BrB 951
0.85 WY 472
1.25 RG 950
0.85 GR 313
0.85 GR 312
0.85 GR 954
0.85 BG 955
0.85BW 492
0.85 LG 507
0.85 BP 494
0.85 GR 311
0.85 GR 310
0.85 WL482
0.85 PL 484
0.85 BL 490
2B 700
BG 660
BG 652
BG 651
BG 650
1.25 B 731
1.25 B 730
2B 600
0.85 L 481
0.85 L 480
680
681
CN A0
CN A1
GrR 504
LgR 503
LgR 502
OG 514
WG 513
OR 506
BW 505
BY 498
GR 511
LW 512
VG 576
BL 782
YL 488
VY 577
W 497
O 487
Y 486
L 496
P 588
1.25 B 743
CN 7
CN 8
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
39
42
33
51
54
52
34
35
36
37
38
40
41
43
44
45
46
7
8
9
10
11
12
13
14
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
47
48
49
50
53
55
56
57
1
2
4
15
16
5
17
6
HEAT RELAY
NV VB
PS (GE) PWR VB
GLOW LAMP SIGNAL
TF SENSOR (SIG)
GND (MV)
VBB (RED 4)
GND (RED 4)
SHLD (RED 4)
GND (RED 4)
VBB (RED 4)
REGULATION (RED 4)
5V (RED 4)
REGULATION DEBIT CARBURANT
CAN-H
V 1ST (RED 4)
5V (RED 4)
Q ADJUST RES.
CAN-L
CAN GND
KEY SWITCH
KEY SWITCH
ACCEL VOLUME (5V)
START SWITCH
MAP SELECT-1
DIAG-MODE SWITCH
THROTTLE (SIG)
THROTTLE (SIG)
TW SENSOR (SIG)
OVER HEAT (WATER)
ENGINE ROTATE
MAP SELECT-0
TECH 2 (TXD)
DIAG-LAMP OUT
MAIN POWER (VB)
MAIN POWER (VB)
TECH 2 (RXD)
CHECKER SELECT
GND
GND
ENGINE STOP MOTOR
CX 135SR EXCAVATOR
A2
5 B 796
ELECTRICAL SCHEMATIC
M6 M6 Part Number 9-43660