Case Crawler Excavator cx75sr cx80 Tier 3 Service Manual PDF Free

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CRAWLER EXCAVATOR CX75SR/CX80 TIER 3

SERVICE MANUAL
TABLE OF CONTENTS
DIVISION/SECTION SECTION N° REFERENCE N°
1 GENERAL INFORMATION
Safety, general information and standard torque data..................................... 1001 7-27691EN
General specifications and special torque setting ........................................... 1002 SC75SRCX80-1002-2EN
2 ENGINE
Removal and installation of the engine............................................................ 2000 SM75SR2000-0EN
Engine specifications..............................................................................................*
Disassembly and assembly of the engine ..............................................................*
3 FUEL SYSTEM
Removal and installation of the fuel tank......................................................... 3001 SM75SR3001-0EN
Fuel engine system ................................................................................................*
4 ELECTRICAL SYSTEM
Electrical and engine functions and service support ....................................... 4001 SC75SRCX80-4001-0EN
Electrical equipment and electrical circuit diagrams........................................ 4020 SC75SRCX80-4020-0EN
5 UNDERCARRIAGE
Removal and installation of tracks ................................................................... 5001 SM75SR5001-0EN
Rollers ............................................................................................................. 5003 SM75SR5003-0EN
Take-up roller................................................................................................... 5005 SM75SR5005-0EN
6 DRIVE TRAIN
Removal and installation of the drive motor and
final drive transmission................................................................................ 6001 SM75SR6001-0EN
Disassembly and assembly of the drive motor and
final drive transmission................................................................................ 6002 SM75SR6002-0EN
Removal and installation of the swing motor and
swing reduction gear ................................................................................... 6003 SM75SR6003-0EN
Disassembly and assembly of the swing reduction gear ................................. 6004 See 8019
7 UNDERCARRIAGE HYDRAULICS
* Consult the Engine Service Manual
Copyright © 2008 CNH France S.A.

Printed in France
CNH Lep SM75SRTOC-0EN March 2008
Copyright ©
DIVISION/SECTION SECTION N° REFERENCE N°

8 UPPERSTRUCTURE HYDRAULICS
Specifications, troubleshooting, checks and
hydraulic pressure settings..........................................................................8001 SC75SRCX80-8001-1EN
Removal and installation of the hydraulic reservoir .........................................8002 SM75SR8002-0EN
Removal and installation of the main hydraulic pump......................................8003 SM75SR8003-0EN
Removal and installation of the main hydraulic control valve - CX75SR .........8004 SM75SR8004-0EN
Removal and installation of the main hydraulic control valve - CX80 ..............8004 SM80-8004-0EN
Removal and installation of the attachment cylinders......................................8005 SM75SR8005-0EN
Removal and installation of the hydraulic swivel ..............................................8006 SM75SR8006-0EN
Removal and installation of the pilot blocs.......................................................8007 SM75SR8007-0EN
Disassembly and assembly of the main hydraulic pump .................................8010 SM75SR8010-0EN
Disassembly and assembly of the main hydraulic control valve - CX75SR .....8011 SM75SR8011-0EN
Disassembly and assembly of the main hydraulic control valve - CX80 ..........8011 SM80-8011-0EN
Disassembly and assembly of the attachment cylinders .................................8012 SM75SR8012-0EN
Disassembly and assembly of the hand control levers ....................................8013 SM75SR8013-0EN
Disassembly and assembly of the foot control levers ......................................8014 SM75SR8014-0EN
Disassembly and assembly of the solenoid valve block ..................................8015 SM75SR8015-0EN
Disassembly and assembly of the cushion valve.............................................8016 SM75SR8016-0EN
Disassembly and assembly of the hydraulic swivel .........................................8018 SM75SR8018-0EN
Disassembly and assembly of the swing motor ...............................................8019 SM75SR8019-0EN
Hydraulic functions ..........................................................................................8020 SC75SRCX80-8020-0EN
Hydraulic component functions........................................................................8030 SC75SRCX80-8030-0EN
9 UPPERSTRUCTURE
Air conditioning unit .........................................................................................9007 SM75SR9007-0EN
Large size hydraulic schematics - CX75SR.................................................. Pocket 87725706A
Large size electrical schematics - CX75SR.................................................. Pocket 87732675A
Large size hydraulic schematics - CX80....................................................... Pocket KAJ11600-E00
Large size electrical schematics - CX80....................................................... Pocket KAJ11060-E00
NOTE: CNH Company reserves the right to make changes in the specification
and design of the machine without prior notice and without incurring any obliga-
tion to modify units previously sold.
The description of the models shown in this manual has been made in accord-
ance with the technical specifications known as of the date of design of this
document.
Lep SM75SRTOC-0EN Issued 03-08

Copyright ©
1001
Section
1001
SAFETY, GENERAL INFORMATION

AND TORQUE SPECIFICATIONS

Printed in France
CNH Lep 7-27691EN February 2006
Copyright ©
1001-2
TABLE OF CONTENTS
GENERAL INFORMATION .......................................................................................................................................3
SAFETY..................................................................................................................................................................... 4
STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS............................................................................... 6
WARNING : This symbol is used in this manual to indicate important safety messages. Whenever you see
! this symbol, carefully read the message that follows, as there is a risk of serious injury.
Lep 7-27691EN Issued 02-06

Copyright ©
1001-3
GENERAL INFORMATION
Cleanning Gears
Clean all metal parts except bearings, in a suitable Check all gears for wear and damage. Replace gears
cleaning solvent or by steam cleaning. Do not use that have wear or damage.
caustic soda for steam cleaning. After cleaning, dry
and put oil on all parts. Clean oil passages with Oil seals, O-rings and gaskets
compressed air. Clean bearings in a suitable cleaning
Always install new oil seals, O-rings and gaskets. Put
solvent, dry the bearings completely and put oil on
petroleum jelly on seals and O-rings.
the bearings.
Inspection Shafts
Check all shafts that have wear or damage. Check
Check all parts when the parts are disassembled.
the bearing and oil seal surfaces of the shafts for
Replace all parts that have wear or damage. Small
damage.
scoring or grooves can be removed with a hone or
crocus cloth. Complete a visual inspection for Service parts
indications of wear, pitting and the replacement of
parts necessary to prevent early failures. Always install genuine Case service parts. When
ordering refer to the Parts Catalog for the correct part
Bearings number of the genuine Case replacement items.
Failures due to the use of other than genuine Case
Check bearings for easy action. If bearings have a
replacement parts are not covered by warranty.
loose fit or rough action replace the bearing. Wash
bearings with a suitable cleaning solvent and permit Lubrication
to air dry. DO NOT DRY BEARINGS WITH
COMPRESSED AIR. Only use the oils and lubricants specified in the
Operator’s or Service Manuals. Failures due to the
Needle bearings use of non-specified oils and lubricants are not
covered by warranty.
Before you press needle bearings in a bore always
remove any metal protrusions in the bore or edge of
the bore. Before you press bearings into position put
petroleum jelly on the inside and outside diameter of
the bearings.

Copyright ©
1001-4
SAFETY
This symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED. The message that follows the
! symbol contains important information about safety. Carefully
read the message. Make sure you fully understand the
causes of possible injury or death.
To prevent injury always follow the Warning, Caution

and Danger notes in this section and throughout the
manual. WARNING: Before starting engine, study
Operator’s Manual safety messages. Read
Put the warning tag shown below on the key for the all safety signs on machine. Clear the area of
keyswitch when servicing or repairing the machine. other persons. Learn and practice safe use
One warning tag is supplied with each machine. of controls before operating.
Additional tags Part Number 331-4614 are available
from your service parts supplier
! It is your responsibility to understand and
f o l l o w m a n u f a c tu r e r s i n s tr u c t i o n s o n
. machine operation, service and to observe
pertinent laws and regulations. Operator’s
WARNING: Read the operator’s manual to and Service Manuals may be obtained from
your Case dealer.
! familiarize yourself with the correct control
functions.
WARNING: If you wear clothing that is too

WARNING: Operate the machine and loose or do not use the correct safety
equipment controls from the seat position equipment for your job, you can be injured.
! only. Any other method could result in Always wear clothing that will not catch on
serious injury. ! objects. Extra safety equipment that can be
required includes hard hat, safety shoes, ear
protection, eye or face protection, heavy
WARNING: This is a one man machine, no gloves and reflector clothing.
! riders allowed.
WARNING: When working in the area of the

! fan belt with the engine running, avoid loose
clothing if possible, and use extreme caution.
WARNING: When doing checks and tests

on the equipment hydraulics, follow the
! procedures as they are written. DO NOT
change the procedure.
WARNING: When putting the hydraulic

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

Copyright ©
1001-5
WARNING: Use insulated gloves or mittens WARNING: When servicing or repairing the
! when working with hot parts. machine, keep the shop floor and operator’s
compartment and steps free of oil, water,
! grease, tools, etc. Use an oil absorbing
WARNING: Lower all attachments to the material and/or shop cloths as required. Use
ground or use stands to safely support the safe practices at all times.
! attachments before you do any maintenance
or service.
WARNING: Some components of this
machine are very heavy. Use suitable lifting
WARNING: Pin sized and smaller streams ! equipment or additional help as instructed in
of hydraulic oil under pressure can penetrate this Service Manual.
the skin and result in serious infection. If
hydraulic oil under pressure does penetrate
the skin, seek medical treatment
WARNING: Engine exhaust fumes can
immediately. Maintain all hoses and tubes in
! good condition. Make sure all connections
cause death. If it is necessary to start the
engine in a closed place, remove the exhaust
are tight. Make a replacement of any tube or
hose that is damaged or thought to be
! fumes from the area with an exhaust pipe
extension. Open the doors and get outside
damaged. DO NOT use your hand to check
air into the area.
for leaks, use a piece of cardboard or wood.
WARNING: When the battery electrolyte is

WARNING: When removing hardened pins frozen, the battery can explode if (1), you try
such as a pivot pin, or a hardened shaft, use to charge the battery, or (2), you try to jump
start and run the engine. To prevent the
! a soft head (brass or bronze) hammer or use
a driver made from brass or bronze and a
! battery electrolyte from freezing, try to keep
steel head hammer. the battery at full charge. If you do not follow
these instructions, you or others in the area
can be injured.
WARNING: When using a hammer to
remove and install pivot pins or separate
parts using compressed air or using a
! grinder, wear eye protection that completely
encloses the eyes (approved goggles or
other approved eye protectors).
WARNING: Use suitable floor (service)

jacks or chain hoist to raise wheels or tracks
! off the floor. Always block machine in place
with suitable safety stands.

Copyright ©
1001-6
STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS

Tightening of cap screws, nuts
Tighten alternately so that tightening torque can be applied evenly. The numbers in the figure below indicate the
order of tightening.
JS00481A
Cap screws which have had Loctite used (white residue remains after removal) should be cleaned with loght oil or
suitable cleaning solvent and dried. Apply 2-3 drops of Loctite to the thread portion of the cap screw and then
tighten.
Torque table
Tighten cap screws and nuts according to the table below if there are no other special instructions.
Cap Screw Name Size (Size) M6 M8 M10 M12 M14 M16 M18 M20
[mm] 10 13 17 19 22 24 27 30
Spanner
[in.] 0.39 0.51 0.67 0.75 0.87 0.95 1.06 1.18
Cap Screw
Tightening [Nm] 6.9 19.6 39.2 58.8 98.1 156.9 196.1 294.2
torque [lb-ft] 5.1 14.5 28.9 43.4 72.3 115.7 144.6 217
[mm] 5 6 8 10 12 14 14 17
Spanner
Socket [in.] 0.20 0.24 0.32 0.39 0.47 0.55 0.55 0.67
Head Cap
Screw [Nm] 8.8 21.6 42.1 78.5 117.7 176.5 245.2 343.2
Tightening
torque
[lb-ft] 6.5 15.9 31.1 57.9 86.9 130.2 181 253.2

Copyright ©
1002
Section
1002
SPECIFICATIONS
AND SPECIAL TORQUE SETTINGS
Copyright @ 2008 CNH France SA

Lep SC75SRCX80-1002-0EN Printed in France
CNH Mars 2008
Copyright ©
1002-2
TABLE OF CONTENTS
WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see this
! symbol, carefully read the message which follows. Your safety depends on it.
TYPE, SERIAL NUMBER

AND YEAR OF MANUFACTURE OF THE MACHINE..................................................................................................... 5
Machine ....................................................................................................................................................................... 5
Engine .......................................................................................................................................................................... 5
Serial numbers of the components .............................................................................................................................. 5
FLUIDS AND LUBRICANTS ............................................................................................................................................ 6
Hydraulic fluid .............................................................................................................................................................. 6
Transmission component oil ........................................................................................................................................ 6
Grease ......................................................................................................................................................................... 6
Engine Oil .................................................................................................................................................................... 7
Engine fuel, maintenance of fuel filters and fuel storage ............................................................................................. 8
Anti-freeze/Anti-corrosion........................................................................................................................................... 10
Environment ............................................................................................................................................................... 10
Plastic and resin parts................................................................................................................................................ 10
SPECIFICATIONS ......................................................................................................................................................... 11
Main data ................................................................................................................................................................... 11
Performance .............................................................................................................................................................. 11
Main body dimensions ............................................................................................................................................... 11
Engine ........................................................................................................................................................................ 11
Cooling system .......................................................................................................................................................... 12
Capacity of coolant and lubricants ............................................................................................................................. 12
Air conditioning .......................................................................................................................................................... 12
Hydraulic oil filter........................................................................................................................................................ 12
Fuel filter .................................................................................................................................................................... 12
Operating devices ...................................................................................................................................................... 12
Hydraulic system........................................................................................................................................................ 13
Hydraulic Cylinders .................................................................................................................................................... 15
Rotating Joint ............................................................................................................................................................. 16
Swing unit .................................................................................................................................................................. 21
Travel lower body....................................................................................................................................................... 21
Work Unit ................................................................................................................................................................... 22
COMPONENT WEIGHT................................................................................................................................................. 24
Major component weight (CX75SR)........................................................................................................................... 24
Major component weight (CX80)................................................................................................................................ 25
Other component weight ............................................................................................................................................ 26
DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY .................................................................................. 27
Sprocket ..................................................................................................................................................................... 27
Idler wheel.................................................................................................................................................................. 28
Upper roller ................................................................................................................................................................ 29
Lep SC75SRCX80-1002-0EN Issued 03-08

Copyright ©
1002-3
Lower roller .................................................................................................................................................................30
Track...........................................................................................................................................................................31
DIMENSIONS AND WEAR LIMITS OF ATTACHMENT LINKAGES (MONO BOOM) ...................................................32
1. Boom foot/Frame ....................................................................................................................................................32
2. Boom cylinder foot/Frame.......................................................................................................................................33
3. Boom cylinder head/Boom......................................................................................................................................33
4. Dipper cylinder foot/Boom ......................................................................................................................................34
5. Boom/Dipper...........................................................................................................................................................34
6. Dipper cylinder head/Dipper ...................................................................................................................................34
7. Bucket cylinder foot/Dipper.....................................................................................................................................35
8. Connecting rod/Dipper............................................................................................................................................35
9. Compensator/Bucket ..............................................................................................................................................35
10. Connecting rod/Compensator/Bucket cylinder head ............................................................................................36
11. Dipper/Bucket .......................................................................................................................................................36
DIMENSIONS AND WEAR LIMITS OF ATTACHMENT LINKAGES (CX75SR OFFSET BOOM) .................................37
1. Base Boom/Offset boom.........................................................................................................................................37
2.Base Boom/Offset cylinder/Rod...............................................................................................................................38
3. Offset Boom/ Offset cylinder...................................................................................................................................38
4. Offset Dipper/Rod ...................................................................................................................................................39
5. Offset arm/Offset Boom ..........................................................................................................................................39
6. Offset Dipper/ Dipper cylinder.................................................................................................................................39
7. Offset dipper/Dipper................................................................................................................................................40
8. Dipper/Dipper cylinder ............................................................................................................................................40
9. Dipper/Bucket cylinder............................................................................................................................................40
DIMENSIONS AND WEAR LIMITS OF BLADE AND BLADE CYLINDER .....................................................................41
10. Blade/Blade cylinder .............................................................................................................................................41
11. Lower frame/Blade cylinder ..................................................................................................................................41
12. Lower frame/Blade................................................................................................................................................42
LIST OF SHIMS ..............................................................................................................................................................43
For Adjusting Attachment Gaps..................................................................................................................................43
For Adjusting Attachment Gaps (for Boom Foot)........................................................................................................47
SPECIAL TORQUE SETTINGS CX75SR.......................................................................................................................49
SPECIAL TORQUE SETTINGS CX80............................................................................................................................52
MACHINE OVERALL DIMENSIONS ..............................................................................................................................55

Copyright ©
1002-4

Copyright ©
1002-5
TYPE, SERIAL NUMBER
AND YEAR OF MANUFACTURE OF THE MACHINE
For all part orders, request for information or assistance, always specify the type and the serial number of the machine
to your Case dealer.
Fill in the following lines with the required information: Type, serial number, year of manufacture of the machine and the
serial numbers of the hydraulic and mechanical components.
Machine
CT04A171A
(1) Type .......................................................................................................................................................................

(2) Serial number.........................................................................................................................................................
(3) Year of manufacture ...............................................................................................................................................
Engine
Make and type.............................................................................................................................................................
Serial number ..............................................................................................................................................................
Serial numbers of the components

Hydraulic pump ...........................................................................................................................................................
Swing reduction gear...................................................................................................................................................
Travel reduction gears .................................................................................................................................................
Control valve................................................................................................................................................................

Copyright ©
1002-6
FLUIDS AND LUBRICANTS
Lubricants must have the correct properties for each application.
WARNING: The conditions of use for individual fluids and lubricants must be respected.
!
Hydraulic fluid
CASE/AKCELA hydraulic fluid is specially designed for high pressure applications and for the CASE hydraulic system.
The type of fluid to be used depends on the ambient temperature.
Temperate climates: -20°C to +40°C (-4° to 104° F)
CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID (MS 1230. ISO VG 46. DIN 51524 PART 2 HV)
Hot climates: 0°C to +50°C (32° to 122° F)
CASE/AKCELA: AW HYDRAULIC FLUID 68 HV (MS 1216. ISO VG 68. DIN 51524 PART 3 CATEGORY HVLP)
Cold climates: -25°C to +20°C (-13° to 68° F)
CASE/AKCELA: AW HYDRAULIC FLUID 32 (MS 1216. ISO VG 32. DIN 51524 PART 2)
Biodegradable fluid: -30°C to +40°C (-22° to 104° F)
This yellow-colored fluid is miscible with standard fluid. If used to change standard fluid, it is advised to drain the circuit
completely before refilling with this fluid.
CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID BIO (MS 1230. ISO VG 46. DIN 51524 PART 2 HV)
Transmission component oil

Extreme pressure oil used for enclosed transmission components.
CASE/AKCELA: GEAR 135H EP (SAE 80W-90. API GL 5. MIL-L-2105 D. MS 1316. ZF TE-ML 05A)
Grease
CASE/AKCELA: MOLY GREASE 251H EP-M (251H EP-M. NLGI 2)
"Extreme Pressure" multipurpose grease with lithium soap and molybdenum disulphide.
CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (251H EP. NLGI 2)
"Extreme Pressure" multipurpose grease with lithium soap and calcium.
CASE/AKCELA: PREMIUM GREASE EP2 (NLGI 2)
"Extreme Pressure" multipurpose grease with lithium soap.
Hydraulic breakers
CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (NLGI 2).

Copyright ©
1002-7
Engine Oil
THE CASE/AKCELA No. 1 engine oil is recommended
for your engine. This oil ensures proper lubrication of
your engine for all operating conditions.
If the CASE/AKCELA Multigrade "No. 1 ENGINE OIL"
cannot be obtained, use the oil corresponding to one of
the following categories: ACEA E7. API CI-4.
CP02N001
Oil viscosity / Oil range
1
2
2
3
3
CT02M001
1) With mineral base

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

Copyright ©
1002-8
Engine fuel, maintenance of fuel filters and fuel storage
In order to meet the emission control regulation of 3rd-stage, the engine components have been made precisely and
they are to be used under high-pressure conditions.
Therefore, the specified fuel must be used for the engine.
As a matter of course, not only the guarantee will not be given for the use of a fuel other than the specified but also it
may invite a serious breakdown.
In addition, since suitable specifications for the fuel filter elements have been established for this engine, use of the gen-
uine filter is essential.
The following describes the specifications and the requirements of the fuel to be applied, and maintenance of the fuel
and the fuel elements.
Fuel to be applied
Selection of fuel
Following conditions must be met for the diesel engines, that is the one;
1 In which no dust even fine one is mixed,
2 With proper viscosity,
3 With high cetane rating,
4 With good flow properties in lower temperature,
5 With not much sulfur content, and
6 With less content of carbon residue
Applicable standards for diesel fuel
Applicable Standard Recommendation
JIS (Japanese Industrial Standard) NO.2
DIN (Deutsche Industrie Normen) DIN 51601
SAE (Society of Automotive Engineers)
Based on SAE-J-313C NO. 2-D
BS (British Standard)
Based on BS/2869-197 Class A-1
EN590
If a standard applied to the fuel for the diesel engine is stipulated in your country, check the standard for details.
Requirements for diesel fuel
Although conditions required for the diesel fuel are illustrated above, there are other requirements exerting a big
influence on its service durability and service life.
Be sure to observe the following requirements for selecting fuel.
Sulfur content............................................................................... 2500 ppm or less
HFRR*.......................................................................................... 460 mm or less
Water content............................................................................... 0.05 wt% or less
* HFRR (High-Frequency Reciprocating Rig.): An index showing lubricating properties of the fuel.
Sulfur content reacts to moisture to change into sulfuric acid after combustion.
Use of a fuel containing much sulfur content allows it to accelerate internal corrosion and wear.
In addition, much sulfur content quickens deterioration of engine oil allowing its cleaning dispersive property to be
worse which results in acceleration of wear of sliding portions.
HFRR is an index that indicates lubricating property of a fuel.
Large value of the index means poor lubrication so that seizure of the machine components may result if such a
fuel is used.
Since a fuel with high HFRR value also has lower viscosity, it can easily be leaked out.

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1002-9
If the fuel is mixed with the engine oil, the oil is diluted to deteriorate its lubricating property resulting in accelera-
tion of wear.
Water content allows inside of the fuel tank to rust which in turn blocking the fuel line and the fuel filter.
IMPORTANT : In cold weather, fill the fuel tank at the end of the day's work, in order to prevent the formation of conden-
sation.
This may also cause wear and seizure of the machine components.
If atmospheric temperature goes below the freezing point, moisture content in the fuel forms fine particle of ice
allowing the fuel line to be clogged.
IMPORTANT : Obtain table of analysis for the fuel you are using from the fuel supplier to confirm that it meets the crite-
ria described above.
IMPORTANT : If a fuel which does not meet the specifications and the requirements for the diesel engine, function and
performance of the engine will not be delivered. In addition, never use such a fuel because a breakdown of the engine
or an accident may be invited.
Guarantee will not be given to a breakdown caused by the use of a improper fuel.
Some fuels are used with engine oil or additives mixed together with diesel engine fuel.
In this case, do not use these fuels because damage to the engine may result as the fuel has been contaminated.
It is natural that the emission control regulation of 3rd-stage will not be cleared in case where a fuel that does not
meet the specifications and the requirements is used.
Use the specified fuel for compliance of the exhaust gas control.
IMPORTANT : It you use diesel fuel which contains much sulfur content more than 2500 ppm, be sure to follow the
items below for the engine oil selection and maintenance of engine parts. Guarantee will not be given to breakdowns
caused by not to follow these items.
1 Selection of engine oil
Use API grade CF-4 or JASO grade DH-1.
2 Exchange the engine oil and engine oil filter element by the periodical interval reported on the Operator’s
Manual.
3 Inspect and exchange the EGR (*)parts and fuel injector parts of engine every 3000 hour of use.
* EGR: Exhaust Gas Recircultion
Maintenance of fuel filters
Be sure to use the genuine fuel filters.
The fuel injection system is precisely constructed and the genuine filter employs finer mesh than conventional fil-
ters to improve protection of machine equipment.
If a filter with coarse mesh is used, foreign object passing through the filter enters into the engine so that machine
equipment can wear out in a short period of time.
IMPORTANT : If a fuel filter other than the genuine filter is used, guaranty will not be applied to a fault caused by the
use of a wrong filter.
Two kinds of fuel filter, the pre-filter and the main filter, are mounted on the machine.
Be sure to use the genuine fuel filters and replace them at the periodic intervals reported on the operator’s Man-
ual.
IMPORTANT : Since the pre-filter also has a function of water separation, discharge water and sediment when the float
reaches lower part of the filter elements. CHECK EVERY DAY before to start the engine.
Time to replace filters may be advanced according to properties of the fuel being supplied.
• Therefore, take measures to prevent dust or water from being entered in the fuel tank when supplying fuel.
• When supplying fuel directly from a fuel drum can, leave the drum as it stands for a long period of time to supply
clean fuel standing above a precipitate.
• If it is hard to leave the drum for a long period of time, install a fuel strainer and a water separator before the fuel
tank of the machine to supply clean fuel.
Water drain cock is provided on the bottom side of the fuel tank.
• Drain water before starting the engine every morning.
• In addition, remove the cover under the tank once a year to clean up inside of the tank.

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1002-10
Fuel storage
Long storage can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can often be
traced to the presence of water in the fuel.
The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off
water and impurities regularly.
Anti-freeze/Anti-corrosion
Use anti-freeze in all seasons to protect the cooling system from corrosion and all risk of freezing.
CASE/AKCELA: PREMIUM ANTI-FREEZE (MS 1710)
For areas where the temperature goes down to -38°C (-36.4°F), mix 50/50 with water.
IMPORTANT : Do not mix products of a different origin or brand. The same product must be used when topping up the
system.
Environment
Before carrying out any maintenance operation on this machine and before disposing of used fluids or lubricants,
always think of the environment. Never throw oil or fluid on the ground and never place it in leaking receptacles.
Contact your local ecological recycling centre or your CASE Dealer to obtain information on the correct method of dis-
posing of these lubricants.
Plastic and resin parts

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

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1002-11
SPECIFICATIONS
Main data
Model name ...............................................CX75SR, CX80 (Mono Boom), CX75SR (Offset Boom) Hydraulic Excavator
Operating weight:
Mono Boom ...............................................................................................................................7950 kg (17526.73 lbs)
Mono Boom (CX80) ........................................................................................................................ 8470 kg (18673 lbs)
Offset Boom (CX75SR) .............................................................................................................. 8290 Kg (18276.3 lbs)
Engine output ......................................................................................................................................... 40 kW / 1800 rpm
Performance
Swing speed....................................................................................................................................................... 9.5 Tr/min.
Travel speed:
Low Speed.................................................................................................................................... 3.3 km/h (2.05 mph)
High Speed .................................................................................................................................... 5.1 km/h (3.16 mph)
Maximum drawbar pull .................................................................................................................... 59.5 kN (13376.13 lbf)
Maximum drawbar pull (CX80)....................................................................................................................... 59.2 kN ( lbf)
Grade ability ........................................................................................................................................................70% (35°)
Ground pressure:
Mono Boom .................................................................................................. 36 kPa (450 mm (17.72 in) grouser shoe)
Offset Boom.................................................................................................. 37 kPa (450 mm (17.72 in) grouser shoe)
Main body dimensions

Main body length............................................................................................................................... 3280 mm (129.13 in)
Main body length (CX80) .................................................................................................................. 3510 mm (138.18 in)
Main body width .................................................................................................................................. 2320 mm (91.34 in)
Upper swing body width ...................................................................................................................... 2225 mm (87.60 in)
Cab width ............................................................................................................................................ 1065 mm (41.93 in)
Main body height............................................................................................................................... 2700 mm (106.30 in)
Main body height (CX80)
1.71 m (Arm)................................................................................................................................. 2700 mm (106.29 in)
2.12 m (Arm)................................................................................................................................. 2950 mm (116.14 in)
Swing radius (rear end)....................................................................................................................... 1235 mm (48.62 in)
Swing radius (rear end), (CX80) ......................................................................................................... 1655 mm (65.15 in)
Swing body rear end distance............................................................................................................. 1235 mm (48.62 in)
Swing body rear section bottom height ................................................................................................. 745 mm (29.33 in)
Distance between tumblers...................................................................................................................... 2210 mm (87 in)
Overall track length ................................................................................................................................ 2845 mm (112 in)
Overall track width............................................................................................................................... 2320 mm (91.33 in)
Distance between tracks ..................................................................................................................... 1870 mm (73.62 in)
Width of track shoe .............................................................................. 450 mm (17.72 in), (Optional: 600 mm (23.62 in))
Minimum ground clearance (To bottom of lower frame) ........................................................................ 360 mm (14.17 in)
Engine
Name..................................................................................................................................................... ISUZU, AU-4LE2X
Type: ........................................................................ water-cooled, 4-cycle diesel, 4-cylinder in-line, direct injection type
............................................................................................. (electronic control), turbocharger with air cooled intercooler.
No. of cylinders - bore x stroke................................................................................. 4 - Ø85 mm x 96 mm (3.35 x 3.78 in)
Displacement .................................................................................................................................. 2179 cc (132.98 cu-in)
Compression ratio ........................................................................................................................................................18.3
Rated output ........................................................................................................................................ 40 kW / 2000 min-1
Maximum torque ................................................................................................... 200 N.m (147.51 lb-ft) / 2000rpm min-1
Fuel consumption ratio.............................................................................................................................. 240g/KW.h max
Engine dimensions (LxWxH)........................................................................ 757.1x650.7x753.7 mm (29.8 x25.6x29.7 in)
Oil pan............................................................................................................................... All direction 0.61 rad, inclinable
Oil pan capacity........................................................ Maximum: 10.4 L (2.7 gal) Minimum: 7 L (2 gal) (excluding oil filter)
Direction of rotation ...................................................................................................................... Right (as seen from fan)
Starter, reduction type.....................................................................................................................................24 V, 3.2 kW
Alternator, AC type ............................................................................................................................................. 24 V, 50 A
Battery..................................................................................................................................................2 x 12V, 64 Ah/5 Hr

Copyright ©
1002-12
Cooling system
Fan type............................................................................................ Ø 650 mm (25.59 in), suction type - 7 blades, intake
Radiator
Capacity .................................................................................................................................................... 5.1L (1.3 gal)
Fin type .................................................................................................................................................................. wavy
Fin pitch ................................................................................................................................................ 2 mm (0.079 in)
Oil cooler
Capacity ................................................................................................................................................... 4.4 L (1.2 gal)
Fin type .................................................................................................................................................................. wavy
Fin pitch ........................................................................................................................................... 1.75 mm (0.069 in)
Inter-cooler
Capacity ................................................................................................................................................... 4.1 L (1.1 gal)
Fin type .................................................................................................................................................................. wavy
Fin pitch ........................................................................................................................................... 1.75 mm (0.069 in)
Capacity of coolant and lubricants

Coolant ..................................................................................................................................................... 10.2 L (2.70 gal)
Fuel ......................................................................................................................................................... 100 L (26.42 gal)
Lubricant for engine....................................................................................................................................... 9 L (2.38 gal)
Lubricant for travel reduction gear (one side) ............................................................................................. 1.1 L (0.29 gal)
Hydraulic oil............................................................................................................................................ 97.3 L (25.70 gal)
Capacity of hydraulic oil tank..................................................................................................................... 50 L (13.21 gal)
Air conditioning
R134 gas load ..............................................................................................................................................1Kg (2.20 Ibs)
Hydraulic oil filter

Suction filter (inside tank) ....................................................................................................................................150 mesh
Return filter (inside tank) ............................................................................................................................................ 6 µm
Pilot line filter (inside housing).................................................................................................................................... 8 µm
Fuel filter
Main filter.................................................................................................................................................................... 4 µm
Pre-filter.................................................................................................................................................................... 10 µm
Operating devices
Operator's seat
Location: left side
Structure: Adjustable forward and back and up and down, reclining mechanism, with seat suspension.
Cab
Sealed steel type, all reinforced glass.
Levers and pedals
For travel use: Lever and pedal type (hydraulic pilot type) (x2)
For operating machine use: Lever type (hydraulic pilot type) (x2)
For blade use: Lever type (hydraulic pilot type) (x1)
For offset-boom operating use (CX75SR)............................................................. Pedal type (hydraulic pilot type) (x1)
Instruments and switches
Work mode select switch: 2 modes (N/Standard operating mode, E/Economy operating mode)
Travel mode select switch: Low-speed/high-speed switch type
One-touch idle: Knob switch type
Engine emergency stop: Switch type
Monitor device
Machine status display (full-dot liquid crystal)
Work mode selection status: N/E
Instruments (full-dot liquid crystal, except for hour meter)
Fuel gauge: Analog
Engine coolant temperature gauge: Analog
Hour meter: digital type
Machine Status and Warning Alarms *Items have a warning alarm
Over heat* Battery charge* Check engine*
Refill fuel* Engine oil pressure* Engine preheat

Copyright ©
1002-13
Lighting
Working light Cab top: 24V, 55W (x1)
Boom up: 24V, 70W (x1)
Interior light 24V, 6W (x1)
Horn Electric horn x2
Other
Wiper with intermittent function, window washer, air conditioner, rear view mirrors, clock
Hydraulic system
Hydraulic pump drive system, direct engine link (no transmission)
Main pump
Manufacturer ...................................................................................................................................... Bosch Rexroth
Pump type ........................................................................................double variable displacement piston pump x 1
Gear pump ........................................................................................................................................................... x 2
Gear pump (for blade use) ........................................................................................................................24.2 L/min
Displacement volume ..................................................................................................34.0 cm3 (2.07 cu in) x 2 /rev
Operating pressure Rated .................................................................................................... 29.4 MPa (4264.11 psi)
Input revolution speed Rated................................................................................................. 2000 min-1 (2000 rpm)
Maximum input revolution speed ........................................................................................... 2250 min-1 (2250 rpm)
Maximum discharge flow ........................................................68 x 2 L/min at 2000 min-1 (18 x 2 gpm at 2000 rpm)
Pilot pump
Pump type ................................................................................................................Fixed displacement gear pump
Displacement volume ......................................................................................................... 10.7 cm3 (0.65 cu in)/rev
Operating pressure........................................................................................................................ 4.2 MPa (610 psi)
Maximum flow.................................................................................................... 21.4 L/min (5.6 gpm) at 2000 min-1
Gear pump (for blade)
Pump type ................................................................................................................Fixed displacement gear pump
Displacement volume .......................................................................................................................... 12.1 cm3 / rev
Operating pressure.................................................................................................................... 22.6 MPa (3280 psi)
Maximum flow.................................................................................................... 24.2 L/min (6.4 gpm) at 2000 min-1
Control method
Full hosepower angle control in concurrence.
Horsepower control by blade pump operation pressure.
Set pressure of main relief valve
Boom/Arm/ Bucket/Travel .................................................................................................... 29.4 MPa (4264.11 psi)
Swing.................................................................................................................................... 22.6 MPa (3277.85 psi)
Blade .................................................................................................................................... 22.6 MPa (3277.85 psi)
Set pressure of overload relief valve
Boom/Arm/ Bucket............................................................................................................... 31.9 MPa (4626.70 psi)
Blade .................................................................................................................................... 25.5 MPa (3698.46 psi)
Control Valve
Model; Double spool x 1 Quintuple spool x 2
Operation method: hydraulic pilot method: travel, swing, blade and operating machine
Maximum flow
Mono Boom with blade ................................................................................... 75.8 L / min (20 gpm) (at 2230 min-1)
Offset Boom with blade (CX75SR) .............................................................. 75.2 L / min (19.8 gpm) (at 2320 min-1)
Overload set pressure
Other:
Mono Boom with blade .......................................................................... 31.9 ± 0.3 MPa (4630 ± 44 psi) at 20 L/min
Offset Boom with blade (CX75SR) ........................................................ 31.9 ± 0.3 MPa (4630 ± 44 psi) at 20 L/min
Boom (CX80):
Swing right ........................................................................................ 33.3 ± 0.3 MPa (4830 ± 44 psi) at 20 L/min
Swing left .......................................................................................... 31.9 ± 0.3 MPa (4630 ± 44 psi) at 20 L/min
Boom up/down (CX75SR)
Mono Boom with blade ..................................................................... 25.5 ± 0.3 MPa (3700 ± 44 psi) at 20 L/min
Offset Boom with blade..................................................................... 25.5 ± 0.3 MPa (3700 ± 44 psi) at 20 L/min
Offset right (CX75SR)
Offset Boom with blade..................................................................... 31.9 ± 0.3 MPa (4630 ± 44 psi) at 20 L/min
Copyright ©
1002-14
Offset left (CX75SR)
Offset Boom with blade ..................................................................... 33.3 ± 0.3 MPa (4830 ± 44 psi) at 20 L/min
Main relief set pressure ................................................................................. 29.4 ± 0.3 MPa (4260 ± 0.4 psi) at 44 L/min
Functions
Travel priority
Boom up / arm 2 pumps internal flow
Boom load holding circuit
Arm-in forced regenerative circuit
Swing priority
2 pumps flow is joined at reserve section

Copyright ©
1002-15
Hydraulic Cylinders
Mono boom spec. Offset boom spec.
with dozer blade with dozer blade
Boom cylinder
Cylinder bore ................................................................................. Ø110 mm (Ø4.33 in)
Rod diametre ................................................................................... Ø70 mm (Ø2.75 in)
Maximum retracted length ...............................................................1408 mm (55.43 in)
Stroke ................................................................................................911 mm (35.87 in)
Arm (dipper) cylinder
Cylinder bore ................................................................................... Ø95 mm (Ø3.74 in) ............Ø95 mm (Ø3.74 in)
Rod diametre ................................................................................... Ø60 mm (Ø2.36 in) ............Ø60 mm (Ø2.36 in)
Maximum retracted length ....................................................................1270 mm (50 in) ............... 240 mm (9.45 in)
Stroke ................................................................................................797 mm (31.38 in) ............. 685 mm (26.97 in)
Bucket cylinder
Cylinder bore ................................................................................... Ø85 mm (Ø3.35 in)
Maximum retracted length ...............................................................1035 mm (40.75 in)
Stroke ................................................................................................665 mm (26.18 in)
Blade cylinder
Cylinder bore ................................................................................. Ø100 mm (Ø3.94 in)
Maximum retracted length .................................................................530 mm (20.87 in)
Stroke ..................................................................................................180 mm (7.09 in)
Offset cylinder (CX75SR)
Maximum retracted length ..............................................................710 mm (Ø27.95 in)
Stroke .............................................................................................315 mm (Ø12.40 in)
Boom swing cylinder (CX80)
Maximum retracted length ..................................1085 ± 30 mm (Ø42.71 in ± 1.18 mm)
Stroke ................................................................640 ± 2.0 mm (Ø25.19 in ± 0.078 mm)

Copyright ©
1002-16
Rotating Joint
Operating pressure
High pressure passage (ABCDEF)............................................................................................ 29.4 MPa (4260 psi)
Drain port (T) .............................................................................................................................. 0.5 MPa (72.52 psi)
Pilot port (P)................................................................................................................................... 3.9 MPa (566 psi)
Flow
High pressure passage (ABCDEF)............................................................................................... 68 L/min (18 gpm)
Drain port (T) .................................................................................................................................. 15 L/min (4 gpm)
Pilot port (P).................................................................................................................................... 23 L/min (6 gpm)
Port A; forward right ................................................................................................................................................G1/2
Port B; forward left ..................................................................................................................................................G1/2
Port C; backward right.............................................................................................................................................G1/2
Port D; backward left ...............................................................................................................................................G1/2
Port E; blade up ..................................................................................................................................................... G3/8
Port F; blade down ..................................................................................................................................................G3/8
Port T; drain port .....................................................................................................................................................G3/8
Port P; pilot port ......................................................................................................................................................G1/4
Number of revolutions....................................................................................................................15 min-1 (15 rpm)
Torque:
No load ...................................................................................................................................... 160 Nm (1420 lbf.in)
When pressurizing 2 ports......................................................................................................... 190 Nm (1480 lbf.in)
Solenoid Valve (4 stack)
Manufacturer ................................................................................................................................ Yuken kogyo co., LTD
Maximum flow ............................................................................P -> B: 20 L/min (5.3 gpm) Other: 5 L/min (1.32 gpm)
Rated pressure ............................................................................................................................. 4.5 MPa (652.67 psi)
Port size
P, T, B port...........................................................................................................................................................G3/8
C1, C2, C3 port...................................................................................................................................................G1/4
Solenoid specifications
Operating voltage ................................................................................................................................DC 20 to 32 V
Power consumption .................................................................................................................................. 17 W max.

Copyright ©
1002-17
Hand control valve
Manufacturer................................................................................................................................................... Kawasaki
Operating pressure .......................................................................................................................... 3.92 MPa (569 psi)
Secondary pressure, primary short type .......................................................... 0.64 to 2.45 MPa (92.82 to 355.34 psi)
Operating angle
Ports 1, 3 .............................................................................................................................................................. 19°
Ports 2, 4 .............................................................................................................................................................. 25°
Operating torque
Ports 1 ................................................................................................................... 0.58 - 2.03 Nm (0.42 - 1.49 (lb-ft)
Ports 3 ................................................................................................................... 0.47 - 1.92 Nm (0.34 - 1.41 (lb-ft)
Ports 2, 4 ............................................................................................................... 0.71 - 2.30 Nm (0.52 - 1.69 (lb-ft)
Port 1, 3 Port 2, 4
4.0 4.0
Secondary
Secondary pressure (MPa)
pressure

3.0 3.0
2.0 2.0
1.0 1.0
Secondary
pressure
0 0
2 4 6 7 2 4 6 8 9.4
Push rod stroke (mm) Push rod stroke (mm)
0 5 10 15 19 0 5 10 15 20 25
Operating angle (deg.) Operating angle (deg.)
RST-03-01-001B
Foot control valve (for travel)

Manufacturer....................................................................................................................................... Nishina industrial
Operating angle ..................................................................................................................................................... 12.4°
Operating torque
Valve....................................................................................................................... 2.62 - 8.58 Nm (1.93 - 6.33 lb-ft)
Damper................................................................................................................... 6.87 Nm at 0.018 m/s (60.8 lb-ft)
3.9
3.0
2.0
1.0
Secondary
pressure
0
2 4 5.5
Push rod stroke (mm)
0 5 10 12.4
Operating angle (deg.)
RST-03-01-001D
Copyright ©
1002-18
Foot control valve (for Dozer Blade)
Manufacturer ....................................................................................................................................... Nishina industrial
Secondary pressure, primary short type........................................................... 0.64 to 2.45 MPa (92.82 to 355.34 psi)
Operating angle......................................................................................................................................................... 10°
Operating torque ............................................................................................................................See the figure below
Operating torque (Nm) (lbf-ft)

Secondary
pressure
Push rod stroke (mm) (in)

Copyright ©
1002-19
Foot control valve (for Offset Boom) (CX75SR)
Manufacturer....................................................................................................................................... Nishina industrial
Operating angle ..................................................................................................................................................... 12.4°
Operating torque............................................................................................................................ See the figure below
Operating torque (Nm) (lbf-ft)

Secondary
pressure
Push rod stroke (mm) (in)

Copyright ©
1002-20
Foot control valve (for Boom Swing) (CX80)
Manufacturer ....................................................................................................................................... Nishina industrial
Secondary pressure, primary short type................................................. 0.59 ± 0.1 to 3.14 ± 0.3MPa (85.6 to 455 psi)
Operating angle.............................................................................................................................................10.0 ± 0.3°
Operating torque .......................................................................................................2.80 to 5.70 Nm (2.06 to 4.20 psi)

Copyright ©
1002-21
Swing unit
Swing circle ........................................................................................................... Swing bearing type (with internal gear)
Swing hydraulic motor ..................................................................................................... Fixed displacement piston motor
Reduction gear....................................................................................................... Planetary gear 2-stage reduction gear
Swing parking brake................................................................................ Mechanical lock (operational lever linkage type)
Displacement .............................................................................................................................................44.1 cm3 /rev
Operating pressure ........................................................................................................................ 22.6 MPa (3280 psi)
Operating flow................................................................................................................................... 68 L/min (18 gpm)
Mechanical brake torque ................................................................................................... 174.1 Nm (1540.7 lb-ft) min.
Brake off pressure .................................................................................................................4.9 MPa (710.68 psi) max
Relief valve set pressure ....................................................... 22.6 ± 0.3 MPa at 57.5 L/min (3280 ± 44 psi at 15 gpm)
Reduction ratio.....................................................................................................................................................20.615
Travel lower body

Travel hydraulic motor (x2) ......... Variable displacement piston motor, automatic 2-speed switch-over with parking brake
Displacement ..................................................................................................................................... 48.0/30.5 cm3/rev
Operating pressure ........................................................................................................................ 29.4 MPa (4260 psi)
Operating flow................................................................................................................................ 68.0 L/min (18 gpm)
Brake torque ..............................................................................5.54 KNm (40.86 Ib-ft) min. (including reduction gear)
Relief valve set pressure...................................................................... 38.25 ± 1.45 MPa at 15 L/min (5550 ± 210 psi)
Automatic 2-speed switch-over pressure .......................................................... 23.8 MPa at 3.9 MPa (3450 at 570 psi)
Reduction ratio.......................................................................................................................................................45.97
Travel brake.................................................................................................................................................. Hydraulic lock
Parking brake ................................................................................................... Mechanical lock (travel lever linkage type)
Track shoe
Model ........................................................................................................................Assembly type triple grouser shoe
Number of shoes (per side) ........................................................................................................................................39
Shoe width
Standard ....................................................................................................................................... 450 mm (17.72 in)
Optional ....................................................................................................................................... 600 mm (23.62 in)
Grouser height ...................................................................................................................................... 20 mm (0.79 in)
Link pitch............................................................................................................................................. 154 mm (6.06 in)
Roller
Number of upper rollers (per side)................................................................................................................................1
Number of lower rollers (per side) ................................................................................................................................5
Track belt tension adjuster ...............................................................................Grease cylinder type (with cushion spring)
Mounting length of spring ................................................................................................................. 402 mm (15.83 in)

Copyright ©
1002-22
Work Unit
Model..................................................................................................................................................Backhoe attachment
Components / dimensions / working dimensions
CX75SR
Model MONO BOOM OFFSET BOOM
Boom length 3870 mm (152.36 in)

Arm type Standard Long Standard
1.710 mm 2.120 mm 1.750 mm
(67.32 in) (83.46 in) (68.90 in)
1710 mm 2120 mm 1740 mm
Arm (dipper) length
(67.32 in) (83.46 in) (68.50 in)
Heaped 0.28 m3 Heaped 0.22 m3 Heaped 0.28 m3

Bucket capacity
(Leveled 0.20 m3) (Leveled 0.16 m3) (Leveled 0.20 m3)
Bucket width 730 mm (28.74 in) 600 mm (23.62 in) 730 mm (28.74 in)
Bucket width with side cutter 804 mm (31.65 in) 673 mm (26.50 in) 804 mm (31.65 in)
Bucket weight with side cutter 204 kg (449.74 lb) 178 kg (392.42 lb) 204 kg (449.74 lb)
Bucket radius 1450 mm (57.08 in) 1050 mm (41.34 in) 1450 mm (57.08 in)
Bucket wrist action 177°
6520 mm 6900 mm 6080 mm
Maximum digging radius
(256.69 in) (271.65 in) (239.40 in)
6390 mm 6770 mm 6360 mm
Maximum digging radius at ground line
(251.57 in) (266.53 in) (250.39 in)
4140 mm 4540 mm 4190 mm
Maximum digging depth
(162.99 in) (178.74 in) (164.96 in)
3640 mm 4100 mm 4580 mm
Maximum vertical straight wall digging radius
(143.31 in) (161.42 in) (180.31 in)
7330 mm 7620 mm 7195 mm
Maximum digging height
(288.58 in) (300 in) (283.27 in)
5250 mm 5540 mm 5150 mm
Maximum dump height
(206.69 in) (218.10 in) (202.75 in)
1785 mm 2085 mm 2230 mm
Minimum swing radius at front
(70.27 in) (82.08 in) (87.79 in)
5620 mm 5650 mm 5700 mm
Height for minimum swing radius at front
(221.26 in) (222.44 in) (224.41 in)

Copyright ©
1002-23
CX80
Model MONO BOOM
Boom length 3500 mm (137.79 in)

Arm type Standard Long
1.710 mm 2.120 mm
(67.32 in) (83.46 in)
1710 mm 2120 mm
Arm (dipper) length
(67.32 in) (83.46 in)
Heaped 0.28 m3 Heaped 0.22 m3

Bucket capacity
(Leveled 0.20 m3) (Leveled 0.16 m3)
Bucket width 730 mm (28.74 in) 600 mm (23.62 in)
Bucket width with side cutter 804 mm (31.65 in) 673 mm (26.50 in)
Bucket weight with side cutter 204 kg (449.74 lb) 178 kg (392.42 lb)
Bucket radius 1050 mm (41.34 in) 1050 mm (41.34 in)
Bucket wrist angle 177°
7030 mm 7400 mm
Maximum digging radius
( 276.77 in) (291.33 in)
6390 mm 7270 mm
Maximum digging radius at ground line
(275.19 in) (286.21 in)
4180 mm 4590 mm
Maximum digging depth
(164.56 in) (180.70 in)
3080 mm 3550 mm
Maximum vertical straight wall digging radius
(121.25 in) (139.76 in)
6390 mm 6600 mm
Maximum digging height
(251.57 in) (259.84 in)
4390 mm 4600 mm
Maximum dump height
(172.83 in) (181.10 in)
2750 mm 2910 mm
Minimum swing radius at front
(108.26 in) (114.56 in)
5060 mm 5080 mm
Height for minimum swing radius at front
(199.21 in) (199.99 in)

Copyright ©
1002-24
COMPONENT WEIGHT
Major component weight (CX75SR)
(MONO BOOM) (OFFSET BOOM)
AQ29001-001_EU
Weight (kg) information is approximate
Symbol Component Name MONO BOOM SPEC. OFFSET BOOM SPEC.

A Operating weight 7952 (17531 lbs) 8292 (18280 lbs)
Upper mechanism (including coun-
B 3892 (8580 lbs) 3892 (8580 lbs)
terweight and turntable bearing
C Counterweight 1357 (2991 lbs) 1357 (2991 lbs)
Lower mechanism (with standard
D 2801 (6175l bs) 2801 (6175 lbs)
grouser shoe)
E Main Unit Weight 6693 (14755 lbs) 6691 (14751 lbs)
F Attachments 1176 (2592 lbs) 1518 (3346 lbs)
G Boom (including cylinders) 703 (1549 lbs) 1043 (2299 lbs)
Arm (dipper) (including cylinders
H 263 (579 lbs) 266 (586 lbs)
and linkage)
I Blade 332 (732 lbs) 332 (732 lbs)

Copyright ©
1002-25
Major component weight (CX80)
D E
F H I
AS09001-001
Weight (kg) information is approximate
Symbol Component Name

A Operating weight 8470 (18673 lbs)
B Upper mechanism (including counterweight and turntable bearing 4527 (9980 lbs)
C Counterweight 1237 (2727 lbs)
D Lower mechanism (with standard grouser shoe) 2801 (7175 lbs)
E Main Unit Weight 7328 (16155 lbs)
F Attachments 1063 (2343 lbs)
G Boom (including cylinders) 595 (1311 lbs)
H Arm (dipper) (including cylinders and linkage) 262 (577 lbs)
I Blade 332 (732 lbs)

Copyright ©
1002-26
Other component weight
Engine ....................................................................................................................................................194 kg (427.6 lbs)
Air cleaner ...................................................................................................................................................1.7 kg (3.7 lbs)
Hydraulic pump ........................................................................................................................................51.4 kg (113 lbs)
Attachment control valve
Mono Boom with blade............................................................................................................................82 kg (181 lbs)
Mono Boom with blade (CX80) ..........................................................................................................85 kg (187.39 lbs)
Offset boom with blade (CX75SR) ..........................................................................................................88 kg (194 lbs)
Swing unit..............................................................................................................................................80.0 kg (176.3 lbs)
Travel unit ....................................................................................................................................................83 kg (183 lbs)
Rotary joint ....................................................................................................................................................40 kg (88 lbs)
Solenoid valve (4 stack) (CX80) ..............................................................................................................4.7 kg (10.36 lbs)
Solenoid valve (4 stack) (CX75SR) .................................................................................................................5 kg (11 lbs)
Hand control valve.....................................................................................................................................1.6 kg (3.52 lbs)
Blade control valve ......................................................................................................................................0.7 kg (1.5 lbs)
Offset control valve (CX75SR) ....................................................................................................................0.7 kg (1.5 lbs)
Foot control valve ......................................................................................................................................4.7 kg (10.4 lbs)
Foot control valve (for boom swing) (CX80) ................................................................................................0.7 kg (1.5 lbs)
Boom cylinder ...........................................................................................................................................103 kg (227 lbs)
Boom swing cylinder (CX80) ..................................................................................................................56 kg (123.45 lbs)
Arm (dipper) cylinder (Mono Boom With Dozer Blade) ............................................................................78 kg (3172 lbs)
Arm (dipper) cylinder (Offset Boom With Dozer Blade) (CX75SR) .............................................................81 kg (179 lbs)
Bucket cylinder ............................................................................................................................................51 kg (112 lbs)
Blade cylinder............................................................................................................................................... 34 Kg (75 lbs)
Offset cylinder (CX75SR) ............................................................................................................................. 41 Kg (90 lbs)
Turntable bearing......................................................................................................................................91.6 kg (202 lbs)
Counterweight ................................................................................................................................... 1356.4 kg (2990 Ibs)
Counterweight (CX80).......................................................................................................................... 1235 kg (2723 Ibs)
Muffler .....................................................................................................................................................13.0 kg (28.7 lbs)
Radiator total weight....................................................................................................................................50 kg (110 lbs)
Oil cooler ................................................................................................................................................12 kg (26.4 lbs)
Radiator ...................................................................................................................................................5.4 kg (12 lbs)
Air cooler ..................................................................................................................................................4.5 kg (10 lbs)
Idler wheel ...............................................................................................................................................45.1 kg (99.4 lbs)
Upper roller..................................................................................................................................................4.3 kg (9.5 lbs)
Lower roller..............................................................................................................................................13.5 kg (47.1 lbs)
Recoil spring assembly ...........................................................................................................................37.3 kg (82.3 lbs)
Recoil spring .......................................................................................................................................14.1 kg (31.1 lbs)
Grease cylinder assembly.....................................................................................................................8.8 kg (19.4 lbs)
Threaded rod ........................................................................................................................................6.3 kg (13.9 lbs)
Yoke .........................................................................................................................................................7.7 kg (17 lbs)
Track chains (per side)
450 mm (17.72 in) ...........................................................................................................................425.4 kg (937.6 lbs)
600 mm (23.62 in) .........................................................................................................................479.8 kg (1057.5 lbs)
450 mm (17.72 in) Rubber Track.................................................................................................... 424.4 kg (935.4 Ibs)
450 mm (17.72 in) Rubber Track (with special core metal) ............................................................ 421.0 Kg (927.9 lbs)

Copyright ©
1002-27
DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY
Sprocket
Dimensions
a P
Ød
Øb Øc
CS01B512
Mark Dimension (mm)

Standard 35
a
Limit 30
Standard 480.81
Øb
Limit 474.91
Standard 533.61
Øc
Limit 527.61
Standard 522.47
Ød
Limit ---
Standard 154
P
Limit ---
Gauge
185
153 - 155
48.89 25
12
.7
40.
3.9 3.9 °
7°
90°
.7
28
15.1
R
82.8
70
R3
21.6
.8
53
to 6
R
0.8
R2
17.1° 17.1°
AQ19002-031A

Copyright ©
1002-28
Idler wheel
Dimensions
Mark Dimension (mm)
c Standard 400
Øa
Limit 369
Standard 28
b b
Limit 25
Standard 44
c
Limit 40
Standard 42
Ø d (shaft)
Limit 41
Standard 42
Ø d (bushing)
Limit 42.8
Øa Standard 42
e
Limit 41.6
Standard 20
f
Limit 19.5
e f
Ød
AQ19002-001A
Gauge
110
94 - 98
39 - 44
38.4
10 10°
3°
40°
28
6-
R 5
2-
R3
AQ19002-032A

Copyright ©
1002-29
Upper roller
Dimensions
Mark Dimension (mm)
Standard 80
Øa
Limit 70
Standard 30
Ø b (shaft)
Limit ---
Øa
Øb
AQ19002-002A
Gauge
Measure with a slide caliper.

Copyright ©
1002-30
Lower roller
Dimensions
f g
Øa Øe
AQ19002-003A
Mark Dimension (mm) Mark Dimension (mm)

Standard 118 Standard 40
Øa Ø e (ring)
Limit 112 Limit 40.8
b f
Limit 11 Limit 37.6
Standard 44 Standard 30.2
d g
Limit 40 Limit 29.7
Standard 40
Ø e (shaft)
Limit 39
Gauge
170
150.5 - 151.5
105.7 - 106.3
44
15°
2-
R3
2-
50
R4
6.5
4-
13
R5
1 .5
R6
3°
°
AQ19002-033A

Copyright ©
1002-31
Track
Øf
Øf'
d c
Øe' Øe
Øg' Øg
h h
AQ19002-004A

a Ø e (ring)
Limit 20 Limit 40.3
b Ø f (ring)
Limit 71.5 Limit 23.8
c Ø g (shaft)
Limit 50 Limit 23.2
d h
Limit 100 Limit 150
Standard 41.26
Ø e' (bushing)
Limit 40.26
Standard 24.5
Ø f' (bushing)
Limit 25.2
Standard 24
Ø g' (shaft)
Limit 23

Copyright ©
1002-32
DIMENSIONS AND WEAR LIMITS OF ATTACHMENT LINKAGES (MONO
BOOM)
4
5 1
6
7
8
10 11 9
AQ19002-005A
1. Boom foot/Frame
a
b
c
Ød e
AQ19002-006A
Mark Dimension (mm)

Standard 400
a (frame)
Limit 410
Standard 399
b (boom)
Limit 397
Standard 1.0 to 3.5
c (a - b)
Limit Shims
Standard 60
Ø d (shaft)
Limit 59
Standard 60
Ø d (bushing)
Limit 61.5

Copyright ©
1002-33
2. Boom cylinder foot/Frame
b c
Ød Øe
AQ19002-007A
Mark Dimension (mm)

Standard 91
a (frame)
Limit 92
Standard 90
b (cylinder)
Limit 88
Standard 1.0 to 3.5
c (play)
Limit Shims
Standard 65
Ø d (shaft)
Limit 64
Standard 65
Ø e (bushing)
Limit 66.5
3. Boom cylinder head/Boom
Øe Ød
b
c
a
AQ19002-008A
Mark Dimension (mm)

Standard 91
a (boom)
Limit 87
Standard 90
b (cylinder)
Limit 88
Standard 0.5 to 3.5
c (play)
Limit Shims
Standard 65
Ø d (shaft)
Limit 64
Standard 65
Ø d (bushing)
Limit 66.5

Copyright ©
1002-34
4. Dipper cylinder foot/Boom
Mark Dimension (mm)
b Standard 81
c a (boom)
a Limit 87
Standard 80
b (cylinder)
Limit 78
Standard 0.5 to 3.0
Øe Ød c (a - b)
Limit Shims
Standard 55
Ø d (shaft)
Limit 54
Standard 55
Ø d (bushing)
Limit 56.5
AQ19002-009A
5. Boom/Dipper
Mark Dimension (mm)
c Standard 184.5
a (boom)
Limit 187.5
Standard 184
b (dipper)
Øe Ød Limit 182
Standard 0.5 to 1.1
c (play)
Limit Shims
b Standard 60
Ø d (shaft)
f a Limit 59
Standard 60
Ø e (dipper)
Limit 61.5
AQ19002-010A
Standard 45
Ø f (boom)
Limit Refer a and b
6. Dipper cylinder head/Dipper

a Mark Dimension (mm)
Standard 81
b c a (dipper)
Limit 87
Standard 80
b (cylinder)
Limit 78
Standard 0.5 to 3.0
c (a - b)
Øe Ød Limit Shims
Standard 60
Ø d (shaft)
Limit 59
Standard 60
Ø e (bushing)
Limit 61.5
AQ19002-011A

Copyright ©
1002-35
7. Bucket cylinder foot/Dipper
Mark Dimension (mm)
Standard 76
a (dipper)
Limit 82
Standard 75
b (cylinder)
Øe Ød Limit 73
Standard 0.5 to 3.0
c (a - b)
Limit Shims
b c Standard 50
Ø d (shaft)
Limit 49
a
Standard 50
Ø e (bushing)
AQ19002-012A
Limit 51.5
8. Connecting rod/Dipper
c Mark Dimension (mm)
a (connecting Standard 25
a rod) Limit 22
Standard 190
b (dipper)
Limit 188
b Standard 1.0 to 1.5
c (play)
Limit Shims
Øe
Standard 50
Ø d (shaft)
a Limit 49
Standard 50
Ø e (bushing)
Ød Limit 51.5
AQ19002-013A
9. Compensator/Bucket
Mark Dimension (mm)
Ød c Standard 191
a (bucket)
Limit 197
b Standard 190
Øe (compensator) Limit 188
Standard 0.5 to 3.5
a c (play)
b Limit Shims
Standard 50
Ø d (shaft)
Limit 49
Standard 50
Ø e (bushing)
Limit 51.5
AQ19002-014A

Copyright ©
1002-36
10. Connecting rod/Compensator/Bucket cylinder head
Mark Dimension (mm)
c a (connecting Standard 25
a rod) Limit 22
f b Standard 190
(compensator) Limit 188
b Standard 1.0 to 1.5
Øi Øe Ød c (play)
Limit Shims
Øh d (connecting Standard 71
rod) Limit 73
a Standard 70
e (cylinder)
Øg Limit 68
Øg
Standard 1.0 to 2.0
f (d - e)
Limit Shims
AQ19002-015A Standard 55
Ø g (shaft)
Limit 54
Øh Standard 55
(compensator) Limit 56.5
Standard 55
Ø i (cylinder)
Limit 56.5
11. Dipper/Bucket
c Mark Dimension (mm)
Standard 210
a (bucket)
Øg Limit 216
d Standard 190
Øf b (dipper)
Limit 188
Standard 1.0 to 3.5
c (a - b)
a b Limit Shims
Standard 19
d (bucket)
Limit 11
Standard 50
Ø e (shaft)
Limit 49
Standard 50
Øe Ø f (dipper)
Limit 51.5
Standard 50
AQ19002-016A Ø g (bucket)
Limit 51.5

Copyright ©
1002-37
DIMENSIONS AND WEAR LIMITS OF ATTACHMENT LINKAGES (CX75SR
OFFSET BOOM)
4 3 1
7 6 2
8
9 5
AQ19002-017A
1. Base Boom/Offset boom

c
b a
Ød
Øe
AQ19002-018A
Mark Dimension (mm)

Standard 361
a (boom)
Limit 367
b (offset Standard 360
boom) Limit 358
Standard 0.5 to 1.5
c (a - b)
Limit Shims
Standard 100
Ø d (shaft)
Limit 99
Standard 100
Ø d (bushing)
Limit 101.5

Copyright ©
1002-38
2.Base Boom/Offset cylinder/Rod
h
a b
c
f
d e
g
i
AQ19002-019A

Standard 71 Standard 0.5 to 3.0
a (frame) f (play)
Limit 77 Limit Shims
b (offset cylin- Standard 70 Standard 55
Limit 68
g (shaft) Limit 54
der)
Standard 0.5 to 3.0 h (bushing off- Standard 55
c (play) Limit Shims set cylinder) Limit 56.5
d (boom) i (bushing rod)
Limit 164 Limit 56.5
Standard 157
e (rod)
Limit 152
3. Offset Boom/ Offset cylinder
b a
Øe
Ød
AQ19002-020A
Mark Dimension (mm)

a (offset Standard 71
boom) Limit 77
b (offset cylin- Standard 70
der) Limit 68
Standard 0.5 to 3.0
c (play)
Limit Shims
Standard 55
d (shaft)
Limit 54
e (bushing off- Standard 55
set cylinder Limit 56.5

Copyright ©
1002-39
4. Offset Dipper/Rod
Mark Dimension (mm)
c a (offset Standard 158
dipper) Limit 164
Standard 157
b (rod)
Limit 155
b a
Standard 0.5 to 3.0
c (a - b)
Limit Shims
Standard 55
Ø d (shaft)
c Limit 54
Ød
Ø e (bushing Standard 55
Øe
rod) Limit 56.5
AQ19002-021A
5. Offset arm/Offset Boom

Mark Dimension (mm)
dipper) Limit 287
b (offset Standard 280
b a boom) Limit 278
Standard 0.5 to 1.5
c (play)
Limit Shims
c Standard 100
Ø d (shaft)
Limit 99
d
e Ø e (bushing Standard 100
AQ19002-022A offset boom) Limit 101.5
6. Offset Dipper/ Dipper cylinder

Mark Dimension (mm)
a
b
dipper) Limit 257
c
b dipper Standard 250
cylinder) Limit 248
Standard 0.5 to 3.0
d c (a - b)
e Limit Shims
Standard 60
Ø d (shaft)
Limit 59
dipper Limit 61.5
AQ19002-023A
cylinder)

Copyright ©
1002-40
7. Offset dipper/Dipper
Mark Dimension (mm)
a
b a (offset Standard 184.5
dipper) Limit 190.5
Standard 184
b (dipper)
Limit 182
Standard 0.5 to 1.1
Ød Øe c (a - b)
Limit Shims
Standard 60
Ø d (shaft)
Limit 59
c
AQ19002-024A dipper) Limit 61.5
8. Dipper/Dipper cylinder
Mark Dimension (mm)
a
Standard 81
b a (dipper)
Limit 87
c b (dipper Standard 80
cylinder) Limit 78
Standard 0.5 to 3.0
c (play)
Ød Øe Limit Shims
Standard 50
Ø d (shaft)
Limit 49
arm cylinder) Limit 51.5
AQ19002-025A
9. Dipper/Bucket cylinder
Mark Dimension (mm)
a
Standard 76
b a (dipper)
Limit 82
b (bucket Standard 75
cylinder) Limit 73
Standard 0.5 to 3.0
c (play)
Limit Shims
Ød Øe Standard 50
Ø d (shaft)
Limit 49
Standard 50
Ø e (bushing)
c Limit 51.5
AQ19002-026A

Copyright ©
1002-41
DIMENSIONS AND WEAR LIMITS OF BLADE AND BLADE CYLINDER
10 11 12
AQ19002-027A
10. Blade/Blade cylinder

Mark Dimension (mm)
Standard 71
a (blade)
Limit 77
b ( cylinder Standard 70
blade) Limit 68
Standard 1.0 to 2.5
c (play)
Ød Øe Limit Shims
Standard 55
d (shaft)
Limit 54
Standard 55
b c e (bushing)
Limit 56.5
a
AQ19002-028A
11. Lower frame/Blade cylinder

Mark Dimension (mm)
Standard 76
a (frame)
Limit 82
b (cylinder Standard 75
blade) Limit 73
Standard 3.0 to 4.5
c (play)
Ød Øe Limit Shims
Standard 55
Ø d (shaft)
Limit 54
Standard 55
b c Ø e (bushing)
Limit 56.5
a
AQ19002-029A

Copyright ©
1002-42
12. Lower frame/Blade
Mark Dimension (mm)
Standard 69
a (frame)
Limit 75
Standard 65
b (blade)
Limit 63
Standard 3.0 to 5.0
c (play)
Limit Shims
Ød Øe
Standard 45
d (shaft)
Limit 44
Standard 45
e (bushing)
b c Limit 46.5
a
AQ19002-030A

Copyright ©
1002-43
LIST OF SHIMS
For Adjusting Attachment Gaps
(Units: mm)
Part No. I.D. O.D. Shim Thickness Material
KMV0650 30.2 50 0.4 SPCC
KMV0651 30.2 50 0.8 SPCC
KMV0652 30.2 50 1.6 SPHC
KMV0653 30.2 50 3.2 SPHC
KMV0654 30.2 50 4.5 SS00
KMV0655 30.2 50 6.0 SS00
KMV0912 32 45 0.4 SPCC
KMV0913 32 45 0.8 SPCC
KMV0914 32 45 1.2 SPCC
KHV0327 36 65 1.2 SPHC
KHV0316 36 70 1.2 SPHC
KHV0315 41 75 1.2 SPHC
KHV0324 41 80 1.2 SPHC
KHV0317 41 90 1.2 SPHC
KAV0058 43 90 1.6 SPHC
KHV0347 46 80 1.2 SPHC
KAV0180 46 80 1.6 SPHC
KAV0682 46 90 1.2 SPHC
KHV0299 46 100 1.2 SPHC
KHV0328 51 85 1.2 SPHC
KAV0160 51 85 1.6 SPHC
BHV1030 51 90 1.2 SPHC
BHV1031 51 90 2.6 SPHC
KHV0330 51 95 1.2 SPHC
KAV0813 51 100 1.2 SPHC
KAV1951 51 100 2.6 SPHC
KAV0061 51 101.6 1.6 SPHC
KHV0348 51 105 1.2 SPHC
KAV0805 51 120 1.2 SPHC
KAV0812 56 90 1.2 SPHC
KAV0558 56 100 1.2 SPHC
BHV1033 56 100 2.6 SPHC
KHV0298 56 105 1.2 SPHC
KAV0395 56 110 0.8 SPHC
KAV0060 56 110 1.6 SPHC
KAV0396 56 115 1.2 SPHC
KAV0427 56 120 1.2 SPHC
KMV0771 60.5 76 1.2 SPHC
KAV0161 61 90 1.6 SPHC

Copyright ©
1002-44
(Units: mm)
KAV0811 61 110 1.2 SPHC
KNV0230 61 110 1.2 SPHC
KAV0059 61 110 1.6 SPHC
KHV0286 61 120 1.2 SPHC
KAV0801 61 130 1.2 SPHC
KMV0942 61 140 3.2 SPHC
KMV1246 61 160 1.2 SPHC
KMV0693 65.5 90 1.2 SPHC
KNV0538 66 100 1.2 SPHC
KLV0034 66 110 1.2 SPHC
KNV0535 66 120 1.2 SPHC
KMV0122 66 130 1.2 SPHC
KHV0273 66 150 1.2 SPHC
KHV0458 66 170 1.2 SPHC
KNV0696 71 110 1.2 SPHC
KNV0539 71 130 1.2 SPHC
KRV0823 71 130 1.2 SPHC
KMV0144 71 135 1.2 SPHC
KMV0145 71 135 2.6 SPHC
KMV0774 71 150 1.2 SPHC
KMV0775 71 150 2.6 SPHC
KMV0941 71 150 3.2 SPHC
KNV0189 71 150 1.2 SPHC
KRV1176 76 130 1.2 SPHC
KRV1177 76 140 1.2 SPHC
KRV1584 76 140 1.2 SPHC
KHV0169 76 140 1.2 SPHC
KNV0534 76 160 1.2 SPHC
KRV2264 76 180 1.2 SPHC
KAV0776 77 120 1.2 SPHC
KSV0141 78 170 1.2 SPHC
KSV0142 78 170 2.6 SPHC
KSV0143 78 170 3.2 SS00
KAV0095 81 105 1.6 SPHC
KLV0170 81 110 1.2 SPHC
KRV1197 81 140 1.2 SPHC
KRV0822 81 150 1.2 SPHC
KRP1350 81 150 2.6 SPHC
KLV0035 81 170 1.2 SPHC

Copyright ©
1002-45
(Units: mm)
KSP0408 81 200 1.2 SPHC
KSP0409 81 200 2.6 SPHC
KBV0122 82 120 3.2 SS00
KBV0123 82 120 4.5 SS00
KBV0124 82 120 6.0 SS400
KBV0373 82 180 1.0 SPCC
KRV1178 86 130 1.2 SPHC
KRV1585 86 150 1.2 SPHC
KHV0170 86 150 1.2 SPHC
KBV0389 87 210 1.0 SPCC
KBV0390 87 210 1.6 SPCC
BHV1030 90 51 1.2 SPHC
KBV0837 91 135 1.2 SPHC
KSV0477 91 145 1.2 SPHC
KSP0411 91 145 2.6 SPHC
KMV0121 91 159 1.2 SPHC
KBV0769 91 160 1.2 SPHC
KSP0269 91 160 2.6 SPHC
KBV0764 91 165 1.2 SPHC
KRV0559 91 180 1.2 SPHC
KRV1180 91 190 1.2 SPHC
KSP0412 91 200 1.2 SPHC
KSP0413 91 200 2.6 SPHC
KBV0381 92 180 1.0 SPCC
KBV0382 92 180 1.6 SPCC
KBV0383 92 180 2.0 SPCC
KBV0384 92 180 3.2 SS00
KBV0377 92 220 1.0 SPCC
KBV1749 96 140 1.2 SPHC
KNV0468 96 150 1.2 SPHC
KSP0828 96 150 1.2 SPHC
KBV1629 96 170 1.2 SPHC
KBV0361 97 250 1.0 SPCC
KBV0362 97 250 1.6 SPCC
BHV1032 100 56 1.2 SPHC
KSV0478 101 160 1.2 SPHC
KSP0415 101 160 2.6 SPHC
KSP0416 101 180 1.2 SPHC
KSP0417 101 180 2.6 SPHC
KBV0474 101 219 1.2 SPHC

Copyright ©
1002-46
(Units: mm)
KBV0369 102 210 1.0 SPCC
KSV0138 103 190 1.2 SPHC
KSV0139 103 190 2.6 SPHC
KSV0140 103 190 3.2 SS00
KSV0135 103 213 1.2 SPHC
KSV0136 103 213 2.6 SPHC
KSV0137 103 213 3.2 SS00
KSP0827 106 170 1.2 SPHC
KHV0190 111 150 1.2 SPHC
KSP0418 111 180 1.2 SPHC
KSP0419 111 180 2.6 SPHC
KTV0533 111 190 1.2 SPHC
KSV0476 111 230 1.2 SPHC
KBV0214 112 150 6.0 SS400
KBV0215 112 150 9.0 SS400
KBV0357 112 270 1.0 SPCC
KHV0193 121 155 1.2 SPHC
KMV1517 121 220 0.4 SPHC
KMV1518 121 220 0.6 SPHC
KMV1519 121 220 0.8 SPHC
KHV0296 121 230 1.2 SPHC
KTV0534 121 250 1.2 SPHC
KWV0101 131 170 1.2 SPHC
KSV0839 131 200 1.2 SPHC
KHV0287 131 240 1.2 SPHC
KTV0850 141 225 1.2 SPHC
KHV0297 141 240 1.2 SPHC
KHV0288 151 300 1.2 SPHC
KUV0080 171 280 1.2 SPHC

Copyright ©
1002-47
For Adjusting Attachment Gaps (for Boom Foot)
R
O.D I.D H
000-6-10-02-02a1
Shim
Part No. I.D. O.D. R H Thick- Material
ness
KNV1132 76 160 100 30 1.2 SPHC
KRV2390 91 190 115 30 1.2 SPHC
KBV1441 101 220 130 30 1.2 SPHC
KBV1748 101 230 135 30 1.2 SPHC
KSV1805 111 240 140 30 1.2 SPHC

Copyright ©
1002-48
R
O.D I.D H
000-6-10-02-02b1
Shim
Part No. I.D. O.D. R H Thick- Material
ness
KSV1930 111 240 140 30 1.0 Urethone
KSV11380 111 240 140 30 2.0 Urethone
KSV1931 116 240 140 30 1.0 Urethone
KSV11390 116 240 140 30 2.0 Urethone
KTV10730 121 245 150 50 2.0 Urethone
KTV10740 121 245 150 50 1.0 Urethone
KTV10750 121 260 150 50 2.0 Urethone
KTV10760 121 260 150 50 1.0 Urethone
KWV0097 141 280 160 50 1.0 Urethone
KWV10510 141 280 160 50 2.0 Urethone
KWV0096 141 300 180 50 1.0 Urethone
KWV10500 141 300 180 50 2.0 Urethone
KUV10150 141 300 170 30 1.0 Urethone
KUV10160 141 300 170 30 2.0 Urethone
KUV10130 151 300 170 30 1.0 Urethone
KUV10140 151 300 170 30 2.0 Urethone

Copyright ©
1002-49
SPECIAL TORQUE SETTINGS CX75SR
No. Component Screw Wrench (mm) Torque setting
1* Travel motor and reduction gear assembly M16 24 267-312 Nm (197-230 lb-ft)
2* Drive sprocket M14 22 173-202 Nm (127-149 lb-ft)
3* Idler wheel M10 17 63-73 Nm (46-54 lb-ft)
4* Upper roller M16 24 267-312 Nm (197-230 lb-ft)
5* Lower roller M20 30 521-608 Nm (384-448 lb-ft)
6 Shoe bolt M14 22 267-312 Nm (197-230 lb-ft)
7 Counterweight M24 36 850-992 Nm (627-658 lb-ft)
8 Turntable bearing (lower frame) M16 24 280-322 Nm (206-237 lb-ft)
9 Turntable (swing frame) M16 24 280-322 Nm (206-237 lb-ft)
10 * Swing unit M16 24 273-318 Nm (201- 234 lb-ft)
11 * Engine (engine mount) M16 24 265-314 Nm (196-231 lb-ft)
12 * Engine bracket M10 17 64-74 Nm (47-54 lb-ft)
13 Radiator M12 19 64-74 Nm (47-54 lb-ft)
14 * M10 17 63-73 Nm (47-54 lb-ft)
Hydraulic pump 10
15 * M12 Hexagon 109-127 Nm (80-94 lb-ft)
socket head
16 * Hydraulic reservoir M12 19 69-79 Nm (51-58 lb-ft)
17 Fuel reservoir M10 17 36-44 Nm (26-32 lb-ft)
M16 24 267-312 Nm (197-230 lb-ft)
18 * Control valve
M12 19 88-107 Nm (65-79 lb-ft)
19 * Hydraulic swivel M12 19 88-107 Nm (65-79 lb-ft)
20 Cab M16 24 71-86 Nm (52-63 lb-ft)
21 Battery M10 17 64-74 Nm (47-54 lb-ft)
NOTE: Use Loctite 262 or an equivalent on retaining screws of those components marked with an asterisk (*).

Copyright ©
1002-50
17 21
16
13
18
20
11 12
14 15
10
19 10
1 7
2
5
4
8,9 3
1 , 2
2
FRONT 1
3 , 4 , 5 , 6 7
4
6
5 7
AQ09002-001

Copyright ©
1002-51
8 , 9 , 10 11 , 12 ,13
10
9
8
11 12 11 12 13
14 , 15 16 17
17
15
14
17
16
17
18 19
19
18
20 21
21
20
AQ09002-002

Copyright ©
1002-52
SPECIAL TORQUE SETTINGS CX80
No. Component Screw Wrench (mm) Torque setting
1* Travel motor and reduction gear assembly M16 24 267-312 Nm (197-230 lb-ft)
2* Drive sprocket M14 22 173-202 Nm (127-149 lb-ft)
3* Idler wheel M10 17 63-73 Nm (46-54 lb-ft)
4* Upper roller M16 24 267-312 Nm (197-230 lb-ft)
5* Lower roller M20 30 521-608 Nm (384-448 lb-ft)
6* Front guard M16 24 267-312 Nm (197-230 lb-ft)
7 Shoe bolt M14 22 220-270 Nm (162-199 lb-ft)
8 Counterweight M24 36 850-992 Nm (627-658 lb-ft)
9 Turntable (swing frame) M16 24 252-283 Nm (186-209 lb-ft)
10 * Swing unit M16 24 273-317 Nm (201-234 lb-ft)
11 * Engine (engine mount) M16 24 265-313 Nm (196-231 lb-ft)
12 * Engine bracket M10 17 64-74 Nm (47-54 lb-ft)
13 Radiator M10 17 36-44 Nm (26-32 lb-ft)
14 * M10 17 63-73 Nm (47-54 lb-ft)
Hydraulic pump Hexagon
15 * M12 socket head 109-126 Nm (80-93 lb-ft)
16 * Hydraulic reservoir M12 19 69-78 Nm (51-57 lb-ft)

17 * Fuel reservoir M12 19 98-108 Nm (72-80 lb-ft)
18 * Control valve M12 19 53-64 Nm (39-47 lb-ft)
19 * Hydraulic swivel M10 17 63-73 Nm (46-54 lb-ft)
NOTE: Use Loctite 262 or an equivalent on retaining screws of those components marked with an asterisk (*).

Copyright ©
1002-53
FRONT
FRONT

Copyright ©
1002-54
FRONT

Copyright ©
1002-55
MACHINE OVERALL DIMENSIONS
MONO BOOM SPEC (CX75SR)
1. Standard Arm (1.71 m)
NOTE: Numbers are subject to change without notice due to design change or other reasons.
The figures give values that include the shoe lug height (20 mm (0.79 in)
2. Long Arm (2.12 m)

Copyright ©
1002-56
MONO BOOM SPEC (CX80)
NOTE: Numbers are subject to change without notice due to design change or other reasons.
The figures give values that include the shoe lug height (20 mm (0.79 in)
2. Long Arm (2.12 m)

Copyright ©
1002-57
OFFSET BOOM SPEC (CX75SR)

Copyright ©
1002-58
NOTES
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Copyright ©
Section
2000
REMOVAL AND INSTALLATION OF THE ENGINE
2000

Printed in France
CNH Lep SM75SR2000-0EN August 2008
Copyright ©
2000-2
TABLE OF CONTENTS
ENGINE.................................................................................................................................................................... 3
Lep SM75SR2000-0EN Issued 08-2008

Copyright ©
2000-3
ENGINE
100 11 4.9 to 5.9 Nm
6 7 8 744 9
8.8 to 9.8 Nm
8.8 to 9.8 Nm
144 200 21 222

133 2
X3 X3 68.7 to 98.1 Nm
B 155 166 177
18 199
5 200
X2
4
8.8 to 9.8 Nm 2 8
C X2
655 666
1 100 11
4 122
X4
288 322 31 399
63.8 to 73.6 Nm
244 255 266
264.9 to 313.9 Nm X4
288 299
63.8 to 73.6 Nm 244 255 266 277
264.9 to 313.9 Nm 233
A
4.9 to 5.9 Nm
4.9 to 5.9 Nm
4.9 to 5.9 Nm 522 4.9 to 5.9 Nm
X2
2 X2
5 599
500 51 533 555
61
599 4.9 to 5.9 Nm
622
30
63
64
655
66
244 255 266 277 288

233 X4
X4 X4
288 300 677 688 699 700 233 244 255 266 277 288 722 71 733
288 322
63.8 to 73.6 Nm 63.8 to 73.6 Nm
264.9 to 313.9 Nm 63.8 to 73.6 Nm
KAH11280-E02
1. Coat the thread of sym (24) (30) (32) (45) with loc- 3. Tighten up the clip; jubilee from the direction
tite 262 or equivalent after removing any oil film and shown on the drawing.
fasten by tightening torque. 4. Arrow mark ( ) in the labels (69) represent the top.
2. apply packing liquid (50) to the connection of radia-
tor hose after removing any oil film and fasten by
tightening torque.
Lep ASM-17-11-002EN Issued 08-2008

Copyright ©
2000-4
1. Air inlet pipe (1)
2. Hose clamp (2)
3. Radiator stay (1)
4. Bolt (6)
5. Air hose (1)
6. Vacuum indicateur (1)
7. Cushion seal (1)
8. Radiator (standard) assy (1)
9. Label (1)
10. Rubber hose (L = 800) (1)
11. Corrugated tube 13 x 8 00 (1)
12. Hose band (3)
13. Jubilee clip 50 - 65 (1)
14. Hose clamp (1)
15. Air hose (1)
16. High strength nut M8 (3)
17. Spring washer 8 (3)
18. Exhaust pipe (1)
19. Clamp (1)
20. Diesel engine dom (1)
23. Elastic rubber (8)
24. High strength bolt M16 x 130 (4)
25. High strength washer 16 (4)
D
26. Plate (4)
27. Nut (4)
28. Bond 262 (-)
29. Engine supt (1)
30. Bolt M10 x 25 (10) X2
2 366
4 333 344 355
31. Engine supt (1)
32. Bolt M10 x 30 (8) 8.8 to 9.8 Nm B
33. Bracket (1)
34. Cushion seal (1)
35. Hose clamp (1)
37. Reserve tank (1)
38. Harness band L = 250 (1) 400
39. Rubber hose (L = 900) (1) 41
40. Muffler (1) X8
41. U bolt M8 (2) 422

42. Franged nut M8 (8) 433
43. Hose band (1) 444
44. Muffler bracket (1) 288 455 46
45. High strength bolt M10 x 35 (3) 63.8 to 73.6 Nm
46. High strength washer 10 (3)
47. Tube L = 700
48. Bolt M8 x 25 (1)
49. Clamp M8 (1)
50. Liquid packing (-)
51. Hose clamp 38 - 50 (2)
52. Jubilee clip 58 - 75 (1)
53. High strength bolt M8 x 45 (2)
54. Plain washer 8 (2) 477
55. Seal retainer (2)
C
57. Bolt M10 x 20 (2)
58. Bracket (1)
59. Jubilee clip 68 - 85 (3) 366
60. Air hose (1)
61. Air hose (1)
62. Bracket (1) 344
63. Bolt M8 x 20 (2) 722
64. Air cleaner (1)
65. Bolt M6 x 16 (2)
66. Holder (1) D
67. Engine supt (1) KAH11280-E02b
68. Hose band (1)
69. Rubber hose L = 600
70. Engine supt rf (1)
72. Acoustic insulation (1)
73. Blot M12 x 30 (4)
74. Radiator (standard) assy (1)

Copyright ©
3001
Section
3001
REMOVAL AND INSTALLATION

OF THE FUEL TANK

Printed in France
Copyright ©
3001-2
TABLE OF CONTENTS
FUEL TANK ............................................................................................................................................................. 3

Copyright ©
3001-3
FUEL TANK
See detail A
2
1
x2
7
2 x2
7
12
8
11
3 x2x2 x2 x2
4 5 6 7 8 9
10
13
See detail B
21
22
x2
7 23 25
14
See detail C 22
3
20
14 6 24
x2x2
15 16 17
18 19
KAH10760-D00
NOTE:
1. The specifications of fuel tank refer to the bollows.
Tank capacity: 100L
Limited inclined angle: 35°
2. Do not cover the drill hole.
Lep AST-15-11-003 Issued 08-2008

Copyright ©
3001-4
1. Fuel tank
2. Bracket 12
33 34 35 36
3. Tank belt
4. Hige strength washer
5. High strength nut
6. Bracket
7. Sems bolt M10x25
8. Hose band
9. Rubber hose
10. Sems bolt M10x16
11. Drain cock
12. Plate
13. Filter A
14. Bracket
15. High strength bolt M10x40
16. Hige strength washer
17. Bond 262 21 36 35 34 37
18. Sponge cushion
19. Sponge cushion
20. Sensor cover
21. Bracket
22. Rubber plate
23. Rubber plate
24. Rubber plate
25. Rubber plate
26. High strength bolt
27. Tank frange
28. Rubber packing B
29. Fuel sensor
30. Non-asbestos packing
31. Liquid packing
32. Pan screw hd M5x12
33. High strength bolt 5.9 to 6.9 Nm
x8
34. High strength washer 26
35. Spacer
36. Rubber cushion 27 28
37. High strength bolt M10x65 29 30 31
x5
32
C
KAH10760-D00
Lep AST-15-11-003 Issued 08-2008

Copyright ©
4001
Section
4001
ELECTRICAL AND ENGINE FUNCTIONS,

&
SERVICE SUPPORT

Printed in France
CNH Lep SC75SRCX80-4001-0EN March 2008
Copyright ©
4001-2
TABLE OF CONTENTS
CNH-EST DIAGNOSTIC TOOL ..................................................................................................................................... 3

Monitor Display ...................................................................................................................................................... 4
Engine Control ....................................................................................................................................................... 6

Copyright ©
4001-3
CNH-EST DIAGNOSTIC TOOL
The EST (Electronic Service Tool) system allows diagnoses on machines and engines by detecting the operating
parameters of electronic control components (control units, sensors etc). It is also capable of reading fault codes.
To use this tool, please refer to the book provided during the training sessions.

Copyright ©
4001-4
Monitor Display
1. Monitor Switch Panel
1.Fuel gauge 4.Overheat 10.Wiper switch

2.Coolant temperature gauge 5.Abnormal engine oil pressure 11.Washer switch
3.Hour meter 6.Low fuel 12.Working light switch
7.Battery charge error 13.High speed travel switch
8.
9.Glow (Preheat) Indicator

Copyright ©
4001-5
2. List of Functions
Functions Remarks
1 Engine Start-up Control See page 6
Engine Start-up Circuit 2.1 Throttle control See page 8
2 2.2 One-touch idling See page 10
2.3 EGR cut control See page 11
Monitor Output Control 3.1 2-speed travel See page 13
3.2 Swing brake See page 14
3.3 Travel alarm See page 15
3
3.4 Working light See page 16
3.5 Windshield wiper/washer See page 17
3.6 Power cut delay See page 19
Monitor Display Control 4.1 Overheat warning See page 20
4.2 Engine oil pressure warning See page 22
4.3 Low fuel warning See page 23
4.4 Battery charging warning See page 24
4.5 Glow timer (auto) See page 25
4
4.6 Hour meter
Gate lock
Horn
Radio AM/FM
Interior light
4 Heater
5 Air Conditioner (optional) See Air Conditioner
6 Combined Line for Breaker and Crusher (optional) See Hydraulic Circuit
Interference Prevention System See Interference
7
Prevention System

Copyright ©
4001-6
Engine Control
1. Engine start-up control
[1] Power supply (key switch at ON position)
1) Battery relay is energized.
2) Power is supplied to the initial excitation port (IG) in the alternator. (The alternator does not generate elec-
tricity until the input signal is recognized).
3) Power is supplied to the monitor to initiate operation.
[2] Cranking (key switch at Start)

1) Energizing the safety relay will initiate the power to be supplied to the starter relay integrated in the starter
motor, thus activating the starter motor.
2) When the engine is started through the starter motor, signals will be output from the alternator to the safety
relay.
3) When the engine reaches to the required rotational speed, the signals from the alternator to the safety relay
will be activated then the power supply to the starter motor stops.
As a result the starter motor stops its operation (if the cranking continues).
4) When the engine starts, the power generation begins at the alternator B terminal and the supply of power is
supplied to each load while batteries are also recharged. The terminal L on the alternator starts its output at
the same time, activating the battery charging warning and the hour meter.
(See Monitor Display for details.)
[3] Low-temperature start-up feature / preheat (key switch at HEAT or at ST)
1) The heat relay is also energized during cranking (key switch at ST) to supply power to the air heater.
This is to maintain the temperature achieved through manual preheating.

4001-7
Issued 03-08
FUSE BOX
Copyright ©
FUSE
AO28002-001a
KEY SW. OPTIONAL
POWER AUX.
GW 225
5WR 020
VW 170
1.25WR 200
g 175
0.85PW 230
GR 255
1.25LW 180
1.25GR 185
0.85W 160
0.85BrW 270
0.85VR 195
8R 106
5R 102
1.25GrR 330
R 150
0.85BrR 190
LgW
600
1.25B 700
700
KEY SW. OPTION
OPTION LINE (KNOB SW.) GR 255
B G1 G2 ACC
C M ST FUEL PUMP 255
HEAT
A TRAVEL MODE
GR 252
OFF TRAVEL ALARM GW 225
ACC SWING BRAKE GR 250
AIR-CON.
RELAY R11
ON 1.25WR 200
STARTER
HORN LgW
g 175
ST WIPER/WASHER 0.85BrR 190
CUT
0.85RW 120
0.85WR 290
LAMP (SWING)
g 500
0.85GrR 009
1.25GR 185
LAMP (CAB.BOOM) 1.25LW 180
0.85LgR
LEVER LOCK VW 170

THROTTLE MOTOR
0.85BrW 270
MONITOR 0.85W 160
BACK UP R 150
LIMIT AIR-CON BACK LIGHT VR 196
LEVER
(GATE) BACK UP AIR-CON R 151
B 707 0.85GrR 010 SWITCH LOCK SOLENOID 151
VW 170 GLOW LAMP
YR 852 OR 851 G 022
KEY. ACC 0.85WR 290
0.85LgR
g 500 KEY. M 0.85LgR
g 504
KEY. ST 0.85GrR 011
011
BATTERY RL
0.25WR 520
g 500
0.85WR 520
BATTERY CHARGE 520

0.858Br 510
0.85LgR
510
0.85PW 230
5WR 009 GLOW TIMER RL. FUEL FEED PUMP
8R 030
G 022
60R 001
M
2. Engine Start-up Circuit
1.25G 505
0.85LgR
g 501
5WR 003
0.85LgR 501 0.85Y 310 WATER TEMP. SENSOR
0.85Br 510
5L 021
1.85G 505
8R 105
1
GLOW PLUG
8R 030
0.85GrR 01 STARTER MOTOR
B
0.85BrR 51 60R 001
Lep SC75SRCX80-4001-0EN
1.25SR 102 B R L M ENG.
0.85BG G04
101 E C
0.85B 753
60R 1.25B 750
3B 767
BATTERY BATTERY
8B 797
0.85B 779
60R 100 ALTERNATOR
RL. SAFTY RL.
2B 700
60B 799
2B 600
3Y 330 3Y 331
Copyright ©
4001-8
[1] Throttle control

1) Configuration
IDLING
POWER SUPPLY 24V
MONITOR
THROTTLE
VOLUME ONE-TOUCH IDLING SWITCH
CONTROL DEVICE
IDLING SPRING
GEAR DC
GOVERNOR
POTENTIOMETER MOTOR
LEVER
PULL CABLE
SPRING CHAMBER
RACK IDLING ADJUSTMENT
SCREW
THROTTLE MOTOR
PULL SIDE L/S
RETURN SIDE L/S
STROKE = 28mm (1.10 in)

PULL SIDE L/S: ON PULL SIDE L/S: OFF NOTE: WITH KEY SWITCH ON AND THROTTLE
RETURN SIDE L/S: ON VOLUME AT FULL, SECURE BY FIRST FASTENING
RETURN SIDE L/S: OFF
WITH NUT (A) FOR 4 TURNS (APPROX. 5.0 mm 0.19
PULL SIDE STOP RETURN SIDE STOP in), THEN AN TIGHTENING ADDITIONALLY WITH
HIGH-IDLING NUT (A) AND (B).

PULL SIDE L/S: OFF
POWER SUPPLY 24V MONITOR
RETURN SIDE L/S: ON
THROTTLE
OPERATION THROUGH ONE-TOUCH IDLING SWITCH
VOLUME
THROTTLE VOLUME
CONTROL DEVICE
HIGH-IDLING
DC
MOTOR ADJUSTMENT SCREW
THROTTLE MOTOR AO28002-002A
Note:The idling and the high-idling positions for the engine governor are pre-adjusted by the engine sup-
plier before delivery.

Copyright ©
4001-9
1) Operational Description
1) When the power is supplied to the throttle motor, the control device compares the throttle volume sig-
nal and the potentiometer signal. It then outputs a signal to the DC motor to move the rack to the target
position set by the throttle volume.
2) The DC motor then makes a normal or reverse rotation according to the signal received from the con-
trol device.
3) The output from the DC motor will be transferred to the reduction gears via the rack. The rack rotates
the governor lever by allowing the PULL cable to stroke to increase/decrease the engine revolutions.
4) The potentiometer signals interlock with the rack. When the signal coincides with the throttle volume
signal, the control device will stop the output of the command signal for motor rotation.
5) The rack strokes are controlled by the Pull side L/S and the Return side L/S.
STROKE ENGINE RPM

28 mm
PULL SIDE L/S: ON, RETURN SIDE L/S: ON HIGH-IDLING
(1.10in)
2150 RPM
SPRING BEND AREA

PULL SIDE L/S: OFF,
POTENTIOMETER RETURN SIDE L/S: ON
VOLTAGE
CABLE SLACK AREA
IDLING
PULL SIDE L/S: OFF, RETURN SIDE L/S: ON 1100 RPM
6) When the working tension on the throttle motor reaches 15 kgf or above, the overload protection circuit
will be initiated to prevent the DC motor seizure.
Note: When the limit switch becomes damaged by an open circuit or a short circuit, the conditions will be
as follows:
• Damage by open circuit: The DC motor alters the engine rpm in response to the throttle volume. The
current continues to flow to the DC motor at the time of maximum engine rpm and during idling. The
overload is thus detected and the output to the DC motor will be stopped.
• Damage by short circuit: The rack does not move to the side where a short circuit has taken place in
the limit switch. If the limit switch has a short circuit on the Pull side, the rack can only move toward the
Return side from the location it was in when the short circuit took place (to the limit switch on the
Return side).
If the limit switch had a short circuit on the Return side, the rack can move to the Pull side only (to the
limit switch on the Pull side).

Copyright ©
4001-10
[2] One-touch idling

POWER SUPPLY 24V MONITOR
THROTTLE ONE-TOUCH IDLING SWITCH
VOLUME
GND
GND
CONTROL DEVICE
DC
MOTOR GOVERNOR
PULL CABLE LEVER
SPRING CHAMBER
IDLING ADJUSTMENT
SCREW
THROTTLE
VOLUME
POWER SUPPLY
MONITOR
CONTROL DEVICE
5V
ONE-TOUCH IDLING SWITCH
GND
GND
COMMAND SIGNAL FOR
MOTOR ROTATION
DC
MOTOR
GND
ON=24 V
MONITOR POWER
SUPPLY OFF=0 V
OFF=24 V
ONE-TOUCH IDLING
SWITCH ON=0 V
OFF=5 V
MONITOR OUTPUT RESET
ON=0 V
PROGRAMMED POSITION FOR THROTTLE VOLUME

THROTTLE POSITION
IDLING POSITION
AO28002-004A
Note:When the motor output is ON, the control device moves the rack to the idling position regardless of
the throttle volume location.

Copyright ©
4001-11
[3] EGR cut control

The purpose of EGR cut control is to reduce nitrogen oxide (NOx), which occurs easily at high combustion
temperatures, by opening EGR and partially mixing the exhaust gas with the suction air to reduce the com-
bustion temperature.
1) Operation explanation
1) When the coolant temperature reaches 60°C or higher, the EGR cut relay is turned ON. (When the
coolant temperature is less than 60°C EGR is closed. However, note that there is a hysteresis setting
for the opening side at 60°C and the closing side at 55°C and EGR will not close immediately even if
the coolant temperature drops below 60°C)
2) When the EGR cut relay is ON, the sensor reads the boost pressure and engine speed and the follow-
ing graph operations are performed.
15 EGR OPEN
EGR OPEN
Boost Pressure (KPa)
EGR OPEN EGR OPEN

EGR CLOSE
EGR CLOSE EGR CLOSE
EGR CLOSE
4
0
0 1250 1400 1820 1850
Engine Speed (min -1)
AQ28002-024A
When the boost pressure is less than 4 kPa, EGR opens when the engine speed is 1850 min-1 or higher,
and EGR closes when the engine speed is less than 1820 min-1.
15 EGR OPEN
EGR OPEN
EGR OPEN EGR OPEN

EGR CLOSE
EGR CLOSE EGR CLOSE
EGR CLOSE
0
0 1250 1400 1820 1850
AQ28002-025A

Copyright ©
4001-12
When the boost pressure is 15 kPa, EGR opens when the engine speed is 1400 min-1 or higher, and EGR
closes when the engine speed is less than 1250 min-1.
*:Once EGR is open, it does not close until the engine speed reaches a level where it is set to close.Con-
versely, once EGR is closed, it does not open until the engine speed reaches a level where it is set to
open.
15 EGR OPEN
EGR OPEN
EGR OPEN EGR OPEN

EGR CLOSE
EGR CLOSE EGR CLOSE
EGR CLOSE
4
0
0 1250 1400 1820 1850
AQ28002-026A
When the boost pressure is 4 kPa or higher but less than 15 kPa, EGR opens when the engine speed is
1850 min-1 or higher, and EGR closes when the engine speed is less than 1250 min-1.
*:Once EGR is open, it does not close until the engine speed reaches a level where it is set to close.Con-
versely, once EGR is closed, it does not open until the engine speed reaches a level where it is set to
open.
15 EGR OPEN
EGR OPEN
EGR OPEN EGR OPEN

EGR CLOSE
EGR CLOSE EGR CLOSE
EGR CLOSE
4
0
0 1250 1400 1820 1850
AQ28002-027A

Copyright ©
4001-13
3. Monitor Output Control
[1] 2-Speed travel
1) Configuration
MONITOR
RELAY
TRAVEL SOLENOID
CHANGE-
OVER SWITCH
2) Operation
TRAVEL CHANGE-
OVER SWITCH
MONITOR
OUTPUT RESET
LIGHTS ON
LIGHTS
OUT
LED DISPLAY
LAMP CHECK LAMP CHECK
• If the key switch is turned ON again after it was turned OFF, the low travel speed is always selected.

Copyright ©
4001-14
[2] Swing brake

1) Configuration
MONITOR
KEY.M RELAY
KEY SWITCH
SWING RIGHT PRESSURE SWITCH

SWING LEFT PRESSURE SWITCH
ATTACHMENT PRESSURE SWITCH

SOLENOID
2) Operation
POWER CUT
DELAY
KEY.M
(KEY SWITCH ON)
SWING PRESSURE
SWITCH
ATTACHMENT
PRESSURE SWITCH
MONITOR OUTPUT
SWING BRAKE
SOLENOID
BRAKE ON BRAKE ON
• The brake will go ON 5 s after the attachment switch is turned OFF.

• The brake will go ON 3 s after the power cut delay.

Copyright ©
4001-15
[3] Travel alarm

1) Configuration
MONITOR
TRAVEL ALARM
TRAVEL PRESSURE SWITCH
2) Operation
TRAVEL PRESSURE SWITCH
MONITOR OUTPUT
• The travel pressure switch will also be turned ON through steering/pivot turn operations, thus activating
the alarm.

Copyright ©
4001-16
[4] Working light

1) Configuration
RELAY
SWING WORKING LIGHT
MONITOR
REAR LIGHT
LAMP
RELAY
BOOM WORKING LIGHT
WORKING
LIGHT SWITCH CAB WORKING LIGHT
REAR LIGHT LAMP REAR LIGHT LAMP
CRANE MONITOR
AIR CONDITIONER PANEL

AO28002-010A
2) Operation
WORKING LIGHT
SWITCH
MONITOR OUTPUT RESET

LIGHTS ON LIGHTS ON
LIGHTS
WORKING LIGHT OUT
REAR LIGHT RESET
• If the key switch is turned ON again after it was turned OFF, the working lights and the rear lights will
be reset.

Copyright ©
4001-17
[5] Windshield wiper / washer

1) Configuration
POINT OF CONTACT
WIPER MOTOR FOR OPERATION
IGN IGN
MONITOR M
RELAY GND
WIPER SWITCH
GND
INT LED OUT 1
CNT LED GND IGN RELAY
GND
WASHER MOTOR
M
WASHER SWITCH OUT 2
GND GND
GND
GND AO28002-011A
2) Operation
1) Wiper
WIPER SWITCH
WIPER OUTPUT
OUT 1
LIGHTS ON LIGHTS OUT LIGHTS ON

INT LED DISPLAY
(INTERMITTENT) LAMP CHECK
LIGHTS ON LIGHTS OUT

CNT LED DISPLAY LIGHTS OUT
(CONTINUOUS)

Copyright ©
4001-18
2) Windshield wiper / washer
WIPER SWITCH
WIPER OUTPUT
OUT 2
WIPER OUTPUT
OUT 1
• The LED for intermittent/continuous movements will not be turned ON when the windshield washer
switch is turned ON.

Copyright ©
4001-19
[6] Power cut delay

1) Configuration
MONITOR
KEY SWITCH BATTERY
BATTERY RELAY
KEY. M
2) Operation
KEY. M
KEY SWITCH ON
MONITOR OUTPUT
• Due to the overcurrent protection circuit provided in the monitor output, the monitor will not be dam-
aged in the event that a short circuit occurs in the harness or in the battery relay coil.

Copyright ©
4001-20
4. Monitor Display Control
[1] Overheat warning
1) Configuration
MONITOR
COOLANT TEMPERATURE GAUGE
THERMO-SENSOR
(COOLANT)
THERMO-SWITCH OVERHEAT
(COOLANT) SIGNAL
THERMO-SWITCH
(OIL)
Thermo-sensor specifications for analog meter
Temperature (°C {°F}) 50 80 100 120

{122} {176} {212} {248}
Resistance (ohm) 153.9 32.3 18.4 16.1
Thermostat switch (coolant) specifications
Switch ON (°C {°F}) 105

{221}
Thermostat switch (oil) specifications
Switch ON (°C {°F}) 98

{208.4}
Switch OFF (°C {°F}) 91
{195.8}

Copyright ©
4001-21
2) Operation
OVERHEAT SIGNAL
LAMP CHECK
OVERHEAT
WARNING LED
BUZZER CHECK
BUZZER
• When the overheat signal falls 1V or below, the monitor recognizes this as the switch being ON and
turns the LED on. Therefore, even when the signal line is removed, the LED will still be turned ON.

Copyright ©
4001-22
[2] Engine oil pressure warning

1) Configuration
MONITOR
ENGINE OIL
PRESSURE SWITCH
CRANKING SIGNAL
KEY. ST
Pressure switch 0.029 MPa {4.2 psi} or less

2) Operation
IGN
KEY ST (CRANKING)
ENGINE OIL
PRESSURE SWITCH
LAMP CHECK
ENGINE OIL PRESSURE

WARNING LED
BUZZER CHECK
BUZZER
• Even if a warning is requested, the buzzer will not be activated until the key switch signal (cranking sig-
nal) is received.

Copyright ©
4001-23
[3] Low fuel warning

1) Configuration
MONITOR
FUEL GAUGE
FUEL SENSOR UNIT

FUEL SENSOR
FUEL THERMISTOR
Fuel sensor specifications

Fuel remaining Empty 1/2 Full
Sensor resistance
90 38 10
(ohm)
FUEL
EMPTY
2) Operation
IGN
LOW FUEL
WARNING SIGNAL
(TERMISTOT)
LAMP CHECK
FUEL REMAINING
WARNING LED
BUZZER CHECK
BUZZER
• When the thermistor resistance falls to 37 ohm or below, the monitor recognizes this as the signal
being ON and turns on the LED.

Copyright ©
4001-24
[4] Battery charge warning

1) Configuration
MONITOR
ALTERNATOR
BELOW 6V
CRANKING SIGNAL
KEY. ST
2) Operation
IGN
KEY. ST
(CRANKING)
ALTERNATOR
SIGNAL
LAMP CHECK
BATTERY CHARGE
WARNING LED
BUZZER CHECK
BUZZER
• Even if a warning is requested, the buzzer will not be activated until the key switch signal (cranking sig-
nal) is received.
• When the alternator signal falls below 6V, the monitor turns the warning ON.

Copyright ©
4001-25
[5] Glow timer (auto)

1) Configuration
KEY SWITCH
OFF
ON
ST
PREHEAT LAMP
3 1
A
GLOW PLUG
BATTERY TIMER 4
DC24V B
5 6
GLOW TEMPERATURE
PLUG SENSOR
AO28002-022A
2) Operation
ST
ST
KEY SWITCH ON ON ON
OFF
ON
LAMP
OFF
ON
GLOW PLUG
OFF
AO28002-023A

Copyright ©
4001-26
NOTES
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Copyright ©
Section
4020
ELECTRICAL EQUIPEMENT
&
ELECTRIC CIRCUIT DIAGRAMS
4020

Printed in France
Copyright ©
4020-2
TABLE OF CONTENTS
ELECTRIC CIRCUIT DIAGRAMS .................................................................................................................................. 4

List of components ................................................................................................................................................... 4
Electric Circuit Diagram 1 ......................................................................................................................................... 5
Electric Circuit Diagram 2 (CX75SR) ....................................................................................................................... 6
Electric Circuit Diagram 2 (CX80) ............................................................................................................................ 7
Electric Circuit Diagram: Air Conditioner 1 ............................................................................................................... 8
Electric Circuit Diagram: Air Conditioner 2 ............................................................................................................... 9
WIRING DIAGRAM ..................................................................................................................................................... 11
Electrical Components and Wiring For Upper (frame) ........................................................................................... 11
Electrical Components and Wiring for Cab ............................................................................................................ 12
Electrical Components and Wiring for Upper Frame (engine) ................................................................................ 13
Electrical Components and Wiring for Upper Frame (battery) ............................................................................... 14
Heater .................................................................................................................................................................... 15
Air Conditioner (inside Frame) ............................................................................................................................... 16
Air conditioner (inside cab) ..................................................................................................................................... 17
ELECTRICAL CONNECTOR WIRING DIAGRAM ....................................................................................................... 18
Main Frame Harness (CX75SR) ............................................................................................................................ 18
Main Frame Harness (CX80) ................................................................................................................................. 19
Cab Main Harness (inside cab) .............................................................................................................................. 20

Copyright ©
4020-3

Copyright ©
4020-4
ELECTRIC CIRCUIT DIAGRAMS
List of components
A7. OVER LOAD WARNING CONTROLLER P4. MONITOR DISPLAY
A9. AIR CONDITIONER CONTROLLER P5. HOURMETER
A11. CONTROLLER EGR CUT P6. AIR CONDITIONER CONTROL PANEL
B1. COOLANT TEMPERATURE SENSOR P10. SWITCH PANEL
B2. HYDRAULIC OIL TEMPERATURE SENSOR R1. GLOW PLUG
B21. ENGINE OIL PRESSURE SWITCH R3. THROTTLE VOLUME
B22. SWING PILOT PRESSURE SWITCH R4. THERMISTOR INNER TEMPERATURE
B26. UPPER PILOT PRESSURE SENSOR R5. FUEL SENSOR
B27. TRAVEL PILOT PRESSURE SENSOR R7. RESISTOR
B41. ENGINE RPM SENSOR S1. KEY SWITCH
B45. OVERLOAD INDICATOR PRESSURE SWITCH S2. TRAVEL MODE SWITCH
B47. BOOST PRESSURE SENSOR S6. ROTARY LIGHT SWITCH
B51. BOOST TEMPERATURE SENSOR S10. WORKING LIGHT SWITCH
B81. HORN S11. WIPER SWITCH
E2. WORKING LIGHT (ATTACHMENT) S12. WASHER SWITCH
E3. WORKING LIGHT (CAB) S13. OVERLOAD SWITCH
E4. CAB LIGHT S15. HORN SWITCH
E8. SWING LAMP S16. IDLE SWITCH
E51. CIGARETTE LIGHTER S28. TRAVEL ALARM
E52. AIR CONDITIONER S33. OPTION 2 SOLENOID VALVE SWITCH
F1. FUSE 65A ; MAIN FUSE FOR F8 TO F26 S34. OPTION 2 SOLENOID VALVE SWITCH
F3. FUSE 15A ; KEY SWITCH AND MAIN FUSE S35. CRUSHER OPTION TWO FLOW SOLENOID
F7. FUSE 10A ; MEMORY, CAB LIGHT, RADIO S51. HYDRAULIC FUNCTION CANCELLATION LEVER
F8. FUSE 30A ; ENGINE PRE-HEATING S52. AIR CONDITIONING COMPRESSOR CLUTCH
F9. FUSE 10A ; SOLENOID EGR CUT U1. DC-DC (24V-12V) CONVERTER
F10. FUSE 5A ; AIR CONDITIONER HEATER UNIT W1. ANTENNA
F11. FUSE 15A ; AIR CONDITIONER BLOWER X2. ROTARY LIGHT CONNECTOR
F12. FUSE 5A ; AIR CONDITIONER COMPRESSOR X8. RADIO CONNECTOR
F13. FUSE 10A ; SOLENOID X15. ACCESSORY SOCKET
F14. FUSE 15A ; WINDSHIELD WIPER / WASHER Y2. PILOT PRESSURE SOLENOID VALVE (BLUE
F15. FUSE 10A ; HORN Y3. SWING BRAKE SOLENOID VALVE (WHITE
F16. FUSE 15A ; LAMP (BOOM, HOUSE) Y4. 2 STAGE TRAVEL SOLENOID VALVE (RED
F17. FUSE 20A ; FUEL FILLER PUMP Y8. AIR CONDITIONER MAGNET CLUTCH
F18. FUSE 15A ; CIGAR. LIGHTER Y9. CRUSHER OPTION TWO FLOW SOLENOID
F19. FUSE 10A ; OVER-LOAD WARNING Y22. ENGINE STOP SOLENOID
F20. FUSE 10A ; DC /DC CONVERTER Y45. SOLENOID EGR CUT
F21. FUSE 10A ; BEACON
F22. FUSE 10A ; MONITOR
F23. FUSE 10A ; FUEL SUPPLY PUMP
F24. FUSE 15A ; LAMP (SWING) OPTION POWER
F25. FUSE 10A ; LEVER LOCK (GATE)
F26. FUSE 15A ; THROTTLE MOTOR
F27. FUSE 50A; SAFETY RELAY
F33. FUSE 20A; ENGINE STOP SOLENOID
F34. FUSE BOX
G1. BATTERY
G2. ALTERNATOR
H3. OVER LOAD WARNING AUDIBLE ALARM
H4. SPEAKER RIGHT
H5. SPEAKER LEFT
K3. RELAY-HORN
K4. RELAY-WORKING LIGHT
K5. RELAY-ROTARY LIGHT
K7. RELAY BATTERY
K8. RELAY SAFETY
K18. RELAY-TRAVEL MODE
K19. RELAY-SWING BRAKE
K20. RELAY-WIPER MOTOR
K21. RELAY-WASHER PUMP MOTOR
K22. RELAY-AIR CONDITIONER MAGNET CLUTCH
K23. RELAY-LOW BLOWER
K24. RELAY-MEDIUM BLOWER
K25. RELAY-HIGH BLOWER
K34. RELAY STARTER CUT
K47. RELAY EGR CUT
K48. RELAY GLOW TIMER
K49. RELAY LAMP SWING
M1. STARTER MOTOR
M3. WIPER MOTOR
M4. WASHER MOTOR
M5. MOTOR (AIR CHANGING)
M6. AIR VENT DIRECTION CONTROL MOTOR
M7. MOTOR ACT (AIR-MIX)
M8. BLOWER MOTOR
M10. THROTTLE MOTOR
M14. FUEL FEED PUMP MOTOR
M20. ELECTRIC FUEL PUMP
P2. SWITCH PANEL (LEFT-HAND)
P3. SWITCH PANEL (RIGHT-HAND)
Copyright ©
4020-5
Electric Circuit Diagram 1
E4
H4
H5
M3
E3
X8
K20
M4
P4
K21
E2 K4
E8 K49
K18
K19
S51

Copyright ©
4020-6
Electric Circuit Diagram 2 (CX75SR)
R3
500
160
THROTTLE VOLUME
2B 700
LGR 500
0.85W 160
M10
0.85Y
0.85L
ALTERNATOR
W-LAMP
BATTERY RELAY
RELAY BATTERY
0.85Y Y 810
5
THROTTLE MOTOR
0.85W 0.75R 410 0.85W 160
4 13
2
6POLE
0.85G 0.75W 430 0.85W 161

1 4
0.85P
MONITOR SW.PANEL
0.85R 0.85LgR
g 504
1 2
M
12
2
0.85B 0.85B 745 0.85GrR 011
1 17 15
6
0.75BW 650 0.85WR 520
WL 821 P4
0.85Br 510
513
0.85Br
HOUR
SENSOR
FUEL
0.85VG 413 METER 0.85BrW 514

R5 0.25BG 640
20
10
11 12
0
0
0.85YB 412 0.85YB 412
0.85WB 318
(FOR METER)
SENSOR
TEMP
WATER
B1 0.85B 705
6
1.25R 318 0.85B 706
R)
7
ENGINE
B51
SW
HEAT
OVER
1.25R 347 0.85VG 413

T
R
7
0.85WB 467
B21
1
P-SW
OIL
ENG..
MONITOR SW.PANEL
0.85Br 344 0.85Br 344
W
9
1
3
SW
TEMP
OIL
BG 643 L 465 LR 461

B2 P4
P
YR 460
P.SW
SWING
BG 647
B22 GR 462 6
G
14 13
0.85BG 605
P.SW
SWING
BG 648 GR 463 YL 860

B22
G
P.SW
ONE TOUCH IDLE
BG 646 LR 461
B27
P.SW
UPPER
BG 645 YR 460
B26
E
0.85BG 605
0.85BG 720
S16
BG 610
0 YL 860
KNOB(R)
R
B 747 L 865 B 712

KNOB(L)
175
B81
S15
AO30001-002

Copyright ©
4020-7
Electric Circuit Diagram 2 (CX80)
R3
M10
P4
R5
B1
B51
B21
B2 P4
B22
B22
B27
B26
B22
B22
S34
S16
S33
B81 S15

Copyright ©
Issued 03-08
AO30001-003
A9
AIR CON. CONTROL AMP. CONTROLLER AMP.

AIR CONDITIONER UNIT CN-AC1 30POLE
15 1 19 10 7 24 3 9 11 6 17 5 13 12 14 27 2 16
WG 547
WR 554
0.85VR 195
WB 564
LW 543
GR 548
BG 557
GY 581
0.85B 720
1.25WR 200
YR 556
RY 555
OL 545
O 549
LR 546
R 151
g 553
1
M8
LgB
M
2
AIR CON.BACK UP R 150

BLOWER MOTOR 150
AIR CON.POWER
200
0.85LB 540
3
195
205
4POLE
2
R7
0.85LY 541
1
0.85LW 542
4
RESISTOR
O 549
5
YR 556
4
BG 557
6
YW 558
WB 564
WL 559
WR 554
GY 581
BG 562
LY 563
3
G 560
0 550
RY 555
2 4 3 2 1
2
M
LgB
g 553
CN-WATER VALVE CN-WATER VALVE
1
OR
R
Electric Circuit Diagram: Air Conditioner 1
MODE BOX
K25
K22
K23
K24
O 551
0.
0.
0.
0.8
1
M M
R4
WATER VALVE RECIRCULATE/FRESH
M6
M5
1.25W 981
Y8
S52
COMPRESSOR
4020-8
4020-9
Issued 03-08
AO30001-004
Copyright ©
P6
A9
CONTROL AMP CONTROL PANEL

14 4 13 18 2 16 7 8 5 3 6 17 8 7 6 15 16 13 3 18 4 5 14 1 2
WL 822
VR 196
LW 576
GW 570
RY 567
RW 569
OR 572
LgR
g 571
BrR 575
LR 566
GR 577
BW 573
WR 568 W-LAMP
820
WG 574
195
Electric Circuit Diagram: Air Conditioner 2
2B 700
2B 600
2B 700
2B 600
Copyright ©
4020-10
NOTES
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Copyright ©
4020-11
WIRING DIAGRAM
Electrical Components and Wiring For Upper (frame)
CN181 DESCRIPTION SYM QTY

CN146
(PRESS. SW;TRAVEL:2PINS) (BOOM LAMP HARNESS;2PINS) PRESS. SWITCH 1 2
WITHOUT COLOR TAPE
WIRE HARNESS 2 1
CND12
(RECIEVER DRIER;2PINS) PRESS. SWITCH 3 2
HORN 4 1
THERMO SWITCH 5 1
WIRING HARNESS 6 1
TRAVEL ALARM 7 1
MARKING POSITION ; FIT

THE HARNESS'S WHITE TAPE C~ KHR20160
CABLE;BATTERY
TANK;SUMP CN135
TANK;FUEL (FUEL LEVEL SENSOR:3PINS)
CN180
A
(PRESS. SW;UPPER:2PINS) D
WITH RED TAPE 1
A~ MARKING POSITION
F
D~
DETAIL-E
B
CN.147
(WASHER MOTOR;2PINS) C
L AIR COMPRESSER
THROTTLE MOTOR
SEE DETAIL-E
CONNECT TO HARNESS;WIRE G HOSE COOLER
H
K
2 J
J~
MARKING POSITION ; FIT THE HARNESS'S WHITE TAPE
B~ F~
4 I
3 PRESSURE SWITCH (UPPER) 2PINS
L~
CN188
(OIL TEMP SW;2PINS) 6
CN.G1(GROUND)
CN127 CN.G3 (ALTERNATOR GROUND)
(TRAVEL ALARM;TERMINAL) 5 CN128 CN.G4 (ENGINE STOP GROUND) CN136
(SHUT OFF S.V;2PINS) (FUEL PUMP:2PINS)
(SWING BREAK S.V;2PINS)
WITH BLUE TAPE
WITH PINK TAPE
CN129 G~
(TRAVEL S.V;2PINS)
WITH RED TAPE
KHR20160
CABLE;BATTERY
MARKING POSITION ; FIT H~
7 THE HARNESS'S WHITE TAPE
I~
K~
KAR10930-D00

Copyright ©
4020-12
Electrical Components and Wiring for Cab
STARTER CUT(WHITE TAPE) DESCRIPTION SYM QTY

HORN(WHITE TAPE) SWING BRAKE
1 1 8 7
CONNECTOR:OVER LORD WARNING(8PIN) LOUD SPEAKER 1 2
LANP SWING
X10 EGR CUT RADIO SET AM/FM ST(12/24V) NA 2 1
4 9
A 6 ANTENNA CODE 3 1
BEACON(WHITE TAPE) PIN TERMINAL:PRESSURE CHECK
CONNECTOR:DC-DC COMVERTER B
(7PIN) BLOWER L DC-DC CONVERTER 4 1
BLOWER M WIRE HARNESS 5 1

CONNECTOR:GROW TIMER 2
BLOWER H BUZZER (24V) 6 1
CONNECTOR:GROW TIMER 1
SOCKET (DC12V) 7 1
BOX;FUSE COMPRESSOR
7 (ATTACHMENT FOR CAB MAIN HARNESS) CONTROLLER 8 1
FRAME MAIN HARNESS LAMP(WHITE TAPE) CHANGE OVER RELAY 9 10

TRAVEL MODE(WHITE TAPE)
ROCKER SWITCH 10 1
WASHER(WHITE TAPE)
WORKING LIGHT 11 1
WIPER(WHITE TAPE)
B MONITORÅ@24V 12 1
DETAIL OF ASSEMBLING RELAY
STARTER SWITCH ASSY 13 1
CONNECTOR:CONT EGR CUT(13PIN)
ROCKER SWITCH 14 1
5 CONNECTOR;THERMISTOR
CONNECTOR;AIRCON CONTROLER ROCKER SWITCH 15 1
CONNECTOR;BLOWER MOTOR
CONNECTOR:OPTION POWER MARKING POSITION 5 CONNECTOR;RESISTOR
(4PIN) (FIT HARNESS WHITE TAPE)
(FIX WITH RED TAPE) CONNECTOR:SUB HARNESS
(2PIN)
(FIX WITH RED TAPE)
DETAIL OF ELEC. BRACKET CONNECTOR;MODE BOX
2
13 12
12V OUTPUT
(FIX WITH RED TAPE)
3
DETAIL OF ASSEMBLING RADIO
11
14
BACKSIDE OF COVER;TOP (RIGHT) PANEL;CONTROL
CONNECTOR;WATER VALVE CONNECTOR;FRESH AIR

DETAIL OF AIRCON HARNESS
13 12
8
BACKSIDE OF COVER;TOP (LEFT)
10 15
HARNESS;BEACON SW(WHITE TAPE)
HARNESS;OVER LOAD WARNING SW(BLUE TAPE)

CONNECT TO CAB HARNESS DETAIL OF ASSEMBLING SWITCH
CONSOLE RIGHT
FRAME MAIN HARNESS
SWITCH;LIMIT
3
CONNECT TO ANTENNA CORD OF CAB
CONSOLE LEFT
KAR10750-E00

Copyright ©
4020-13
Electrical Components and Wiring for Upper Frame (engine)
CN193 DESCRIPTION SYM QTY

CN189
CN192 TERMINAL(FEMALE) CN196
RING TERMINAL M4 RING TERMINAL M4 THERMO SENSOR 1 1
(EGR CUT;2PINS) (WATER TEMP. SENSOR 1)
(GLOW) (OIL PRESS SWITCH)
HEATER HOSE
DETAIL-A
CN194
PIN TERMINAL(FEMALE)
(TACHO SENSOR)
SEE DETAIL-A
CN195
PIN TERMINAL(MALE)
(TACHO SENSOR)
CN.D13
(AIR COMPRESSOR)1PIN
CODE COLOR:WHITE AIR COMPRESSOR
B~
B
BE CAREFUL OF THE DIRECTION OF
BATTERY CABLE
STARTER MOTOR
CN190 (ATTACHMENT FOR ENGINE)
(ENGINE STOP;3PINS)
CN109
TERMINAL(FEMALE)
(STARTER MOTOR S)
DETAIL OF STARTER MOTOR
KAR10690
(HARNESS;WIRE) CN.179
RING TERMINAL M4
(WATER TEMP. SENSOR 2)
CN187 CODE COLOR:RED
(BOOST PRESS SENSOR;3PINS)
CN186
RING TERMINAL M4
(OVER HEAT SWITCH)
CODE COLOR:RED
SAFTY RELAY(ATTACHMENT
FOR ENGINE) CN.111
RING TERMINAL M6
C
(ALTERNATOR:B) 1
CN110 CODE COLOR:RED ENGINE EARTH
(ALTERNATOR L,R;2PINS) (ATTACHMENT FOR ENGINE)
CN.112
~ RING TERMINAL M6 E
(ALTERNATOR:E)
CODE COLOR:BLACK
CN108 C~
CN106 (SAFTY RELAY:C)1PIN
(SAFTY RELAY:S.R.E)3PIN E~
KHR20160
CABLE;BATTRY
CN107
DETAIL-D (SAFTY RELAY:C)1PIN
KHR20160 SEE DETAIL-D
CABLE;BATTRY
KAR10940-D00

Copyright ©
4020-14
Electrical Components and Wiring for Upper Frame (battery)
DESCRIPTION SYM QTY

6 CN104
RING TERMINAL M4(BATTERY RELAY COIL) BATTERY CABLE 1 1
CODE COLOR:WHITE BASE,RED STRIPE BATTERY HOLDER 2 1
CN103
RING TERMINAL M4(BATTERY RELAY COIL) BATTERY 95D31R 3 2
CODE COLOR:LIGHT GREEN BASE,RED STRIPE
1 BATTERY CABLE 4 1
TANK;SUMP BATTERY CABLE 5 1
BATTERY CABLE 6 1
BATTERY RELAY 7 1
FUSE 8 1
5
FUSE 50A 9 1
4
2
7
M8(ATTACHMENT FOR BATTERY) CNG1

6
TIGHTENING TORQUE 6.0 + or - 0.5 Nm(4 POINTS) (GROUND) CN105
3 CODE COLOR:BLACK (BATTERY RELAY GND)1PIN
DETAIL OF BATTERY (DETACH PLATE;RUBBER) CN100

CN101 (BATTERY RELAY B+)
5 (BATTERY RELAY 1GN) 5
6 WITH WHITE TAPE
CODE COLOR:RED
M10(ATTACHMENT FOR BATTERY) DETAIL OF BATTERY RELAY

TIGHTENING TORQUE 11.8 + or - 1.2 Nm(4 POINTS)
HOUSE;FRAME
CNF3
(FUSE:KEY 15A)2PINS
A CNF4
(FUSE:ENGINE STOP 20A)2PINS WITHOUT TAPE
WITH RED TAPE
8 9
CNF7
(FUSIBLE LINK 65A)2PINS CNF2
CODE COLOR:RED (FUSIBLE LINK 50A)2PINS
KAR10690 CODE COLOR:RED WHITE BASE,RED STRIP
(HARNESS;WIRE)
A~
DETAIL OF BATTERY (INSIDE) DETAIL OF FUSE
KAR10860-D00

Copyright ©
4020-15
Heater
HEATER(ENG.OUT)
THE HOSE LENGTH FROM THIS CLAMP

TO THE HEATER UNIT. WHITE MARKING
HEATER INLET:780 mm
HEATER OUTLET:660 mm
HEATER(ENG.RETURN)
DETAIL-A
IN
OUT
CONNECT HEATER UNIT CONNECT HEATER UNIT
HEATER(ENG.RETURN)
HEATER(ENG.OUT)

TO THE NIPPLE. DETAIL-A
HEATER INLET:550 mm
KAR10850-D00

Copyright ©
4020-16
Air Conditioner (inside Frame)
THE HOSE LENGTH FROM THIS CLAMP OUT

TO THE COMPRESSOR. IN HEATER(ENG.OUT)
DISCHARGE:290 mm
HEATER(ENG.RETURN)
WHITE MARING.
TO THE UNIT;AIR CONDITIONER. SEE DETAIL-B
LIQUID 2:800 mm
SUCTION:700 mm
HEATER INLET:780 mm
DETAIL-A
DETAIL RECEIVER;DRIER ASSEMBLING
BE CAREFUL OF DIRECTION.
HEATER(ENG.RETURN)
IN
CONNECT AIR CON UNIT OUT
CONNECT AIR CON UNIT
LIQUID
CONNECT AIR CON UNIT HEATER(ENG.OUT)
DETAIL-B
SUCTION
CONNECT AIR CON UNIT
SUCTION
SEE DETAIL-A
DETAIL PULLY ASSEMBLING
.
THE HOSE LENGTH FROM THIS CLAMP THE HOSE LENGTH FROM THIS CLAMP
TO THE NIPPLE AND COMPRESSOR. TO THE RECEIVER;DRIER AND CONDENSER
HEATER OUTLET:700 mm LIQUID 2:930 mm DISCHARGE
HEATER INLET:550 mm DISCHARGE:830 mm
SUCTION:520 mm
KAR10830-E00

Copyright ©
4020-17
Air conditioner (inside cab)
DESCRIPTION SYM QTY

CHANGE OVER RELAY 1 3
CONTROL PANEL 2 1
WHITE MARKING
CONNECT TO DCCT;SPL
COOLER INLET
COOLER OUTLET
HEATER OUT
HARNESS;WIRE
CONTROLLER
MODE BOX
BLOWER MOTOR
THERMISTOR BLOWER H
X3
1 BLOWER M
BLOWER L
COMPRESSOR
ONLY AIR CONDITIONER

RESISTOR 1
10
DETAIL OF RELAY ASSEMBLING 2
10
A BOX;CONSOLE(L)
COVER;FRONT
KHR3949Z-D07

Copyright ©
4020-18
ELECTRICAL CONNECTOR WIRING DIAGRAM
Main Frame Harness (CX75SR)
CMF7M
KAR10690-E00

Copyright ©
4020-19
Main Frame Harness (CX80)
CMF7M
(FUSIBLE LIMK
(FUSE BOX))

Copyright ©
4020-20
Cab Main Harness (inside cab)
CN28F
(AIRCON CONTROLER AMP 2)
CN29F
KAR10710-E00

Copyright ©
5001
Section
5001

OF THE TRACKS

Printed in France
Copyright ©
5001-2
TABLE OF CONTENTS
TRACK SHOE.......................................................................................................................................................... 3
Removal ............................................................................................................................................................ 4
Installation ......................................................................................................................................................... 5
TRACK LINK CHANGING PROCEDURE ...................................................................................................................... 6

Copyright ©
5001-3
TRACK SHOE
1
10 2
8
5
11
9
11
3 13
7
12
13
4
16
14
15
AQ10002-001
1. Grouser shoe 9. Master bushing

2. Track link assembly 10. Master pin
3. Track link (right) 11. Collar
4. Track link (left) 12. Locking pin
5. Master link (right) 13. Seal
6. Master link (left) 14. Shoe plate
7. Track bushing 15. Shoe bolt
8. Track pin 16. Shoe nut

Copyright ©
5001-4
1 Removal
[1] Position the master pin (1) of the track shoe as shown in
the drawing on the left.
Place track shoe support blocks as shown in the draw-
ing.
AQ10002-002
[2] Loosen the track shoe.
WARNING: Discharge the grease from the grease cylinder

gradually by loosening the cylinder check valve. Loosen the
check valve slowly and carefully. Stop loosening when the
grease starts to comes out.
(If the valve is loosened too much, the extremely high pressure
inside may cause grease to erupt or the plug to pop out).
AQ10002-003
[3] Separate the track shoe.

1) Remove the locking pin (2).
2) Pull out the master pin using a jig.
3) Remove the track shoe supporting blocks.
AQ10002-004
[4] Lift one side of the lower frame about 20 cm and hold it
there.
WARNING: Place protection blocks under the lower frame and

secure them.
Move the travel unit as shown in the drawing to the left to remove
the track shoe.
AQ10002-006

Copyright ©
5001-5
2 Installation
[1] Lift the track shoe and align it to the drive sprocket.
AQ10002-007
[2] Feed the track shoe toward the take-up roller by moving
the travel unit slowly as shown in the drawing to the left.
NOTE: Be careful. Sudden and quick movements may cause

the track shoe to jump and run off.
(During work, lift the roller shoe using the steel bar when
crossing over the upper roller).
[3] Remove protection blocks and lower the lower frame.
AQ10002-008
[4] Wind the end of the track shoe onto the take-up roller of
the track shoe.
[5] Connect the track shoe.
1) Place the track shoe supporting blocks.
2) Insert the master pin using a jig.
3) Insert a locking pin.
AQ10002-009
[6] Adjust the track shoe to the specified tension.

1) Fasten the check valve to the original position.
2) Fill the grease cylinder with grease, while observ-
ing the track shoe tension.
NOTE: For the track shoe tension adjustment, refer to Inspec-
tion and Maintenance in the Instruction Manual.
AQ10002-010

Copyright ©
5001-6
1 Track link changing procedure
1) Remove the track shoe.
2) Remove bolts, nuts and shoe plates for three sec-
tions, including the sections on both sides of the
damaged link section.
3) Pull the track pin using a jig.
4) Remove the damaged link.
5) Align a new track link.
6) Press fit the track pin using a jig.
7) Align the shoe plate and tighten the bolts to the
specified torque.
8) Install the track shoe.
AQ10002-011

Copyright ©
Section
5003
5003
UPPER AND LOWER ROLLERS

Lep SM75SR5003-0EN Printed in France
CNH August 2008
Copyright ©
5003-2
TABLE OF CONTENTS
TRACK SHOE.......................................................................................................................................................... 3
UPPER ROLLER ..................................................................................................................................................... 3
Removal ............................................................................................................................................................ 4
Installation ......................................................................................................................................................... 4
Tools and jigs .................................................................................................................................................... 5
Disassembly instructions................................................................................................................................... 7
Assembly instructions ....................................................................................................................................... 9
Assembly drawings ......................................................................................................................................... 13
LOWER ROLLER .................................................................................................................................................. 14
Removal .......................................................................................................................................................... 15
Installation ....................................................................................................................................................... 15
Component diagram........................................................................................................................................ 16
Tools and jigs .................................................................................................................................................. 16
Disassembly instructions................................................................................................................................. 18
Assembly instructions ..................................................................................................................................... 21

Copyright ©
5003-3
TRACK SHOE
1 Upper roller
AQ10002-023
1. Upper roller
2. Bolt
3. Loctite 262
4. Shim

Copyright ©
5003-4
1 Removal
[1] Loosen track shoe. See “Track shoe, removal”.
[2] Place the hydraulic jack (A) as shown in the drawing to
the left.
AQ10002-024
A
[3] Using the hydraulic jack (A), lift the track shoe high
enough that the upper roller can be removed.
[4] Place blocks between the track shoe and side frame A
and secure them.
[5] Loosen the upper roller mounting bolt (2) slightly (so
that the bolt head comes off 2 to 4 mm).
[6] Hit the upper roller gently with a copper hammer and
detach it from the side frame.
[7] Attach lifting tools on the upper roller.
[8] Remove the upper roller by removing mounting bolts (2)
completely while lifting the upper roller using the lifting
AQ10002-025
tools.
NOTE: Be careful to keep fingers and hands clear.
2 Installation
[1] Apply Loctite No. 262 to the upper roller mounting bolts
(2).
[2] Finger tighten all upper roller mounting bolts (2) while
lifting the upper roller.
NOTE: Adjust the position of the upper roller if necessary, using

shims (4) so that the track links are evenly supported.
[3] Tighten the upper roller mounting bolts (2) to the speci-
fied torque.
[4] Remove the blocks and jack.
[5] Fill grease into the grease cylinder and give the track
shoe the specified tension.
(See Track shoe, installation).

Copyright ©
5003-5
3 Component diagram
1. Cover
2. O-ring
3. Plug
4. Snap ring
5. Ball bearing
6. Roller
7. Shaft
8. Oil seal
9. Cover
10. Bracket
AQ14002-001
4 Tools and jigs

1. Tools
Hammer
AQ13002-002
Hexagon bar wrench
AQ13002-003

Copyright ©
5003-6
2. Jigs
Install jig.
AQ13002-004
Pulling jig
AQ13002-005

Copyright ©
5003-7
5 Disassembly instructions
[1] Preparation
Prior to disassembly, take full preparatory measures.
1) Workbench with vises
Prepare a suitable workbench large enough to arrange and keep parts and perform the work.
2) Tools and Jigs
For tools and jigs, refer to the previous section.
[2] General cautions
1) Handle precision parts carefully during the operation; do not drop or hit them on other parts during the operation.
2) Do not attempt to finish the operation quickly; do not forcedly pry or hit the parts.
Perform the operation carefully and patiently in order to prevent parts deformation, oil leakage and lower effi-
ciency.
3) As disassembled parts tend to get rusted or collect dust and dirt, dust proof and rust prevention treatment should
be applied immediately after disassembling the parts.
[3] Disassembling procedure
1)
1) Clean the upper roller with kerosene.
2) Remove the plug (3) from the cover to drain the
oil.
AQ14002-006
2)
1) Remove the cover (1) from the upper roller (6) using
a press and a pulling jig.
2) Remove O-ring (2) from the cover (1).
AQ14002-003

Copyright ©
5003-8
3) Remove snapring (4) from shaft (7).
AQ14002-004
4) Pull out the roller (6) from the shaft (7).
AQ14002-005
5) Remove the cover (9) and oil seal (8) from roller using
a press and a pulling jig.
AQ14002-006

Copyright ©
5003-9
6) Remove ball bearings (5) from roller (6) using a press
and a pulling jig.
Do not disassemble ball bearings (5) unless they are
unusable due to wear.
AQ14002-007
7) Cleaning parts
1) Place parts in the preparatory cleaning container containing cleaning oil.
NOTE: Wash off deposited substances which may cause scratches.
NOTE: Leave the parts submerged in the kerosene until the dirt and grease come off and float up
2) Put the parts in the finish cleaning container containing cleaning oil and wash them by slowly moving them.
3) Wipe off remaining cleaning oil with clean cloth.
NOTE: Place the parts somewhere free of dust and moisture, and dry them using compressed air. After drying, apply
engine oil to the parts.
6 Assembly instructions
[1] Prior to assembly
• Clean all the parts.
• Polish scratches, flashes or burrs using oil stons.
• Change sealing parts such as O-rings with new ones.
[2] Assembling procedure
1) Press fit the shaft (7) into the bracket (10). Press fitting
should be securely conducted through the side of the
plug hole.
NOTE: In an ordinary case, do not disassembly the bracket from

the shaft. Reassembly will be a very difficult task.
AQ14002-008

Copyright ©
5003-10
2) Install the ball bearings (5) on roller (6) using a jig and a
hammer.
NOTE: Use new ball bearings (5).
AQ14002-009
3)
1) Install the oil seal (8) and cover (9) to the roller (6).
2) Apply oil to the surface (lip section) of the floating
seal.
NOTE: Do not reuse oil seal (8).
AQ14002-010
4)
1) Apply grease to the shaft (7) surface.
2) Install roller (6) into shaft (7).
AQ14002-011

Copyright ©
5003-11
5) Install snap ring (4) on shaft (7).
NOTE: Do not reuse O-ring (4).
AQ14002-012
6)
1) Apply grease to O-ring (2) and install on cover (1).
2) Press fit the cover (1) with the O-ring attached on
roller (6), using a press and a jig.
NOTE: Use a new O-ring.
AQ14002-013
7) Check for leakage in the assembly using compressed

air. Compressed air pressure: 0.2 MPa.
AQ14002-014

Copyright ©
5003-12
8) Fill oil through the plug hole.
AQ14002-015
9) Install the plug (3).

NOTE: Clean the assembly and dry it using compressed air.
AQ14002-016
Now the assembly has been completed.

Copyright ©
5003-13
7 Assembly drawings
-##<$
1. Cover (1) 6. Roller (1)

2. O-ring 1B-G65 (1) 7. Shaft (1)
3. Plug 1/8 (1) 8. Oil seal (1)
4. Snap ring (1) 9. Cover (1)
5. Ball bearing (2) 10. Bracket (1)

Copyright ©
5003-14
2 Lower roller
AQ10002-026
1. Lower roller
2. Bolt
3. Loctite 262
ASM-17-10-002 Issued 08-2008

Copyright ©
5003-15
1 Removal
[1] Loosen track shoe. See “Track shoe, removal”.
[2] Remove the lower roller mounting bolts (2).
[3] Lift one side of the lower frame about 200 mm and hold
it there. (Lift it high enough that the lower roller can be
removed from the track shoe).
[4] Place protection blocks under the lower frame and
secure them.
AQ10002-027
[5] Remove the lower roller (1) from the track shoe.
AQ10002-028
2 Installation
[1] Place the lower roller on the track links with its fitting
surface up.
[2] Remove the protection blocks.
[3] Lower the frame slowly and gradually to where the bolts
can be installed.
NOTE: Be careful to keep fingers and hands clear. (Keep the

frame raised about 5 to 10 mm, instead of lowering it
completely.)
[4] Align the lower roller to the frame fitting position.
[5] Apply Loctite No. 262 to the lower roller mounting bolts
(2).
[6] Tighten the lower roller mounting bolts (2) to the speci-
fied torque.
[7] Fill the grease cylinder with grease to give the track
motor cover shoe the specified tension.
(See Track shoe, installation).
ASM-17-10-002 Issued 08-2008

Copyright ©
5003-16
3 Component diagram
1. Collar (without plug)
2. Roller
3. Shaft
4. Bushing
5. Floating seal
6. O-ring
7. Wire clip
8. Collar (with plug)
9. Plug
AQ15002-001
4 Tools and jigs

1. Tools
Hammer
AQ13002-002
Hexagon bar wrench
AQ13002-003
ASM-17-15-002 Issued 08-2008

Copyright ©
5003-17
2. Jigs
Install jig
AQ13002-004
Pulling jig
AQ13002-005
ASM-17-15-002 Issued 08-2008

Copyright ©
5003-18
[1] Preparation
2) Tools and Jigs
Do not attempt to finish the operation quickly; do not forcedly pry or hit the parts.
2) Perform the operation carefully and patiently in order to prevent parts deformation, oil leakage and lower effi-
ciency.
1)
1) Clean the lower roller with kerosene.
2) Remove the plug (9) from the collar (8) to drain the
oil.
AQ15002-002
2)
1) Remove the wire clips (7) from the shaft (3).
2) Remove the collars (1), (8) from the shaft (3).
AQ15002-003
ASM-17-15-002 Issued 08-2008

Copyright ©
5003-19
3) Remove the floating seals (5) from the collars (1), (8)
using pulling jig.
AQ15002-004
4)
1) Remove the O-rings (6) from the shaft (3).
2) Draw out the shaft (3) from the roller (2).
AQ1002-005
5) Remove the floating seals (5) from the roller (2).
AQ15002-006
ASM-17-15-002 Issued 08-2008

Copyright ©
5003-20
6) Remove the bushings (4) from the roller (2) using pull-
ing jig and press.
AQ15002-007
7) Cleaning parts
1) Place parts in the preparatory cleaning container containing kerosene.
2) Put the parts in the finish cleaning container containing kerosene and clean them by slowly moving them.
3) Wipe off kerosenel with clean cloth.
ASM-17-15-002 Issued 08-2008

Copyright ©
5003-21
• Polish scratches, flashes or burrs using oil stone.
1) Install the bushings (4) to the roller (2) using jig and
hammer.
NOTE: Pay full attention when inserting the bushings by

hammering. Do not reuse bushings (4).
AQ15002-008
AQ15002-009
2) Install the floating seals (5) to the roller (2).

NOTE: Do not reuse floating seals (5).
AQ15002-006
ASM-17-15-002 Issued 08-2008

Copyright ©
5003-22
3)
1) Apply grease to the surface of the shaft (3).
2) Install the shaft (3) to the roller (2).
3) Install the greased O-rings (6) to the shaft (3).
AQ15002-005
4) Install the floating seals (5) to the collars (1), (8).

AQ15002-004
5) Apply oil to the surface (lip section) of the floating seal.
AQ15002-010
ASM-17-15-002 Issued 08-2008

Copyright ©
5003-23
6) Press fit the collars (1), (8) to the shaft (3) and install
the wire clips (7). (Temporary fastening)
NOTE: Do not reuse wire clips (7).
AQ15002-003

air. Compressed air pressure: 0.2 MPa.
AQ15002-011
8) Intall the wire clips (7) using a hammer.

NOTE: Do not reuse wire clip (7).
AQ15002-012
9)
1) Fill oil through the plug hole.
AQ15002-002
ASM-17-15-002 Issued 08-2008

Copyright ©
5003-24
7 Assembly drawings
-##<%
1. Collar (without plug) (1) 6. O-ring 1B-G35 (2)

2. Track roller (1) 7. Wire clip (2)
3. Roller shaft (1) 8. Collar (with plug) (1)
4. Bushing (2) 9. Plug 1/8 (1)
5. Floating seal (2)
ASM-17-15-002 Issued 08-2008

Copyright ©
Section
5005
TAKE-UP ROLLER
AND
TENSION SHOCK ABSORBER
5005

Lep SM75SR5005-0EN Printed in France
CNH August 2008
Copyright ©
5005-2
TABLE OF CONTENTS
TAKE-UP ROLLER AND TENSION SHOCK ABSORBER .................................................................................... 3
Removal ............................................................................................................................................................ 4
Installation ......................................................................................................................................................... 5
GREASE CYLINDER ................................................................................................................................................ 6
Component diagram.......................................................................................................................................... 6
Tools and jigs .................................................................................................................................................... 6
Assembly instructions ....................................................................................................................................... 8
TAKE-UP ROLLER ................................................................................................................................................ 11
Component diagram........................................................................................................................................ 11
Tools and jigs .................................................................................................................................................. 11
Disassembling instructions.............................................................................................................................. 13
Assembling instructions .................................................................................................................................. 16

Copyright ©
5005-3
TAKE-UP ROLLER AND TENSION SHOCK ABSORBER

#3
1. Yoke 10. Check valve

2. Bolt 11. Dust seal
3. Threaded rod 12. Piston rod
4. Castle nut 13. Grease cylinder
5. Spring pin 14. Bracket
6. Spring 15. High strength bolt
7. Grease cylinder assembly 16. Spring washer
8. O-ring 17. Take-up roller
9. Backup ring
ASM-17-10-002 Issued 08-2008

Copyright ©
5005-4
1 Removal
[1] Remove track shoe. See “Track shoe, removal”.
[2] Pull out the recoil spring assembly from the side frame
using a steel bar.
[3] Attach a lifting tool to the recoil spring assembly..
AQ10002-019
[4] Lift the recoil spring assembly out from the side frame
using the lifting tool.
[5] Place the recoil spring assembly on blocks.
[6] Remove the take-up roller mounting bolts (2) to sepa-
rate the take-up roller and coil spring.
[7] Prepare hydraulic jack and jigs for recoil spring disas-
sembling and reassembling.
[8] Set recoil spring in jig as shown in the drawing to the
left.
[9] Raise the hydraulic jack to compress the spring.
[10]Pull out the spring pin (5) and remove the castle nut (4). AQ10002-020
[11]Lower the hydraulic jack to restore the spring to its orig-

inal position.
[12]Take the recoil spring components out from the jig in
the following order: yoke (1), spring (6) and grease cylinder (7).
ASM-17-10-002 Issued 08-2008

Copyright ©
5005-5
2 Installation
[1] Set the recoil spring components in the recoil spring jig
in the following order: grease cylinder (7) spring (6) and
yoke (1).
[2] Raise the hydraulic jack to compress the spring.
Mounting length of spring: 402 mm
[3] Attach the castle nut (4) and lock it with spring pin (5).
AQ10002-021
[4] Lower the hydraulic jack to restore the spring to the orig-
inal position.
[5] Remove the recoil spring from the jig.
[6] Apply Loctite No. 262 to the take-up roller mounting
bolts (2).
[7] Tighten the take-up roller mounting bolts (2) to the spec-
ified torque to reassemble the take-up roller and recoil
spring.
[8] Attach lifting tool to recoil spring assembly.
[9] Place recoil spring assembly on side frame using a lift-
ing tool.
AQ10002-022
[10]Set the recoil spring assembly in the side frame using a
steel bar.
[11]Install the track shoe. (See Track shoe, installation.)
WARNING: A jig should be used for disassembly and
reassembly because the coil spring is compressed.
ASM-17-10-002 Issued 08-2008

Copyright ©
5005-6
1 Grease cylinder
1 Component diagram
KAA1160Z-C01
1. Dust seal 6. High strength bolt

2. Backup ring 7. Spring washer
3. O-ring 8. Bracket
4. Piston rod 9. Check valve
5. Grease cylinder
2 Tools and jigs
1. Tools
Hammer
AQ16002-002
Spanner
AQ16002-003
Socket
AQ16002-004
Ratchet handle
AQ16002-005
2. Jigs
Install jig
AQ16002-006
Pulling jig
AQ16002-007
ASM-17-16-002 Issued 08-2008

Copyright ©
5005-7
[12]Preparation
2) Tools and Jigs
[13]General cautions
2) Do not attempt to finish the operation quickly; do not forcedly pry or hit the parts. Perform the operation carefully
and patiently in order to prevent parts deformation, oil leakage and lower efficiency.
[14]Disassembling procedure
1)
1) Clean grease cylinder with kerosene.
2) Remove bolts (6), washers (7) and then remove
the bracket (8).
3) Remove check valve (9) from grease cylinder (5).
AQ16002-008
2) Draw out piston rod (4) from grease cylinder (5).
AQ16002-009
ASM-17-16-002 Issued 08-2008

Copyright ©
5005-8
3) Remove dust seal (1) from grease cylinder (5) using
pulling jig.
AQ16002-010
4) Remove back-up ring (2) and O-ring (3) from grease

cylinder (5).
AQ16002-011
• Polish scratches, flashes or burrs using oil stone.
[2] Assembling instructions
1)
1) Install grease-applied O-ring (3) to grease cylinder
(5).
2) Install back-up ring (2).
NOTE: Do not reuse back-up ring (2) and O-ring (3).
AQ16002-011
ASM-17-16-002 Issued 08-2008

Copyright ©
5005-9
2)
1) Install dust seal (1) to grease cylinder (5) using a
jig and hammer.
2) Apply grease on lip section of dust seal.
NOTE: Do not reuse dust seal (1).
AQ16002-010
AQ16002-013
3)
1) Apply grease to the surface of piston rod (4).
2) Insert piston rod (4) into grease cylinder (5).
AQ16002-012
4)
1) Install check valve (9) to grease cylinder (5) by
applying specified tightening torque.
2) Install bracket (8), and then fasten it with bolts (6)
and washers (7).
AQ16002-008
ASM-17-16-002 Issued 08-2008

Copyright ©
5005-10
5 Assembly drawings
KAA1219Z-B01
1. Dust seal (1) 6. High strength bolt M8 x 16 (2)

2. Back-up ring T-P60 (1) 7. Spring washer 8 (2)
3. O-ring 1B-P60 (1) 8. Bracket (1)
4. Piston rod (1) 9. Check valve (1)
5. Grease cylinder (1)
ASM-17-16-002 Issued 08-2008

Copyright ©
5005-11
2 Take-up roller
1 Component diagram
1. Take-up roller
2. Bushing
3. Floating seal
4. O-ring
5. Shaft
6. Spring pin
7. Hub (with plug)
8. Plug
9. Hub (without plug)
AQ13002-001
2 Tools and jigs

1. Tools
Hammer
AQ13002-002
Hexagon bar wrench
AQ13002-003
ASM-17-13-002 Issued 08-2008

Copyright ©
5005-12
2. Jigs
Install jig
AQ13002-004
Pulling jig
AQ13002-005
ASM-17-13-002 Issued 08-2008

Copyright ©
5005-13
3 Disassembling instructions
[1] Preparation
2) Tools and Jigs
Do not attempt to finish the operation quickly; do not forcedly pry or hit the parts.
2) Perform the operation carefully and patiently in order to prevent parts deformation, oil leakage and lower effi-
ciency.
1)
1) Clean the take-up roller with kerosene.
2) Remove the plug (8) from the hub (7) to drain the
oil.
AQ13002-006
2)
1) Remove the spring pin (6) from the shaft (5) (or hub
(7). The removal is to be performed on one side only.
2) Remove the hub (7) from the shaft (5). The removal
is to be performed on one side only.
AQ13002-020
ASM-17-13-002 Issued 08-2008

Copyright ©
5005-14
3)
1) Take-up roller (1) is reversed.
2) Remove the O-ring (4) from the shaft (5).
3) Pull out the shaft (5) from the take-up roller (1).
AQ13002-008
4)
1) Remove the spring pin (6) from the shaft (5) (or
hub (9).
2) Remove the hub (9) from the shaft (5).
3) Remove the O-ring (4) from the shaft (5).
AQ13002-009
5) Remove the floating seals (3) from the hubs (7),(9).
AQ13002-010
6) Remove the floating seals (3) from the take-up roller

(1).
AQ13002-011
ASM-17-13-002 Issued 08-2008

Copyright ©
5005-15
7) Remove the bushings (2) from the take-up roller (1)
using pulling jigs, press and other instruments.
NOTE: Do not attempt to disassemble bushings (2) unless
they are unusable due to wear.
AQ13002-012
8) Cleaning parts
1) Place parts in the preparatory cleaning container containing cleaning oil.
2) Put the parts in the finish cleaning container containing cleaning oil and wash them by slowly moving them.
3) Wipe off remaining cleaning oil with clean cloth.
ASM-17-13-002 Issued 08-2008

Copyright ©
5005-16
4 Assembling instructions
• Polish scratches, flashes or burrs using oil stones.
1) Install bushings (2) to the take-up roller (1) using a jig
and hammer.
NOTE: Pay full attention when inserting the bushings (2) by

hammering. Do not reuse bushings (2).
AQ30002-013
AQ30002-014
2) Install the floating seals (3) to take-up roller (1). apply

grease to the floating seals.
AQ13002-011
ASM-17-13-002 Issued 08-2008

Copyright ©
5005-17
AQ30002-015
3) Install the floating seals (3) to the hubs (7), (9).

AQ13002-010
AQ30002-016
4)
1) Install the greased O-ring (4) to the shaft (5). The
installation is to be performed on one side only.
2) Install the shaft (5) to the hub (9) and secure them
with a spring pin (6).
NOTE: Do not reuse spring pin (6) and O-ring (4).
AQ13002-022
ASM-17-13-002 Issued 08-2008

Copyright ©
5005-18
5)
1) Apply grease on the surface of the shaft.
2) Install the shaft (5) to the take-up roller (1).
3) Install the greased O-ring (4) to the shaft (5).
AQ13002-021
6) Install the hub (7) to the shaft (5) and secure them with
a spring pin (6).
NOTE: Do not reuse spring pin (6).
AQ13002-020

air. Compressed air pressure: 0.2 MPa
AQ13002-017
8) Fill oil through the plug.
AQ13002-018
ASM-17-13-002 Issued 08-2008

Copyright ©
5005-19
AQ13002-019
ASM-17-13-002 Issued 08-2008

Copyright ©
5005-20
5 Assembly drawings
-##<%
1. Track-up roller (1) 6. Spring pin (2)

2. Bushing (2) 7. Hub (with plug) (1)
3. Floating seal (2) 8. Plug 1/8 (1)
4. O-ring 1B P36 (2) 9. Hub (without plug) (1)
5. Roller shaft (1)
ASM-17-13-002 Issued 08-2008

Copyright ©
6001
Section
6001
REMOVAL AND INSTALLATION OF THE

DRIVE MOTOR AND
FINAL DRIVE TRANSMISSION

Printed in France
Copyright ©
6001-2
TABLE OF CONTENTS
TRAVEL UNIT.......................................................................................................................................................... 3
Precautions when installing............................................................................................................................... 3
Removal ............................................................................................................................................................ 4
Installation ......................................................................................................................................................... 5

Copyright ©
6001-3
TRAVEL UNIT
8
7
AQ10002-012
1. Travel motor 5. Bolt

2. Bolt 6. Drain port
3. Loctite 262 7. Oil level check port
4. Drive sprocket 8. Oil fill port
1 Precautions when installing

[1] Be careful of direction when attaching sprockets to the machine.
The side having the C2 chamfer of the sprocket must face the traction motor.
[2] Coat the threads with loctite 262 or equivalence, and fasten them by tightening torque.
[3] When starting the machine after assembling, bleed the air from the upper drain port (6).
[4] Set the reduction gear as shown in the follewing fig when checking and filling the oil.
(The lowest point of oil level port (7) is the standard oil level.)
[5] When changing the reduction gear oil, remove drain plugs from the reduction gear side, and let the oil drain out.
Next, screw the plugs back in and fill the oil the normal oil level.
ASM-17-10-002 Issued 08-2008

Copyright ©
6001-4
2 Removal
[1] Remove track shoe. See “Track shoe, removal”.
[2] Lift one side of lower frame about 200 mm and hold it
there.
(Lift it high enough for the drive sprocket to be removed
from the track shoe).
[3] Place protection blocks under lower frame and secure
them.
[4] Stop engine and release pressure in the hydraulic cir-
cuits. (See the procedures for bleeding the hydraulic
pressure in Operator’s Manual).
[5] Remove motor cover.
AQ10002-013
[6] Remove drive sprocket mounting bolts (2).

[7] Separate drive sprocket (4) from mounting flange on
travel unit using a steel bar.
[8] Attach a lifting tool onto the drive sprocket.
AQ10002-014
[9] Using the lifting tool, lift the drive sprocket and remove it
from the travel unit.
[10]Attach marking tags to the travel motor hoses to tell
them apart when they are reconnected.
[11]Remove the hoses and put bull plugs or caps on them
to keep out dust.
[12]Attach the lifting tool onto the travel unit.
NOTE: Lift the travel unit until the wire on the lifting tool is
tense.
AQ10002-015
[13]Remove travel unit mounting bolts (5).

[14]Remove travel unit using a steel bar.
AQ10002-016
ASM-17-10-002 Issued 08-2008

Copyright ©
6001-5
3 Installation
[1] Lift travel unit and align it so that it fits on the frame. (Be Bolt tightening order:
careful of the fitting angles.). Tighten the four numbered bolts evenly in the
[2] Apply Loctite No. 262 to threads of travel unit mounting sequence shown below and then fasten the remain-
bolts (5) and finger tighten all mounting bolts. ing bolts.
[3] Tighten travel unit mounting bolts (5) to the specified
torque alternatively, up/down and left/right, so that the
tightening force acts on them equally. (Refer to Tighten-
ing torque in the Maintenance Instructions.)
[4] Lift drive sprocket and confirm that it is oriented cor-
rectly.
[5] Align drive sprocket to mounting flange on the travel unit
using a steel bar.
AQ10002-017
[6] Apply Loctite No. 262 to threads of drive sprocket
mounting bolts (2), and finger tighten all mounting bolts.
[7] Tighten drive sprocket mounting bolts (2) to the speci-
fied torque alternatively, up/down and left/right, so that the tightening force acts on them equally. (Refer to Tighten-
ing torque in the Maintenance Instructions.)
[8] Connect hoses to travel motor.
[9] Check reduction gear oil level. Fill if necessary.
[10]Bleed air from travel motor. (Fill motor with hydraulic oil)
[11]Remove protection blocks.
[12]Lower the lower frame on the track shoe.
[13]Install track shoe. See “Track shoe, installation”.
[14]Check to ensure that there is no oil leakage. If leakage is found, take appropriate measures.
[15]Install motor cover.
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6001-6
NOTES
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6002
Section
6002
DISASSEMBLY AND ASSEMBLY OF THE

DRIVE MOTOR AND
FINAL DRIVE TRANSMISSION

Printed in France
Copyright ©
6002-2
TABLE OF CONTENTS
TRAVEL UNIT.......................................................................................................................................................... 3
SERVICE OUTLINE.................................................................................................................................................. 3
Tools ................................................................................................................................................................. 3
Tightening torque table ..................................................................................................................................... 7
Weight table ...................................................................................................................................................... 7
DISASSEMBLY ....................................................................................................................................................... 8
Preparations. ..................................................................................................................................................... 8
General suggestion when working .................................................................................................................... 8
Disassembly procedure..................................................................................................................................... 9
SERVICE PREPARATION ....................................................................................................................................... 26
ASSEMBLY .......................................................................................................................................................... 28
PERFORMANCE CONFIRMATION TEST.................................................................................................................... 44
Required measuring devices........................................................................................................................... 44
Test procedure ................................................................................................................................................ 44
EXPLODED DIAGRAM OF REDUCTION GEAR ........................................................................................................... 45
EXPLODED DIAGRAM OF HYDRAULIC MOTOR......................................................................................................... 46
INTERNAL STRUCTURE DIAGRAM .......................................................................................................................... 47
TRAVEL UNIT PART TABLE ................................................................................................................................... 48

Copyright ©
6002-3
TRAVEL UNIT
1 Service outline
1 Tools
1) Standard tools
No Name Description and remarks Q’ty

1 Hexagon wrench 3, 6, 10, 12 mm One of each
2 Socket wrench (ratchet handle) (JIS B 4641) Barrel type 1
Dial type, approx. 12 N 1
3 Torque wrench (JIS B 4650)
Nominal socket 13, 30
4 Torque wrench adapter One of each
Nominal rod size 3, 6, 8
Opposite side
5 Hexagon socket One of each
13, 17, 24, 36 mm
6 Extension bar (JIS B 4637) 150 mm 1
7 Hand hammer Nominal 12 mm 1
8 Plastic hammer About L = 300 mm 1
50 mm 1
9 Flat-blade screwdriver (JIS B 4609)
150 mm 1
For shafts 1
10 Snap ring pliers
For holes 1
11 Cutting pliers (JIS B 4623) 200 mm 2
Lifting load 2940 N or more 1
12 Lifting tool (crane) Eyebolt (For PF3/8) 2
Wire with hook 1
Volume:
13 Receptacles 2
W450 x D300 x H120
14 Leather gloves 1 pair
2) Bolts
No Name Description Q’ty

Approx. M6 (P1.0) x 50 1
1 Hexagon socket head bolt (JIS B 1176) Approx. M16 (P2.0) x 40 2
Approx. M16 (P2.0) x 150 3
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6002-4
3) Equipment and materials
Applicable parts
Name Description and remarks Q’ty
(Usage method or parts No.)
For disassembling and reassembling
General work bench 1
works
For washing motor and parts Washing tank 1
104, 149 Press machine Press capacity: 1960 N or more 1
Heating capacity: over 100°C
149 Heating tank 1
Volume: 500 x 500 x 500 mm
For drying washed parts Compressed air supply Pressure: 0.29 - 0.49 MPa
4) Manufacturing tools
Name: Travel motor workbenchp
• Workbench for easily and safely disassembling and
assembling the travel motor.
AQ21002-001
Name: Fixture
• For connecting spindle (2) and hub (1).
AQ21002-002
Name: Holder ( I )
• For inserting spring (114), washer (110) and snap ring
(145) into cylinder block (104).
• For removing spring (114) from cylinder block (104).
AQ21002-003
Name: Holder ( II )
• For removing ball bearing (149) from or insertingit
onto shaft (102).
AQ21002-004
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6002-5
Name: Holder ( III )
• For press fitting oil seal (132) into the oil seal holethe
spindle (2).
AQ21002-005
Name: Press tool

• For press fitting ball bearing (24) into hub (1).
AQ21002-006
Name: Steel rod ( I )

• For removing ring (45) from hub (1).
AQ21002-007
Name: Bearing preload adjuster

• For fitting ring nut (22) to spindle (2).
AQ21002-008
Name: Eyebolt
• For lifting the GM motor, spindle (2) and hub (1).
“A”:
Hub, M14
Spindle, M16
GM motor, M16
AQ21002-009
Name: Slice
• For removing timing plate (109) from rear flange
(301).
AQ21002-010
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6002-6
Name: Aluminium rod
• For removing the outer race of ball bearing (24).
AQ21002-011
Name: Cover removable jig

• For removing cover (13) from hub (1).
AQ21002-012
Name: Floating seal installation tool ( I )

• For installing floating seal (31) to hub (1).
AQ21002-013
Name: Floating seal installation tool ( II )

• For installing floating seal (31) to hub (1) and spindle
(2).
AQ21002-014
Name: Floating seal installation tool ( III )

• For installing floating seal (31) to spindle (2).
AQ21002-015
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6002-7
Name: Thrust washer installation tool (carrier(3))
• For installing three thrust washers 3 (12) to the carrier
(3) with hexagon head bolt.
AQ21002-016
Name: Thrust washer installation tool (spindle(2))

• For installing four thrust washers 1 (10) to the spindle
(2) with hexagon head bolt.
AQ21002-017
2 Tightening torque table
Part No. Bolt/Nut used

Width across flats Tightening torque
(structure Nominal Q’ty
Part name (mm) (Nm)
drawing) designation
33 Plug PF3/8 8 1 58.8 ± 9.81
39 Socket plug PF3/8 8 2 58.8 ± 9.81
40 Hexagon head bolt M8 (P1.25) 13 7 33.3 ± 4.9
47 Hexagon socket set screw M6 (P1.0) 3 2 4.9 ± 0.98
51 Hexagon socket set screw M6 (P1.0) 3 2 4.9 ± 0.98
221 Plug PF1/4 6 2 29.4 ± 4.9
224 Plug M25 (P1.5) 30 2 196 ± 44.7
226 Plug M20 (P1.5) 8 2 78.5 ± 9.81
Hexagon socket head cap
243 M8 (P1.25) 6 6 29.4 ± 4.9
screw
3 Weight table
Applicable parts
Name Weight (kg)
(structure drawing)
- Travel motor assembly Approx. 53
1 Hub Approx. 15
2 Spindle Approx. 15
201 Rear flange assembly Approx. 6.2
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6002-8
2 Disassembly
1 Preparations.
1) Perform the following preparations before disassembling.
1) Workbench preparations
Provide a travel motor workbench.
Provide a sturdy workbench with which the internal parts of the travel motor can be disassembled or assem-
bled, is wide enough to place parts so they do not move or fall off the bench while working.
Spread a rubber or vinyl sheet on the workbench.
2) Preparation of tools and materials.
Provide the tools and materials listed in 1.Tools.
2 General suggestion when working
WARNING: Internal parts are coated with hydraulic fluid and gear oil during disassembly and are slippery. If a
part slips out of your hand and falls, it could result in bodily injury or could damage the part. Be very careful when
! handling.
WARNING: Combustibles such as white kerosene are used for washing parts. These combustibles are easily
! ignited, and could result in fire or injury. Be careful when handling.
[1] Before disassembling, perform inspections and clearly determine the nature of any abnormalities which might be
occurring, and work according to the disassembly procedure.
[2] Each part is manufactured to extreme precision. Handle with care and be sure not to hit the parts together or drop
them.
[3] When working, do not attempt to forcefully beat or wrench tightly fitting parts.
Doing so could produce burrs or damage the parts so they can’t be mounted or may reduce their performance.
You should exercise patience when working.
[4] If you leave parts disassembled or partially disassembled, rust could develop on the parts due to moisture or dirt.
If you have to interrupt work before completion, be careful to take measures to protect against rust or dust.
[5] Place a counter mark on mating faces of parts when disassembling.
[6] Arrange removed parts neatly when disassembling so as not to damage or lose the parts while working.
[7] As a rule, once any type of seal is disassembled it should be replaced with a new one even if it shows no signs of
damage. You should have a new ready when disassembling.
[8] The photographs and drawings contained in the manual are of representative models.
Disassembly procedure is however not affected even if the product you are using differs in part.
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6002-9
3 Disassembly procedure
[1] Washing the GM motor
1) Fasten the eyebolts to spindle (2).
NOTE: Fasten the two eyebolts in the screw holes for
mounting the spindle so they are positioned symmetrically.
AQ21002-018
2) Hook the wire in the eyebolts, hoist the GM motor

with a crane and carry to the washing tank.
3) Wash each part of the GM motor with a brush.
NOTE: Earth and sand get in the clearance between hub
(1) and spindle (2) (floating seal mounting section). Be sure
to wash this part with special care.
AQ21002-019
[2] GM motor installation.

1) Set the GM motor on a workbench.
NOTE: While matching the screw holes of hub (1) and screw
holes of the workbench, carefully place the travel motor in the
mounting holes of the workbench.
AQ21002-020
2) Mount the GM motor on the workbench so that the

two hexagon socket head cap screws are posi-
tioned symmetrically.
WARNING: Tighten the hexagon socket head cap

screws securely. Failure to do so could result in injury
! cased by the GM motor falling when it is inverted.
AQ21002-021
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6002-10
[3] Lubricating oil extraction
NOTE: If disassembling the rear flange only, proceed to the
item [8] Rear flange removal of page 12.
1) Invert the GM motor. (Turn up the side of reduc-
tion gear)
2) Loosen and remove plug (33) and socket plug
(39).
NOTE: When extracting the lubricating oil, place a container
under the workbench.
AQ21002-022
3) Invert slowly the GM motor and extract the lubri-

cating oil. (Turn up the side of motor)
4) Remove O-ring (37) from plug (33) and socket
plug (39).
NOTE: Do not reuse O-rings (37) which have been removed.
AQ21002-023
[4] Cover removal

1) Turn the workbench. The side of reduction gear is
turned up.
2) Remove ring (45) using steel rod.
3) Fix two inside bolts of a cover removal jig to in the
threaded holes of plug (33) and socket plug (39)
of cover (8).
(plug (33) and socket plug (39) are fixed usually.)
AQ21002-024
4) Place a block against two bolts outside of the

cover removal jig and tighten the bolts to allow the
cover (13) to come off little by little.
NOTE: In case of the cover (13) is hard to remove because of
resistance of O-ring (35), lift it up while lightly tapping the
outer rim of the cover by a plastic hammer.
5) Remove O-ring (35) from hub (1).
NOTE: Do not reuse O-ring (35) which has been removed.
AQ21002-025
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6002-11
[5] Sun gear 1 removal
1) Remove sun gear 1 (4).
2) Remove steel ball (41) from the sun gear 1 (4).
AQ21002-026
[6] Carrier assembly removal

1) Remove the carrier assembly from hub (1).
NOTE: The carrier assembly may pull out together with thrust
collar 1 (9).
AQ21002-027
2) Disassemble carrier assembly

1. Loosen three hexagon head bolts (40) and
remove them from carrier (3).
2. Remove thrust washer 3 (12) (3 pcs), planetary
gear 1 (5) (3 pcs), needle roller bearing (27) (3
pcs), and inner ring (29) (3 pcs) from carrier
(3).
AQ21002-028
3) Remove retaining ring (50) from sun gear 2 (6).

4) Remove sun gear 2 (6) from carrier (3).
AQ21002-029
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6002-12
[7] Planetary gear 2 removal
1) Loosen hexagon head bolt (40) (4 pcs) and
remove them from spindle (2).
AQ21002-030
2) Remove planetary gear 2 (7) (4 pcs), needle roller

bearing (28) (4 pcs) and inner ring (30) (4 pcs).
3) Remove thrust washer 2 (11) (4 pcs) from spindle
(2).
4) Remove thrust collar 1 (9) from spindle (2).
AQ21002-031
[8] Rear flange removal

1) Turn the workbench so rear flange (301) is on top.
NOTE: This work is carrying out to remove easily the plugs at
the next work.
Do not loosen the bolts if the rear flange inside is not disas-
sembled.
2) Temporarily loosen sleeve (203) (2 pcs).
AQ21002-032
3) Temporarily loosen plug (324) (2 pcs).
AQ21002-033
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6002-13
4) Temporarily loosen plug (382) (2 pcs).
AQ21002-034
5) Temporarily loosen plug (382).
AQ21002-035
6) Loosen and remove hexagon socket head cap

screw (345) (8 pcs) from rear flange (301).
AQ21002-036
7) Remove rear flange (301) from spindle (2).

NOTE: Hold the rear flange by both hands, hold it up gently
upright to remove it. Perform the work with care not to forcibly
pry or strike the flange.
Otherwise it may cause the timing plate (109) to drop and be
damaged.
AQ21002-037
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6002-14
8) Pull out parallel pin (42) (2 pcs) from spindle (2).
AQ21002-038
9) Remove O-ring (43) (2 pcs), (44) from spindle (2)

NOTE: Do not reuse O-ring (43), (44) which have been
removed.
AQ21002-039
[9] Disassembly of the rear flange mounting the parts

1) Lay removed rear flange (301) on the workbench.
(Face up the mating face with spindle (2)).
2) Remove timing plate (109) from rear flange (301).
NOTE: The timing plate might be found stuck to the mating
face of the rear flange. To separate timing plate, insert a flat
bar into the groove of the rear flange and raise the timing plate
slowly. Never try to ply the timing plate off with a sharp or
pointed tool or the precision finished mating faces will suffer
costly damage.
AQ21002-040
3) Pull out parallel pin (342) from rear flange (301).
AQ21002-041
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6002-15
4) Pull out deep groove ball bearing (150) from rear
flange (301).
AQ21002-042
[10] Disassemble SRV into rear flange

1) Remove sleeve (203) (2 pcs) from rear flange
(301).
AQ21002-043
2) Remove O-ring (207) and backup ring (208) from

valve seat (202) one by one.
NOTE: Do not reuse O-ring (207) and backup ring (208)
which has been removed.
AQ21002-044
3) Remove O-ring (212) from sleeve (203).

AQ21002-045
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6002-16
[11] Disassemble brake valve part into rear flange
1) Remove plug (324) (2 pcs) from rear flange (301).
AQ21002-046
2) Remove spring retainer (325) (2 pcs) and spring

(328) (2 pcs) from rear flange (301).
3) Remove spool (323) from rear flange (301).
NOTE: To remove spool (323), place your hand on one part
of the plug port of the rear flange (301) and tilt it down.
Then the spool (323) falls down. Hold the tip and remove it.
AQ21002-047
4) Remove O-ring (336) from plug (324).

AQ21002-048
5) Remove plug (382) (2 pcs) from rear flange (301).
AQ21002-049
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6002-17
6) Remove spring (330) (2 pcs) and valve (327) (2
pcs) from rear flange (301).
AQ21002-050

AQ21002-051
[12] Removing pilot valve into rear flange

1) Remove plug (382) from rear flange (301).
AQ21002-052
3) Remove spool (363) and spring (366) from rear

flange (301).
AQ21002-053
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6002-18
[13] Disassembly of the parking brake
WARNING: The abrupt injection of compressed air

could cause the piston (112) to pop out.
! To ensure your safety hold a protective cover over
the piston (112).
1) Remove piston (112) from spindle (2) by injecting

compressed air into the access hole in the spindle
(2).
2) Remove O-ring (135), (139) from piston (112).
AQ21002-054
NOTE: Do not reuse O-ring (135), (139) which have been
removed.
3) Remove spool (363) and spring (366) from rear
flange (301).
AQ21002-055
[14] Disassembly of the Hydraulic motor

NOTE: Place an oil receptacle just below the motor to catch
the oil.
1) Turn the GM motor 90 degrees.
2) Drain the hydraulic oil from the motor.
3) Take out mating plate (116) (3 pcs) and friction
plate (115) (2 pcs).
AQ21002-056
4) Hold the cylinder block (104) by hand, turn alter-

nately 2 - 3 times, and cut off shoe (106) adhered
on the swash plate (103).
NOTE: If remove the cylinder block (104) as-is, shoe (106)
remains adhered on swash plate (103), and the parts (piston,
shoe and etc.) mounted on the cylinder block will come off the
cylinder block and fall into the spindle (2).
AQ21002-057
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6002-19
5) Draw out cylinder block (104) from shaft (102).
6) Remove the piston ASSY ( piston (105), shoe
(106) ) and retainer plate (107) ) from cylinder
block (104).
NOTE: When removing the piston ASSY, grip retainer plate
(107) with both hands and remove together with the retainer
plate.
The piston ASSY is a minimum unit.
If replacement is necessary, replace the piston ASSY as one
unit.
AQ21002-058
7) Remove piston ASSY (9 pcs) ( piston (105), shoe

(106) ) from retainer plate (107).
AQ21002-059
8) Remove thrust ball (108) from cylinder block

(104).
AQ21002-060
9) Remove washer (111) needle roller (151) (3 pcs)

from cylinder block (104).
AQ21002-061
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6002-20
[15] Removal of the spring inside the cylinder block
1) Place cylinder block (104) on the press bench.
NOTE: The spring is removed only when replacing.
The spring is removed by lining up the shaft centers of holder ( I )
(A) and washer in order to prevent damage to the cylinder block
through contact.
Cover the cylinder block with a vinyl sheet to prevent the sliding
surfaces of the cylinder block from being damaged.
AQ21002-062
2) Place holder ( I ) on the washer (110), and while

clamping the holder with the press, remove snap
ring (145) with a snap ring pliers.
WARNING: Release press slowly. Sudden releasing

may cause spring to fly out incurring the danger of
! injury.
AQ21002-063
3) Remove snap ring (145), washer (110),spring

(114) and washer (110) from inside cylinder block
(104).
AQ21002-064
[16] Removal of the swash plate

1) Take out swash plate (103) from shaft (102).
NOTE: When removing the swash plate (103), ensure that
pivot (167) is not adhered on the swash plate.
AQ21002-065
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6002-21
2) Pull shaft (102) out of spindle (2).
Then deep groove ball bearing (149) is removed
together.
NOTE: Be careful to lightly strike the tip of the shaft on the
reduction side using a plastic hammer to allow the shaft to
come off easily. Otherwise the shaft may pop out.
AQ21002-066
3) Take out pivot (167) (2 pcs) and parallel pin (177)

(2 pcs) from spindle (2).
4) Blow compressed air through passage of the spin-
dle (2). Take out the 1st/2nd speed piston kit and
spring (190) from spindle (2).
Piston (161) + shoe (162) = piston assembly.
AQ21002-067
[17] Removal of the deep groove ball bearing

NOTE: The deep groove ball bearing is removed only when
replacing.
1) Place holder ( II ) (B) on the press bench and put
shaft (102) into the holder.
2) Remove deep groove ball bearing (149) from shaft
(102) by pressing on the shaft end with press.
NOTE: Do not reuse the removed deep groove ball bearing.
AQ21002-068
[18] Removal of the ring nut

1) Fix hub (1) and spindle (2) with the fixture. The fix-
ture should be tightened in symmetrical positions
with each other.
2) Invert the GM motor.
(The side of reduction gear is turned up).
AQ21002-069
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6002-22
3) Remove hexagon socket set screw (47) (2 pcs).
AQ21002-070
4) Loosen ring nut (22) with the bearing preload

adjuster (C).
NOTE: Do not reuse removed ring nut (22).
AQ21002-071
AQ21002-072
5) Take out ring nut (22) from spindle (2).
AQ21002-073
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6002-23
[19] Removal of the ring nut
1) Invert the GM motor. (Turn up the side of motor).
2) Remove the fixture.
3) Fasten the eyebolt (2 bolts, for M16) in the mount-
ing holes of spindle (2) so they are symmetrically
positioned.
4) Hook the hook on the eyebolts, gently and slowly
hoist with a crane and remove spindle (2) from
hub (1).
At this time, floating seal (31) and oil seal (132)
come off together. AQ21002-074
[20] Ball bearing removal

1) Remove floating seal (31) from hub (1).
NOTE: Do not reuse floating seal (31) which has been
removed.
AQ21002-075
2) Tapping the end face of ball bearing (24) with alu-

minum rod (pin punch) and hammer, remove the
ball bearing from hub (1).
NOTE: When the fit section of the outer race of ball bearing
(24) comes out of hub (1), the ball bearing (24) drop from the
hub (1).
Therefore place a receptacle under the workbench and
spread a rubber mat on the receptacle so as not to damage
the parts.
3) Turn over the travel motor.
4) Tapping the end face of outer race of ball bearing
AQ21002-076
(24) with aluminum rod (pin punch) and hammer,
remove the ball bearing from hub (1).
NOTE: Remove ball bearing (24) little by little, tapping evenly
the end face of outer race of the ball bearing at 3 or 4 points
so that the ball bearing is not suck.
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6002-24
[21] Removal of the spindle fittings
1) Remove floating seal (31) from spindle (2).
AQ21002-077
2) Remove oil seal (132) from spindle (2).

NOTE: Do not reuse floating seal (31) and oil seal (132) which
have been removed.
AQ21002-078
[22] Washing
1) Separate hub (1), spindle (2), cover (13) and rear
flange (301) from other parts. (hereafter called the
built-in parts).
2) Wash the built-in parts in a wash tank.
NOTE: Carefully wash to remove any darts from the external
surfaces.
AQ21002-079
WARNING: Wash all parts carefully with kerosene.

Take notice of a possibility of due to combustibility.
To prevent the built-in parts from being marred by dirt
! during washing, immerse the parts in kerosene long
enough for any dirt or oil to become loose and
surface before washing them,
3) Full a primary washing vessel with kerosene. Put

the built-in parts in it and wash them.
AQ21002-080
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6002-25
[23] Finish washing
1) Rinse the washed parts in the rinsing sink filled
with clean kerosene by gently shaking each parts
in the kerosene.
2) Using clean, list-free cloth, wipe each rinsed part
to remove dripping kerosene.
NOTE: Dry the inside of hub (1) and spindle (2) by spraying
with compressed air until they are dray and clean.
Let other parts dry naturally until they are dry and clean.
After drying, coat every part with oil.
AQ21002-081
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6002-26
3 Service preparation
Follow these standards when disassembling and inspecting the GM motor. Handle the various parts carefully.
Be especially careful not to damage the moving and sliding parts.
1) Seals
Once disassembled, all seals (O-rings, oil seals, floating seals) should be replaced with new ones even if no dam-
age is observed.
2) Service standards for parts subject to wear
1) Replace all parts which show striking damage.
2) Replace if various parts have the following problems (phenomenon).
No Part name Phenomenon Standard Service limit

Serious damage in appearance.
(1) Hub Occur pitting phenomenon on tooth flank of ring gear. - -
Abnormal wear such as scuffing.
Serious damage in appearance.
(2) Spindle - -
Abnormal wear such as scuffing.
(3) Carrier assembly Abnormal wear such as scuffing. - -
(4) Sun gear 1
(6) Sun gear 2 Pitting on tooth surface.
- -
(5) Planetary gear 1 Flaking phenomenon on rolling surface of bearing.
(7) Planetary gear 2
(9) Thrust washer 1
(11) Thrust collar 4 Sliding surface is tarnished. - -
(12) Thrust washer 3
Has indentation.
(24) Ball bearing Exhibits flaking phenomenon. - -
Worn unequally.
(27) Pitting phenomenon on roller.
Needle roller bearing - -
(28) Cage end face has abnormally worn.
(29)
Inner ring Exhibit flaking phenomenon on rolling face of bearing. - -
(30)
(301) Rear flange Flaw on sliding part with spool (323). - -
Working face with oil seal (132) is worn.
(102) Shaft - -
Spline is worn.
(103) Swash plate Has burning phenomenon. - -
Spline section is worn.
Inner surface of bore is worn too much.
(104) Cylinder block - -
Flaw and wear on sliding surface with timing plate
(109).
Piston assembly Clearance is found in the axial direction between
(105) Clearance Clearance
Piston piston (105) and shoe (106).
(106) 0.05 mm 0.15 mm
Shoe Shoe is abnormally worn and nequally worn.
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6002-27
No Part name Phenomenon Standard Service limit

Sliding part with shoe (106) is worn unequally.
(107) Retainer plate Flaw and unequal wear on sliding surface with - -
thrust ball (108).
Ball surface sliding part with retainer plate (107) is
(108) Thrust ball - -
worn unequally.
Sliding surface has burning phenomenon and une-
(109) Timing plate - -
qual wear.
Braking Braking
Both end faces are unequally worn.
(115) Friction plate torque torque
Torque is not specified torque.
(116) Mating plate 120 Nm 120 Nm
Has burning phenomenon.
or more or more
(105) Piston Flaw on circumference - -
Has indentation.
(149) Deep groove ball
Exhibits flaking phenomenon. - -
(150) bearing
Worn unequally.
Dual speed piston kit
(161) Circumference is abnormally worn.
Piston - -
(162) Shoe is abnormally worn and unequally worn.
Shoe
(323) Circumference worn unequally.
Spool - -
(363) Flaw on circumference.
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4 Assembly
Assembly, as a rule, assembly is carried out by performing the procedure for disassembly in reverse.
1) Preparations.
1) Provide a workbench, tools and materials in the same way as for disassembly of section 2.
2) General suggestion when working
1) Pay the same attention as for general suggestions for disassembly of section 2.
2) When assembling, remove all foreign objects or metal fragments from parts, and make sure there are no
burrs or dents, etc., on parts. If there are burrs or dents, remove with an oilstone.
3) Replace O-ring, oil seals and floating seals with new ones.
4) Grease is applied to the threaded portions, tapped holes of spindle (2) as adhesive agent when assembling.
Remove their grease by using the tap (M10 P1.5), and wash with solvent. After that, degrease solvent of the
holes by spraying with compressed air.
Replace hexagon head bolt (51) with new ones.
5) Grease is applied to the threaded portions, tapped holes of carrier (3) as adhesive agent when assembling.
Remove their grease by using the tap (M8 P1.25), and wash with solvent. After that, degrease solvent of the
holes by spraying with compressed air.
Replace hexagon head bolt (40) with new ones.
6) Be careful not to damage O-rings, oil seals and floating seals when mounting. (Apply a small amount of
grease to make them slippery.)
7) Be sure to coat the moving and sliding parts of the hydraulic motor section and valve section with clean
hydraulic fluid (NAS standard class 9 or less) and assemble.
8) Do not use cloth gloves for assembly. (To prevent fiber pieces from causing faulty operation.)
9) Bolts and plugs should be tightened by the torque value given in 2. Tightening Torque table.
10) When assembly is complete, plug all ports to prevent dirt from entering.
11) The photographs and drawing contained in the manual are of representative models.
Disassembly procedure is however not affected even if the product you are using differs in part.
3) Assembly procedure
NOTE: If reassembling after replacing parts, preload adjustment of the main bearing is necessary.
Before assembling, therefore, make sure the following parts have been replaced.
NOTE: If reassembling after replacing the parts listed above, be sure to reassemble using parts that have been
adjusted. If you reassembly with parts that have not been adjusted, it will cause the travel motor to operate poorly or
break down prematurely.
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[1] Hub section reassembly
1) Place hub (1) on the press bench.
2) Insert the ball bearing (24) into hub (1).
Place a press tool (A) on the peripheral rim of ball
bearing (24) and press it and fit the ball bearing
into the hub little by little.
3) Turn the hub (1) upside down.
4) Insert ball bearing (24) into hub (1) in the same
way.
NOTE: Make sure that the installing direction ofball bearing
AQ21002-082
(24) is correct.
5) Apply thinly grease on the outside circumference

ofthe O-ring of floating seal (31), and fit the float-
ing seal in the floating seal groove of hub (1).
NOTE: When applying grease to the O-ring of the floating
seal, remove the O-ring from the floating seal and apply lightly
grease to the entire surface of it .
NOTE: To mount floating seal, place the floating seal installa-
tion tool ( II ) (D), floating seal and floating seal installation tool
( III ) (E) in that order, and press in until floating seal installa-
tion tool ( II )) reaches floating seal installation tool ( III ).
Remove the installation tools, and make certain that the end
face of the hub and the face of the floating seal are parallel AQ21002-083
with each other within a tolerance of 1 mm.
6) Fasten two eyebolts in the screw holes of hub (1)
so they are symmetrically positioned.
7) Hook the hook and wire in the eyebolts, hoist the
hub (1) with a crane, and set the hub (1) on the
workbench.
NOTE: While matching the screw holes of hub (1) and mount-
ing holes of the workbench, place the hub gently in the mount-
ing holes of the workbench.
AQ21002-084
8) Fasten hub (1) to the workbench so that the hexa-

gon socket bolts are symmetrically positioned.
WARNING: Tighten the hexagon socket bolts

securely.
! WARNING: Failure to do so could result in injury if
the travel motor is inverte
AQ21002-085
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6002-30
[2] Spindle assembly
1) Apply grease thinly on the outside circumference
of the O-ring of floating seal (31) and mount the
floating seal in the floating seal groove of spindle
(2).
NOTE: To mount the floating seal, place the floating seal installa-
tion tool ( III ) (E), floating seal and floating seal installation tool (
II ) (D) in that order, and press in until floating seal installation tool
( II ) reaches floating seal installation tool ( III ).
Remove the installation tools, and check the inclination of the
surface of the floating seal to make sure it is within 1 mm.
AQ21002-086
2) Install eyebolts to spindle (2) so they are symmet-

rically positioned.
3) Hook a wire with hook to eyebolts, lift the spindle
(2) by crane, and then insert the spindle in hub (1)
slowly.
AQ21002-087
4) Fix hub (1) and spindle (2) with the fixture in diag-
onal position.
AQ21002-088
5) Invert the GM motor. (Turn up the side of reduction

gear).
6) Apply Loctite 638 to the thread part of ring nut
(22).
7) The ring nut to the spindle (2) with the bearing
preload adjuster (F).
Then, fit the ring nut (22) to the spindle (2) so that
a side with large camfering may be on a ball bear-
ing (24) side.
Tightening torque: 588 ± 55.8 Nm
AQ21002-089
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8) Tighten hexagon socket set screw (47) (2 pcs)
with specified torque.
Tightening torque : 9.81 ± 1.60 Nm
9) After tightening up the screws, deform the
entrance of the threaded holes for avoiding loos-
ening screws.
AQ21002-090
10) Inver the GM motor. (Turn up the side of motor)

11) Remove the fixture.
AQ21002-091
[3] Assemblng spindle fittings

1) Press fit oil seal (132) into spindle (2) with the
holder ( III ) (E) and a hammer.
NOTE: Apply lithium grease the lip section of the oil seal when
mounting the oil seal.
Press oil seal (132) bore to spindle (2) using the holder ( III ) and
hammer.
AQ21002-092
2) Install parallel pin (177) (2 pcs) into the pin holes

of the spindle (2).
3) Apply lithium grease to the hemispherical surface
of pivot (167) (2 pcs), and fit it into parallel pin
(177) of spindle (2).
4) Apply lithium grease to spring (190), and install
the spring into the piston kit (piston (161), shoe
(162)).
5) Apply hydraulic fluid to the sliding surface of the
piston ASSY, install it into the piston hole of spin-
dle (2).
AQ21002-093
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[4] Installing shaft
WARNING: Wear thick leather grooves in handling

! the heated deep groove ball bearing.
1) Put deep groove ball bearing (149) in a heating

tank to heat it at 100 ± 10°C for ten minutes, it
puts on the holder ( II ) (D), it does shaft (102) at
the press fitting by the press.
AQ21002-094
2) Fit motor shaft (102) slowly into the spindle (2).

3) Turn the workbench 90 degrees.
NOTE: Take care not to scratch or cut the lip portion of the oil
seal in place with the splined foremost end of the shaft.
AQ21002-095
4) Install swash plate (103) to spindle (2).

NOTE: Apply lithium grease to the swash plate (103) where mat-
ing surface of the spindle (2).
Make sure that the locating the pivot (167) of the spindle (2)
enters the pivots hole of the swash plate (103).
AQ21002-096
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[5] Assembly of cylinder block interior
NOTE: Introduce the sharp side of the angled section of the THS
snap ring (145) and washer (110) as shown in the figure on the
left.
1) Insert washer (110), spring (114), washer (110)
and snap ring (145) in that order into cylinder
block (104).
2) Place cylinder block (104) on the press bench.
AQ21002-097
WARNING: Press force of spring (114) is 1180 N or

more.
Protect by covering cylinder block (104) with a vinyl
! sheet so the contact surface with timing plate (109) of
cylinder block (104) does not become damaged.
3) Place holder ( I ) on washer (110), and while

clamping with press, fit snap ring (145) in the snap
ring groove of cylinder block (104) with a snap ring
pliers.
AQ21002-098
[6] Assembly of the hydraulic motor parts

1) Place needle roller (151) (3 pcs) into the cylinder
block (104) and place thrust ball (108) on the top.
AQ21002-099
2) Install the piston assembly (9 pcs) into the retainer

plate (107).
NOTE: After assembling, dip the whole thing in hydraulic fluid.
3) Fit retainer plate (107) and the piston assembly (9
pcs) into cylinder block (104).
NOTE: Match the round surface sections of retainer plate
(107) and thrust ball (108).
AQ21002-100
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4) Install cylinder block (104) to shaft (102).
NOTE: Install cylinder block (104) into the spline of shaft (102)
by aligning the spline hole with the spline of the shaft.
AQ21002-101
5) After installing the cylinder block (102), turn it by

hand and make sure that it fits properly. If not,
inspect it.
NOTE: After installing the cylinder block (104), do not raise it.
If it raises, thrust ball (108) separates and cylinder block do
not rotates.
AQ21002-102
[7] Assembly of parking brake section

NOTE: Install the friction plate to the cylinder block after
immerse the friction plate (115) in hydraulic fluid.
1) Turn the workbench 90 degrees.
2) Install mating plate (116).
AQ21002-103
3) Friction plate (115) into the groove outside of cyl-

inder block (104) alternately.
Then install mating plate (116), friction plate (115)
and mating plate (116).
4) Fit O-ring (135), (139) to the O-ring groove of pis-
ton (112).
At this time, apply a thin coat of grease to the O-
rings.
5) Install piston (112) into spindle (2).
NOTE: If the piston (112) doesnÕt fit into the spindle (2)
because of the resistance of the O-rings, tap the edge of the
AQ21002-104
piston (112) lightly and equally with a plastic hammer.
Be careful not to damage the O-rings at this time
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6002-35
[8] Assembly of the brake valve parts in the rear flange
1) Fit O-ring (338) (2 pcs) to the plug (382) (2 pcs).
NOTE: Apply grease to O-ring (338) (2 pcs).
2) Install valve (327) (2 pcs), and spring (330) (2 pcs)
on rear flange (301).
At this time, apply grease and on it to connect the
valve (327), spring (330) and plug (382) by cohe-
sion of the grease.
AQ21002-106
3) Insert the plug (382) (2 pcs) assembled in one

piece in rear flange (301) and temporarily tighten.
NOTE: For insertion of plug (382), place facing the tapped
hole for plug mounting of rear flange (301) upward and align
the center of tapped hole with the plug center. This is intended
to prevent the O-ring from being damaged and spring (330)
from coming out of valve (327) due to contact between the
bore of the rear flange and the valve.
NOTE: If spring (330) separates from valve (327), valve (327)
do not touch the sheet side of rear flange (301) correctly, and
causes an leak of oil.
AQ21002-107
4) After inserting plug (382) (2 pcs), temporarily

tighten into rear flange (301) by a hexagon
wrench.
AQ21002-108
5) Insert spool (323) into rear flange (301).

NOTE: Apply hydraulic fluid to the spool and insert the spool
into the rear flange.
To install the spool, align the hole of the rear flange with the
spool shaft center so as to prevent the inner surface of the
rear flange and the outer surface of the spool from being dam-
aged due to interference.
Otherwise internal leaks will occur after reassembly, resulting
in performance deterioration of the travel motor.
AQ21002-109
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6) Insert O-ring (336) into plug (324).
NOTE: Apply grease to O-ring (336).
AQ21002-110
7) Install stopper (325) and spring (328) to the plug

(324) (2 pcs).
8) Tighten plug (324) (2 pcs) into rear flange (301).
NOTE: When tighten the plugs into the rear flange, insert
carefully so as not to deform the spring.
9) Temporarily tighten two plugs (324) into rear
flange (301) by spanner.
AQ21002-111
[9] Reassembling SRV part into rear flange

1) Attaches O-ring (207) and backup ring (208) onto
valve sheet (201).
2) Attaches O-ring (212) onto sleeve (203).
NOTE: Apply grease to O-ring (207), (212).
AQ21002-112
AQ21002-113
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6002-37
3) Insert sleeve (203) onto rear flange (301).
AQ21002-114
4) Temporarily tighten sleeve (203) (2 pcs) by span-

ner.
NOTE: When thrusting plug into rear flange (301), insert plug
carefully so that a spring may not change.
AQ21002-115
[10] Assembly of the rear flange mounted parts

1) Put rear flange (301) on the workbench, with its inner
face up.
1) It unites as a spindle (2), a field is turned down,
and a rear flange is placed.
2) Insert spring (366) and spool (363) into rear flange
(301).
NOTE: When thrusting plug into rear flange, insert plug care-
fully so that a spring may not change.
AQ21002-116
3) Fit O-ring (338) to plug (382).

4) Tighten plug (382) into rear flange (301).
5) Temporarily tighten plug (382) into the rear flange
(301).
2) Apply hydraulic fluid to deep groove ball bearing (150),
and fit the deep groove ball bearing into rear flange
(301).
3) Insert parallel pin (342) (2 pcs) in the pin holes of rear
flange (301).
AQ21002-117
4) Apply grease to the mating face of timing plate (109) in
contact with rear flange (301) of timing plate (109).
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6002-38
5) Fit timing plate (109) on rear flange (301) using parallel
pin (342) and deep groove ball bearing (150) as a
guide.
NOTE: Fitting of timing plate (109) is carried out until the tim-
ing plate adheres to the rear flange (301).
Adhesion prevents the timing plate (109) from falling from the
rear flange (301) when mounting the rear flange (301) on
spindle (2).
6) Install spring (113) (10 pcs) into rear flange (301).
NOTE: Apply grease to the spring enough prevents the spring
(113) (10 pcs) falling from the rear flange (301).
AQ21002-118
[11] Connection of the rear flange with the spindle

1) Fit O-ring (43), (44) in the O-ring groove of spindle
(2).
NOTE: Fit O-ring (43) without applying grease.
If reassembled with grease applied, the grease may bleed
from the mating face of rear flange (301) and spindle (2) when
the travel motor is running.
This may be mistaken as an oil leak, so do not apply grease.
AQ21002-119
2) Insert parallel pin (42) (2 pcs) into spindle (2).

3) Apply hydraulic fluid in timing plate (109) of cylin-
der block (104).
AQ21002-120
4) Install rear flange (301) onto spindle (2) so that

two parallel pins (42) on the spindle enter the pin-
holes in the rear flange.
AQ21002-121
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6002-39
5) Tighten hexagon socket head cap screw (345) (8
pcs) equally and evenly with the specified torque.
NOTE: When it installs rear flange (301) onto spindle, mount
spring (113) (10 pcs) to rear flange side.
Apply grease to the spring enough prevents the springs falling
from the rear flange (301).
AQ21002-122
6) Tighten plug (382) with the specified torque.

Tightening torque: 98.1 ± 19.6 Nm
AQ21002-123
7) Sleeve (203) with the specified torque.

AQ21002-124

AQ21002-125
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6002-40
AQ21002-126
[12] Carrier assembly

1) Insert sun gear 2 (6) on carrier (3), and insert
retaining ring slot of sun gear 2 (6).
AQ21002-127
2) Install inner ring (29) (3 pcs), needle roller bearing

thrust (27) (3 pcs), planetary gear 1 (5) (3 pcs)
and washer 3 (12) (3 pcs) in that order to carrier
(3).
NOTE: If the tapped hole of carrier (3) is smeared oil or
grease, degrease it by using the tap (M8 P1.25). After that
clean it with solvent, and degrease the solvent of the holes by
spraying with compressed air.
Otherwise axial-force does not occur enough, and it may
cause bolt to loosen.
AQ21002-128
3) Install thrust washers 3 (12) (3 pcs) in that order to

carrier (3) with installation tool (carrier (3)).
4) Install thrust washer 3 (12) (3 pcs) to the carrier
(3) with hexagon head bolt (40) (3 pcs).
Tightening Torque: 33.3 ± 4.9 Nm
NOTE: When it do not use jig, be careful circumference of a
companion of tighten thrust washer 3 (12). After tightening,
check to rotate planetary gear smooth.
AQ21002-129
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6002-41
[13] Planetary gear 2 assembly
1) Turn the workbench upside down. (Turn up the
side of reduction gear).
2) Install thrust collar 1 (9) to spindle (2).
AQ21002-130
3) Install thrust washer 2 (11) (4 pcs), finner ring (30)

(4 pcs) to the pole of spindle (2).
NOTE: It is careful in the inserting direction of four thrust
washers 2 (11) (4 pcs).
Bigger chamfered
or press droop
AQ21002-131
4) Install thrust washer 2 (11) (3 pcs) and inner race

(30) (4 pcs) onto the pole of spindle (2).
5) Install needle roller bearing (28) (4 pcs) onto the
pole of spindle (2).
6) Fit planetary gear 2 (7) (4 pcs) to each pole of
spindle (2), meshing with internal teeth of hub (1).
NOTE: If the tapped hole of spindle (2) is smeared oil or
grease, degrease it by using the tap(M10 P1.5). After that
clean it with solvent, and degrease the solvent of the holes by
spraying with compressed air.
Otherwise axial-force does not occur enough, and it may
AQ21002-132
cause bolt to loosen.).
7) Install thrust washers 3 (12) (3 pcs) in that order to

carrier (3) with installation tool (carrier (3)).
8) Install thrust washer 3 (12) (3 pcs) to the carrier
(3) with hexagon head bolt (40) (3 pcs).
Tightening Torque: 57.9 ± 9.81 Nm
NOTE: When it do not use jig, be careful circumference of a
companion of tighten thrust washer 3 (12). After tightening,
check to rotate planetary gear smooth.
AQ21002-133
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6002-42
[14] Carrier assembly
1) Install the carrier ASSY, meshing with internal
teeth of hub (1) and planetary gear 2 (7).
AQ21002-134
[15] Sun gear 1 assembly

1) Insert sun gear 1 (4) to shaft (102).
At this time , install steel ball (41) to sun gear 1
(4).
NOTE: When installing the steel ball, apply grease to the steel
ball (41) for prevent it falling down from the sun gear 1.
2) Fit sun gear 1 (4), meshing with planetary gears 1
(5) (3 pcs).
AQ21002-135
[16] Cover assembly

1) Fit O-ring (35) in the O-ring groove of hub (1).
2) Place cover (13) on hub (1).
NOTE: Install cover (13) onto the hub (1), tapping the outer
circumference of the cover (13) with a plastic hammer. Be
careful not to install the cover (13) forcibly by striking.
Otherwise the O-ring (35) is damaged resulting in oil leakage,
and it may cause lubricating oil to belch from tapped holes.
AQ21002-136
3) Install ring (45) in the ring groove of hub (1).

NOTE: The free gap of ring (45) does not install onto the
notch of hub (1).
AQ21002-137
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6002-43
4) Introduce 1.1 liters of lubricating oil into hub (1).
AQ21002-138
5) Fit O-ring (37) to plug (33) and socket plug (39).

NOTE: Apply grease thinly to O-ring (37) thinly.
6) Tighten plug (33) and socket plug (39) with the
specified torque to the cover (13).
AQ21002-139
[17] Remove the reassembled GM motor from the work-

bench
1) Turn the workbench upside down.
2) Remove the bolts securing the GM motor to the
workbench.
3) Fasten two eyebolts to spindle (2).
NOTE: Be sure that the two eyebolts are opposite to each
other.
4) Hook the hook and wire on the eyebolts and
remove the GM motor from the workbench with a
AQ21002-140
crane.
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6002-44
5 Performance confirmation test
After servicing the GM motor, perform the following tests by the following procedure.
1 Required measuring devices
1 Pressure gauge for 3.43 MPa 2 pieces
2 Measuring cylinder (for 5 liters) 1 piece
3 Stop watch 1 piece
2 Test procedure
Installation and Install and connect the travel motor to the machine body (frame section).
1 connection of However, do not attach the track shoe.
travel motor This is to perform the travel motor performance test (no-load operation)
Note : • When connecting, connect the travel motor so that the pressure gauge
(main circuit) can be installed and the drain amount of the hydraulic motor
can be measured.
• Whem installing GM motors, do not strike them with a hammer or other
instrument. Use the bolt holes to gently install the motor.
Travel motor
Travel motor Rotation Operation
2 breaking-in Switching Pressure
speed direction time
operation
Low speed rotation 10 min-1 Each 1 min.

No load Left or right
or longer
High speed rotation 20 min-1
3 Travel motor performance confirmation test
Pre-test preparation operation

• Perform preparation operation until the temperatures indicated below are reached.
1
• Hydraulic oil temperature: 45~55°C
• Reduction gear hub external temperature: 40~80°C
Confirmation test
• Measure the items below at low speed to determine whether travel motor is acceptable.
2 Criteria for acceptability
Travel motor drive pressure difference: 1.57 MPa or less at 10 min-1
Hydraulic motor drain amount: 0.6 L/min at 10 min-1
Acceptable Not acceptable
Attach the track shoe Disassemble and adjust again
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6002-45
6 Exploded diagram of reduction gear
AQ21002-0142
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6002-46
7 Exploded diagram of hydraulic motor
AQ21002-0143
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6002-47
8 Internal structure diagram
KAA10310-A01
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6002-48
9 Travel unit part table
Sym Part name Q’ty Sym Part name Q’ty Sym Part name Q’ty
1 Hub 1 103 Swash plate 1 208 Backup ring 4
2 Spindle 1 104 Cylinder block 1 211 O-ring 2
3 Carrier 1 105 Piston 9 212 O-ring 2
4 Sun gear 1 1 106 Shoe 9 213 Shim 2
5 Planetary gear 1 3 107 Retainning plate 1 214 Piston 2
6 Sun gear 2 1 108 Thrust ball 1 215 O-ring 2
7 Planetary gear 2 4 109 Timing plate 1 216 Backup ring 4
9 Thrust coller 1 1 110 Washer 2 301 Rear flange 1
10 Thrust washer 1 4 111 Washer 1 321 Plug 1
11 Thrust washer 2 4 112 Piston 1 323 Spool 1
12 Thrust washer 3 3 113 Spring 10 324 Plug 2
13 Cover 1 114 Spring 1 325 Spring retainer 2
22 Ring nut 1 115 Spring 2 327 Valve 2
24 Ball bearing 2 116 Mating plate 3 328 Spring 2
27 Needle roller bearing 3 132 Oil seal 1 330 Spring 2
28 Needle roller bearing 4 135 O-ring 1 336 O-ring 2
29 Inner ring 3 139 O-ring 1 338 O-ring 3
30 Inner ring 4 145 Snap ring 1 342 Parallel pin 1
31 Floating seal 2 149 Ball bearing 1 345 Hex. socket bolt 8
33 Plug 1 150 Ball bearing 1 352 Hex. socket plug 5
35 O-ring 1 151 Roller 3 363 Spool 1
37 O-ring 3 161 Piston 1 366 Spring 1
39 Socket plug 2 162 Shoe 1 368 Steel ball 1
40 Hex. head bolt 3 167 Pivot 2 375 Hex. socket plug 4
41 Steel ball 1 171 Parallel pin 2 377 Orifice 2
42 Parallel pin 2 190 Spring 1 379 Filter 1
43 O-ring 2 201 Valve seat 2 380 Orifice 1
44 O-ring 1 202 Valve 2 382 Plug 3
45 Ring 1 203 Sleeve 2 383 Plug 1
47 Hex. socket set screw 2 204 Coller 2 392 O-ring 1
50 Retainning ring 1 205 Plug 2 399 Name plate 1
51 Hex. head bolt 4 206 Spring 2
102 Shaft 1 207 O-ring 2
ASM-17-21-002 Issued 08-2008

Copyright ©
Section
6003
6003

SWING MOTOR AND SWING REDUCTION GEAR

Printed in France
Copyright ©
6003-2
SWING UNIT
Air bleeder
9 10
X7
8 11
272.6 to 317.7 Nm
1
7 X22
2 252.0 to 283.4 Nm
KAC0178Z-C05
1. Turn table bearing assembly (1) 7. Liquid packing

2. High strength bolt M16x80 (22) 8. Loctite
3. High strength bolt M16x90 (24) 9. Swing motor (1)
4. Cover plate (1) 10. Knock pin (1)
5. Cork packing (1) 11. High strength bolt M16x50 (7)
6. Bolt M10x20 (2) 12. Spl bolt M16x80 (2)
ASM-17-11-002 Issued 08-2008

Copyright ©
6003-3
Notes
Coat the thread with loctite 262 after removing any oil
Inner race soft zone X24
film. (S mark position) 3 8 252.0 to 283.4 Nm
Liquid gasket should be applied between the turn table 12 252.0 to 283.4 Nm
Outer race soft zone
bearing and the revolving frame, lower frame. (Slot position)
1
The air in the swing motor should be bled off, in starting
engine after assembly or after long term storage of this
machine. And the air in the swing motor should be bled
off in accordance with the following procedure.
1) Set the engine rev. at low idle speed. loosen the
air bleeding plug of swing motor. then select lever
of swing gentlY. And should be confirm hyd. oil
coming out from air bleeding port. grease nipple
2) Completely tighten the air bleeding plug. 12

252.0 to 283.4 Nm
Tightening torque : 44.1 ~ 53.9 Nm
X2
6 4 5
KACO178Z-C05
ASM-17-11-002 Issued 08-2008

Copyright ©
6003-4
Notes
Use hydraulic of motor drain for lubrication of the gear
box. Feelthe hydrauric motor case with working fluid
before strating. (The hydraulic motor and the reduction Air bleeder
gear are not filled with the hydraulic oil. when it is deliv-
ered.) Suitable piping is recommended, such as the
motor and reduction gear are filled with the hydraulic oil
always.
Install a filter in drain line:
Recommended filtration rate:
0.074 mm (200 mesh).
1. Swing motor
2. Reduction gear assembly
-#%:#
ASM-17-11-002 Issued 08-2008

Copyright ©
8001
Section
8001
SPECIFICATIONS, TROUBLESHOOTING,
INSPECTIONS AND HYDRAULIC PRESSURE SETTING

Printed in France
Copyright ©
8001-2
TABLE OF CONTENTS
WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see
! this symbol, carefully read the message which follows. Your safety depends on it.
SPECIFICATIONS .................................................................................................................................................... 3
SPECIAL TOOLS ...................................................................................................................................................... 3

Tester .................................................................................................................................................................... 3
IDENTIFICATION OF HYDRAULIC COMPONENTS ............................................................................................... 5

Pump..................................................................................................................................................................... 5
Control valve (CX75SR MONO BOOM)................................................................................................................ 6
Control valve (CX80)............................................................................................................................................. 8
Control valve (CX75SR OFFSET BOOM)........................................................................................................... 10
MEASURING PRESSURE...................................................................................................................................... 12
PRESSURE ADJUSTMENT ................................................................................................................................... 18
BLEEDING AIR ....................................................................................................................................................... 21
FLOW CURVE ........................................................................................................................................................ 22

Copyright ©
8001-3
SPECIFICATIONS
See section 1002.
SPECIAL TOOLS
Tester
1 2
3
CD01B005
2. FEMALE COUPLING JOINT E47894 (1)
PRESSURE TEST POINT 14X1.5 A3237549 (2)
MALE COUPLING JOINT WITH UNION (3) AND
PLUGS (4) CONTAINED IN THE SUITCASE CAS
CP96E001
30038
1. TEST KIT E5444449 FOR MULTI-HANDY 2051
The Multi-Handy tester can be used every day in the
workshop for normal operations.
The Multi-Handy can be used for:
Checking pressure (two pressure scales), maximum
pressure, differential pressure (P delta), temperature,
engine rpm and flow.
1 Multi-Handy 2051 tester .......................... D5444448
2 pressure detectors (0-600 bar)................ V5344460
2 straight unions for detector..................... W5344461
1 elbow union for detector .......................... X5344462
1 engine rpm detector ................................ Z5344463
3 cables (5 m long)..................................... E3144472
CD98M009
1 electrical outlet 220V 50Hz ..................... D5344467
3. 600 LITRE FLOWMETER, ORDER THE
1 cigarette lighter cable .............................. E5344468
FOLLOWING:
1 instruction manual .................................... -------------
1 carrying case........................................... N5344476 ONE FLOWMETER RE3 Z5344486
TWO PLATES (M45X2) D4323359
TWO FLANGES (Ø 24) B8230183
FOUR HALF FLANGES D4024267
EIGHT SCREWS (12 X 75) Z1232983

Copyright ©
8001-4
CS99B532
4. SET OF UNIONS FOR PRESSURE TEST AND
HYDRAULIC FLOW CAS 30038.
CD99C002
5. SET OF HIGH PRESSURE HYDRAULIC HOSES
CAS XXXXX (INCLUDING TWO HIGH
PRESSURE HOSES).

Copyright ©
8001-5
IDENTIFICATION OF HYDRAULIC COMPONENTS
Pump
MUFFLER BRACKET
R2 R1
A2
G2
A1
G1
PPG S
A3
P3G
PP
AO14001-001
Port Description Location

S Inlet port SAE 2
A1, A2 Delivery port G3/4
A3 Delivery port G1/2
PP Pilot port G3/8
PPG Gauge port (pilot) G1/4 (plug)
P3G Gauge port (3rd pump) G1/4 (plug)
R1 Drain port G1/2 (plug)
R2 Air bleeding port M10 x 1.0 (plug)
G1, G2 Gauge port G1/4 (plug)

Copyright ©
8001-6
Control valve (CX75SR MONO BOOM)
PR5 T2 B8 B7 B6 P3
P2
BR2
A6
AR2
A7
pcc
T4
A8
BLADE
STRAIGHT
BOOM 1
pc2
BUCKET
TRAVEL
ARM 2
TRAVEL
dr2 DR1
pa7 pa6 T3
pa8
pa2
pa9
pa1
pa5
pa4 pa3 PP
BACKUP
BOOM 2
TRAVEL
SWING
ARM 1
A5 A1
T1 PT
A3 A2
P1
B1
T5 B2
B5
B3
pb5 pb4 pb3
pb2
pb1
pb6
pb8 pb7
pb9

Copyright ©
8001-7
Port Description Port Description

A1 Travel line (backward left) pb1 Travel (forward left) Pilot Line
A2 Backup Line pb2 Backup Pilot Line
A3 Swing-right Line pb3 Swing-left Pilot Line
A5 Arm-out Line pb4 Boom-down 2-speed Pilot Line
A6 Travel Line (backward right) pb5 Arm-in Pilot Line
A7 Bucket-close Line pb6 Travel (forward right) Pilot Line
A8 Boom-up Line pb7 Bucket-open Pilot Line
B1 Travel-line (forward left) pb8 Boom-down Pilot Line
B2 Backup Line pb9 Arm-in 2-speed Pilot Line
B3 Swing-left Line pc2 Load Holding at Boom
B5 Arm-in Line T1, T2, T3, T4 Return Line
B6 Travel Line (forward right) T5 Bypass Filter
B7 Bucket-open Line dr2 Pilot drain
B8 Boom-down Line pcc Backup Confluence Pilot Line
DR1 Drain AR2 Blade-up line
P1, P2, PR5, PP Pressure Line BR2 Blade-down line
P3, P4 Backup Confluence Line pra2 Blade-up pilot line
PA Attachment Signal Pressure prb2 Blade-down pilot line
Measurement
PT Travel Signal Pressure
Measurement
pa1 Travel (backward left) Pilot Line
pa2 Backup Pilot Line
pa3 Swing-right Pilot Line
pa4 Boom-up 2-speed Pilot Line
pa5 Arm-out Pilot Line
pa6 Travel (backward right) Pilot Line
pa7 Bucket-close Pilot Line
pa8 Boom-up Pilot Line
pa9 Arm-out 2-speed Pilot Line

Copyright ©
8001-8
Control valve (CX80)
BR2 PR5 BR1 T2 B8 B7 B6 P3

P2
BR3
A6
AR3
A7
AR2 T6 pcc
T4
A8
AR1
pra3
pra1
pra2
BACKUP 2
BOOM SWING
BLADE
BOOM 1
BUCKET
pc2
TRAVEL
STRAIGHT
ARM 2
TRAVEL
pa7 DR1
dr2
pa8 T3
pa9 pa6
pa5 pa1
BACKUP 1
pa2
MOUNTING DIRECTION
pa4
TRAVEL
BOOM 2
pa3
SWING
ARM 1
PP
A3
UP
PT
PA
A5
A1
T1
A2
B5 P1
P4
T5
B4 B1
B3 B2
pb5 pb4 pb3 pb2 pb1
prb3 prb2 prb1
pb9 pb8 pb7 pb6

Copyright ©
8001-9

A2 Backup Line pb2 Backup Pilot Line
A7 Bucket-close Line pb6 Travel (forward right) Pilot Line
B1 Travel-line (forward left) pb8 Boom-down Pilot Line
B2 Backup (1) Line pb9 Arm-in 2-speed Pilot Line
P1, P2, PP Pressure Line BR2 Blade-down line
P3, P4 Backup Confluence Line pra2 Blade-up pilot line
Measurement
PT Travel Signal Pressure pra1 Swing-right pilot line
Measurement
pa1 Travel (backward left) Pilot Line prb1 Swing-left pilot line
pa2 Backup Pilot Line AR1 Swing-right line
pa3 Swing-right Pilot Line BR1 Swing-left line
pa4 Boom-up 2-speed Pilot Line pra3, prb3 Buckup (2) pilot line
pa5 Arm-out Pilot Line AR3, BR3 Buckup (2) line
pa6 Travel (backward right) Pilot Line PR5 Blade pressure line
pa7 Bucket-close Pilot Line B4 Plug

Copyright ©
8001-10
Control valve (CX75SR OFFSET BOOM)
PR5 T2 B8 B7 B6 P3
P2
BR2
A6
AR2
A7
pcc
T4
A8
pc2
BLADE
STRAIGHT
BUCKET
BOOM 1
TRAVEL
ARM 2
TRAVEL
dr2 DR1
pa7 pa6 T3
pa8
pa2
pa9
pa1
pa5
pa4 pa3 PP
BACKUP
BOOM 2
TRAVEL
SWING
ARM 1
A5 A1
T1 PT
A3 A2
P1
B1
T5 B2
B5
B3 pb3 pb2
pb5 pb4
pb1
pb6
pb8 pb7
pb9

Copyright ©
8001-11

A2 Backup left Line pb2 Offset right Pilot Line
A7 Bucket-close Line pb6 Travel (forward line) Pilot Line
B1 Travel line (forward left) pb8 Boom-down Pilot Line
B2 Offset right Line pb9 Arm-in 2-speed Pilot Line
P1, P2, PR5, PP Pressure Line BR2 Blade-down line
P3 Backup Confluence Line pra2 Blade-up pilot line
Measurement
PT Travel Signal Pressure
Measurement
pa1 Travel (backward left) Pilot Line
pa2 Offset left Pilot Line
pa3 Swing-right Pilot Line
pa4 Boom-up 2-speed Pilot Line
pa5 Arm-out Pilot Line
pa6 Travel (backward right) Pilot Line
pa7 Bucket-close Pilot Line

Copyright ©
8001-12
MEASURING PRESSURE
1) Basic Conditions
Oil temperature 45 - 55 °C {113 - 131°F°}

Engine revolutions at no load 2200 rpm {2200 min-1}
2) Pressure Settings
Relief valve Actual readings

Method of
Individual pressure measured on machines
measurement
settings (reference)
29.4 MPa at 44 L/min 29.7 MPa
Main relief pressure Arm relief
{4264 psi at 11.6 gpm} {4307 psi}
Fasten main relief 180°
Up +
{4626 psi at 5.3 gpm} {4858 psi}
Boom overload Boom-up relief
relief Fasten main relief 180°
Down +
{4626 psi at 5.3 gpm} {4815 psi}
Boom-down relief
Out +
{4626 psi at 5.3 gpm} {4742 psi}
Arm overload Arm-out relief
In +
{4626 psi at 5.3 gpm} {4786 psi}
Arm-in relief
Open +
{4626 psi at 5.3 gpm} {4800 psi}
Bucket overload Bucket-open relief
Close +
{4626 psi at 5.3 gpm} {4800 psi}
Bucket-closed relief
22.6 MPa at 57.5 L/min 25.0 MPa
Right Swing relief
{3277 psi at 15.2 gpm} {3625 psi}
Swing relief
22.6 MPa at 57.5 L/min 25.0 MPa
Left Swing relief
{3277 psi at 15.2 gpm} {3625 psi}
33.3 MPa at 20 L/min 33.7 MPa Fasten main relief 180°
Right
Boom Swing port {4830 psi at 5.3 gpm} {4888 psi} + Boom swing-right relief
relief (CX80) 31.9 MPa at 20 L/min 32.9 MPa Fasten main relief 180°
Left
{4626 psi at 5.3 gpm} {4772 psi} + Boom swing-left relief
Main Blade-up relief
{3277 psi at 6.3 gpm} {3379 psi}
Fasten blade main relief 180°
Blade Over- Up +
{3698 psi at 5.3 gpm} {3843 psi}
load Blade-up relief
relief 25.5 MPa at 20 L/min 26.5 MPa Fasten blade main relief 180°
Down
{3698 psi at 5.3 gpm} {3843 psi} + Blade-down relief
4.2 MPa 3.8 MPa
Pilot relief Lever neutral
{609 psi} {551 psi}

Copyright ©
8001-13
3) Ports for Measuring Pressure
1] Main pump
MAIN PUMP
ENGINE
BLADE PUMP
PILOT PUMP
G2
PRESSURE DETECTION PORT G1/4
A2 RIGHT TRAVEL SIDE DELIVERY

PORT
G1 PRESSURE DETECTION PORT G1/4
FRONT SIDE OF BODY
A1 LEFT TRAVEL SIDE DELIVERY PORT
PG3 BLADE PUMP PRESSURE DETECTION PORT G1/4
2] Pilot line
PRG

Copyright ©
8001-14
4) Preparation for Measuring Pressure
1] Items needed
•Pressure gauges for 50 MPa {7250 psi}
for 10 MPa {1450 psi}
•Tools: Spanners (closed wrench),
17 mm and 27 mm
Hexagonal bar wrenches,
5 mm and 6mm
•Other: Cloth, cleaning solution,
temperature gauge
Temperature gauge
2] Positioning the machine

•Position the machine on solid level ground.
Lower the boom so the arm end touches the ground with the bucket cylinder out at stroke end and
the arm cylinder out at stroke end.
The blade should also be lowered to touch the ground.

Copyright ©
8001-15
3] Relieving pressure in circuit
•Turn the starter switch off and confirm that the engine has stopped. Turn the key on again.
NOTE: Do not start the engine.
•Operate each lever 10 times or more and check that the attachments no longer move. Then turn off
the starter switch.
4] Relieving pressure in hydraulic oil tank

•Press the air breather button located on the hydraulic oil tank to release the pressure in the tank.
5] Attaching the pressure gauge

See section 3 on the previous page for the port positions for measuring.
Measuring actuator Port Pressure gauge Port size Tool

Main, Left travel, Off- 49.1 MPa Hexagonal bar wrench
G1 G1/4
sett,Swing, Arm {7221 psi} 6 mm
Main, Right travel, 49.1 MPa Hexagonal bar wrench
G2 G1/4
Bucket, Boom {7221 psi} 6 mm
9.8 MPa
Pilot P2 G1/4 Spanner 17 mm
{1421 psi}
49.1 MPa Hexagonal bar wrench
Blade P3G G1/4
{7221 psi} 6 mm
6] Checking oil temperature

Check hydraulic oil temperatures using a temperature gauge.
Oil temperature 45 - 55 °C (113 - 131 °F)
If the oil temperature is low, follow the instructions for warm-up in the Operator’s Manual to
increase the temperature.
The preparation is now complete.

Copyright ©
8001-16
5) Measuring Pressure
1] Main relief pressure
Lever operation Arm-in relief

Pressure gauge to be used 50 MPa {7250 psi}
Pressure setting 29.4 ± 1.0 MPa {4264 ± 145 psi}
2] Swing relief pressure
Lever operation Swing relief

Attach the pressure gauge to the G1 side of the pressure detection port on the main pump.
When measuring the pressure for swing, first activate the mechanical brake by disconnecting the
connector on the swing pressure switch located on the lower left of the cab.
The swing pressure switch will be revealed after removing the side cover located on the lower left
of the cab. See the figure below.
CAUTION
Before positioning the swing lever in place for the first time, the engine revolutions should
be reduced to approximately 1100 min-1{1100 rpm}.
When the swing is confirmed to be no longer moving, increase the engine revolutions to
the maximum.
Disconnecting the hose to the swing motor’s parking release port PB or inserting the
connector of the solenoid valve for switching for high speed into swing brake solenoid to
change the speed to high mode would also work for measuring pressure along with dis-
connecting the connector.
(At this point, leave the connector for the swing brake solenoid disconnected.)
HIGH
SPEED TRAVEL
GATE LOCK
FRONT SIDE
OF BODY
SWING BRAKE
BOTTOM OF CAB SWING PRESSURE SWITCH

Copyright ©
8001-17
3] Pilot relief pressure
Lever operation Neutral

4] Blade relief pressure
Main relief pressure for blade
Lever operation Blade up

Overload relief pressure for blade
Lever operation Blade up/down

Overload relief pressure for boom swing (CX80)
Lever operation Boom swing-right/left

Pressure gauge to be used 49.1 MPa {7121 psi}
Actual pressure setting (Right) 33.7 ± 1.0 MPa {4888 ± 145 psi}
Actual pressure setting (Left) 32.9 ± 1.0 MPa {4772 ± 145 psi}
When measuring the overload relief pressure, fasten the main relief valve of the blade 180° to
temporarily adjust it.
5] Other overload relief pressures
Boom Boom Bucket Bucket Offset right Offset left

Lever operation Arm out Arm in
up down open closed (CX75SR) (CX75SR)
Actual pressure 33.5 ± 1.0 MPa 33.4 ± 1.0 MPa 32.8 ± 1.0 MPa 32.9 ± 1.0 MPa 33.7 ± 1.0 MPa
reading {4860 ±145 psi} {4844 ±145 psi} {4760 ±145 psi} {4770 ±145 psi} {4890 ±145 psi}
Port for detection G2 G1 G2 G1
Temporary adjustments are required because the overload relief pressures of the attachments
are set higher than those for the main relief.

Copyright ©
8001-18
PRESSURE ADJUSTMENT
1) Pressure Adjusting Points
1] Control valve (CX75SR)
OFFSET RIGHT OFFSET LEFT
BLADE UP BLADE DOWN
ARM 1 OUT
ARM 2
ARM 1 IN BOOM 1
B00M 2 UP BOOM 1 UP
BOOM 2 DOWN DOWN
SWING RIGHT BUCKET BUCKET
SWING LEFT CLOSED OPEN
OPTION IN OPTION OUT TRAVEL
TRAVEL FORWARD
TRAVEL BACKWARD
TRAVEL BACKWARD RIGHT
FOWARD RIGHT
LEFT
LEFT
FRONT SIDE OF BODY FRONT SIDE OF BODY

VIEWED FROM THE INTERNAL SIDE BODY
VIEWED FROM THE EXTERNAL SIDE OF BODY
Tool needed
Pressure per one turn of
Location Adjustment Pressure setting
Lock nut adjustment screw
screw
1 Main 29.4 MPa {4260 psi} 17.8 MPa {2580 psi}
2 Boom up
33.5 MPa {4860 psi}
3 Boom down
4 Arm out
33.4 MPa {4844 psi}
5 Arm in
6 Bucket open
32.8 MPa {4760 psi}
7 Bucket closed Hexagonal
17 mm wrench
8 Option in 6 mm 21.2 MPa {3070 psi}
31.9 MPa {4630 psi}
9 Option out
10 Blade, offset main 23.0 MPa {3335 psi}
11 Blade up
26.4 MPa {3830 psi}
12 Blade down
13 Offset right 32.9 MPa {4770 psi}
14 Offset left 33.7 MPa {4890 psi}

Copyright ©
8001-19
2] Control valve (CX80)
OPTION (2) IN OPTION (2) OUT
BLADE UP BLADE DOWN
BOOM SWING RIGHT BOOM SWING LEFT
ARM 1 IN ARM 1 OUT ARM 2

BOOM 2 DOWN B00M 2 UP BOOM 1 UP BOOM 1 DOWN
SWING LEFT SWING RIGHT BUCKET BUCKET OPEN
CLOSED
OPTION IN OPTION (1) OUT TRAVEL TRAVEL
BACKWARD FORWARD
TRAVEL TRAVEL
RIGHT RIGHT
FOWARD BACKWARD
LEFT LEFT
FRONT SIDE OF BODY FRONT SIDE OF BODY

VIEWED FROM THE INTERNAL SIDE BODY
VIEWED FROM THE EXTERNAL SIDE OF BODY
Tool needed
Location Adjustment Pressure setting
screw
1 Main 29.7 MPa {4308 psi} 17.8 MPa {2582 psi}
2 Boom up 33.5 MPa {4859 psi}
3 Boom down 33.2 MPa {4815 psi}
4 Arm out 32.7 MPa {4743 psi}
5 Arm in 33.0 MPa {4786 psi}
6 Bucket open 33.1 MPa {4801 psi}
7 Bucket closed 33.1 MPa {4801 psi}
8 Option (1) in Hexagonal
17 mm wrench
9 Option (1) out 6 mm 21.2 MPa {3070 psi}
10 Boom swing-right 33.7 MPa {4888 psi}
11 Boom swing-left 32.9 MPa {4772 psi}
12 Blade main 23.3 MPa {3379 psi}
13 Blade up 26.5 MPa {3844 psi}
14 Blade down 26.5 MPa {3844 psi}
15 Option (2) in
16 Option (2) out

Copyright ©
8001-20
3] Hydraulic pump
4] Swing motor
Tool needed
Name Adjustment Pressure setting
screw
13 Pilot 24 mm 14 mm 3.9 MPa {570 psi} 0.6 MPa {87 psi}
Hexagonal
14 Swing Motor 17 mm wrench 24.6 MPa {3570 psi} 9.7 MPa {1410 psi}
6 mm

Copyright ©
8001-21
BLEEDING AIR
MAIN PUMP
AIR BLEEDING VALVE
BLADE PUMP
PILOT PUMP
DIA Ø 6.3 mm
(0.24 in) HEX. WAF
10 mm
(0.39 in)
RUBBER CAP
SEAT FACE
FRONT SIDE OF BODY
Start the engine and keep it at idle. Remove the rubber cap on the air bleeder. Loosen the air bleeding valve gradu-
ally to bleed air.

Copyright ©
8001-22
FLOW CURVE
Torque: Nm
Leakage flow
line
Shift pressure P3 MPa

ΣP = P1 + P2
Flow: Q1, Q2 L/min
AQ08002-001

Copyright ©
8002
Section
8002

OF THE HYDRAULIC RESERVOIR

Printed in France
Copyright ©
8002-2
TABLE OF CONTENTS
HYDRAULIC RESERVOIR ...................................................................................................................................... 3

Copyright ©
8002-3
HYDRAULIC RESERVOIR
x4
x4x4 6
2 3 1 6
2.94 to 4.90 Nm
4
9
5
See detail A
10
7 8
15
16
17
14
X4 X4
9 11 12 13
68.6 to 78.5Nm KAJ11230-D00
Lep AST-15-11-003 Issued 08-2008

Copyright ©
8002-4
1. Air breather
2. Hex bolt soc HD M6 x 16 18 12.75Nm
3. Spring washer
4. Sems bolt M10 x 30
5. Hydraulic reservoir
6. Sems bolt M10 x 20
7. Plate shim (T=2)
8. Plate shim (T=0.8)
9. Plug G3/4
10. Cushion seal
11. High strength bolt M12 x 45
12. High strength washer
13. Bond #262
14. Strainer
15. Compression spring
16. Relief valve
17. Return filter
18. Oil gauge level A
9 9
KAJ11230-D00
Lep AST-15-11-003 Issued 08-2008

Copyright ©
Section
8003
8003

MAIN HYDRAULIC PUMP

Printed in France
Copyright ©
8003-2
HYDRAULIC PUMP
X4 X4
1 2 3
108.9 to 126.5 Nm
R2 R1
A2
4 G2 10
A1
A
X9
G1
1 5
62.8 to 72.6 Nm 8 9
6 7
A
PPG S
130 to 150 Nm
8 9
100 to 120 Nm
A3
P3G
PP
130 to 150 Nm
A A KAJ11370-C00
1. Bond 262 (-) 6. Bushing (3)

2. Spring washer 12 (4) 7. Cplg plug (3)
3. Hex bolt soc hd M12 x 30 (4) 8. Hydraulic pump (1)
4. Mount flange (1) 9. Hydraulic pump (for blade) (1)
5. Bolt M10 x 30 (9) 10. Pump coupling (1)
Mark Name Bore Mark Name Bore

S Suction port SAE2 1/2 P3G Gauge port (gear) G1/4 Plug
A1, A2 Delivery port G3/4 R1 Drain port G1/2 Plug
A3 Delivery port G1/2 R Air-bleeding port M10 x 1.0
PP Pilot port G3/8 G1, G2 Gauge port G1/4 Plug
PPG Gauge port (pilot) G1/4 Plug - - -
1. Loctite 262 or equivalent should be applied on the 3. The pump shaft and flange surfaces should be
thread of the bolts after removing the oil film. cleaned. (for removing anti-rust material)
All hexagon socket head cap screws for the drive plate
coupling have been already done by vender.
2. After assembled the machine or long term storage
of the machine. At first loose the air-bleeding plug
R2 and fill inside of the pump with the hydraulic oil
before starting the engine.
ASM-17-11-002 Issued 08-2008

Copyright ©
Section
8004
8004
MAIN HYDRAULIC CONTROL VALVE
CX80 TIER 3

Printed in France
CNH Lep SM80-8004-0EN August 2008
Copyright ©
8004-2
CONTROL VALVE
pp
p
pa1
T3 DR11 pa2
p
p
pa6 pa
p p
pa3
dr
p
pa p
pa4
p
pa p
pra1
p
pa5
pra2
p
X4 p
pra3
1 4
T5
pcc X4
AR1 2 3 4 5 6 7
A8 T4 T6
A7 AR2
A6 pc2 AR3 A5 A3 A2 A1 PT PA
R3 P1
2
B5
5
B44
P2
2 P3 B6 B7 B8 T2 B3
3
prb3
p B2
2
prb2 B1
rb1 p
pb5
p
pb4
p
pb3
p
pb2
p
pb1
KAJ11680-D00
1. Sems bolt M12 x 30 (4) 5. Plug (1)

2. High strength M12 x 40 (4) 6. Protection cap (1)
3. High strength washer 12 (4) 7. Plate (1)
4. Bond 262 (-) 8. Control valve (1)
Main line Pilot port Line name Main line Pilot port Line name
P1, P2 - Pressure line A8 pa8, pa4 Boom line up
T1, T2 - Low pressure line B8 pb8, pc2 Boom line down
A1 pa1 Traction line left backward T3 - Swing line
B1 pb1 Traction line left forward AR1 pra1 Swing right
A2 pa2 Option 1 BR1 prb1 Swing left
B2 pb2 Option 1 AR2 pra2 Blade line up
A3 pa3 Swing line right BR2 prb2 Blade line down
B3 pb3 Swing line left AR3 pra3 Option 2
B4 - Plug (boom 2) BR3 prb3 Option 2
A5 pa5, pa9 Arm line out PR5 - Blade line pressure
B5 pb5, pb9 Arm line in T5 - Plug
A6 pa6 Traction line right backward P3, T4 - Plug
B6 pb6 Traction line right forward - PP Pilot pressure line
A7 pa7 Bucket line close - PT, PA Pressure detection
DR1, pcc,
B7 pb7 Bucket line open - Drain line
dr2, pb4
ASM-19-04-001 Issued 08-2008

Copyright ©
Section
8005

ATTACHMENT CYLINDERS
8005

Printed in France
Copyright ©
8005-2
TABLE OF CONTENTS
ATTACHMENT CYLINDERS................................................................................................................................... 3
BUCKET CYLINDER ................................................................................................................................................ 3
Removal ............................................................................................................................................................ 3
Installation ......................................................................................................................................................... 5
DIPPER CYLINDER ................................................................................................................................................. 7
Removal ............................................................................................................................................................ 7
Installation ......................................................................................................................................................... 9
BOOM CYLINDER ................................................................................................................................................. 11
Removal .......................................................................................................................................................... 11
Installation ....................................................................................................................................................... 13
BOOM SWING CYLINDER (CX80 ONLY) ................................................................................................................. 16
Removal .......................................................................................................................................................... 16
Installation ....................................................................................................................................................... 17

Copyright ©
8005-3
1 Bucket cylinder
1 Removal
1) Lower the attachment to the ground.
800-5-03-00-21A
2) Put a block between the bucket cylinder and the dipper.
MQ12001-001-003
3) Stop the engine and release pressure in the hydraulic

circuit.
NOTE: Refer to the procedures for bleeding the hydraulic
pressure in Operator’s manual. When releasing pressure from
the tank, stop the engine and press the button to completely
release the internal pressure. The hydraulic oil may be hot, so
be careful not to get burned.
800-5-03-00-20C
4) Remove the nuts and bolt.
800-5-03-00-20D
MSM-17-12-001 Issued 08-2008

Copyright ©
8005-4
5) Drive out the pin, using a steel bar and hammer.
800-5-03-00-20E
6) Fasten a wire to prevent the cylinder rod from extend-

ing.
800-5-03-00-20F
7) Remove the hoses. Install bull plugs or caps.
MQ12001-002
8) Lift the bucket cylinder, using a sling.
MQ12001-003
MSM-17-12-001 Issued 08-2008

Copyright ©
8005-5
9) Remove the nuts and bolt. Drive out the pin, using a
steel bar and hammer.
10)Remove the bucket cylinder.
MQ12001-004
2 Installation
1) Lift the bucket cylinder and position it so that it is
aligned for installation in the dipper.
MQ12001-005
2) Install the pin and fasten it with a bolt and nuts.
MQ12001-006
3) Connect the hoses to the bucket cylinder.
MQ12001-007
MSM-17-12-001 Issued 08-2008

Copyright ©
8005-6
4) Position the cylinder head so that it is aligned for instal-
lation in the link.
MQ12001-008

NOTE: Cycle the cylinder to bleed air from the cylinder. After
leading air, check for oil leakage.
MQ12001-009
MSM-17-12-001 Issued 08-2008

Copyright ©
8005-7
2 Dipper cylinder
1 Removal
800-5-03-00-21A
2) Put a block between the dipper cylinder and the boom.
700-5-03-00-22R

circuit.
pressure in Operator’s Manual. When releasing pressure from
800-5-03-00-20C
4) Remove the nuts and bolt.
MQ12001-010
MSM-17-12-001 Issued 08-2008

Copyright ©
8005-8
5) Drive out the pin, using a steel bar and hammer.
MQ12001-011
6) Fasten a wire to prevent the cylinder rod from extend-

ing.
800-5-03-00-20F
MQ12001-012
8) Remove the grease hose.
MQ12001-013
MSM-17-12-001 Issued 08-2008

Copyright ©
8005-9
9) Lift the dipper cylinder, using a sling.
700-5-03-00-22Y
10)Remove the nuts and bolt. Drive out the pin, using a
11)Remove the dipper cylinder.
MQ12001-014
2 Installation
1) Lift the dipper cylinder and position it so that it is
aligned for installation in the boom.
700-5-03-00-22AA
MQ12001-015
MSM-17-12-001 Issued 08-2008

Copyright ©
8005-10
3) Install the grease hose to the dipper cylinder.
MQ12001-016
4) Connect the hoses to the dipper cylinder.
MQ12001-017
5) Position the cylinder head so that it is aligned for instal-

lation in the arm.
MQ12001-018
6) Install the pin and fasten it with a bolt and spacer.

When putting in a pin, it unites with the circle boss of a
dipper.
bleeding air, check for oil leakage.
MQ12001-019
MSM-17-12-001 Issued 08-2008

Copyright ©
8005-11
3 Boom cylinder
1 Removal
800-5-03-00-21A
2) Remove the grease hose.
700-5-03-00-22AH
3) Attach a sling to the boom cylinder.
700-5-03-00-22AI
4) Remove the nuts and bolt to remove the collar.

5) Pull out the pin, using a steel bar and hammer.
000-5-03-00-20AC
MSM-17-12-001 Issued 08-2008

Copyright ©
8005-12
6) Lower the cylinder and place on a stand.
700-5-03-00-22AK
7) Attach a wire to prevent the cylinder rod from extend-

ing.
MQ12001-020

circuit.
pressure in Operator’s Manual. When releasing pressure from
800-5-03-00-20C
MQ12001-021
MSM-17-12-001 Issued 08-2008

Copyright ©
8005-13
10)Remove the nuts and bolt and drive out the pin, with a
MQ12001-022
11)Remove the boom cylinder.
MQ12001-023
2 Installation
1) Lift the boom cylinder and position it so that it is aligned
for installation in the frame.
MQ12001-024
MQ12001-025
MSM-17-12-001 Issued 08-2008

Copyright ©
8005-14
3) Connect the hoses to the boom cylinder.
MQ12001-026
4) Position the cylinder so that the head is aligned for

installation in the boom.
700-5-03-00-22AS
5) Install the pin with a steel bar and hammer.
700-5-03-00-22AM
6) Attach the collar and install the bolt and nuts.
MQ12001-027
MSM-17-12-001 Issued 08-2008

Copyright ©
8005-15
7) Install the grease hose.
bleeding air, check for oil leakage.
700-5-03-00-22AU
MSM-17-12-001 Issued 08-2008

Copyright ©
8005-16
4 Boom swing cylinder (CX80 only)
1 Removal
5
2
9
8
AS05001-043
[1] Use wire to lift the boom swing cylinder (1).

[2] Use a wrench to remove the bolt (5) on the cylinder head (piston rod side) (2).
[3] Use a steel rod and hammer to remove the pin (3).
WARNING: When removing the pin, be careful not to let it fall or get caught.
[4] Secure the piston rod (2) with wire so that it will not fall out.
[5] Remove the hose (4) and cover the hose with either a plug or cap.
[6] Use a wrench to remove the bolt (8) on cylinder bottom (cylinder tube side) (6) and washer (9).
[7] Use a steel rod and hammer to remove the pin (7).
[8] Lift the boom swing cylinder (1) and remove it.
[9] Place the boom swing cylinder (1) on crossties.
MSM-17-12-001 Issued 08-2008

Copyright ©
8005-17
2 Installation
To install, perform the reverse of the removal procedure.
[1] Use wire to lift the boom swing cylinder (1), and align the cylinder bottom (cylinder tube side) (6) with the installa-
tion position.
[2] Insert the pin (7) and secure it with the bolt (8) and washer (9).
[3] Connect the boom swing cylinder (1) to the hose (4).
• Do not pull out the piston rod (2) before connecting the hose. This can cause hydraulic oil to fly out from the line.
[4] Align the cylinder head (piston rod side) with the installation position.
[5] Use a steel rod and hammer to insert the pin (3).
[6] Secure the bolt (5) with the pin (3).
[7] Remove wire, etc.
• Bleed off air and check that there is no oil leaking.
• As the final step, always grease up each pin.
MSM-17-12-001 Issued 08-2008

Copyright ©
8005-18
NOTES
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MSM-17-12-001 Issued 08-2008

Copyright ©
Section
8006

HYDRAULIC SWIVEL
8006

Printed in France
Copyright ©
8006-2
TABLE OF CONTENTS
ROTATING JOINT ................................................................................................................................................... 3
Removal ............................................................................................................................................................ 4
Installation ......................................................................................................................................................... 5

Copyright ©
8006-3
ROTATING JOINT
AQ10002-029
1. Bolt
2. Lock bar
3. Rotating joint assembly
ASM-17-10-002 Issued 08-2008

Copyright ©
8006-4
1 Removal
1) Jack up the body.
2) Stop engine and release pressure in the hydraulic
circuits.
3) Place protection blocks under the lower frame and
secure them.
AQ10002-030A
4) Remove the under cover.
AQ10002-030B
5) Attach marking tags to the rotating joint hoses to

tell them apart when they are reconnected.
6) Remove the hoses and put blank plugs or caps on
them to keep out dust.
AQ10002-030C
7) Remone the lock bar mounting bolts (1).

8) Remove the lock bar (2).
9) Remove the rotating joint mounting bolts (3).
10) Lift out the rotating joint.
AQ10002-030
ASM-17-10-002 Issued 08-2008

Copyright ©
8006-5
2 Installation
1) Align it so that it fits on the lower frame.
2) Apply Loctite No. 262 to the rotating joint mounting bolts (3).
3) Tighten the rotating joint mounting bolts (3) to the specified torque.
4) Apply Loctite No. 262 to the lock bar mounting bolts (1).
5) Tighten the lock bar mounting bolts (1) to the specified torque to install the lock bar (2).
6) Connect the hoses.
7) Check to ensure that there is no oil leakage. If leakage is found, take appropriate measures.
8) Install the under cover.
9) Remove the blocks.
10) Lower the body.
ASM-17-10-002 Issued 08-2008

Copyright ©
8006-6
NOTES
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ASM-17-10-002 Issued 08-2008

Copyright ©
Section
8007

PILOT FUNCTION BLOCKS
8007

Printed in France
Copyright ©
8007-2
TABLE OF CONTENTS
REMOTE CONTROL VALVE .................................................................................................................................. 3

Copyright ©
8007-3
REMOTE CONTROL VALVE
41.1 ± 2.9 Nm
41.1 ± 2.9 Nm 54 59 63 67 17 18 X4 X4 X4
17 18 23 60 64 68 20 22
19 61 X4 24
19 61
X4
4 X4
4 X4
20 21 22
5 6 70.6 ~ 86.2 Nm
25
46
26
12
13 14
X44 5 6 70.6 ~ 86.2 Nm

31 32
33
X44 X4
28 29 30
27
X4
7 2
66
3
X4
2
1
4
56
70.6 ~ 86.2 Nm 5
7
8
10 9
51
X10
11 X2
2 X2 46
X 15
13 14
2
70.6 ~ 86.2 Nm 5 6 KHJ2287Z-E26A

7
1. Frame console (1) 20. Hex soc hd bolt M6 x 30 (8)

2. Bolt M10 x 25 (28) 21. Spring washer 6 (8)
3. Vinyl cap (1) 22. Plain washer 6 (8)
4. Hand lever(1) 23. Knob left 2 switch (1)
5. Washer (4) 24. Frame console unit (1)
6. U-nut (4) 25. Rubber grommet (1)
7. Mount rubber (4) 26. Rubber grommet (1)
8. Rubber grommet (2) 27. Bracket left (1)
9. Floor (1) 28. High strength bolt M8 x 20 (4)
10. Floor (1) 29. Plain washer 8 (4)
11. Bolt M12 x 30 (10) 30. Bolt M8 x 25 (4)
12. Pedal (2) 31. Remote control valve (1)
13. High strength bolt M10 x 30 (4) 32. Remote control valve (1)
14. High strength washer 10 (6) 33. Bolt M10 x 20 (4)
15. Bracket right (1) 34. Floor mat (SB)
17. Jam nut M14 (2) 35. Floor mat (BH)
18. Vinyl cap (2) 36. Bolt M10 x 16 (3)
19. Remote control valve
ASM-17-11-002 Issued 08-2008

Copyright ©
8007-4
36
37
X2 X2 X2
36 39 2 40 38 2
A
X2
41
X2
42 17.7 ~ 20.6 Nm
34 35 69 70
B
46 46
B
3 - Swing left
P - Port 2 - Arm closed
T - Port
4 - Arm open
1 - Swing right
57
1 - Bucket closed
T - Port 4 - Boom up
D 58
50
14 45
2 - Boom down P - Port
3 - Bucket open
46
C KHJ2287Z-E26
37. Cover (1) 54. Knob right (1)

38. Foot rest left (1) 55. Rubber grommet (1)
39. Cover (1) 56. Cushion seal (1)
40. Foot rest right (1) 57. High strength bolt M6 x 16 (2)
41. Knob L type (2) 58. Side cover (1)
42. High strength nut M12 x 1.25 (2) 59. Knob right 4 switch (1)
43. Hand lever left (1) 60. Knob left 4 switch (1)
44. Hand lever right (1) 61. Remote control valve (2)
45. High strength bolt (2) 62. Harness band L= 250 (-)
46. Cushion seal (2) 63. Knob right 2 switch (1)
47. Cushion seal (2) 64. Knob left 2 switch (1)
48. Cushion seal (1) 65. Boot (2)
49. Cushion seal (1) 66. Boot (for short lever) (2)
50. Safety trim (1) 67. Knob right 4 switch (1)
51. Cover (1) 68. Knob left 4 switch (1)
52. Bolt M10 x 30 (8) 69. Floor mat (1)
ASM-17-11-002 Issued 08-2008

Copyright ©
Section
8010

MAIN HYDRAULIC PUMP
8010

Printed in France
Copyright ©
8010-2
TABLE OF CONTENTS
HYDRAULIC PUMP................................................................................................................................................. 3
DISASSEMBLING AND ASSEMBLING INSTRUCTIONS .................................................................................................. 3
Tools and jigs needed ....................................................................................................................................... 3
Precautions ....................................................................................................................................................... 3
Disassembling main pump .............................................................................................................................. 4
Disassembling the cover section..................................................................................................................... 7
Removing the power adjuster (only if required) .............................................................................................. 8
Removing the pilot relief valve (only if required) ............................................................................................. 9
Assembling instructions .................................................................................................................................... 9
Assembling the cover section ......................................................................................................................... 9
Installing the cylinder..................................................................................................................................... 10
Installing the main pump ............................................................................................................................... 11
Disassembling the gear pump......................................................................................................................... 16
Removing the gear pump (G1)...................................................................................................................... 16
Disassembling the gear pump (G1) .............................................................................................................. 16
Disassembling the gear pump (GSP2).......................................................................................................... 17
Reassembling gear pump ............................................................................................................................... 19
Reassembling the gear pump (GSP2) .......................................................................................................... 19
Assembling the gear pump (G1) ................................................................................................................... 21
STRUCTURE DRAWING ......................................................................................................................................... 25
No. 1 Shaft assembly ...................................................................................................................................... 26
No. 2 Swash plate assembly ........................................................................................................................... 26
No. 3 Rotary group .......................................................................................................................................... 27
No. 4 Cover assembly ..................................................................................................................................... 27
No. 5 Control spring assembly ........................................................................................................................ 28
No. 6 Control piston assembly ........................................................................................................................ 28
No. 7 Gear pump............................................................................................................................................. 29
No. 30 Relief valve assembly .......................................................................................................................... 29

Copyright ©
8010-3
HYDRAULIC PUMP
1 Disassembling and assembling instructions
1 Tools and jigs needed
Name Size (nominal) Quantity

Hexagon wrenches (torque wrench) 4, 5, 6, 8, 12 mm One of each
Wrenches (torque wrench) 14, 17, 24, 27 mm One of each
Screwdriver (flathead) Medium-sized 2
Snap ring pliers Internal (for snap ring 80) 1
Plastic hammer Medium-sized 1
Magnet Bar-shaped: approximate diameter 5 mm 1
Grease Industrial grease As needed
Cleaning solution As needed
Adhesive agent Three bond No. 1305 As needed
Support 1
To be used for standing the pump vertically
2 Precautions
[1] Precautions for disassembling
1) Adjusting screws are pre-adjusted according to the specifications. Do not disassemble unless necessary. If
disassembled, settings will be altered, adversely affecting the machine.
2) After draining oil from the pump, clean the outside of the pump. Conduct work in a clean area.
3) Use a clean cloth and take sufficient measures to keep foreign substances from entering the pump.
4) Each pump is composed of pre-adjusted parts. Mark each part with a pen or the like so that they can be
aligned correctly during reassembly.
[2] Precautions for assembling
1) Replace old seals with new ones.
2) Conduct work in a clean area and take sufficient measures to keep foreign substances from entering the
pump.
3) Fasten screws with proper tightening torque.
4) Apply grease to all sliding sections.
ASM-17-20-002 Issued 08-2008

Copyright ©
8010-4
1 Disassembling main pump
1) Remove gear pump.
Remove hexagon socket head bolts: (M10 x 25 x2)
Hexagon wrench (width across flats: 8)
Remove coupling and collar.
AQ20002-002
2) Remove cover section.

Remove the following hexagon socket head bolts:
(M14 x 40 x2)
(M14 x 65 x2)
(M14 x 75 x1)
AQ20002-003
3) Grasp both sides of cover and remove it by lifting

straight up.
Take care to keep the shift piston and control plate
from falling off. Place the cover section in a level
position immediately after removal.
If it is difficult to remove, hammer it out by hitting it
lightly with a plastic hammer.
AQ20002-004
AQ15002-002
ASM-17-20-002 Issued 08-2008

Copyright ©
8010-5
4) Remove parts from inside the housing:
Packing on the mating surface of cover
Spring (external)
Spring (internal)
Guide
Take out spring seat.
AQ20002-005
5) Take out rotary group.

This is done with the pump on its side.
AQ20002-006
6) Make sure that all pins (dia. 3 x 30 x3) are

removed from the housing when removing the
rotary group.
AQ20002-007
ASM-17-20-002 Issued 08-2008

Copyright ©
8010-6
7) Removing the shaft section.
Remove C-shaped snap ring (internal 80).
Snap ring pliers (internal snap ring 80).
AQ20002-008
8) Remove the oil seal case.

Also, remove the O-ring located in the back of the
oil seal case.
Two flathead screwdrivers (medium size)
AQ20002-009
9) Withdraw the shaft.

If it is difficult to pull out, hit the back end of the
shaft lightly with a plastic hammer.
AQ20002-010
ASM-17-20-002 Issued 08-2008

Copyright ©
8010-7
10) Take out the swash plate.
AQ20002-011
11) Remove the guides.

Remove the guide (delivery side).
Remove the guide (suction side).
AQ20002-012
2 Disassembling the cover section

1) Remove the control plate
AQ20002-013
ASM-17-20-002 Issued 08-2008

Copyright ©
8010-8
2) Remove the piston.
Remove the cylinder.
Wrench (width across flats: 27)
AQ20002-014
3) Remove the piston.

Remove the Belleville spring and shim.
AQ20002-015
3 Removing the power adjuster (only if required)

1) Loosening the Hexagon nut will change the power
setting.
Remove hexagon socket head bolts (M10 x 30
x2) and remove cover.
AQ20002-016
ASM-17-20-002 Issued 08-2008

Copyright ©
8010-9
2) Take out spring seat.
Handle carefully. Shim[s] may come out with the
spring seat.
AQ20002-017
4 Removing the pilot relief valve (only if required)

1) Disassembling the valve will change the pilot pres-
sure setting. Prior to disassembly, record the
screw height and make counter marks.
Loosen and remove the locknut and adjusting
screw.
Remove the spring.
Remove the spool.
NOTE: Using a magnet or M5 bolt will aid removal of the
spool. AQ20002-018
1 Assembling the cover section
1) Installing the pilot relief valve
Install the spool.
Install the spring.
Fasten the locknut and adjusting screw according
to the screw height and counter marks recorded
before disassembly.
Tightening torque: 9.8 Nm.
AQ20002-019
ASM-17-20-002 Issued 08-2008

Copyright ©
8010-10
2) Install the spring seat.
If the spring seat has a shim, install the shim.
AQ20002-020
3) Install the power adjuster section.

Hexagon socket head bolts (M10 x 30 x2)
Tightening torque: 55 - 69 Nm.
AQ20002-021
2 Installing the cylinder

1) Assemble the piston, Belleville spring and shim
into the cylinder and install the assembly on the Cylinder
cover.
To keep these parts from falling off when screwing
in the cylinder, apply grease to each part.
NOTE: Apply a small amount of Three Bond No. 1305 to the Piston
threaded section of cylinder.
Belleville spring
Shim
AQ20002-022
ASM-17-20-002 Issued 08-2008

Copyright ©
8010-11
2) Fasten the cylinder.
Install the piston.
AQ20002-023
3) Install the control plate.

To keep the control plate from falling off, apply
grease to the mating surface with the cover.
AQ20002-024
3 Installing the main pump

1) Install the guide (delivery side).
Install the guide (suction side).
To keep guides from falling off, apply grease to the
mating surfaces with the housing.
AQ20002-025
ASM-17-20-002 Issued 08-2008

Copyright ©
8010-12
2) Install the swash plate.
To keep the swash plate from falling off, apply
grease to the area (spherical) in contact with the
guide.
AQ20002-026
3) Install the shaft.

Do this with the housing on its side.
NOTE: Be careful that the swash plate does not fall off.
AQ20002-027
4) Apply grease to the O-ring and install.
AQ20002-028
ASM-17-20-002 Issued 08-2008

Copyright ©
8010-13
5) Install the oil seal case with the oil seal installed.
Apply grease to lip section of the oil seal.
AQ20002-029
6) Install C-shaped snap ring (internal 80).

Snap ring pliers (internal snap ring 80)
AQ20002-030
7) Assembling the rotary group.

Apply grease to pins (dia. 3 x 30 x3) and install
them in the spline grooves in the cylinder block.
AQ20002-031
ASM-17-20-002 Issued 08-2008

Copyright ©
8010-14
8) Assemble pistons (x10) into retainer, and apply
grease to the spherical part of the guide and
install it inside retainer.
At the same time the pistons are installed into the
holes, carefully place the guide on the three pins.
AQ200020-032
9) Install the rotary group.

Align the spline with the shaft and install.
AQ20002-033
10) Install the parts in the housing.

Place the pump in an upright position, and install
the following parts:
Spring seat
Guide
Spring (internal)
Spring (external)
Packing on the mating surface with the cover.
AQ20002-034
ASM-17-20-002 Issued 08-2008

Copyright ©
8010-15
11) Installing the cover section:
Install by lowering the cover perpendicularly onto
the pump.
Verify that packing is straight.
AQ200020-035
12) Fasten the following hexagon socket head bolts:

(M14 x 40 x2)
(M14 x 65 x2)
(M14 x 75 x1)
AQ20002-036
13) Install the gear pump:

Install the coupling.
Attach the collar.
AQ20002-037
ASM-17-20-002 Issued 08-2008

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8010-16
14) Installing the gear pump.
Hexagon socket head bolts (M10 x 25 x2)
AQ200020-038
5 Disassembling the gear pump

1 Removing the gear pump (G1)
1) Remove the hexagon socket head bolts (M8 x 50
x4).
Hexagon bar wrench (width across flats: 6)
AQ20002-039
2 Disassembling the gear pump (G1)

1) Position as if for pulling out the drive gears and
remove the side plate, backup ring, square ring
and gears.
AQ20002-040
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8010-17
2) Remove the idle gear.
AQ20002-041
3 Disassembling the gear pump (GSP2)

1) Remove Hexagon bolts (M10 x 95 x4).
(AP2D36-904 only)
Wrench (nominal: 17)
AQ20002-042
2) Remove the front frame.
AQ20002-043
3) Remove the intermediate frame.
AQ20002-044
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8010-18
4) Remove the square ring.
AQ20002-045
5) Remove the plate, guide and O-ring.
AQ20002-046
6) Remove the plate.
AQ20002-047
7) Remove the drive gear, idle gear and side plate.
AQ20002-048
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6 Reassembling gear pump
1 Reassembling the gear pump (GSP2)
1) Install the square ring onto the side plate.
NOTE: At this time, pay attention to suction and delivery ori-
entation.
Suction side
Delivery side
Square ring insertion orientation

AQ20002-082
AQ20002-049
2) Install the drive gear and idle gear on the side

plate.
AQ20002-050
3) Install the drive gear, idle gear and side plate.
AQ20002-051
4) Install the O-ring on the guide, and then insert

them into the plate.
Side with larger R

Guide
AQ20002-052
AQ20002-053
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8010-20
5) Install the plate, guide and O-ring as an assembly.
AQ20002-054
6) Assemble the 2 plates.

NOTE: At this time, pay attention to suction and delivery ori-
entation.
Suction side Delevery side
AQ20002-056
AQ20002-055
7) Install the drive square ring.
AQ20002-057
8) Assemble the 2 parallel pins into the front frame.
AQ20002-058
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9) Install the front frame.
AQ20002-059
2 Assembling the gear pump (G1)

1) Install the drive gear in the housing.
AQ20002-060
2) Install the idle gear.
AQ20002-061
3) Apply grease to the square ring and backup ring to

keep them from falling off, and install them into the
side plate in that order.
AQ20002-062
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4) Install side plate assembled in (3. ) on the hous-
ing.
AQ20002-063
5) Assemble the 2 parallel pins into the intermediate

frame.
AQ20002-064
6) Install the O-ring on the intermediate frame.
AQ20002-065
7) Install the intermediate frame.
AQ20002-066
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8) Using hexagon socket head bolts (M8 x 50, four),
fasten the intermediate frame.
Hexagon bar wrench (width across flats: 6)
Tightening torque: 29 Nm.
AQ20002-067
9) Assemble the 2 parallel pins into the intermediate

frame.
AQ20002-068
10) Install the coupling on the end of the shaft on the

GSP2 side.
AQ20002-069
11) Connect GSP2 and G1.
AQ20002-070
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12) Fasten GSP2 and G1 firmly with hexagon bolts
(M10 x 95 x4)
Wrench (nominal: 17)
Tightening torque: 59 Nm.
AQ20002-071
13) Install the O-ring on the front frame.
AQ20002-072
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2 Structure drawing
AQ20002-073
1. Shaft assembly (1) 13. Plug (1)

2. Swash plate assembly (1) 14. Packing (1)
3. Rotary groupt (1) 15. Shim (1)
4. Cover assembly (1) 16. Plug (1)
5. Control spring assembly (1) 17. Name plate assembly (1)
6. Control piston assembly (1) 18. Plug assembly (1)
7. Gear pump (1) 19. Plug (1)
8. Housing (1) 22. Plug (1)
9. Air vent valve (1) 23. Orifice (1)
10. Bushing (1) 25. Square ring (1)
11. Steel ball (1) 30. Relief valve assembly (1)
12. Plug (1)
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1 No. 1 Shaft assembly

#3
AQ20002-074
1. Shaft (1) 5. Oil seal (1)

2. Seal case (1) 6. O-ring (1)
3. Bearing (1) 7. Retaining ring (C type) (1)
4. Retaining ring (C type) (2)
2 No. 2 Swash plate assembly
AQ20002-075
1. Swash plate (1) 7. Backup-ring (1)

2. Guide (1) 8. Plug (1)
4. Guide (1) 9. Parallel pin (1)
6. O-ring (1) 10. Bushing (1)
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3 No. 3 Rotary group
AQ20002-076
1. Piston assembly (10) 6. Spring (1)

2. Cylinder block (1) 7. Parallel pin (3)
3. Retainer (1) 8. Spring seat (2)
5. Guide (1) 9. Retaining ring (C type) (1)
4 No. 4 Cover assembly
AQ20002-077
1. Cover (1) 8. O-ring (1)

2. Control plate (1) 9. Square ring (2)
3. Parallel pin (2) 10. Plug assembly (4)
4. Hexagon socket head bolt M14 x 40 (2) 11. Plug (2)
5. Hexagon socket head bolt M14 x 65 (2) 12. Plug (1)
6. Hexagon socket head bolt M14 x 75 (2) 15. Packing (1)
7. Bearing (1)
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5 No. 5 Control spring assembly
AQ20002-078
1. Spring seat (1) 8. Hexagon socket head bolt M10 x 30 (2)

2. Spring seat (1) 9. Hexagon nut M20 (1)
3. Cover (1) 10. Guide (1)
4. Adjust screw (1) 34. Shim (0.3 mm) (2)
5. Spring (1) 44. Shim (0.5 mm) (2)
6. Spring (1) 54. Shim (1.0 mm) (2)
7. O-ring (1)
6 No. 6 Control piston assembly
AQ20002-079
1. Cylinder (1) 5. Distance piece (3.3) (1)

2. Piston (1) 6. Distance piece (3.4) (1)
3. Piston (1) 7. Distance piece (3.5) (1)
4. Coned disc spring (4) 8. Distance piece (3.6) (1)
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7 No. 7 Gear pump
AQ20002-080
1. Frame (1) 12. Hexagon socket head bolt M8 x 55 (4)

2. Housing (1) 13. O-ring (1)
3. Gear (1) 14. Frame (1)
4. Gear (1) 15. Hexagon head bolt M10 x 25 (4)
5. Thrust plate (1) 16. O-ring (1)
6. Metal (4) 17. O-ring (1)
7. Backup-ring (1) 18. O-ring (1)
8. Parallel pin (4) 19. O-ring (2)
9. Square ring (1) 20. O-ring (1)
10. Coupling (1) 21. Bushing (1)
11. Retaining ring (C type) (1) 22. Hexagon socket head bolt M10 x 25 (2)
8 No. 30 Relief valve assembly
AQ20002-081
1. Spool (1) 4. Spring (1)

2. Adjusting screw (1) 5. Hexagon nut (1)
3. O-ring (1) 6. Shim (1)
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NOTES
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8011
Section
8011

MAIN HYDRAULIC CONTROL VALVE
CX80 TIER 3

Printed in France
CNH Lep SM80-8011-0EN August 2008
8011-2
TABLE OF CONTENTS
CONTROL VALVE................................................................................................................................................... 3
MAINTENANCE INSTRUCTIONS ................................................................................................................................ 3
Disassembling ................................................................................................................................................... 3
Disassembling Procedures ............................................................................................................................... 3
CLEANING ............................................................................................................................................................. 7
INSPECTION........................................................................................................................................................... 7
ASSEMBLING......................................................................................................................................................... 7
Subassemblies .................................................................................................................................................. 7
Assembling the Control Valve Main Body ......................................................................................................... 9
RELIEF VALVES ................................................................................................................................................... 13
Instructions for Disassembling and Assembling the Main body Relief Valves ................................................ 13
Instructions for Disassembling and Assembling the Add-on Relief Valves ..................................................... 14
Instructions for Disassembling and Assembling the Overload Relief Valves .................................................. 15
Instructions for Disassembling and Assembling the Negative Control Relief Valves ...................................... 15
Adjusting the Relief Valves ............................................................................................................................. 16
INSTALLATION ..................................................................................................................................................... 16
OPERATION ......................................................................................................................................................... 16
LIST OF CONTROL VALVE SPECIFICATIONS ............................................................................................................ 17
TROUBLESHOOTING............................................................................................................................................. 17
Control valves in general................................................................................................................................. 17
Relief valves .................................................................................................................................................... 18
Hydraulic system in general ............................................................................................................................ 18
REFERENCE DRAWING ........................................................................................................................................ 19
Parts list .......................................................................................................................................................... 19
Overall View 1/3 .............................................................................................................................................. 20
Overall View 2/3 .............................................................................................................................................. 22
Overall Drawing 3/3......................................................................................................................................... 25
Reference number (2): Spool section assembly ............................................................................................. 28
Reference number (3): Inlet section assembly................................................................................................ 29
Reference number (40): Anti-drift valve assembly .......................................................................................... 30
Reference number (29): Shut-off valve assembly ........................................................................................... 31
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8011-3
CONTROL VALVE
1 Maintenance instructions
1 Disassembling
[1] Disassembling Precautions
1) Stop the engine after the pressure in the actuator has been completely released.
WARNING: Do not replace valve assemblies or disassemble valves when unreleased pressure remains.
Pressurized hydraulic oil may spray out, or parts may fly out under pressure.
! When disassembling, place the bucket firmly on the ground, and then completely release the pressure from the
circuits.
2) Release the air pressure from the tank.

3) Thoroughly clean around the area to be disassembled to prevent any foreign substances from getting into
the valves during disassembly.
4) Put tags on the disassembled parts so that their location can be easily identified for reassembly.
5) Replace all disassembled seals with new ones (O-rings and backup rings).
6) Do not replace spools, because they are selectively fit with their valve housings and sleeves.
2 Disassembling Procedures
* Numbers for parts contained in an assembly are expressed as (assembly no. - part no.).
1 Disassembling the main spools (2 through 10) (80-2)
1) Loosen socket head bolts (65) (80-12) (WAF: 6), and disassemble long caps (11 and 15) (80-3). Remove O-
rings (12) (80-4) from the grooves in the valve housing.
2) Loosen socket head bolt (66) (WAF: 5), and disassemble caps (46 and 47). Remove O-ring (42) from the
cap.
3) Pull each spool out of the valve housing as a subassembly.
WARNING: Pull the spools straight up so they will not be dented or scratched. If the spools are dented or
scratched, they may damage the holes in the body as they come out and may not fit back in at reassembly. Even
if they go in, they may not operate correctly.
! Place tags on each spool so that their location can be easily identified for reassembly.
If a wrong spool is installed, the actuator will not function properly, and this is extremely dangerous.
4) Loosen socket head bolts (65) (80-12) (WAF: 6) and disassemble short caps (13 and 14) (80-5). Remove O-
rings (12) (80-4) from the grooves of the valve housing.
5) Loosen spool ends (2-4, 3-4, 4-4, 5-4, 7-4, 9-4, 10-4 and 80-2-4; WAF: 6) of spools (2 to 5, 7, 9, 10 and 8-2),
and remove spring seats (2-2, 3-2, 4-2, 5-2, 7-2, 9-2, 10-2 and 80-2-2) and springs (2-3, 3-3, 4-3, 5-3, 7-3,
9-3, 10-3 and 80-2-3).
6) Loosen spool end (6-4) (WAF: 6) of spool (6), then remove spring seat (6-2) and spring (6-3). Loosen plug
(6-5; groove width 3) and remove poppet (6-6), spring (6-7), O-ring (6-8) and backup ring (6-9).
7) Loosen spool end (8-4) (WAF: 6) of spool (8), then remove spring seat (8-2) and spring (8-3). Loosen plug
(8-5; groove width 3), then remove poppet (8-6), spring (8-7), O-ring (8-8) and backup ring (8-9).
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8011-4
WARNING: Secure the spool between blocks in a vise in order to avoid damaging the spool during disassembly.
At this time, secure the spool as close to the spool end as possible to avoid bending the spool.
Adhesive is applied to the threaded part of the spool end. Use an industrial dryer to heat the threaded part of the
outside of the spool until the spool end can be easily tightened (heating temperature should be 200 to 250°C).
! Replace with a new one if overheated. Overheating may cause thermal deformation of the spring, resulting in
poor performance and durability. Note that the spring will be extremely hot after it is heated. Handle with care to
avoid burns from direct contact with bare hands.
Blocks for spool disassembly/reassembly

AS07001-001
2 Disassembling the subassembly spools (41 and 48)

1) Loosen spool ends (43) (WAF: 5) of spools (41 and 48), then remove spring seats (43) and spring (44).
2) Adhesive is applied to the threaded parts of the spool and to the joint section of the spool end. Disassemble
following the note above.
3 Disassembling the sub-spool section (52)
1) Loosen plug (49) (WAF: 32) and remove O-ring (50).
2) Remove spring (51) and pull out spool (52-1).
3) Draw it out by hooking a wire inside the hole on the near side of the sleeve (52-2). Piston (52-3) is pulled out
at the same time.
4) Remove backup ring (53) and O-ring (54).
4 Disassembling the boom and arm anti-drift valves
1) Loosen socket head bolt (67) (WAF: 6), remove body assembly (30), and then remove O-ring (31) from the
groove on the housing.
WARNING: If the control valve is attached to the machine during disassembly, unreleased pressure can cause
parts to fly out.
! Loosen socket head bolt (67) slowly, and verify that there is no more resistance from unreleased pressure.
2) Remove spacer assembly (29) using a M6 x 1.0 screw, and then remove O-rings (29-2 and 29-4) and
backup ring (29-3).
3) Remove spring (28) and poppet (27).
4) Secure body assembly (30) in a vise, taking care not to damage the mating face on the mounting side of O-
ring (31).
5) Loosen plug assembly (30-14) (WAF: 38) and remove O-ring.
6) Pull out piston (30-4), spool (30-5) and spring (30-7).
7) Loosen plug (30-3) (WAF 38) and remove O-ring (30-13).
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8011-5
WARNING: If the control valve is attached to the machine during disassembly, unreleased pressure can cause
! parts to fly out. Loosen plug (30-3) slowly, and verify that there is no more resistance from unreleased pressure.
8) Pull out sleeve (30-6) and poppet (30-2). Remove O-rings (30-9 and 30-10) and backup rings (30-11 and
30-12) from around the sleeve.
9) Pull out spring seat (30-15) and spring (30-8) from the back of the hole.
5 Disassembling Travel Right, Swing, Bucket, Booms 1 and 2, Arm1 and Blade load check sections
1) Loosen plug (19) (80-9) (WAF: 27) on the load check and remove O-ring (18) (80-8) from the plug.
2) Remove spring (17) (80-7) and poppet (16) (80-6).
6 Disassembling the check on the Travel Straight restrictor section (Travel Left section)
1) Loosen plug (19) (WAF: 27) on the Travel Straight restrictor section and remove O-ring (18) from the plug.
2) Pull out poppet (26) and spring (17).
7 Disassembling the Arm 2 load check section
1) Loosen socket head bolt (68) (WAF: 8) and remove flange (39) from the main body. Remove O-ring (38)
from the groove of the valve housing.
2) Remove sleeve (33), springs (35 and 37) and poppets (34 and 36).
WARNING: Use caution to keep the springs from falling into the passage. If a spring falls into the passage, it
may get caught on the main spool sliding section, and the spool will stick, which may cause the actuator to
! overrun unstoppably.
8 Disassembling the backup external confluence check section

1) Loosen plug (23) (WAF: 32) and remove O-ring (18) from the plug.
2) Take out spring (25) and poppet (24).
3) Loosen plug assembly (81) (WAF: 27) and remove the O-ring.
9 Disassembling the common check section
1) Loosen plug (19) (WAF: 27) on the check, then remove O-ring (18) from the plug.
10 Disassembling the Arm 1 semi-parallel check section
1) Loosen plug assembly (32) (WAF: 8) and remove the O-ring.
11 Disassembling the relief valves
1) Remove overload relief valve (63) (WAF: 32) from the main body valve and the add-on spool section.
2) Remove main relief valve (62) (WAF: 32) from the main body valve and main relief valve (79) (WAF: 24) from
the add-on inlet section.
3) Remove negative control relief valve (55) (WAF: 32) from the main body valve.
* For disassembly and reassembly of relief valves, refer to appropriate chapter in Section.
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8011-6
12 Disassembling the shut-off valves
4) Loosen plug assembly (64) (WAF: 32), then remove O-rings and backup rings.
13 Disassembling the other plugs
1) Loosen plug assembly (20) (WAF: 19) on the Port PP section and remove the O-ring.
2) Loosen plug (89) (WAF:19) on the backup cap section and remove the O-ring (88).
3) Disassemble G1/8 size plugs (21) (WAF: 5; 3 locations in all), then remove the O-rings.
4) Disassemble G3/8 size plugs (32) (61-2) (WAF: 8; 4 locations in all), then remove the O-rings.
5) Disassemble G1/2 size plugs (69) (78-2) (WAF: 10; 2 locations in all), then remove the O-rings.
6) Disassemble G3/4 size plugs (90) (WAF: 36; 2 locations in all), then remove the O-rings.
7) Disassemble 7/8-14 UN size plug (22) (WAF: 27) and remove O-ring (18).
14 Disassembling the add-on section
1) Loosen and remove hexagonal nuts (72) (WAF: 19) and (74) (WAF: 22).
2) Pull out outlet housing (61-1).
3) Pull out the valve housing for the spool section (80-1) and remove O-rings (80-10 and 80-11) for the mating
surface.
4) Pull out inlet housing (78-1) and remove the O-rings (78-3 and 78-4) from the mating surfaces.
5) Remove O-rings (59 and 60) from the mating surfaces on the main body.
6) Loosen tie rods (71 and 73) and remove from main body valve housing (1). (Use a pipe wrench or the like).
WARNING: When pulling out the add-on section, be careful not to dent or scratch the mating surfaces.
If they are dented or scratched, malfunctioning may occur due to oil leakage from the mating surfaces.
Also, use caution to prevent foreign substances from getting into the oil passages.
! Foreign substances may lodge in the spool sliding section causing the spool to stick, and faulty seating of the
load check may cause the actuator to overrun unstoppably.
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8011-7
2 Cleaning
Thoroughly clean all disassembled parts with clean mineral oil.
Dry with compressed air and place each part on a clean paper or vinyl surface for inspection.
3 Inspection
Inspect all surfaces of each part for burrs, scratches or other damage.
1) Check for scratches and nicks, dents, dirt, and rust on the load check seat surfaces in the valve housing,
and remove small scratches an oilstone.
2) Check for scratches, dents and other damage on the outside of the spool, and remove small scratches with
an oilstone.
3) All sliding parts should move smoothly, and there should be no foreign substances in any grooves or pas-
sages.
4) Broken, severely deformed, or worn springs must be replaced.
5) If the relief valve is not working properly, inspect according to 5. Adjusting the Relief Valves.
6) All O-rings and backup rings on the disassembled parts must be replaced with new ones.
7) After removing caps and plugs, check to see that there is no paint around the holes in the body or on the
plug seats. (If paint chips get into the valve, binding or blockage may occur, leading to malfunctioning or oil
leakage).
4 Assembling
WARNING: Prior to assembly, verify the number of parts, locations for installation and tools required.
!
1 Subassemblies
* Before installing parts onto the valve housing body, assemble the required parts into subassemblies.
1 Main spools (2 to 10) (80-2)
Apply adhesive to the threaded parts of spools (2 to 5, 7, 9, 10 and 80-2).
1) Install spring seats (2-2, 3-2, 4-2, 5-2, 7-2, 9-2, 10-2 and 80-2-2), springs (2-3, 3-3, 4-3, 5-3, 7-3, 9-3, 10-3
and 80-2-3) and spool ends (2-4, 3-4, 4-4, 5-4, 7-4, 9-4, 10-4 and 80-2-4). Secure the spool between blocks
in a vise and tighten the spool end.
Tightening torque: 9.8 to 11.8 Nm
WARNING: Do not apply too much adhesive. Excess adhesive will overflow when the spool is tightened.
Grasp the spool as close as possible to the end so that the spool is not bent by the tightening torque.
! If the spool end is overtorqued, swelling of the spool may cause it to stick, and this may cause the actuator to
everrun unstoppably.
* Observe this precaution when adhesive is used in the instructions below.
WARNING: Springs (5-3 and 10-3) on Boom 2 spool (5) and Travel Straight spool (10) are different from the
springs for other parts.
! Installing incorrect parts may lead to malfunctioning of the actuator.
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8011-8
2) Install poppet (6-6) and spring (6-7) into the hole in spool (6).
Next, apply adhesive to the threaded part of the spool.
Secure the spool between blocks in a vise.
Apply adhesive to the threaded part of plug (6-5).
Install O-ring (6-8) and backup ring (6-9) onto plug (6-5), then fasten the plug.
Install the spring seat (6-2), springs (6-3) and spool end (6-4), then fasten the spool end.
Install poppet (8-6) and spring (8-7) into the hole in spool (8).
Next, apply adhesive to the threaded part of the spool to which plug (8-5) is to be installed.
Install O-ring (8-8) and backup ring (8-9) onto plug (8-5), then fasten the plug.
Apply adhesive to the threaded part of spool to which spool end (8-4) is to be installed.
Install spring seat (8-2), spring (8-3) and spool end (8-4). Secure the spool between blocks with a vise and
tighten the spool end.
Tightening torque: 9.8 to 11.8 Nm.
WARNING: Be careful to assemble O-rings and backup rings in the correct locations. If installed backwards, O-
! rings may break and this may lead to malfunctioning.
2 Sub-spool section (41 and 48)

1) Apply adhesive to the threaded parts of spools (41 and 48).
2) Install spring seat (43), spring (44) and spool end (45). Secure the spool between blocks in a vise and
tighten spool end (45).
Tightening torque: 19 to 22 Nm.
3 Sub-spool section (52)
1) Install backup ring (53) and O-ring (54) on sleeve (52-2).
2) Install a seal onto sleeve (52-2), then install piston (52-3) into the sleeve.
3) Insert spool (52-1) into sleeve (52-2).
4 Boom and arm anti-drift valves
1) Install O-rings (30-9 and 30-10) and backup rings (30-11 and 30-12) in the groove around sleeve (30-6).
! rings may break and increase the natural drop of the actuator.
2) Insert poppet (30-2) and spool (30-5) into the sleeve holes, taking care to orient them correctly.
3) Attach spring seat (30-15) onto the smaller poppet end, place spring (30-8) on spring seat, and then insert
together with sleeve into the hole in body (30-1).
4) Secure body (30-1) in a vise so that the mating faces of the body and the fitting side of the O-ring (31) are
not damaged.
WARNING: Apply grease to seats so that the springs and the spring seats are seated firmly on the poppet.
If the spring is not seated on the spring seat, the spring may be broken by the spring seat, and the broken
! pieces may travel through the flow passage and cause malfunctioning of moving parts.
5) Install spring (30-7) and piston (30-4) onto plug (30-3).

6) Install an O-ring on plug assembly (30-14), then tighten the assembly onto plug (30-3).
Tightening torque: 147 to 157 Nm
7) Install O-ring (30-13) on plug (30-3), then tighten the plug onto body (30-1).
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8011-9
5 Shut-off Valve
1) Install spring (30-7) and piston (30-4) onto plug (30-3).
! rings may break and lead to malfunctioning.
2 Assembling the Control Valve Main Body

1 Assembling the add-on section
1) Install tie rods (71 and 73) onto the main body valve housing (1).
WARNING: Fasten the tie rod up to the effective thread depth. If the threads are not sufficiently engaged, oil
may leak from mating surfaces due to insufficient tightening force on the add-on section, and this may cause
! malfunctioning.
Excessive load may act on the threads to damage them and make them inoperative.
2) Install O-rings (59 and 60) on the mating surfaces of the main body.
3) Mount inlet housing (78-1) on the main body valve housing using the tie rod as a guide. Install O-rings (78-3
and 78-4) on the mating surfaces.
4) Mount valve housing (80-1) for the spool section on the inlet housing using the tie rod as a guide. Install O-
rings (80-10 and 80-11) on the mating surfaces.
5) Mount outlet housing (61-1) on the valve housing for the spool section using the tie rod as a guide.
WARNING: Oil leaking from mating surfaces can cause malfunctioning.

Be careful not to dent or scratch the mating surfaces when installing add-on sections. At the same time, be
! careful to keep foreign substances from lodging between mating surfaces and to keep O-rings from falling off or
protruding.
WARNING: When installing add-on sections, always install the tie rod first and use it as a guide in positioning
the installation.
! If positioned without using the tie rod, the incorrectly aligned O-ring on the mating surface may cause oil
leakage, which may cause malfunctioning.
6) Fasten hexagonal nut (74) onto tie rod (73).

Tightening torque: 152 ± 7 Nm
Fasten hexagonal nut (72) onto tie rod (71).
Tightening torque: 93 ± 4 Nm
WARNING: Always fasten hexagonal nuts to within the specified torque range. Undertorquing may cause oil
leakage from the mating surfaces due to lack of fastening force. Overtorquing may cause the spool to stick due
! to distortion of the valve housing for the spool section, causing the actuator to overrun unstoppably.
Tighten the two nuts alternately so that they will be tightened equally.
WARNING: This control valve is designed so that add-on sections supplied as kits can be added on afterwards.
! When adding add-on sections, always follow the same precautions as for disassembly and reassembly.
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8011-10
2 Assembling Travel Right, Swing, Bucket, Booms 1 and 2, Arm 1 and Blade load check sections
1) Insert poppets (16) (80-6) and springs (17) (80-7) into the valve housing.
2) Install O-rings (18) (80-8) on plugs (19) (80-9), then screw in and tighten the plugs.
3 Assembling the Arm 2 load check section
1) Assemble spring (35) and poppet (34) around the perimeter inside sleeve (33), then insert the sleeve into
the valve housing with poppet (36) and spring (37) inside.
2) Install O-ring (38) onto the groove of the valve housing. Install flange (39) and fasten with socket head bolts
(68).
WARNING: When installing flange (39), ensure that spring (37) is firmly seated in the flange seat. If the spring is
not seated when assembled, it may break.
! When tightening socket head bolts (68), tighten the 2 bolts alternately so that they will be tightened equally.
Observe this precaution when fastening flanges in the instructions below.
4 Assembling the check on the Travel restrictor section (Travel Left section)
1) Insert poppet (26) and spring (17) into the valve housing.
2) Install O-ring (18) on plug (19), then fasten the plug.
WARNING: When installing the flange (19), ensure that the spring (17) is firmly seated in the plug seat. If the
! spring is not seated firmly when assembled, it may break.
Observe this precaution when fastening plugs in the instructions below.

5 Assembling the backup external confluence check section
2) Install O-ring (18) on plug (23) and fasten the plug.
3) Install O-ring on plug assembly (81) and fasten the assembly.
6 Assembling the common check section
7 Assembling the Arm 1 semi-parallel check section
1) Insert poppet (57) and spring (58).
2) Install O-ring on plug (32) and fasten the plug.
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8011-11
8 Assembling the boom and the anti-drift valve
1) Install O-ring (31) on the mating surface.
2) Insert poppet (27) into the valve housing.
3) Install O-rings (29-2 and 29-4) and backup ring (29-3) on spacer (29-1). Press the spacer into the valve
housing together with spring (28).
WARNING: Be careful to assemble so that the spring is seated correctly on the spacer seat.
If the spring is not seated on the spacer, it may be broken by the poppet, and broken pieces may travel through
! the flow passage and cause malfunctioning of moving parts.
4) Pass socket head bolt (67) through body assembly (30) and fasten.
9 Assembling the relief valves
1) Screw in overload relief valves (63) and tighten: total 8 locations.
2) Screw in main body main relief valve (62) and tighten.
3) Screw in add-on main relief valve (79) and tighten.
4) Screw in negative control relief valve (55) and tighten.
10 Assembling the subassembly spools (41 and 48)
1) Assemble spool assemblies (41 and 48) in the same locations as before disassembly.
2) Install O-rings (42) on caps (46 and 47) and install the caps. Pass socket head bolt (66) through the caps
and fasten.
Tightening torque: 8.8 to 10.5 Nm.
WARNING: Hold the spool perpendicular to the hole and insert slowly.
After insertion, slide the spool back and forth by hand to make sure it does not move unevenly or roughly. If the
! spool is inserted so that it moves unevenly or roughly, it may malfunction.
Observe this precaution when inserting spools in the instructions below.

11 Assembling the sub-spool (52)
1) Assemble spool assembly (52) in the same location as before disassembly.
2) Install spring (51).
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8011-12
12 Assembling the main spools (2 through 10) (80-2)
1) Install O-ring (12) (80-4) on the valve housing (1) (80-1).
2) Install short cap (14) on Travel Straight spool (10). Install short caps (13) (80-5) on all the other spools. Pass
socket head bolts (65) (80-12) through the caps and fasten.
3) Install spools (2 through 10) (80-2), assembled as a subassemblies, into spool holes in the same locations
as before disassembly.
4) Install long cap (15) on Travel Straight spool (10). Install long caps (11) (80-3) on all the other spools. Pass
socket head bolt (65) through the long caps and fasten.
WARNING: Be careful that the mating surface O-rings do not fall off when installing the caps.
!
13 Assembling the other plugs
1) Install an O-ring on plug assembly (90) and fasten the assembly.
2) Install O-rings on plug assemblies (32) (61-2) and fasten the assemblies.
5) Install O-rings on plug assemblies (69) (78-2) and fasten the assemblies.
WARNING: After completing the assembly, check for parts that may have been forgotten or not tightened.
Forgetting to tighten parts will cause oil leakage from loose parts.
! All tightening torque values are for under wet conditions (with hydraulic oil applied).
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8011-13
5 Relief valves
1 Instructions for Disassembling and Assembling the Main body Relief Valves
AQ23002-001
[1] Disassembling
This component must be replaced as an assembly.
When disassembling, loosen plug (1) (WAF: 32) with a wrench or the like and remove O-ring (2).
If oil is leaking from the adjuster kit section (3), loosen the kit and replace the O-rings (4).
WARNING: When disassembling the adjuster kit, be careful that parts do not fly out due to the spring, and be
! careful not to lose the poppet.
[2] Assembling
Make sure there is no dirt or paint chips around the threaded section of plug (1) and install a new O-ring (2).
Thoroughly clean the area where the relief valve is to be installed on the valve housing as well. Install the relief
valve and fasten plug (1).
If the adjuster kit has been disassembled, thoroughly clean around the threaded part, then adjust the pressure
according to 5. Adjusting the Relief Valves.
WARNING: All the above tightening torque values are for under wet conditions (with hydraulic oil applied).
!
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8011-14
2 Instructions for Disassembling and Assembling the Add-on Relief Valves
[1] Disassembling
When replacing, loosen plug (1) (WAF: 32) with a wrench or the like and remove O-ring (2).
If there is leakage from the adjuster kit section (3), loosen the adjuster kit and replace the O-rings (4).
[2] Assembling
Thoroughly clean the area where the relief valve is to be installed on the valve housing as well. Install the relief
valve and fasten plug (1).
If the adjuster kit has been disassembled, thoroughly clean around the threaded part, then adjust the pressure
!
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8011-15
3 Instructions for Disassembling and Assembling the Overload Relief Valves
AQ23002-002
[1] Disassembling
When replacing it, loosen cap (1) (WAF: 32) with a wrench, etc. and remove O-ring (2).
If there is a leak from the adjuster kit section (3), loosen the adjuster kit and replace the O-rings (4).
[2] Assembling
Make sure there is no dirt or paint chips around the threaded section of cap (1) and install a new O-ring (2). Thor-
oughly clean the area where the relief valve is to be installed on the valve housing as well. Install the relief valve
and fasten cap (1).
If the adjuster kit has been disassembled, thoroughly clean around the threaded part, and adjust the pressure
!
4 Instructions for Disassembling and Assembling the Negative Control Relief Valves
1 Disassembling
This component cannot be disassembled because Section D is press fit. It must be replaced as an assembly.
2 Assembling
Install a new O-ring (4) on sleeve (2).
Thoroughly clean the area where the relief valve is to be installed on the valve housing as well. Install and fasten
the relief assembly plug (1).
!
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8011-16
5 Adjusting the Relief Valves
1 Main relief valves
(procedure is the same for the main body and add-on relief valves)
1) Attach an accurate pressure gauge at the entry circuit.
2) Run the pump at its rated rpm.
3) Switch spools on the control valve. Read the pressure gauge with the cylinder at stroke end.
WARNING: Switch spools on the actuator, in which the set pressure of the overload relief valve is higher than
! that of the relief valve.
4) Turn the adjuster clockwise until the required pressure is obtained. One turn of the adjuster increases the
pressure by 17.8 MPa.
5) When the pressure reaches the specified value, press down on the adjuster to stop the rotation, then fasten
the lock nut.
2 Overload Relief Valve
WARNING: If the set pressure of the overload relief valve is higher than that of the main relief valve, do not
! adjust the overload relief valve. Replace it with a pre-set relief valve as an assembly.
1) Switch spools on the control valve. Read the pressure gauge with the cylinder at stroke end.
2) Turn the adjuster clockwise until the required pressure is obtained.
One turn of the adjuster increases the pressure by 21.2 MPa.
3) When the pressure reaches the specified value, press down on the adjuster to stop the rotation, then fasten
the lock nut.
4) Increase the pressure again to verify that the specified pressure has been obtained.
6 Installation
1) Piping should be done with caution to avoid excessive outside pressure on the valves.
2) Fasten all mounting bolts equally.
3) Use caution when welding closely to the valves. Seals may be damaged by excessive heat and sputter.
4) To keep foreign substances from getting into ports, do not remove coverings until starting piping work.
7 Operation
1) Verify that hydraulic circuits and hydraulic oil are clean before starting operation.
2) Use hydraulic oil with an aniline point between 82 and 113 °C.
3) Do not exceed the specified set pressure of the relief valve.
4) There must be a difference of 2.0 MPa or more between the set pressures of the main valve and the overload
valve.
5) Bleed air and warm up the machine completely before actual operation.
In particular, if the hydraulic oil temperature and the valve temperature are low, follow the precautions below at
start-up in order to prevent the spool from sticking due to heat shock:
• Do not attempt sudden continuous operation of the main relief valve or the overload valve. Let the hydraulic oil
in all the actuators circulate so the temperature rises uniformly in all the sections.
• Sudden fine adjustments or combined operations at low temperatures generate heat locally due to throttling of
all sections and must be avoided.
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8011-17
8 List of control valve specifications
Rated flow (main body): 160 L/min (Note: 30 L/min in neutral)
Maximum pressure (main body): 35 MPa
Rated flow (add-on Pr): 70 L/min
Maximum pressure (add-on Pr): 28 MPa
Allowable back pressure
Peak pressure: < or = 1.5 MPa
Pressure for normal operation: > or = 0.5 MPa
Allowable oil operating temperature range
For normal operations: -25 to 80°C
Instantaneous maximum: 100°C
(Nitrile rubber is used for seals)
9 Troubleshooting
1 Control valves in general
Problem Cause Remedy

1. Abnormal increase in oil temperature. Remove cause of resistance in oil flow from pipe.
2. Dirty hydraulic oil. Replace hydraulic oil and clean circuit.
3. Over-tightened port joints in piping. Check torque.
4. Valve housing deformed at time of
Loosen mounting bolts and check.
installation.
Attach pressure gauges to pump port and cylinder
5. Pressure is too high.
port to check pressure.
Spool does not cycle.
6. Spool is bent. Replace as a valve assembly.
7. Damaged return spring. Replace damaged parts.
8. Spring or cap is crooked. Loosen cap; center and retighten.
9. Uneven temperature distribution in
Warm up entire circuit.
valve.
10. Valve is blocked by dirt. Flush to remove dirt.
11. Insufficient pilot pressure. Check pilot valve and pilot relief pressure.
1. Oil leakage from cylinder. Check cylinder seals.
2. Oil bypassing from spool. Check spool for damage.
3. Oil leakage from overload relief valve. Clean valve housing seat and relief valve seat.
Disassemble anti-drift valve and clean seats in all
Cannot hold load. parts.
If seats are damaged, replace poppet, or lap pop-
4. Oil leakage from anti-drift valve. pet and seats.
If a problem is found in the anti-drift valve, replace
spools and sleeves at the same time because
they are fit together.
Load drops when spool 1. Dirt in load check valve. Disassemble and clean check valve.
is switched from neutral 2. Damaged poppet or seat in check
to upward position. Replace poppet, or lap poppet and seat.
valve.
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8011-18
2 Relief valves

1. Main poppet, sleeve or pilot poppet is
Pressure does not rise
stuck open, or there is dirt in the seat
at all.
section.
1. Pilot poppet seat is damaged. Replace relief valves.
Unstable relief pres-
sure. 2. Piston or main poppet is stuck.
1. Seat is worn by dirt.
Incorrect relief pres-
sure. Reset pressure, then fasten lock nut to specified
2. Loose lock nut or adjuster.
torque.
1. Damaged seat in relief valve.
Replace relief valves.
Oil leakage. 2. Parts are stuck because of dirt.
3. Worn O-ring. Replace adjusters or O-rings in mounting section.
3 Hydraulic system in general

1. Faulty pump. Check pressure or replace pumps.
2. Faulty relief valve. Replace relief valves
3. Faulty cylinder. Repair or replace.
4. Pump load pressure is too high. Check pressure in circuit.
Hydraulic system does
not function properly or 5. Cracks on valves. Replace as a valve assembly.
does not operate at all.
6. Incomplete spool stroke. Check spool movement.
7. Oil level in tank is too low. Refill with hydraulic oil.
8. Blocked filter in circuit. Clean or replace filter.
9. Restricted piping in circuit. Check piping.
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8011-19
10Reference Drawing
1 Parts list
Sym Part name Q’ty Sym Part name Q’ty Sym Part name Q’ty
1 Valve housing 1 29 Spring 1 57 Plug 1
Shut-off valve assem-
2 Spool section assembly 1 30 Spool 1 58 2
bly
3 Inlet section assembly 1 31 Plug 1 59 Plug 1
4 Spool 1 32 Spring 1 60 Relief valve kit 6
5 Spool 1 33 Outlet housing 1 61 Relief valve kit 1
6 Spool 1 34 Spacer 2 62 Plug assembly 1
7 Spool 1 35 O-ring 2 63 Plug assembly 2
8 Spool 1 36 Backup ring 2 64 Plug assembly 1
9 Spool 1 37 Sleeve 1 65 Plug 3
10 Spool 1 38 Plate 1 66 O-ring 3
11 Spool 1 39 Socket head bolt 44 67 Plug 1
12 Spool 1 40 Anti-drift valve assembly 1 68 Spacer 2
13 Spool 1 41 Poppet 1 69 Poppet 2
14 Cap 10 42 Spring 1 70 Spring 2
15 Cap 10 43 Socket head bolt 4 71 Tie rod 4
16 Spring 8 44 Sleeve 1 72 Nut 4
17 Spool end 10 45 Poppet 3 73 O-ring 1
18 Spring seat 20 46 Spring 3 74 O-ring 2
19 O-ring 20 47 Poppet 2 75 O-ring 1
20 Spring 2 48 Plug 3 76 O-ring 1
21 Plug assembly 1 49 Spring 2 77 Name plate 1
22 Sleeve 1 50 O-ring 4 78 Drive screw 4
23 O-ring 1 51 Sleeve 1 79 O-ring 2
Spool section assem-
24 Backup ring 2 52 Poppet 5 80 1
bly
25 Plug assembly 14 53 Spring 5 81 Relief valve kit 1
26 Poppet 1 54 Plug 4 82 Relief valve kit 2
27 Spring 1 55 O-ring 7
28 Plug assembly 7 56 Poppet 1
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8011-20
2 Overall View 1/3
Arm 1
Boom 2
Swing
Backup
Travel
(right)
KAJ5076S1D01
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8011-21
Blade
W-W
Boom swing
Arm 2
Boom 1
Bucket
Travel
(left)
Travel
(Straight)
KAJ5076S1D01
ASM-19-07-001 Issued 08-2008

8011-22
3 Overall View 2/3
Arm 1
Boom 2
Swing
Option
Travel
(right)
5 spool side
A-A
KAJ5076S2D01
ASM-19-07-001 Issued 08-2008

8011-23
Blade
Boom swing
Arm 2
Boom 1
Bucket
Travel
(left)
Travel
(straight)
KAJ5076S2D01
B-B
(4-Speed side)
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8011-24
D-D
Arm 1
Arm 2
KAJ5076S2D01
E-E
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8011-25
4 Overall Drawing 3/3
Boom 2
Boom 1
F-F
Travel
(right)
Travel
(straight)
KAJ5076S3D01
I-I
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8011-26
Swing
Bucket
G-G
KAJ5076S3D01
J-J
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8011-27
Option
Travel
(left)
KAJ5076S3D01
H-H
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8011-28
5 Reference number (2): Spool section assembly
W W
KAJ5076S6B00
W-W
1. Valve housing (1) 10. Spring (1)

2. Spool (1) 11. O-ring (2)
3. Cap (1) 12. -
4. Cap (1) 13. O-ring (2)
5. Spool end (1) 14. O-ring (1)
6. Spring (1) 15. O-ring (2)
7. Spring seat (2) 16. O-ring (1)
8. Poppet (1) 17. Socket head bolt (4)
9. Plug (1)
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8011-29
6 Reference number (3): Inlet section assembly
B-B
AS07001-004
1. Inlet housing (1) 5. O-ring (1)

2. Relief valve kit (1) 6. O-ring (1)
3. Plug assembly (1) 7. O-ring (2)
4. Plug assembly (1) 8. O-ring (1)
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8011-30
7 Reference number (40): Anti-drift valve assembly
AS07001-005
1. Body (1) 9. O-ring (1)

2. Poppet (1) 10. O-ring (1)
3. Plug (1) 11. Backup ring (1)
4. Piston (1) 12. Backup ring (1)
5. Spool (1) 13. O-ring (1)
6. Sleeve (1) 14. Plug assembly (1)
7. Spring (1) 15. O-ring (2)
8. Spring (1) 16. Spring seat (1)
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8011-31
8 Reference number (29): Shut-off valve assembly
AS07001-006
1. Poppet (1) 4. Plug (1)

2. O-ring (1) 5. Hexagon nut (1)
3. O-ring (1) 6. Set screw (1)
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8011-32
NOTES
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ASM-19-07-001 Issued 08-2008

Copyright ©
8012
Section
8012
ASSEMBLY AND DISASSEMBLY OF THE


Printed in France
Copyright ©
8012-2

Copyright ©
8012-3
TABLE OF CONTENTS
CYLINDER ............................................................................................................................................................... 4
STRUCTURAL DRAWINGS ....................................................................................................................................... 4
Boom cylinder ................................................................................................................................................... 4
Dipper cylinder (mono boom spec.) .................................................................................................................. 6
Dipper cylinder (offset boom spec.) .................................................................................................................. 8
Bucket cylinder (mono boom spec.)................................................................................................................ 10
Bucket cylinder (offset boom spec.) ................................................................................................................ 12
Offset cylinder (offset boom spec.) ................................................................................................................. 14
Blade cylinder.................................................................................................................................................. 16
Swing cylinder ................................................................................................................................................. 18
MAINTENANCE INSTRUCTIONS .............................................................................................................................. 20
Description of functions................................................................................................................................... 20
Maintenance/Inspection and Servicing ........................................................................................................... 24
Error diagnosis ................................................................................................................................................ 25
Storage standards........................................................................................................................................... 29
Instructions for disassembling and assembling............................................................................................... 30
SPECIAL JIGS FOR REPAIR ................................................................................................................................... 44
Dimensions of Tools........................................................................................................................................ 44
Handling the Jigs for Cylinder Repair.............................................................................................................. 45
Structure and features of jigs for cylinder repair ........................................................................................... 46
List of jigs ...................................................................................................................................................... 48
Handling jigs.................................................................................................................................................. 49

Copyright ©
8012-4
CYLINDER
1 Structural drawings
1 Boom cylinder
CX75SR - CX80
KAV2434X-B
ASM-17-24-002 Issued 08-2008

Copyright ©
8012-5
No. Part name Q’ty No. Part name Q’ty No. Part name Q’ty
1 Tube 1 13 Cushion seal 2 25 Pipe 1
2 Rod 1 14 Collar 1 26 Pipe 1
3 Cylinder head 1 15 Backup ring 1 27 Plug 2
4 Bushing 1 16 Cushion seal 1 28 O-ring 4
5 Snap ring 1 17 Piston 1 29 Nipple 1
6 Buffer ring 1 18 Seal ring 1 30 O-ring 1
7 U-ring 1 19 Slide ring 2 31 Pipe holder 2
8 Wiper ring 1 20 Nut 1 32 Bolt 2
9 O-ring 2 21 Set screw 1 33 Grease nipple 1
10 Backup ring 1 22 Steel ball 1 34 Grease nipple 1
11 O-ring 1 23 Pin bushing 2
12 Holder 1 24 Wiper ring 4
Weight: 103 kg
ASM-17-24-002 Issued 08-2008

Copyright ©
8012-6
2 Dipper cylinder (mono boom spec.)
CX75SR - CX80
KAV2436X-B
HOLE (1)
ASM-17-24-002 Issued 08-2008

Copyright ©
8012-7
1 Tube 1 14 Spacer 1 27 Pin bushing 1
2 Rod 1 15 Collar 1 28 Wiper ring 2
3 Cylinder head 1 16 Backup ring 1 29 Pin bushing 1
4 Bushing 1 17 Cushion seal 1 30 Wiper ring 2
5 Snap ring 1 18 Piston 1 31 Nipple 1
6 Buffer ring 1 19 Seal ring 1 32 Pipe 1
7 U-ring 1 20 Slide ring 2 33 Plug 1
8 Wiper ring 1 21 Set screw 1 34 O-ring 2
9 O-ring 2 22 Steel ball 1 35 Pipe holder 1
10 Backup ring 1 23 Cushion seal 1 36 Bolt 1
11 O-ring 1 24 Pin bushing 1 37 Grease nipple 1
12 Holder 1 25 Stopper 2
13 Cushion seal 1 26 Snap ring 1
Weight: 78 kg
ASM-17-24-002 Issued 08-2008

Copyright ©
8012-8
3 Dipper cylinder (offset boom spec.)
CX75SR
KAV2438X-B
ASM-17-24-002 Issued 08-2008

Copyright ©
8012-9
1 Tube 1 14 Spacer 1 27 Snap ring 1
2 Rod 1 15 Collar 1 28 Pin bushing 2
3 Cylinder head 1 16 Backup ring 1 29 Wiper ring 4
4 Bushing 1 17 Lock washer 1 30 Pin bushing 1
5 Snap ring 1 18 Cushion seal 1 31 Pipe 1
6 Buffer ring 1 19 Piston 1 32 Pipe 1
7 U-ring 1 20 Seal ring 1 33 Plug 2
8 Wiper ring 1 21 Slide ring 2 34 O-ring 4
9 O-ring 2 22 Set screw 1 35 Nipple 1
10 Backup ring 1 23 Steel ball 1 36 O-ring 1
11 O-ring 1 24 Cushion ring 1 37 Pipe holder 2
12 Holder 1 25 Cushion seal 1 38 Bolt 2
13 Cushion seal 1 26 Stopper 2 39 Grease nipple 1
Weight: 81 kg
ASM-17-24-002 Issued 08-2008

Copyright ©
8012-10
4 Bucket cylinder (mono boom spec.)
CX75SR - CX80
KAV2440X-B
ASM-17-24-002 Issued 08-2008

Copyright ©
8012-11
1 Tube 1 11 O-ring 1 21 Pipe 1
2 Rod 1 12 Piston 1 22 O-ring 1
3 Cylinder head 1 13 Seal ring 1 23 Bolt 4
4 Bushing 1 14 Slide ring 2 24 Pipe 1
5 Snap ring 1 15 Set screw 1 25 Plug 1
6 Buffer ring 1 16 Steel ball 1 26 O-ring 2
7 U-ring 1 17 Pin bushing 1 27 Pipe holder 2
8 Wiper ring 1 18 Wiper ring 1 28 Bolt 2
10 Backup ring 1 20 Wiper ring 2
Weight: 61 kg
ASM-17-24-002 Issued 08-2008

Copyright ©
8012-12
5 Bucket cylinder (offset boom spec.)
CX75SR
KAV2441X-B
ASM-17-24-002 Issued 08-2008

Copyright ©
8012-13
1 Tube 1 11 O-ring 1 21 Pipe 1
2 Rod 1 12 Piston 1 22 Plug 1
3 Cylinder head 1 13 Seal ring 1 23 O-ring 2
4 Bushing 1 14 Slide ring 2 24 Nipple 1
5 Snap ring 1 15 Set screw 1 25 O-ring 1
6 Buffer ring 1 16 Steel ball 1 26 Pipe holder 1
7 U-ring 1 17 Pin bushing 1 27 Bolt 1
8 Wiper ring 1 18 Wiper ring 1 28 Grease nipple 1
10 Backup ring 1 20 Wiper ring 2
Weight: 61 kg
ASM-17-24-002 Issued 08-2008

Copyright ©
8012-14
6 Offset cylinder (offset boom spec.)
CX75SR
KAV2442X-B
ASM-17-24-002 Issued 08-2008

Copyright ©
8012-15
1 Tube 1 11 O-ring 1 21 O-ring 2
2 Rod 1 12 Piston 1 22 Nipple 1
3 Cylinder head 1 13 Seal ring 1 23 O-ring 1
4 Bushing 1 14 O-ring 2 24 Pipe holder 1
5 Snap ring 1 15 Set screw 1 25 Bolt 1
6 Buffer ring 1 16 Steel ball 1 26 Grease nipple 2
7 U-ring 1 17 Pin bushing 2
8 Wiper ring 1 18 Wiper ring 4
9 O-ring 1 19 Pipe 1
10 Backup ring 1 20 Plug 1
Weight: 41 kg
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8012-16
7 Blade cylinder
CX75SR - CX80
KAV2085X-B
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8012-17
1 Tube 1 11 Seal ring 1 21 Pipe holder 1
2 Rod 1 12 Slide ring 2 22 Bolt 1
3 Cylinder head 1 13 Set screw 1 23 Grease nipple 2
4 Bushing 1 14 Steel ball 1
5 Snap ring 1 15 Pin bushing 1
6 Buffer ring 1 16 Wiper ring 4
7 U-ring 1 17 Pin bushing 1
8 Backup ring 1 18 Pipe 1
9 O-ring 1 19 Plug 1
10 Piston 1 20 O-ring 2
Weight: 34 kg
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8012-18
CX80
ASM-17-24-002
TIGHTENING TORQUE 31.5 ± 5.88 Nm
8 Swing cylinder
TIGHTENING TORQUE 669 Nm(M102 x 2) (M10 x 1.5)CAULKING(2 PLACES)

APPLY THREE BOND #1901 TO THE THREADS TIGHTENING TORQUE 1830 Nm WEIGHT: 56 kg
(M45 x 3 HEX WAF 70)
THE SPACER HAS AN IDENTIFICATION
GROOVE ON ITS CIRCUMFERENCE
S SECTION DETAIL TIGHTENING TORQUE

HOLE(1) (NOT SCALED PROPORTIONALLY) 76.4 ± 3.8 Nm (M16 x 1.5)
CUSHION STROKE CUSHION STROKE
INSIDE DETAIL STROKE 640 FROM BOTTOM

FREE SCALE PIN CENTER
LOCATION OF THE SLIT IS
SHOWN IN THE DRAWING PIPE ATTACHMENT (2 PLACES)
LOCATION OF THE SLIT IS
SHOWN IN THE DRAWING
PORT DETAIL (2 PLACES)
2-PT1/8(WITH PLASTIC CAP)
SECTION Y-Y
PS1/8
TYPE-A MANUFACTURING No. STAMPING POSITION WITH PLASTIC CAP
PT1/8
TIGHTENING TORQUE
17.2 ± 0.9 Nm (2-M8 x 1.25)
CLOSED 1085
KAV2787P1C01
Issued 08-2008
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8012-19
1 Tube 1 13 Cushion seal 1 25 Stopper 2
2 Rod 1 14 Spacer 1 26 Snap ring 1
3 Cylinder head 1 15 Collar 1 27 Pin bushing 2
4 Bushing 1 16 Backup ring 1 28 Wiper ring 4
5 Snap ring 1 17 Cushion seal 1 29 Pipe 1
6 Buffer ring 1 18 Piston 1 30 Pipe 1
7 U-ring 1 19 Seal ring 1 31 Plug 1
8 Wiper ring 1 20 Slide ring 2 32 O-ring 1
9 O-ring 2 21 Set screw 1 33 Pipe holder 1
10 Backup ring 1 22 Steel ball 1 34 Bolt 2
11 O-ring 1 23 Cushion seal 1 35 Grease nipple 1
12 Holder 1 24 Pin bushing 1
Weight: 56 kg
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1 Description of functions
1) Basic functions
The hydraulic piston system is a kind of hydraulic actuator which converts hydraulic energy supplied from the
hydraulic pump into a larger force for linear movement via a piston. In addition, it switches its operational direction
between extension and retraction by way of lever operation on the hydraulic oil direction switch-over valve.
This larger force, linear movement, and operational direction switching over are the basic functions.
2) Function by section
1) Cylinder head assembly
The piston assembly has a bearing function for the piston rod (2) provided by means of bushing (4) press fit-
ted into the inside surface of cylinder head (3). It prevents external oil leakage by means of a buffer ring
(6), U-ring (7) and backup ring (8) inserted into the inside surface of cylinder head. It also prevents dust
from the outside by means of a wiper ring (9) press fitted into the inside surface of the cylinder head.
Engaging with the cushion bearing (13) at the cylinder’s most extended position, it generates high pres-
sure in the cushion chamber and this softens the cylinderÕs impact at the most extended position.
In addition, it also supplies and drains high-pressure oil from the inside of cylinder tube to the ports.
A B
AQ24002-001
A: Black, B: Green, C: Split

Bushing (4)
The bushing is press fitted into the inner face of the cylinder head and is in contact with the piston rod. It
reduces eccentricity, which adversely affects the seal performance, by sharing lateral load applied on the
cylinder together with the slide ring located on the outer circumference of the piston, performing high-bear-
ing linear motion against the piston rod, as well as supporting one end of the piston rod.
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8012-21
Buffer ring (6)
The buffer ring is composed of a slide ring and a square ring and is located between the
U-ring and bushing. It prolongs the life of the U-ring, which is the main seal, by relieving high pressure with
the auxiliary seal which is directly in contact with the high pressure oil in the cylinder, and reducing the load
acting on the U-ring.
U-ring (7)
The U-ring is located between the wiper ring and the buffer ring. The U-ring seals the annular space formed
between the piston rod and cylinder head against the pressure oil
between the U-ring and the backup ring. It also forms suitable oil films on the piston rod to prevent rust.
Wiper ring (9)
The wiper ring is located at the opening end where the piston rod enters into and exits from the cylinder. It
prevents dust and water from entering into the rod seal section of the U-ring and the buffer ring in the cylin-
der from the outside. It also scrapes off mud attached on the surfaces of piston rod through piston rod move-
ments.
2) Piston assembly
The piston assembly has the function of transmitting the propulsion of the cylinder. A seal ring (16) is
mounted on the center of the piston (15) to prevent the flow of pressurized oil from either the left or right
chamber to the other chamber. There are slide rings (18) and (19) mounted at each end of the seal ring.
They have the function of a bearing to receive the cylinder lateral load.
2 1 13 14 15 16 17 18 19 20 21 25 23 22 24
Use caution with the direction of the cut sur-

faces during installation
Face "the split" to the piston side.

RM15001-070
1. Cylinder tube 19. Slide ring

2. Piston rod 20. Locking screw
13. Cushion ring 21. Steel ball
14. Cushion seal 22. Cushion ring
15. Piston 23. Cushion seal
16. Seal ring 24. Stopper
17. Backup ring 25. Snap ring
18. Slide ring
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For some cylinder sizes, the piston (15) and nut (21) are separate.
2 1 13 14 15 16 17 18 19 20 21 22 23 27 25 24 26
Use caution with the direction of the cut sur-

faces during installation
Face "the split" to the piston side.

RM15001-071
1. Cylinder tube 20. Shim

2. Piston rod 21. Nut
13. Cushion ring 22. Locking screw
14. Cushion seal 23. Steel ball
15. Piston 24. Cushion ring
16. Seal ring 25. Cushion seal
17. Backup ring 26. Stopper
18. Slide ring 27. Snap ring
19. Slide ring
Example of parts numbers for separated piston and nut.

Seal ring (16) and backup ring (17)
The seal ring (16) is positioned at the center of the piston (15) and uses the tension force of the O-ring to
seal the ring-shaped gap between the piston and the cylinder tube (1) and form chambers with a high-pres-
sure side and a low-pressure side with the piston as the boundary. The backup ring (17) has the function of
suppressing extrusion of the seal ring into the gap between the piston and the cylinder tube when the pres-
sure operates and of improving durability.
Slide ring (18) and (19)
Slide rings are positioned at both ends of the seal ring (16) and contact the inside surface of the cylinder
tube (1). Together with the bushing (4) positioned on the inside surface of the cylinder head (3), the slide
ring divides the lateral load applied to the cylinder and moves linearly relative to the inside surface of the cyl-
inder tube.
Furthermore, it supports one end of the piston rod (2) and has the functions of minimizing eccentricity, which
has a negative impact on the sealing, and buries and captures any impurities trapped between the cylinder
tube and the slide rings (18) and (19).
Cushion ring (13) and (24)
When the cylinder is fully extended, the cylinder head (3) and the cushion ring (13) fit together. When it is
fully retracted, the cylinder bottom and the cushion ring fit together. In both cases, this forms a ring-shaped
gap and squeezes the oil to reduce the cylinder collision speed at full extension or full retraction and thus
soften the impact.
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3) Pipes (28) and (29)
A pair of pipes are located on each port on the extension and retraction side on the cylinder tubes (1). The
pipes supply and drain high-pressure oil from the flexible hose connection end to the cylinder tube port.
000-7-05-02-19c
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8012-24
2 Maintenance/Inspection and Servicing
To gain full functions of hydraulic cylinder for a long time, conduct periodic inspections and servicing based on the
inspection table below.
Repair faulty sections as soon as possible.
NOTE: When conducting routine inspections and servicing, the first priority should be placed on the operatorÕs safety.
Conduct the operation using common knowledge and expertise.
Locations for
Annu-
inspection / Inspecting and servicing points Daily Monthly Notes
ally
servicing
Is cylinder clean (especially sliding part of the rod)? O
Appearance Is there any oil leakage from the piping fitting part? O
Is there any paint peeling, scaling or rust? O
Is movement smooth? Any abnormal noises? O
Is response good? O
Is there any oil leakage from the sliding parts? O
Operation
Is there any internal leakage? O
Is working pressure normal? O
Is set pressure on over load relief valve normal? O
Is the hydraulic oil dirty or deteriorated? O
Hydraulic oil Is the hydraulic oil changed regularly? O
Are filters changed regularly? O
Is there enough grease on the pins? O
Do the pins make noise or seize up? O
Fitting section Is there any looseness or wear on the pins? O
onto the main
machine Are the pin seals normal? O
Are there any loose or missing screws? O
Retighten fitting screws. O
Is there any wear on sliding parts? O
Are there any scratches or dents on the sliding If the sliding
O
parts? part of the
Piston rod Is plating scraped off on the sliding part? O rod is
exposed for
Are any sliding parts bent? O a long time,
Are there any cracks on or damage to welded apply corro-
O sion inhibitor.
parts?
Are any bolts, nuts (screws) loose? O
Cylinder tubes Retighten bolts and nuts (screws). O

(including Are there any cracks on or damage to welded
piping) O
parts?
Are there any cavity or dents on the tube? O
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3 Error diagnosis
1) Hydraulic cylinder errors and their remedy measures
It is not easy to locate faulty parts. General symptoms, possible reasons and remedy measures are shown in the
table below. For repairs, refer to the possible causes and remedy measures in the table.
However, it is often the case that machine troubles occur because not only one part but many other relating parts
have problems.
Measures other than ones shown in the table may be required.
Item Symptom
Oil leakage on the sliding section of piston rod (for assessment values, refer to 5-(4) Inspections after
1
assembly).
2 Oil leakage from cylinder head fitting section
3 Oil leakage from welded section between pipe and cylinder tube
4 Bad operation
Item Symptom Related parts Error item Preventive/remedy measures

1) Remove scratches with oilstone and smooth
the sliding surfaces (less than 1.5s). If the oil
leakage persists after smoothing the rod sur-
faces, disassemble and inspect the rod
Scratches and rust
because of possible damage in the U-ring
caught by claws on
caused by the scratches.
the sliding surface
2) If scratches and rust are too widespread to
Piston rod repair, replace piston rod and seals such as
U-ring, wiper ring, etc. and piston rod bear-
ing materials.
1) Re-plate or replace piston rod.
2) At this time, check seals and piston rod
Plating is flaking
bearing materials, and if damage is found,
Oil leakage on pis-
replace them.
1 ton rod sliding
section Foreign sub-
stances engaged 1) Remove foreign substances.
in the inside and 2) If a packing is damaged, replace it.
outside surfaces
Scratches on
Rod packing inside and outside Replace
(buffer ring and surfaces
U-ring)
1) Regarded as burning damage by air adia-
batic compression caused by remaining air
Lips and grooves
in the cylinder.
are locally carbon-
2) Perform initial operation at low pressure and
ized (burned).
low speed to bleed air fully after changing
packing.
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8012-26

1) Replace.
2) The life of the packing or hydraulic oil deteri-
Packing has lost oration or high temperature may e the
rubber elasticity cause.
and is crumbling. 1. Change hydraulic oil.
The whole lip is 2. Check hydraulic oil temperature.
also missing. (The oil temperature should be 80 °C or
Rod packing less.)
(buffer ring and 3. Check for uneven hot temperatures.
U-ring)
1) Replace.
2) Abnormal high pressure may act on the
Heel part of the
packing.
packing.
1. Check the pressure when starting opera-
Too much extru-
tion.
sion.
2. Abnormality in the buffer ring if the buffer
ring is attached. Inspect buffer rings.
1) Change rod packings together, as a general
rule. (Buffer rings should be replaced at the
same time if attached).
Backup ring Visible distortion 2) Abnormally high pressure may have caused
this. In this case, check it by following the
Oil leakage on pis- same steps described above for the packing
1 ton rod sliding heel extrusion.
section Foreign sub-
stances engaged Remove foreign substances.
in the lip
Wiper ring The lip is dam-
aged.
Replace.
Other abnormal
damages
Extreme wear, the
clearance with pis-
ton rod exceeds
the allowable max- Replace.
Bearing imum value
material (see 5-3. Mainte-
(Bushing) nance reference)
Significant dam-
1) Replace.
age in sliding sur-
2) Inspect the piston rod.
faces
1) Remove scratches and rust with an oil
Scratches or rust stone.
Cylinder head
in seal fitting area. 2) If repair is not possible, replace the cylinder
head
1) Remove foreign substances.
2) If O-ring is damaged, replace it.
3) Inspect the tube inside: If scratches and rust
Foreign sub- are found, smooth the surfaces with oil-
Oil leakage from stances on the stone.
2 cylinder head fit- O-ring inside and outside 4) Check O-ring grooves in the cylinder head:
ting section surfaces Dam- Same as above
aged O-ring 5) Check backup rings:If distortion or extrusion
is found, replace it.
Change O-rings after confirming items
above.
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8012-27

Distortion and
Backup ring Change together with O-ring.
extrusion.
1) Disassemble cylinder head to check O-rings
and backup rings.
If damage is found, replace it.
2) Check tube and cylinder head threaded sec-
Cylinder head Looseness tions to ensure that there is no damage.
If damage is found, replace it.
3) Upon completion of inspection, fasten with
Oil leakage from specified tightening torque. Refer to Tighten-
2 cylinder head fit- ing torque.
ting section
Looseness,
Replace all bolts and fasten them with specified
Bolt extension and
tightening torque.
breakage
Replace with new ones.
Oil leakage on the fitting section may be caused by
abnormally high pressure
Cylinder tubes Abnormal swelling
(including cushion pressure).
Check for bulging, deformation and circuit pressure
on the tubes.
WARNING:
Oil leakage from Cylinder tube Cracks will progress and end up with breakage.
welded section pipe Cracks on welded - Breakage is a very dangerous condition.
3
between pipe (hollow piston section - If cracks are found, immediately stop the opera-
and cylinder tube rod) tion and replace the parts.
- No effect can be gained if additional welding is
performed on cracked surfaces.
Curved too much;
exceeds specified
curve distortion
level.
Piston rod, Check seals and sliding materials also
(For curve distor-
cyclinder tubes because they may be damaged. If abnormality is
tion, see the corre-
found, replace.
sponding section
in 5-3. Mainte-
Bad operation
nance reference)
4-1
4
Does not move Replace with new ones. Same as above described,
Cylinder tubes Dents
smoothly check seals and sliding materials.
Abnormal wear
and damage on 1) Replace with new ones. Same as above
Piston rod, the sliding parts described, check seals and sliding materials.
cylinder tubes, Foreign sustances 2) Remove foreign substances. Same as
sliding materals engaged in the pis- above described, check seals and sliding
ton and cylinder materials.
head sliding parts
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8012-28

Damage such as
Replace with a new one. Also check the cylinder’s
Piston seal scratches and
inner face.
wear is found.
1) Remove scratches and rust by honing or
4-2 Scratches and rust with oilstone to smooth the surfaces.
Internal oil leak- Cylinder tubes on the inside sur- If scratches are too big to repair, replace cyl-
age makes the face. inder tubes with new ones.
piston rod extend 2) Replace piston seals with new ones.
or retract or fall Fasten with specified tightening torque. Refer to
abnormally while Piston nut Loose tightening.
Tightening torque.
operating or can
not give specified Leakage from Check the valve leakage volume and repair if nec-
Valves
speed output. valves. essary.
WARNING: Hydraulic oil tends to expand and shrink according to changes in

temperature and pressure. This also causes cylinders to extend and retract; therefore, we
sometimes see this as internal oil leakage. Check internal oil leakage under a given
pressure condition.
1. Bleed air.
1) Cylinder without air bleeder: Bleed air by
operating the cylinder several full strokes
under low pressure and at a slow speed.
2) Cylinder with air bleeder: To prevent high
4
temperature inside the cylinder, remove the
4-3
Air remains in the load and loosen air bleeder to release air
Operation is not Air
cylinder. fully.
stable.
When the cylinder stops suddenly, it can
extend or retract to a certain extent.
This phenomenon is caused by hydraulic oil
compressibility.
This phenomenon tends to occur especially
on long stroke cylinders.
4-4
Strong impact Too much clear-
Measure the dimensions of pin and pin bushing,
when switching Pin bushing ance between the
replace the parts that exceed the measured dimen-
over between Pin fitting section and
sions.
extension and pin bushing.
retraction.
4-5 Lubrication Lack of lubrication. Lubricate.
Cylinder sliding
operation makes Pin bushing Scuffing on fitting
Replace with a new one and lubricate.
noise. Pin surfaces.
WARNING: Hydraulic oil tends to expand and shrink according to changes in temperature and pressure.
This also causes cylinders to extend and retract; therefore, we sometimes see this as internal oil leakage.
Check internal oil leakage under given temperature and pressure conditions.
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8012-29
4 Storage standards
We take all possible measures at the time of shipping hydraulic cylinders. However, in order to avoid trouble when
storing them, please handle them following the precautions below.
1) Storing one unit only (as a general rule, store indoors)
Avoid a place with high temperature and high humidity or a place where corrosive gas or liquid is stored. Store
the unit off the floor. To prevent condensation due to temperature difference, we conduct inspections by using test
oil with a given volume of volatile corrosion inhibitor, retract the piston rod using super dry air (dew point 35 °C),
put caps when shipping.
Therefore, do not leave a cylinder with the cap removed or drain the remaining oil from the cylinder without clear
intention.
Storage for more than 6 months

Storage for more than 1 months Storage for more than one year
(3 months for single-acting cylinder)
1. Using clean hydraulic oil, let the 1. As packing may be deteriorated, it
Clean dust from the cylinder and
cylinder reciprocate to introduce cor- is desired to disassemble and
apply corrosion inhibitor to flange
rosion inhibitor into the cylinder fol- inspect, and replace the packing.
section, piston rod and other loca-
lowing the steps described in the left Also, check rust conditions on the
tions that rust easily.
column for 1 month storage. cylinder inner walls.
2. If cylinders, which have been
stored for a long time, are used as
2. If the cylinder does not operate,
they are, there is possibility of oil
add corrosion inhibitor only.
leakage because of temporary poor
sealing conformity.
3. Care is needed to avoid falling, collision, dislodgment and dents while storing.
2) At the time of installing devices

1. Operate cylinder at least once every 1 months.
2. Keep the piston rod in its retracted position, avoid exposure to outside air and apply corrosion inhibitor or grease to the
exposed parts at least once a month.
3. Careful handling is necessary to avoid damage to piston rods.
4. If cylinders are placed under conditions where they are exposed to salty wind (e.g. during exports), always apply corro-
sion inhibitor to piston rods and protect them as much as possible with polyethylene or V.C.I paper.
5. Solutions such as corrosion inhibitors may have adverse effects on sealing materials. Therefore, careful selection and
handling is required to avoid getting oil on dust seals. (Recommended corrosion inhibitors are listed below.)
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8012-30
5 Instructions for disassembling and assembling
1) Preparation
Before starting the disassembly, prepare the following items:
1) Prepare a workbench
2) Choose and prepare a stable and strongly built workbench large enough to arrange and keep parts and per-
form jobs.
2) General precautions for work
1) Before disassembly, fully rinse soil and dust attached to the cylinder outside walls.
2) As each part is a precision component, handle parts carefully and do not drop them or allow them to hit
each other.
3) Do not attempt to hit or pry parts forcedly because they are tightly fitted. Take time and carry out the opera-
tion carefully in order to avoid causing burrs or damage resulting in inability to reassemble a part, oil leakage
or lower efficiency.
4) If components are left disassembled or half-disassembled, the parts may rust because of moisture and dirt.
Rust prevention and dirt-proofing should be considered if the operation is suspended for unavoidable rea-
sons.
3) Maintenance reference
For sliding parts and sealing parts, replace them following the items below:
When a whole quarter of the circumference has worn and turned reddish
1) Bushing
copper color
2) Seals and slide rings Replace with new ones when disassembling cylinders
3) Pin bushing When serious scuffing has occurred
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8012-31
4) Inspection after assembly
Dimension inspection Check the fully retracted length and stroke as instructed on the diagram.
Check for looseness, permanent deformation, and external leaks when the test
Pressure withstand inspection
pressure instructed on the diagram is applied to each stroke end for at least 3 min.
Check the amount of oil leak at the rod section.
Judgment value for rod section oil leak
Move the piston rod back and forth 20 times with the oil at a temperature from 20
°C to 40 °C, and then judge by the state of the oil ring formed on the rod surface. If
the oil ring is in a broken down A state, this is judged to be trouble. See "5. Trouble
Diagnostics" for information on how to solve this.
Oil ring
External leak inspection
2 mm
1 mm
A B C D E F G
Not acceptable Acceptable

R
Oil leak unit: ml/10 min.

Interior Interior Interior
Oil leak Oil leak Oil leak
diameter diameter diameter
amount amount amount
mm mm mm
32 0.4 160 10.0
Internal leak inspection
40 0.6 100 4.0 180 12.6
50 1.0 125 5.6 200 15.6
63 1.6 140 6.0 220 20.0
80 2.3 250 22.0
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5) Required tools
1) General tools
1 9 2 6 2 5 6 7 4 2 6
1 3 9
2 6 4 8
RM15001-080
Tool name
Screwdriver (flathead screwdriver) (1)
RM15001-081
Hexagon wrench (1 set)
RM15001-082
Vise (1)
RM15001-083
Wrench (for piston nuts) (1 set)
RM15001-084
Punch (1)
RM15001-085
Torque wrench (1 set)
RM15001-086
Hammer (Plastic hammer) (1)
RM15001-087
Monkey wrench (1)
RM15001-088
Scoop (1 set)
RM15001-089
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2) Special jig
Cylinder assembly requires the following special jigs.
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8012-34
For bushing removal and press fitting
RM15001-090
For wiper ring press fitting
RM15001-091
Seal ring insertion jig
RM15001-092
Seal ring calibration jig
RM15001-130
For cylinder head insertion
RM15001-093
For piston insertion
RM15001-094
Consult with our company about jigs.
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8012-35
6) Instructions for disassembling
1) Drain oil.
2) Remove piping.
3) Secure cylinder.
Secure the cylinder in a vertical or horizontal posi-
tion.
Vertical securing facilitates the disassembly and
reassembly.
When securing it, stop rotations and axial move-
ment using the bottom pin holes.
Band for piping (not nec-

essary to remove unless
replacement is needed
000-7-05-02-19z1
4) Loosen and remove cylinder head tightening bolts 1.5 m

using hexagonal bar spanner.
Inserting a pipe as shown below facilitates the
operation.
5) Pull out the piston rod.
1. Ensure that the piping ports are open.
2. Place an oil sump at the port on the retraction
side (cylinder head).
3. Pull the cylinder head slowly with the piston
head fully pulled.
AQ24002-050
4. Pull out the cylinder head together with the pis-
ton rod and place them on the sleeper.
WARNING: When carrying out this operation in a vertical posi-
tion, pay special attention to the following:
When the piston rod is first pulled out with all the screws on the
cylinder head removed, pulling the cylinder head out from the
DANGER!
tube makes a space between the piston rod and piston. In this It may fall
situation, it is possible that when the cylinder head reaches a
given height, it may slide down suddenly, causing injury to the
operator. Always keep the cylinder head in contact with the
piston while carrying out this operation.
When performing the operation in a verti-
cal position
AQ24002-051
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WARNING: When the piston rod is pulled out in a horizontal When performing th operation in a horizontal leval position
position, it may drop immediately after it is pulled out, causing
damage to the parts. Pull out the rod using a sleeper to hold it in
a horizontal position.
DANGER! It may fall 000-7-05-02-19ab
6) Secure the piston rod.

1. Stop rotations using the rod head width across
flats or pin holes.
Drill
Steel ball
000-7-05-02-19ac
7) Remove piston nuts.

1. Remove set screws. Piston nut
Crimp with a punch in two places after installing
the set screws.
Loosen the set screws with a hand drill after
removing the crimped parts.
2. Remove the steel ball located behind the set
screw. Jack
3. Remove piston nuts.

The piston nuts are tightened to the torque Hydraulic cylinder
listed in the assembly drawing.To loosen the 000-7-05-02-19ad
piston nut, about 1.5 times as much torque is
required. If larger torque is necessary, prepare
a powered wrench that utilizes a hydraulic jack
or a hydraulic cylinder.
8) Remove piston, cushion bearing, and cylinder head in this order.
Cylinder head
Cushion bearing
Cushion seal
Piston
000-7-05-02-19ae
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9) Disassembly on the retraction side (arm cylinder).
4
5
Screw Flattening
3
6
2
A
Hit with plastic hammer while holding one side 000-7-05-02-19af
1. Remove piston nut (1). With the nut attached, the disassembly cannot proceed.
2. Remove snap ring (2). Remove it by softly hitting with a plastic hammer while being careful to avoid dam-
age to piston rod (3) and cushion bearing (4).
3. Slide cushion bearing to the threaded side of the piston rod, and the stopper (5) (two-piece) will come off.
4. Remove cushion bearing.
5. The cushion seal (6) has a one slit (A). Use it to enlarge the opening.
Remove piston seal.
1. The slide ring (7) and backup ring (8) can be 9
easily removed manually. 7
2. Cut and remove the seal ring (9) by placing a B

screwdriver on the ring as shown in the right fig- D
ure and hitting it with a hammer. C
3. Pull out and remove O-ring (10) with a spatula.
4. Do not reuse the removed seal parts.
10
B: Piston 8
000-7-05-02-19ag
C: Vise
D: Hardwood
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10) Disassembling buffer ring (11)
1. Buffer rings (11) (Teflon seal) is fitted in the inner grooves of the cylinder head.
When removing this seal, pierce it with a sharp tool and lift it up, then insert a spatula and remove it.
2. Do not reuse the removed seals.
11) Disassembling U-rings, backup rings and wiper ring.
17, 18
15
14
16
13 11
12
000-7-05-02-19ah
1. Remove U-ring (12) and back-up ring (13, 18) using screwdriver or equivalent.
2. Wiper rings(14) are press fitted.
Pierce with a tool such as screwdriver on the rubber, hit the tool and remove it.
3. Do not reuse the removed seal parts.
12) Disassembling DU bushing (15). Push with press
1. Remove the snap ring (16) by prying with a
screwdriver from the cylinder head (19).
2. Push out the DU bushing with a press using a E
jig (E).
15
13) Cleaning and Storage
1. Apply hydraulic oil to the removed parts after
cleaning with white kerosene. Cover and store
them.
2. If components are left disassembled, they may
not operate fully as expected after reassembly
because of rusting and dust.
000-7-05-02-19ai
7) Instructions for assembly

WARNING: Careful handling is needed when reassembling because peeled paint from parts may enter into the cylinder.
1) Changing seals
1. Change all seals when the cylinder is disas-
sembled. 18
2. O-ring 17
Before fitting backup rings (18) and O-rings
(17), clean the fitting grooves fully. Foreign sub-
Pressure side
stances in the grooves may cause oil leakage.
Pay attention to the positions of backup rings.
Apply grease or hydraulic oil before fitting to the 19
backup ring and O-ring to make them move 000-7-05-02-19aj
smoothly.
If they do not move smoothly, the O-ring will dis-
tort when being installed and cause oil leakage.
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2) Cylinder head
1. Press fit the DU bushing (15) with press using a
jig (F). Press
(
2. Press fit the wiper ring (14) with press using a

jig (G).
Press holder
CM
3. Fit backup ring (13) and U-ring (12) in the U-

ring groove (H) in this order.
Ensure that there is no remaining permanent 14
deformation such as creases after fitting. G
H
Push with
press
000-7-05-02-19al
3) Buffer ring (11) assembly

1. Install the backup ring (a) and slide ring (b) in
this order by forming U-shape (d) with the fin- a, b
gers, placing them into the groove and pushing
out them toward the outer circumference after
fitting the square ring (c) in the groove. If the
rings are shaped with too small a radius,
creases will remain after fitting. Therefore, use a
radius of 6 mm or more to make a curve.
Ensure that there is no crease after fitting. d
Pay attention to the fitting directions of seals. 000-7-05-02-19am
Reversing them will cause high pressure

between the seal and U-ring and lead to defor-
mation on the cylinder head.
2. Fit DU bushing locking snap ring (16).
11
b
a
16
AQ24002-052
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4) Piston
1. Place the piston (B) on the press and install a seal ring (9) using a jig as shown in the figure to the right.
(Pre-fit O-ring (10) and back up ring (9) to one side.)
2. Immediately after fitting seal ring and backup ring on the other side, correct the seal ring using a correc-
tion jig so that it does not remain expanded.
(This must be strictly observed.)
Reinforcing plate
Push with press Push with press
Jig (A) (nylon pipe) 8
Correction jig (C)
Jig (B)
9 10
AQ24002-053
5) Assembling piston rod

1. Secure the piston rod.
Jig for assembling use
2. Engage the cylinder head.
Care must be taken to confirm that the lips of
the wiper ring and the U-ring are not engaged
with the stepped part.
000-7-05-02-19ap
3. Engage cushion seal (6), cushion bearing (4)

and piston (B). (Cushion seals are not required B
for bucket cylinders) 4
1a
Then, fit shim and fasten the piston nut. (Direct
6 1
the “slit” (A) on the cushion seal toward the pis-
ton side.)
000-7-05-02-19aq
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4. Tighten piston nuts using torque listed in the
J
assembly drawing. Pay attention to a lack of
tightening torque because it may cause internal
leakage, loose nuts, and screw breakage.
5. After tightening the piston nut, put in the steel K
ball (20) and tighten set screw (21) using torque
listed in the assembly drawing.
Crimp (J) with a punch (K) at two places on the
outer circumference. 21
20
000-7-05-02-19ar
6) Installing cushion bearing on the retraction side

1. Install the cushion bearing (4) before fitting the piston nut (1).
With nut attached, the installation cannot proceed.
2. Insert the cushion seal (6) into the groove by facing its slit (A) processed side toward the threaded side.
3. Install the cushion bearing by facing the flattened part as shown in the drawing.
4. Insert stopper (5) into the groove.
5. Push the cushion bearing up to the stopper fully and knock in the snap spring (2).
Softly hit it with a plastic hammer while paying attention to avoid damage to the rod (3) and cushion bear-
ing.
WARNING: Be aware that installing directions of cushion seals and cushion rings are different.
Make sure that the cushion ring moves smoothly up/down and right/left after fitting snap rings.
4
5
3
6
2 A
AQ24002-054
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7) Insert the piston rod into the tube.
Jigs, nylon type
1. Secure the tube vertically or horizontally.
Insert the piston rod into the tube.
When securing vertically, piston rod enters into
the tube by the act of its self-weight. Slide rings
When securing horizontally, push in using lever
hoist or forklift.
2. Careful handling is needed to prevent the slide
ring from dropping when the piston enters the
tube.
000-7-05-02-19at
8) Installing cylinder head

1. Align the cylinder head according to the assem-
bly drawing and set the tightening bolts by spec-
ified torque in the order shown in the drawing
after fastening them alternatively.
The example in the diagram has 8 bolts, but this
number will vary depending on the cylinder
type.The tightening method is fundamentally
the same.
Depending on the cylinder type, the cylinder
head may be threaded or the cylinder may
screw into a tube. 000-7-05-02-19au
9) Fitting piping
1. Ensure that the O-rings are placed correctly in the grooves.
2. First, fit the bolts for port sections.
3. Tighten the bolts using torque listed in the assembly drawing.
4. Tighten the band for piping using torque listed in the assembly drawing so that there is no gap.
Tighten the bolt
Gap closed
Gap closed
Band for piping
Be careful of O-rings
000-7-05-02-19av
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8) Trial run
1) After fitting the cylinder on the machine, move slowly more than 8 times at the full stroke by oper-
ating the switch-over valve. The inside of the cylinder will be filled with oil.
Quick and sudden movement at the initial stage can cause aeration by the hydraulic oil.
2) If air bleeder is attached (boom cylinder), apply pressure to bleed by making its air bleeding side the pres-
sured side (return oil side).
3) Lubricate pins on both ends.
9) Use limits
Wear limits on piston rod outside surfaces
Nominal diameter Minimum outer

Measures
(mm) diameter (mm)
50 to 80 -0.023 Replacement or re-plating
85 to 120 -0.027 Replacement or re-plating
Wear limits on rod bushing inside surfaces
Nominal diameter Standard inner Maximum inner

Measures
(mm) diameter (mm) diameter (mm)
55 to 75 +0.06 to +0.19 +0.30 Replacement bushing
80 to 120 +0.06 to +0.195 +0.30 Replacement bushing
Wear limits of piston slide ring thickness
Nominal diameter Standard thickness Maximum thickness

Measures
(mm) (mm) (mm)
95 to 160 2.42 to 2.48 2.37 Replacement slide ring
165 to 250 2.92 to 2.98 2.87 Replacement slide ring
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3 Special jigs for repair
1 Dimensions of Tools
Wrench for piston nuts
AQ24002-002
Unit: mm
Piston nut Wrench size

Nominal diameter Width across flats H D J B T E R1 R2
M42 65 +0
-1.2 65 +0.8
-0.3 125 350 40 20 20 50 20
M45 70 +0
-1.2 70 +0.8
-0.3 130 350 40 20 20 50 20
M48 75 +0
-1.2 75 +0.8
-0.3 140 350 40 20 20 50 20
M52 80 +0
-1.2 80 +0.8
-0.3 150 350 40 20 20 50 20
M55 85 +0
-1.4 85 +0.8
-0.3 160 350 40 20 20 50 20
M58 85 +0
-1.4 85 +0.8
-0.3 160 350 40 20 20 50 20
M62 90 +0
-1.4 90 +0.8
-0.3 160 350 40 20 20 50 20
M65 95 +0
-1.4 95 +0.8
-0.3 170 350 40 20 20 50 20
M70 100 +0
-1.4 100 +0.8
-0.3 180 400 50 25 25 50 25
M80 115 +0
-1.4 115 +0.8
-0.3 200 400 50 25 25 50 25
M85 120 +0
-1.2 120 +0.8
-0.3 220 400 50 25 25 50 25
M95 1355 +0
-1.2 135 +0.8
-0.3 245 400 60 30 30 50 30
M105 150 +0
-1.2 150 +0.8
-0.3 270 400 60 30 30 50 30
M110 155 +0
-1.2 155 +0.8
-0.3 280 400 60 30 30 50 30
WARNING: Use wrenches of S45C steel with the hardness ranging from HB201 to 269.
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2 Handling the Jigs for Cylinder Repair
Arm cylinder
Boom cylinder
Bucket cylinder
AQ24002-003
1: Jigs for press fitting wiper ring

2: Jigs for extraction bushings
3: Jigs for press fitting bushings
4: Jigs for press fitting wiper ring
5: Jigs for guiding cylinder head insertion
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1 Structure and features of jigs for cylinder repair
1) Jigs for insertion and correction of seal rings
1) Structure of jigs
Item number Item name quantity remarks

KHV0530 Seal ring insertion / correction jig set 1
Inner guide 1
Outer guide 1
Plate 1
Correction 1
NOTE: The item number indicates that the item is intended for seal rings with the tube diameter of 120 mm.
2) Features
Although it normally requires a tremendous amount of time and effort to insert a seal ring due to its extreme
hardness, the use of the jig facilitates quick, easy and secure seal ring insertion into a piston without
scratching the seal ring.
2) Jigs for injection and ejection of bushings and wiper rings

Bushing and wiper ring injection / Ejec- The jigs for press fitting wiper rings can
KHV0514 1
tion jig set be used for this job.
The jigs for press fitting wiper rings can
Chuck assembly 1
be used for this job.
Retainer 1
Block 1 Prepare this item at each service shop.
Lever 1 Prepare this item at each service shop.
Hexagon bar wrench 1 Prepare this item at each service shop.
NOTE: The item number indicates that the item is intended for bushings with the rod diameter of 80 mm.
2) Features
This special jigs facilitate quick, easy and secure slide fit of a cylinder head assembly to a piston rod without
scratching any seals.
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3) Jigs for insertion of cylinder heads

KHV0550 Jigs for insertion of cylinder heads 1
NOTE: The item number indicates that the item is intended for cylinder heads with the rod diameter of 80 mm.
2) Features
It normally requires a tremendous amount of time and effort to extract a bushing because it is press fit with a
hydraulic press near the center of the cylinder head.
The use of the jig, however, facilitates quick, easy and secure extraction of a bushing from a cylinder head
without scratching the inner surface of the cylinder head.
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2 List of jigs
1. Jigs for insertion and correction of seal rings
Part no. KHV10150 KHV0525 KHV0526 KHV0528

Model Cyl. name Bore dia. Ø 85 Ø 95 Ø 100 Ø 110
Boom Ø 110 O
Dipper Ø 95 O
CX75SR Bucket Ø 85 O
Offset Ø 95 O
Blade Ø 100 O
2. Jigs for injection and ejection of bushings and wiper rings
Part no. KHV10130 KHV10140 KHV0512

Model Cyl. name Bore dia. Ø 55 Ø 60 Ø 70
Boom Ø 70 O
Dipper Ø 60 O
CX75SR Bucket Ø 55 O
Offset Ø 55 O
Blade Ø 60 O
3. Jigs for insertion of cylinder heads
Part no. Cyl. name Rod thread size Rod dia. Cushion type Model
KHV10160 Bucket M42
Ø 55
KHV10170 Offset M45
Dipper Fastened CX75SR
KHV10180 M45 Ø 60
Blade
KHV10200 Boom M52 Ø 70
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3 Handling jigs
1) Inserting / correcting seal rings
1) Installing an O-ring
Stretch the O-ring by hand and install it in the
groove of the piston.
O-ring
Piston
AQ24002-004
CAUTION: Install O-rings securely without distorting them. Dis-

torted O-rings will cause oil leakages.
Installed properly O-ring distorted

AQ24002-005
2) Attaching the inner guide jig

Install the inner guide jig from the top side of the
piston. Inner guide jig
O-ring
Piston
AQ24002-006
CAUTION: Carefully install the thin edge of the inner guide jig on Inner guide jig
the top of the piston.
Thin edge
AQ24002-007
3) Installing a seal ring

Apply hydraulic oil to the perimeter of the inner Inner guide jig Seal ring
guide and place the seal ring level with the inner
O-ring
guide.
CAUTION: Use caution to keep foreign substances such as dirt,
particles and lint from the outside of the inner guide jig.
AQ24002-008
4) Installing an outer guide jig

Place a plate on top of the outer guide jig and Plate
press down with hand until the seal ring contacts
the outer guide jig. Outer guide jig
Seal ring
CAUTION: The seal ring must not be installed in the inner guide Inner guide jig O-ring
jig, nor could it be at an angle.
Piston
AQ24002-009
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5) Press fitting
Use a press and push down the seal ring until it Press rod
fits in the groove of the piston.
Plate
CAUTION: Use caution while pushing down the seal ring Seal ring
because it may not be properly fit in the groove if it is at an angle Outer guide jig
O-ring
in the inner guide jig. inner guide jig
Piston
Installation of the ring must be carried out swiftly.
AQ24002-010
6) Removing the jigs

Remove the jigs in the following order, once con- Press rod
firmed that the seal ring has been completely
installed in the groove of the piston. Plate
1. Remove the press rod.
2. Remove the plate. Outer guide jig
3. Remove the outer guide jig.
4. Remove the inner guide jig.
inner guide jig
The installation of a seal ring is now complete.
The instructions for aligning a seal ring using a correction jig
will be given next.
Piston
Seal ring
(O-ring located inside)
#3
7) Preparing a correction jig

Place a correction jig under a press.
CAUTION: Apply a light coat of oil to the tapered area of the cor-
Press rod
rection jig and place the jig with the tapered side up.
Use caution to keep foreign substances such as dirt, particles
and lint off the jig. Correction jig
Knurl
AQ24002-012
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8012-51
8) Inserting a piston
Install a seal ring to the piston and slowly insert
Piston
into the correction jig.
CAUTION: Insert the piston into the correction jig so that the pis- Seal ring
ton rests level.
Correction jig
AQ24002-013
9) Press fitting
Press rod
Correction jig
Correction range
Piston
AQ24002-014
10) Removing the correction jig

After the alignment of the seal ring has been com-
pleted, remove the jig in the following order. Press rod
1. Remove the press rod.
2. Remove the correction jig. Correction jig
The installation and the alignment of the seal ring is now com-
plete.
Piston
Seal ring
(O-ring located inside)
AQ24002-015
Other precautions
1. A specific cylinder bore size requires a specific jig. Refer to
Inner guide jig
the applicable table to choose the correct jig for a specific
bore size.
Thin edge
2. The lower part of the inner guide is structurally very thin,
requiring extra care and attention for handling and storage.
AQ24002-016
3. Clean the seal, piston and jigs with compressed air or by
other suitable method before installation. Insufficient cleaning
may lead to failures such as oil leakage due to foreign sub-
stances (dirt, etc.).
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2) Extracting bushings
1) Setting the cylinder head
Place the cylinder head (A) on a workbench B
with the mating surface (B) with the cylinder
tube up.
CAUTION: The workbench must be clean. Use caution to keep
the pipe joint portion from getting scratched by foreign sub-
stances such as dirt and particles.
A AQ24002-017
2) Extracting the snap ring

Remove the snap ring (C) that is assembled inside
the cylinder head for preventing the bushing from
falling out.
CAUTION: Secure the cylinder head with a vise, etc. Using the
tip of the jig, pry out and remove the snap ring.
Screwdriver
AQ24002-018
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3) Setting the chuck assembly (jig)
Gradually insert the chuck assembly in the cylin-
der head (A) until the blade (D) of the chuck
assembly reaches the edge of the bushing. D
A
Chuck assembly jig
Working face of head bushing

Chuck assembly jig
AQ24002-01
CAUTION: Gradually insert the chuck assembly in cylinder

head. Use extra caution to prevent the inner surface of the cylin- Chuck assembly jig
der head and such from getting damaged by the blade. End face of head bushing
Also use caution to keep the blade from sticking out the end of
bushing.
Blade must not stick out
AQ24002-020
4) Temporal tightening
1. Insert the hexagon bar wrench (E) in the head
of the chuck assembly (jig). Also, insert a lever
in the round hole on the end section of the
chuck assembly at the same time.
2. Tip the hexagon bar wrench and the lever (F)
F E
back and forth and tighten the chuck assembly
to the point that the jig does not fall out with the
cylinder head lifted up.
CAUTION: Less than 0.49 Nm of tightening torque is good
enough. A
A
CAUTION: With the chuck assembly installed in the cylinder
head, firmly grasp both ends of the cylinder head and carefully
move to the press workbench.
Chuck assembly jig

AQ24002-021
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5) Attachment the retainer (jig)
Place the retainer gently on the notches of the Retainer jig
wedge, which is inside the chuck assembly (jig),
so the wedge will be covered by the retainer.
CAUTION: Place the retainer with its larger diameter end up.
See the figure to the left.
The workbench must be clean. Use caution to keep the chuck
assembly bottom from getting scratched by foreign substances
such as dirt and particles. Keep it from tipping, also.
Chuck assembly jig
Larger diameter
end Retainer jig
Wedge
AQ24002-022
6) Secondary tightening
Gradually press down the top of the retainer (jig)
so the blade section of the chuck assembly jig
bites into the bushing face. Press retainer jig
CAUTION: Apply 2 to 3 tons of press load.

CAUTION: The retainer jig must be used for the pressing proce-
dure.
Cylinder head
AQ24002-023
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7) Preparing the block (jig)
Place the cylinder head on top of the block with
the shaft centers aligned.
Block jig
AQ24002-024
Refer to the table and choose the block with the proper figura-
tion and size.
Category d1 d2 h Nominal size
For dia. 75 82 110 80 75
80 87 112 80 80
85 92 124 80 85
AQ24002-0
90 97 130 80 90
95 102 136 80 95
100 107 140 80 100
105 112 146 80 105
110 117 150 80 110
8) For extracting bushings

1. Move the block (jig) and the cylinder head assem-
bly (with the retainer jig and the chuck assembly jig Retainer jig
attached) directly underneath the press.
2. Gradually press down the top of the retainer (jig) Cylinder head
until the bushing comes out from the cylinder head
(until the bottom of the chuck assembly jig falls on
the bench and you actually hear it).
CAUTION: Usually a load of 3 tons or less is needed for the
extraction.
CAUTION: The stroke of press ram is approximately 32 to 52
mm, depending on the size of the cylinder head.
CAUTION: The retainer jig must be used for the pressing proce-
dure.
If the shaft centers of the block and the cylinder head assembly
do not align with each other, stop the procedure, move the block
#3
and align the shaft centers before resuming the operation. Block jig
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9) Removing the chuck assembly (jig) with the bush-
ing attached
1. Pull the cylinder head assembly (with the
retainer jig and the chuck assembly jig attached)
and the block (jig) toward you from right beneath
the press. Remove the retainer from the cylinder Retainer jig
head. Grab both ends of the cylinder head with
both hands and move from there. Cylinder head
2. Remove the assembly with the bushing
attached out of the block and move to the work-
bench.
WARNING: Do not ever attempt to work under the press. Stay
safe.
Chuck assembly jig Bushing
(with bushing attached)
Block jig
AQ24002-027
10) Removing the bushing

1. Place the chuck assembly (B) with the bushing
attached (jig) sideways on the workbench. Insert
the hexagon bar wrench (A) in the adjuster head
on the chuck assembly tip, plus insert the lever (C)
C
into the round hole at the back of the chuck
assembly at the same time. A
2. Tip the hexagon bar wrench and the lever back
and forth to loosen the adjuster.
3. Reposition the chuck assembly so it stands ver-
B
tically. Rotate the adjuster with fingers until about
5 mm of the wedge comes out.
4. Verify that the bushing is disconnected from the
blade section of the chuck, then gently remove the
bushing from the assembly.
Bushing
the chuck bottom and the periphery from getting scratched by
foreign substances such as dirt and particles. Keep it from tip-
ping also.
AQ24002-028
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11) Tightening back the adjuster(A)
Once the bushing is removed from the chuck
assembly (jig), rotate its adjuster with fingers and
tighten until there is no gap between the adjuster
and the top surface of the wedge.
CAUTION: Do not remove the adjuster and the wedge from the
chuck assembly. Keep them in the condition as close to the origi-
nal as possible. A
AQ24002-029
Other precautions
1. A specific piston rod diameter requires a specific jig. Refer to the applicable table to choose the correct jig for a spe-
cific diameter size.
2. The blade section of the chuck assembly is a vital portion and must be handled and stored with extreme care.
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3) Press fitting bushings
1) Setting the cylinder head (A)
Place the cylinder head on a workbench with B
the mating surface (B) with the tube up.
the cylinder head bottom from getting scratched by foreign sub-
stances such as dirt and particles. Keep it from tipping also.
Before starting the procedure, remove foreign substances thor-
oughly with air, etc.
A
AQ24002-030
2) Temporarily setting the bushing(B)

Temporally place the bushing level inside the cyl-
inder head (A).
B
CAUTION: Verify that inner/outer surfaces of the bushing are
free of foreign substances.
A
AQ24002-031
3) Setting the chuck assembly (jig)

Secure the chuck assembly with fingers and grad- B
ually insert into the cylinder head.
A
AQ24002-032
CAUTION: Verify that the chuck assembly adjuster sits by the Gap between adjuster and
wedge with no gap in between. Chuck assembly jig wedge
Wedge
AQ24002-033
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4) Attaching the retainer (jig)
Align and gently place the retainer (A) on the
notches (B) of the wedge in the chuck assembly. A
CAUTION: Place the retainer with its larger diameter end up.
See the figure to the left.
AQ24002-034
5) Preparing for press fitting

With the retainer (B) (jig) and the chuck assembly
(C) (jig) attached, move the cylinder head (A) right
underneath the press.
A AQ24002-035
CAUTION: Align the press (ram) axis with the retainer and the
chuck assembly axes. Press (ram)
Retainer jig
Chuck assembly jig
Bushing
Snap ring
grooves
Insert bushing here Cylinder head

AQ24002-036
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6) Press fitting the bushing
Use a press to push down the bolt head of the
adjuster until the bushing reaches the proper posi-
Retaining jig
tion in the cylinder head (A).
Keep the press load below 5 tons.
CAUTION: Check to see if the bushing edge sits at the back of
the snap ring grooves. Press fit again if not.
A AQ24002-037
7) Removing the retainer (jig) and the chuck assem-

bly (A) (jig) A
Once the press fitting of the bushing is complete,
remove the retainer and the chuck assembly from Retaining jig
the cylinder head. Then, attach the seals and
press fit the wiper ring.
CAUTION: Examine to see if the bushing is press fit properly.
AQ24002-038
Other precautions
1. A specific piston rod diameter requires a specific jig. Refer to the applicable table to choose the correct jig for a spe-
cific diameter size.
2. The blade section of the chuck assembly is a vital portion and must be handled and stored with extreme care.
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4) Press fitting wiper rings
1) Setting the cylinder head
Place the cylinder head (A) on a workbench
with the mating surface with the tube facing
down.
the cylinder head bottom from getting scratched by foreign sub-
stances such as dirt and chips from cutting.
A AQ24002-039
2) Inserting the wiper ring

Insert the lip side of the wiper ring (A) so it faces
the retainer (B) (jig) grooves.
CAUTION: Make sure that the receiver area of the retainer for
the wiper ring is free of dirt or foreign substances. Remove with
air, etc., if any, before starting the procedure.
B
AQ24002-040
3) Attaching the retainer (B) (jig)

B
Gently place the retainer on top of the cylinder
head (A) with the side for wiper ring insertion fac-
ing down.
CAUTION: Place the retainer gently on top of the cylinder head
making sure that it is level with the work bench.
AQ24002-041
A
ASM-17-24-002 Issued 08-2008

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8012-62
4) Preparing for press fitting
With the retainer (jig) on top, move the cylinder
right underneath the press.
AQ24002-042
CAUTION: Align the press (ram) axis with the retainer axis.
Press (ram)
Retainer jig
Wiper ring
Cylinder head
AQ24002-043
5) Press fitting the wiper ring

Use a press to push down the retainer (B) (jig) B
head until the wiper ring reaches the proper posi-
tion in the cylinder head (A).
CAUTION: Keep the press load below 1 ton.
A
CAUTION: Press fit until the jaws of the retainer reach the end
of the cylinder head.
#3
6) Removing the retainer (B) (jig)

Once the press fit of the wiper ring (C) is com-
plete, remove the retainer from the cylinder head
(A).
CAUTION: Examine if the wiper ring is properly press fit. B
A
AQ24002-045
ASM-17-24-002 Issued 08-2008

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8012-63
5) Inserting cylinder head
1) Securing the piston rod
Position the piston rod thread (A) in a direc- A
tion for carrying out the procedure the easi-
est, then secure.
CAUTION: Use extreme care while handling the piston rod to
avoid scratches on the outer surface.
AQ24002-046
2) Attaching the guide (A) (jig)

With the larger diameter side of the guide facing
down, insert till it reaches the end of the piston rod
notch (B).
CAUTION: Use caution and avoid scratches on the piston rod
thread while inserting the guide to the piston rod (C).
Use caution to keep the piston rod thread and the outer surface
of the notches from getting scratched by foreign substances B
such as dirt and chips from cutting.
AQ24002-047
A
3) Inserting the cylinder head

Push in the cylinder head assembly till it reaches
the proper position: let the assembly slide on the
outer surface of the guide (jig) with the side to
attach the wiper ring facing the piston rod head.
CAUTION: Firmly grab the cylinder assembly by both hands.
Use extreme care and do not allow it to drop on your foot.
Applying a thin coat of oil to the guide and the outer surface of
the piston rod facilitates smooth insertion.
AQ24002-048
ASM-17-24-002 Issued 08-2008

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8012-64
4) Removing the guide (jig)
Check to confirm that the cylinder head assembly
is completely inserted into the piston rod.Then
remove the guide from the piston rod. Then,
assemble the piston and the other parts on the
piston rod.
CAUTION: When removing the guide, use extra care to keep
the piston rod thread from being damaged.
AQ24002-049
ASM-17-24-002 Issued 08-2008

Copyright ©
Section
8013
8013

HAND CONTROL LEVERS

Printed in France
CNH SM75SR8013-0EN July 2008
Copyright ©
8013-2
TABLE OF CONTENTS
ASSEMBLY/DISASSEMBLY OF OPERATION CONTROL VALVE ...................................................................... 3
MAINTENANCE PROCEDURES ................................................................................................................................. 3
Required tools and tightening torque ................................................................................................................ 3
Maintenance standards ..................................................................................................................................... 3
DISASSEMBLY PROCEDURES ................................................................................................................................. 4
Preparations ...................................................................................................................................................... 4
General work precautions ................................................................................................................................. 4
Disassembly procedure..................................................................................................................................... 4
ASSEMBLY PROCEDURES .................................................................................................................................... 10
Preparations .................................................................................................................................................... 10
General work precautions ............................................................................................................................... 10
Assembly procedures...................................................................................................................................... 10
CAUSES OF TROUBLE AND COUNTERMEASURES .................................................................................................. 15
ATTACHED DIAGRAM 1. REMOTE CONTROL VALVE ASSEMBLY CROSS-SECTION DIAGRAM ....................................... 16
ATTACHED DIAGRAM 2. JOINT DISASSEMBLY JIG .................................................................................................. 17

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8013-3
ASSEMBLY/DISASSEMBLY OF OPERATION CONTROL VALVE
1 Maintenance Procedures
1 Required tools and tightening torque
Dimensions
Tool Part number Part name Screw size Tightening torque (Nm)
(mm)
Hexagon
Hexagon bar wrench 6 125 socket head M8 20.6±1.5
bolt
22 312 Adjusting nut M14
Wrench 68.6±4.9
32 302 Disk M14
Special jig (diagram in
Attached diagram 2. 24 301 Joint M14 47.1±2.9
Joint disassembly jig)
2 Maintenance standards
Maintenance
Standard Remarks
inspection item
When handle is in neutral: 1000 cc/min or
more Conditions
Leak amount During operation: 2000 cc/min or more Primary pressure 2.94 MPa
If either condition occurs, replace the remote Oil viscosity 23 mm2/s
control valve as one unit.
When wear on the sliding sections exceeds
The same approximate conditions as those
wear on the non-sliding sections by 10 µm or
Spool listed above for leak amount are expected
more, replace the remote control valve as one
when the condition on the left occurs.
unit.
If the end section is worn by 1 mm or more, perform replacement.
(Ø7)
Push rod
1 mm
RM10001-005
Replace the operation section disk (302) and

Operation sec- Make adjustments if the backlash is due to
joint section (301) if there is backlash of 2 mm
tion backlash looseness in the tightening sections.
or more due to wear.
If abnormal noise, hunting, or a drop in primary
pressure occurs and the problem cannot be
Operation stabil-
resolved with "4. Causes of Trouble and Coun-
ity
termeasures", replace the remote control valve
as one unit.
NOTE: It is desirable for seal materials such as O-rings to be replaced with each disassembly, but it is acceptable to
reuse these after it is confirmed that they are not damaged.
Always replace seal washer (121) when a hexagon socket head bolt (125) is loosened.
Lep ASM-17-25-002-EN Issued 08-08

Copyright ©
8013-4
2 Disassembly Procedures
1 Preparations
[1] Prepare a sufficiently spacious, solid and stable work platform so that parts will not fall or move during work.
[2] Prepare the tools and materials indicated in "1. Maintenance Procedures (1) Required tools and tightening
torque".
[3] When disassembling the valve, read the disassembly procedures thoroughly before following the sequence
below.
The numbers in the parentheses after the part names indicate codes in "Attached diagram 1. Remote control
valve assembly cross-section diagram Attached diagram 1. Remote control valve assembly cross-section dia-
gram".
2 General work precautions
[1] Each part has been manufactured with a high degree of precision, so be careful not to let parts bump each other
or fall when handling them.
[2] If parts are struck or pulled with excessive force during work because they are tight, this may cause burrs or dam-
age which lead to faulty assembly causing reduction in performance or oil leaking. Perform work carefully and
thoroughly.
[3] Rust may form on parts due to moisture or debris if the valve is left disassembled or if work is abandoned in the
middle of disassembly. If work must be halted, be careful about preventing rust from forming and dust settling on
parts.
3 Disassembly procedure
[1] Clean the remote control valve with white kero-
sene.
• Place plugs in each port.
[2] Use copper plate (or lead plate) to secure the
remote control valve in a vise.
[3] Remove the bellows (501).
• Be careful not to tear the bellows.
RM10001-006

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8013-5
[4] Use a wrench on the bolt width of the adjusting
nut (312) and disk (302) to loosen them, and
remove the adjusting nut and disk.
RM10001-007
RM10001-008
RM10001-009

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8013-6
[5] Use a jig to rotate the joint (301) to the left and
loosen it.
• The diagram shows the valve with the jig
installed.
• If the return springs (221) are strong, the plate
(151), plugs (211), and push rods (212) will rise at
the same time the joint is loosened, so be careful of
parts flying off when removing the joint.
RM10001-010
RM10001-011
[6] Remove the plate (151).
RM10001-012
[7] If the return springs (221) are weak, the plugs

(211) will remain in the casing (101) due to the
sliding resistance of the O-rings (214), so use a
flathead screwdriver to remove them.
• Use the groove in the outer circumference of the
plugs and remove them while making sure they are
not damaged by an unbalanced load.
• Use caution as plugs may fly off when they are
being removed due to the return springs.
RM10001-013

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8013-7
[8] Remove the push rods (212), plugs (211), pressure
reducing valve assemblies and the return springs
(221) from the casing (101). Record the relation of
parts to the casing hole positions through marking,
etc).
RM10001-014
[9] Secure the pilot valve on the vise by facing port

plate (111) upward.
[10]Loosen and remove the hexagon socket head bolts
(125) using a hexagon bar spanner.
[11]Remove also the port plate (111) and O-ring (122)

from the casing (101). Draw out the bushing (131)
from the casing (101).

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8013-8
[12]For disassembly of pressure reducing valves, press
in the spring seats, move the spring seats (216) to
the side while bending the secondary pressure
springs (241), and remove the springs from the
spools (201) by passing the springs through the
larger hole of the spring seats.
Next, separate the spools, spring seats, secondary
pressure springs, and washers (217).
• Be careful not to scratch the surface of the spools.
• Do not lower the spring seats by 6 mm or more.
• Handle these parts as assemblies until assembly of
the remote control valve.
RM10001-015
RM10001-016
[13]Remove push rods (212) from the plugs (211).
RM10001-018

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8013-9
[14]Remove O-rings (214) and seals (213) from the
plugs (211). Use a small flathead screwdriver, etc. to
remove seals.
• O-rings and seals cannot be reused.
Replace them with new parts.
RM10001-019
RM10001-020
[15]Cleaning parts
1) Clean all parts by placing them in a rough cleaning container filled with white kerosene (rough cleaning).
2) Clean all parts by placing them in a finish cleaning container filled with white kerosene, and thoroughly clean
them up to the interior while slowly rotating them (finish cleaning). Use a rag to thoroughly remove white kero-
sene adhered to parts.
• Scratching can easily occur if cleaning of parts is begun just after parts are immersed in white kerosene, so let
parts sit in white kerosene until debris and grease sufficiently loosen off from the surface of parts and float to the
surface.
• If the white kerosene is dirty, this will encourage damage to parts and result in reduced performance after reas-
sembly. Thoroughly manage the level of cleanliness of the white kerosene.
• Do not dry parts with compressed air, as this will damage parts and cause rust to form due to debris and moisture
being dispersed into the atmosphere.
[16]Preventing rust on parts
Apply an anti-rust agent to each part.
• Rust will form on parts if they are left as is after cleaning, and this will cause reduced performance of functions
after reassembly.

Copyright ©
8013-10
3 Assembly Procedures
1 Preparations
[1] As with disassembly, prepare a work platform, tools and materials.
2 General work precautions
[1] Observe the same general work precautions as with disassembly.
[2] When performing assembly, remove metal fragments and foreign matter from all parts, and check that there are
no burrs or nicks on parts. If there are burrs or nicks, use a whetstone to remove them.
[3] As a rule, replace all O-rings and backup rings with new parts.
[4] When installing O-rings and backup rings, be careful not to damage them. (Apply a thin layer of grease to ensure
smooth installation.)
[5] When installing parts, using grease is good for preventing parts from falling.
[6] Tighten bolts, etc. to the torque values indicated in "Attached diagram 1. Remote control valve assembly cross-
section diagram". Use the torque wrench to measure the tightening torque.
[7] After assembly is complete, place plugs in all of the ports to prevent entry of debris.
3 Assembly procedures
[1] Assemble the bushing (131) and O-ring (122) in the
casing (101).
[2] Fit the port plate (111) to the casing (101) using the
hexagon socket head bolts (125) and seal washers
(121).
• Check the assembling positions so that the spring
pin (126) are inserted into the casing holes.
• Replace the seal washers (121).

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8013-11
[3] Tighten the hexagon socket head bolts (125) by
specified torque.
• Tighten two screws gradually and alternately.
[4] Insert washers (217), secondary pressure springs

(241) and spring seats (216) onto each of the spools
(201) in that order.
RM10001-021
Additionally, press in the spring seats and move

them to the side while bending the secondary pres-
sure springs to pass the seats over the larger holes
and install them on each of the spools.
• Do not lower the spring seats by 6 mm or more.
RM10001-022

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8013-12
[5] Install the return springs (221) in the casing (101).
Install the pressure reducing valve assemblies in the
casing.
• Install them in the positions they were in before dis-
assembly.
RM10001-023
[6] Install O-rings (214) on the plugs (211).
RM10001-024
[7] Install seals (213) on the plugs (211).

• Install so that the seal lips are as shown in the diagram below.
1 2
3
4
RM10001-027 RM10001-025
*1 Seal
*2 Plug
*3 Push rod
*4 Hydraulic oil application

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8013-13
[8] Install push rods (212) into the plugs (211).
• Apply hydraulic oil to surface of the push rods.
RM10001-026
[9] Install the plug assemblies into the casing (101).

If the return springs (221) are weak, they will be
stopped by the sliding resistance of the O-rings
(214).
• Be careful not to scratch the casing holes by forcing
in the spools (201).
RM10001-029
If the return springs are strong, use the plate (151)

to install all 4 plug assemblies at the same time and
temporarily tighten them with the joint (301).
• Be careful of the plug assemblies and plate flying
off.
RM10001-030
[10]Install the plate (151).

[11]Use a jig, and tighten the joint (301) to the casing
(101) to the specified torque.
Tightening torque: 47.1±2.9 Nm
RM10001-031

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8013-14
[12]Install the disk (302) onto the joint (301).
• Screw the disk in until it is equally touching each of
the 4 push rods (212).
Secondary pressure will cause faulty operation of
the machine if the disk is screwed in too much, so
pay attention to adjustment of the tightening posi-
tion.
RM10001-032
[13]Install the adjusting nut (312), use a wrench on the

bolt width of the disk (302) to secure it, and tighten
the adjusting nut to the specified torque.
Tightening torque: 68.6±4.9 Nm
• During tightening, do not move the disk position.
RM10001-033
[14]Apply grease to the rotating section of the joint

(301) and to the top of the push rods (212).
RM10001-034
[15]Install the bellows (501).

• Be careful not to tear the bellows.
[16]Inject vapor corrosion inhibitor into each port and
then place plugs in the ports.
RM10001-035

Copyright ©
8013-15
4 Causes of Trouble and Countermeasures
It is not always easy to find where the source of trouble is located. A few problems that may sometimes occur are
listed in the table below. Repair of these problems can be difficult, so see the suggested causes and solutions in the
table for assistance.
The table below shows general symptoms, suggested causes and also solutions. However, the cause of machine
problems are often not rooted in just a single part. Problems are often due to the relationship of one part with
another. Also keep in mind that solutions other than those listed in the table may sometimes be necessary.
The table below does not include all possible causes and countermeasures. Accordingly, further investigation of
problems and causes should be done by an experienced and qualified repair person, as necessary.
Symptom Cause Solution

1 Insufficient primary pressure 1 Maintain primary pressure.
2 Secondary pressure spring(s) (241) is 2 Replace it (them) with new part(s).
Secondary pressure is (are) broken or worn. 3 Replace the remote control valve as one
not rising. 3 The gap between spool(s) (201) and the unit.
casing (101) is abnormally large. 4 Disassemble and assemble or replace
4 There is backlash in the handle section. the handle section.
1 Repair the sticking sections.
1 Sliding parts are sticking.
Secondary pressure is 2 Return directly to the oil tank.
2 Tank line pressure is variable.
unstable. 3 Perform operation several times and let
3 Air is getting into lines.
out air.
Secondary pressure is 1 Tank line pressure is high. 1 Return directly to the oil tank.
high. 2 Sliding parts are sticking. 2 Repair the sticking sections.

Copyright ©
8013-16
5 Attached diagram 1. Remote control valve assembly cross-section diagram
Tightening torque list

No. Screw size Tightening torque
125 M8 20.6 ± 1.5 Nm
301 M14 47.1 ± 2.9 Nm
312 M14 68.6 ± 4.9 Nm
Grease application to rotating slid-

ing sections. Use caution with
installation direction.
Grease application to top Grease application to top
Contain one secondary pressure

adjustment shim.
Design main value: t = 0.4 x 1
Not to be reused
Ports Ports
Code Part name Qty Code Part name Qty

101 Casing 1 214 O-ring 4
111 Port plate 1 216-1 Spring seating (port 1, 3) 2
121 Seal washer 2 216-2 Spring seating (port 2, 4) 2
122 O-ring 1 217 Washer 4
125 Hexagon socket head bolt 2 221-1 Return spring (port 1) 1
126 Spring pin 1 221-2 Return spring (port 3) 1
131 Bushing 1 221-3 Return spring (port 2, 4) 2
Secondary pressure spring
151 Plate 1 241-1 2
(port 1, 3)
Secondary pressure spring
201 Spool 4 241-2 2
(port 2, 4)
211 Plug 4 301 Joint 1
212-1 Push rod (port 1, 3) 2 302 Disk 1
212-2 Push rod (port 2, 4) 2 312 Adjusting nut 1
213 Seal 4 501 Bellows 1

Copyright ©
8013-17
6 Attached diagram 2. Joint disassembly jig
Bushing
A -A
1 Material: SCM145 N carbu-

rized
WAF
2 Material: S45C A A
Joint installation state
Hole
Shaft
Detailed diagram of jig main unit Detailed diagram of bushing

1 and 2 are inserted by tightening Material: SCM145 N carburized
Quantity: 2
RM10001-037

Copyright ©
8013-18
NOTES
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Copyright ©
Section
8014
8014
FOOT CONTROL PEDALS

Printed in France
Copyright ©
8014-2
TABLE OF CONTENTS
TRAVEL REMOTE CONTROL VALVE................................................................................................................... 3
OFFSET AND BLADE REMOTE CONTROL VALVE ........................................................................................... 10
At neutral....................................................................................................................................................... 10
During operation (same for port A and port B sides)..................................................................................... 10

Copyright ©
8014-3
TRAVEL REMOTE CONTROL VALVE
Description
C C
C C T
P
4 32 1
Hydraulic Circuit
27 26
22 T T 27
34 21 19
33
30 26
30
P
1 2
3 4
25 24 25
31
20 5 7 31
20
2, 4
2 ,4
32 18
23 32
11 23
17
35 11
9
16 9
28 16
1 28
29 1
29
8
8
12 12
13 13
14
14
3, 15 10 10 6 3 ,1 5
C-C
AQ25002-001
ASM-17-25-002 Issued 08-2008

Copyright ©
8014-4
1 Shim 4 13 Compression spring 4 25 Washer 4
2 Orifice 4 14 Compression spring 4 26 Rivet 2
3 Shim 4 15 Shim 4 27 Pin 4
4 Orifice 4 16 Ring 4 28 Snap ring 4
5 Pin 2 17 Cover 2 29 Steel ball 8
6 Body 1 18 Boot 2 30 Steel ball 2
7 Cam 2 19 Name plate 1 31 Steel ball 4
8 Sleeve 1 20 Holder 4 32 Packing 4
9 Piston 2 21 Plug 1 33 O-ring 1
10 Spool 4 22 Plug 1 34 O-ring 1
Hexagon socket head
11 Pusher 4 23 4 35 O-ring 2
bolt
12 Retainer 4 24 Set screw 4
ASM-17-25-002 Issued 08-2008

Copyright ©
8014-5
Operational Description
This pump has ports P, T and 1 through 4. Because the function and operation of ports 1 through 4 are the same,
port 1 will be described here.
Pressure reduction function
Lever operation range: 0 to 1.8° (Figure 2)
• The flow of pressurized oil supplied from port P is cut off from ports 1 and T by spool (10).
• Since port 1 communicates with port T by an internal circuit in spool (10) and is connected to the tank through
port T, the pressure on port 1 is equal to the tank pressure.
10
Figure 2 AQ25002-002
Lever operation range: 1.8 to 11° (Figure 3)

• When the lever [cam (7)] is operated, the spool is pushed downwards together with pusher (11), piston (9),
retainer (12) and spring (14).
• When the angle of operation reaches 1.8°, port P and port 1 are connected by means of section I, and the con-
nection between port 1 and port T is closed by means of section II. As a result, pressure is generated at port 1.
At this time, the following upward force F acts on spool (10):
Pressure P1 at port 1 x spool area a (A)
• When P1 increases and F exceeds the force (FS) of spring (14), spool (10) moves upwards, closing section I
and opening section II, reducing the pressure on port 1. Repetition of this process causes spool (10) to be bal-
anced in the position shown in Figure 3, and the pressure on port 1 is kept at a constant pressure sufficient to
balance the force of spring (14).
FS = F = P1 x A
ASM-17-25-002 Issued 08-2008

Copyright ©
8014-6
• As the lever is operated further, spring (14) is deflected by pusher (11), piston (9) and retainer (12), increasing
the force (FS) of spring (14). At this time, spool (10) generates pressure at port 1 corresponding to the force of
spring (14) while balanced in the position shown in Figure 3.
11
9
12
T
13
14
ll
P
10 Figure 3 AQ25002-003
Lever operation range: 11 to 12.4° (Figure 3)

• When the lever operating angle reaches 11°, the head of spool (10) contacts piston (9) (section III), stopping the
control of spool (10).
• Section I therefore stays open. Section II stays closed and the pressure at port 1 becomes equal to that at port P.
• When the lever is released, the force of spring (13) causes all the parts return to neutral position.

lll

6

ll
2
Figure 4
AQ25002-004
ASM-17-25-002 Issued 08-2008

Copyright ©
8014-7
Damper function
• When the lever is pressed, the hydraulic oil in damper chamber IV is expelled into port T through restrictor V. At
this time, a damping effect is obtained by means of the passage resistance at section V (Figure 5).
• When the lever is returned to its original position, the force of spring (13) causes piston (9) to return, and
because damper chamber IV becomes a vacuum, the steel ball is lifted, drawing hydraulic oil in through port T,
and all the parts return smoothly to neutral position (Figure 6).
lV 30
V
T T
Figure 5 Figure 6
AQ25002-005
ASM-17-25-002 Issued 08-2008

Copyright ©
8014-8
Disassembly and Assembly
General precautions
• Because all the parts in hydraulic valves are precision components, perform valve disassembly and assembly in
a clean and dust-free area. Use clean tools and cleaning solvent.
• Clean disassembled parts and apply a corrosion inhibitor.
• Number parts when disassembling so that they can be put back in their original locations when assembling.
• Clean each part thoroughly, remove foreign substances, and make sure that there are no burrs or dents. If burrs
or dents are found, remove them with an oilstone.
• Replace seals with new ones each time the valves are disassembled.
• When assembling, apply a thin coat of hydraulic oil to sliding surfaces and grease to seals.
• During the operation, if a part does not move smoothly, never hit or pry it.
Disassembling procedure
(Assembly should be done in the reverse order of disassembly).
Precautions
When disassembling, make note of where each part was assembled, using tags and the like, and be sure to
assemble each part into its original location when reassembling.
[1] See figure 7.
• Remove boots (18). (x 2) 18
• Remove Hexagon socket set screws. (x 2)
• Withdraw pins (5). (x 2)
24
• Remove cams (7). (x 2)
7
• Remove Hexagon socket head bolts. (x 4)
5
• Remove covers (17). (x 2)
• Remove pushers (11). (x 4)
• Remove steel balls (31) and holders (20). (4 each) 24
• Remove shims (2 and 4). 17
• Remove U packings. (x 4)
Tightening torque:
Hexagon socket head bolt: 9.8 ± 1.0 Nm 33
Hexagon socket set screw: 9.8 ± 1.0 Nm 31
Disassembly may not be possible if hexagon socket set 20
screws are secured with loctite. In this case, remove 2,4
the hexagon socket head bolt together with cam (7), pin
(5) and cover (10). 11
6
AQ25002-006
Figure 7
ASM-17-25-002 Issued 08-2008

Copyright ©
8014-9
[2] See figure 8.
• Pull out pistons (9). (x 4)
• Remove wires (16) from pistons (9). (x 4)
• Remove snap rings. (x 4)
• Remove washers (1). (x 4)
• Remove steel balls. (x8)
(They are very small. Be careful not to lose them.)
• Remove sleeves (8). (x 4)
• Remove spool assemblies. (x 4)
• Remove springs (13). (x 4)
• Remove O-rings. (x 2)
If wire (16) is deformed during disassembly, replace it
with a new one.
When attaching snap rings, be careful not to damage
the inner surface of body (6).
AQ25002-006 Figure 8
[3] See figure 9.

Disassemble spool assemblies. (x 4)
• Remove retainer (12).
• Remove spring (14).
• Remove shims (3 and 15).
AQ25002-006
Figure 9
ASM-17-25-002 Issued 08-2008

Copyright ©
8014-10
[4] See figure 10.
• Remove flanged plug (21) and remove O-ring(33).
(1 each)
• Remove flanged plug (22) and remove O-ring (34).
(1 each)
Tightening torque:
No.22 Flanged plug: 24.5 ± 2.0 Nm
No.21 Flanged plug: 9.8 ± 1.0 Nm
AQ25002-009
Figure 10
Troubleshooting

Scratches on O-ring sealing surface in port
Repair or replace ports.
External oil leakage. sections.
Sealing part breakage. Replace defective sealing parts.
Secondary pressure Spring (14) is fatigued or broken. Replace springs (16).
does not rise smoothly
Disassemble, clean and repair. (Replace as
or is outside specified Foreign substances lodged in spool (10).
an assembly if repair is impossible).
range.
Disassemble, clean and repair. (Replace as
Lever does not move Foreign substances lodged in piston (9).
an assembly if repair is impossible).
smoothly, or does not Foreign substances lodged in pusher (11). Disassemble, clean and repair.
return to neutral posi-
Foreign substances lodged in pin (5) or cam (7). Disassemble, clean and repair.
tion.
Spring (13) is broken or fatigued. Replace springs (15).
Wire (16) has fallen off. Disassemble, clean and repair.
Damping force is weak. Foreign substances lodged in seat parts in Disassemble, clean and repair. (Replace as
steel ball of sleeve (8). an assembly if repair is impossible).
Damping force is too Foreign substances lodged in orifice section
Disassemble, clean and repair.
strong. (9).
ASM-17-25-002 Issued 08-2008

Copyright ©
8014-11
OFFSET AND BLADE REMOTE CONTROL VALVE
1. Operational Description
The numbers in parentheses before the part names correspond to the part numbers in the structural drawing.
1) At neutral
P is blocked by spool (11) and ports A and B are connected to T via a small hole inside spool (11). At this time, spool
(11) is pressed onto holder (12) by spring (13) and end spool. The holder (12) is pressed onto cover (2) and pusher
assembly (23) by spring (6), maintaining the neutral position.
2) During operation (same for port A and port B sides).
[1] Rising port pressure
As the incline of cam (4) increases, pusher assembly (23) and holder (12) are pressed in, and at the same time,
spool (11) moves toward the bottom of cross-section X. Spool (11) blocks T at section (a) (closing A -> T), and as
it moves further downward, P -> A opens at section (b), and hydraulic oil enters port A increasing the pressure.
This pressure pushes the spring back to block P at section (b), re-opening A -> T and reducing the pressure at
port A to balance with the spring force F of spring (13). When the pressure at port A falls below the spring force F
of spring (13), spring (13) moves spool (11) downward again, opening P -> A at section (b) and increasing the
pressure at port A to balance with spring force F of spring (13).
In this way, pressure that balances with the spring force F of spring (13), is generated at port A by the repeated
opening and closing of P and T. Spool (11), during this time, stays within the range defined by the opening and
closing of P and T.
As cam (4) is inclined further, pusher assembly (23) and holder (12) are pressed to an extent corresponding to
the angle of incline, and spring (13) bends and the spring force increases. Spool (11), responding to the increase
in the force of spring (13), causes repeated opening and closing of P and T as described above, generating pres-
sure at port A that balances with the force of spring (13).
In this way, pressure corresponding to the incline angle of the cam is generated linearly at port A.
[2] Falling port pressure
When cam (4) returns towards the neutral position, spring (6) returns holder spring (12) and pusher assembly
(23) upward, towards cross-section X. By this means, the bend of spring (13) decreases and the force is reduced.
Spool (11) then opens and closes P and T, generating pressure at port A corresponding to the force of spring
(13).
2. Replacing Parts at Servicing
[1] Replace sealing parts such as O-rings and backup rings at every disassembly/reassembly.
[2] If any of the following symptoms affects a related system, replace the body and spool assembly.
1) When the amount of leakage increases.
2) When the secondary pressure is unstable and is not stabilized by disassembly and adjustment.
3) When hunching or abnormal noises do not go away after disassembly and adjustment.
[3] If the steel ball does not rotate in the pusher assembly, replace the pusher assembly.
[4] If the cam chatters badly enough to affect operation, replace the parts that are worn
3. Troubleshooting

Insufficient primary pressure. Secure primary pressure.
Secondary pressure Spring fatigue. Replace or add shims (8) or (9) or (10).
does not rise. Abnormal wear of spool and body. Replace the assembly.
Abnormal wear of cam and pusher. Replace with new ones.
Malfunctioning of sliding parts. Overhaul.
Secondary pressure is
Air trapped in piping. Bleed air.
unstable.
Fluctuating pressure in circuit T. Adjust pressure in circuit T.
Secondary pressure is Malfunctioning of sliding parts. Overhaul.
too high. High pressure in circuit T. Adjust pressure in circuit T.
ASM-17-25-002 Issued 08-2008

Copyright ©
8014-12
4. Disassembling/Assembling Instructions
As a general rule, disassembly and reassembly should be done at the factory, but if unavoidable, they should be per-
formed at a service facility with a thorough knowledge of hydraulic devices. Because hydraulic devices are made of
precision components put together with small tolerances, disassemble and assemble them in a clean area that is free
of dust and handle them carefully, following the instructions below. Never hit a device when it does not move
smoothly.
[1] Tools required
1) Hexagon bar wrenches: Nominal size: 2, 2.5, 6 mm
2) Torque wrench: Capable of applying tightening torque of 0 - 40 Nm.
3) Hexagon bar for wrench: Nominal size: 2, 2.5, 6 mm
4) Scriber
[2] Disassembling Instructions
1) Remove boots (7).
2) Remove set screws (16).
3) Pull out pins (5).
4) Take out cam (4).
5) Secure the whole assembly in a vise, then loosen hexagon socket head bolts (15) with a 6 mm hexagon bar
wrench.
Cover (2) may float up due to the force of the spring.
6) Remove cover (2).
7) Pull out pusher assembly (23) from cover (2), then remove O-ring (21) with a scriber.
Be careful not to scratch the inside of the cover when removing the O-ring.
8) Remove the spool assembly and O-ring (22) from the body.
Record the relative positions of the spool assembly and the hole in the body.
9) To disassemble the spool assembly, secure spool (11) in a vise and fasten end spool with a 2.5 mm hexa-
gon bar wrench.
When securing the spool in the vise, use a copper plate to avoid scratching the spool.
The pressure of the spool assembly is regulated by shims, and it should not be disassembled if possible.
10) Take out spring (13).
[3] Assembling Instructions
Fully clean and degrease parts before assembling. The body, in particular, should be cleaned using a nylon
brush. Always use new sealing parts, and apply a thin coat of hydraulic oil or grease to them prior to assembly.
1) Assemble O-ring (21) and pusher assembly (23) into cover (2).
2) To assemble the spool assembly, secure spool (11) in a vise, then install flat washer (17), shim (3), (10),
spring (13) and spring (12) in that order, and screw on end spool.
Tightening torque: 2.94 Nm
When securing the spool in the vise, use a copper plate to avoid scratching the spool.
Apply loctite 242 to the threaded part.
3) Insert spring (6) into body (1), then install the spool assembly and O-ring (22).
The spool assembly is installed in the same hole in the same position as before disassembly.
4) Install shims (8, 9) to each spring holder section (12).
Install them in the same position as before disassembly.
5) Secure body (1) in a vise, then fasten cover (2) with hexagon socket head bolts (15).
6) Fasten cam (4) with pin (5).
7) Fasten the pin with hexagon socket set screw (16).
Apply loctite 262 to the threaded part.
8) Install boots (7).
ASM-17-25-002 Issued 08-2008

Copyright ©
8014-13
5. Structural drawings
A A
T
P
20 A B
Hydraulic Circuit
T
14
19
P
A B
23,24,25
4 7 16 5 18
25
21 15
2
22 12
13
8,9
6
3,10,17 a 11
1
b
A-A
AQ25002-010
ASM-17-25-002 Issued 08-2008

Copyright ©
8014-14
1 Body 1 10 Shim 2 19 Rivet 2
2 Cover 1 11 Spool 2 20 Pin 2
3 Shim 2 12 Holder 2 21 O-ring 2
4 Cam 1 13 Compression spring 2 22 O-ring 2
5 Pin 1 14 Plate 1 23 Pusher 2
Hexagon socket head
6 Compression spring 2 15 2 24 Pusher 2
bolt
7 Boot 1 16 Set screw 1 25 Steel ball 2
8 Shim 2 17 Washer 2
9 Shim 2 18 Washer 2
ASM-17-25-002 Issued 08-2008

Copyright ©
Section
8005
DISASSEMBLY AND REASSEMBLY

OF THE THREE SOLENOID VALVES BLOCK
8015

Printed in France
CNH Lep SM130B8005-0EN March 2008
Copyright ©
8015-2
TABLE OF CONTENTS
SOLENOID VALVE.................................................................................................................................................. 3
ASSEMBLY DRAWINGS ........................................................................................................................................... 3
THEORY OF OPERATION ......................................................................................................................................... 4
MAINTENANCE ...................................................................................................................................................... 4
Assembling and disassembling precautions ..................................................................................................... 4
Assembling and Disassembling a Solenoid Operated Directional Valve .......................................................... 4
Maintenance Standards .................................................................................................................................... 6
Troubleshooting ................................................................................................................................................ 6

Copyright ©
8015-3
SOLENOID VALVE
1 Assembly drawings
Normally closed type solenoid: SP, S1 Normally open type solenoid: S2
MQ26001-002
1. Body (1) 10. Binding band (blue) (1)

2. Spool (2) 11. Binding band (red) (1)
3. Spool (1) 12. Binding band (pink) (1)
4. Spring (2) 13. Solenoid (3)
5. Spring (1) 14. O-ring (3)
6. Adaptor (3) 15. Hexagon socket head bolt (6)
7. Snap ring(3) 16. Plug (4)
8. Name plate(1) 17. Plug (4)
9. Spring washer (6) 18. Rivet (2)
MSM-17-26-001 Issued 08-2008

Copyright ©
8012-4
2 Theory of operation
The hydraulic fluid supplied from the port P is fed to the
solenoid operated directional valves S1 @ when the
valve SP is energized. The hydraulic fluid is then fed to
the ports C1 depending on whether or not the valves
S1 is energized.
Electromagnetic selector valves S1:
Oil passes through when energized
Electromagnetic selector valves S2:
Oil passes through when not energized
NN16001-002
3 Maintenance
1 Assembling and disassembling precautions
[1] Disassemble the valve with due attention not to damage the O-ring and other parts, and store the parts in a safe
place.
[2] If there is any flaw on the O-ring, replace it with a new one.
[3] Be careful to assemble the parts in the correct orientation and without forgetting any of the parts.
[4] When assembling, reverse the order of disassembling and pay attention not to allow any foreign matters such as
dirt to get into the valve.
2 Assembling and Disassembling a Solenoid Operated Directional Valve
[1] Remove the mounting bolts from the solenoid (C) and remove the coil part. (Tool: 3 mm Hexagon wrench)
[2] Remove the tube, while paying attention not to damage the edges of the flat portion of the core. However, if the
core is removed, replace the O-ring (A) with a new one. (Tool: 23 mm spanner)
[3] Take out the spools (2) and (3) and the springs (4) and (5).
[4] Pry the snap ring (7) off by inserting a flat head screwdriver or the like in the notch, and remove the adapter (6).
[5] Assemble the valve by reversing the order of disassembling. When tightening the core, pay attention not to dam-
age the edges of the flat portion of the core.
When mounting the adaptor, apply grease or other appropriate lubricant to the O-ring (B) and pay attention not to
damage the O-ring.
MSM-17-26-001 Issued 08-2008

Copyright ©
8015-5
1.7VQ2.0 Nm
O-ring
SO-NA-A022
14.4VQ17.6 Nm
O-ring
SO-NB-P18
Item 2 assembly: electronic selector valve SP, S1
Item 3 assembly: electronic selector valve S2

NN16001-003
MSM-17-26-001 Issued 08-2008

Copyright ©
8012-6
3 Maintenance Standards
D
d
MQ26001-001
Measure the clearance between the body and the spool.

Clearance = Ø D - Ø d
Reference value: approx. 0.01mm
4 Troubleshooting

Remove the foreign matters, dismount the
Foreign matters galling the spool.
Spool malfunction. valve, perform flashing, or replace the fluid.
Damaged parts or abnormal wear. Replace the valve.
Terminal disconnection. Insert the terminal.
Solenoid malfunction. Damaged coil.
Replace the solenoid
Broken lead wire.
Loose bolts. Tighten the bolt to the specified torque.
Fluid leakage to outside Damaged O-ring. Replace the O-ring.
Loose hex socket plug. Fasten the plug.
MSM-17-26-001 Issued 08-2008

Copyright ©
Section
8016

CUSHION CONTROL VALVE
8016

Printed in France
CNH Lep SM75SR8016-0EN March 2008
Copyright ©
8016-2
TABLE OF CONTENTS
CUSHION VALVE.................................................................................................................................................... 3
STRUCTURE .......................................................................................................................................................... 3
OPERATIONAL DESCRIPTION .................................................................................................................................. 4
DISASSEMBLY AND ASSEMBLY .............................................................................................................................. 5
General Precautions ......................................................................................................................................... 5
Disassembling procedures ................................................................................................................................ 5

Copyright ©
8016-3
CUSHION VALVE
1 Structure
A B
G 1/4 G 1/4
7
1 8 2 6 15 1 10
A B
11 4 12 3 13 5 13
Figure 1
AQ27002-001
1. Spring 8. Ring
2. Orifice 10. Snap ring
3. Body 11. O-ring
4. Connector 12. O-ring
5. Sleeve 13. O-ring
6. Plunger 15. Plunger assembly
7. Name plate
ASM-17-24-002 Issued 08-2008

Copyright ©
8016-4
2 Operational description
A -> B: Flow control (Figure 2)
• Hydraulic oil supplied from port A passes through orifice (2) and the hole around plunger (6) and drains out to port
B.
• At this time, the resistance of oil passing through orifice (2) causes the pressure in chamber (1) to become greater
than the pressure in chamber (2).
• The plunger therefore moves to the right.
• As plunger (6) moves to the right, section (I) is closed, creating a blind circuit, and the pressure in chambers (1)
and (2) is equalized.
• As the pressure in chambers (1) and (2) is equalized, the force of spring (1) returns plunger (6) to the neutral posi-
tion.
• Repetition of this process causes plunger (6) to be balanced in a position where the force of spring (1) and the
resistance of orifice (2) are equal. (As the flow rate through orifice (2) increases and the resistance increases,
section (I) closes).
FS = FA - FB (FA = P1 x a > P2 x b = FB)

FS: force of spring (1)
FA: force to push the plunger to the right
FB: force to push the plunger to the left
P1: pressure in chamber (1)
P2: pressure in chamber (2)
a, b: outer diameter of plunger (a = b)
• Consequently, a flow rate of oil passing through orifice (2) necessary to generate a passing resistance that bal-
ances the force of spring (1), is maintained, controlling the flow rate from port A into port B at a constant level.
3 2 6 1 5
a
A B
(1) (I) (2)
Figure 2
AQ27002-002
ASM-17-24-002 Issued 08-2008

Copyright ©
8016-5
B -> A: Free flow (Figure 3)
• Hydraulic oil supplied from port B first passes through orifice (2) and drains out to port A.
• Resistance of oil passing through orifice (2) causes the pressure in chamber (1) to become less than the pressure
in chamber (2), moving plunger (6) to the left.
• As plunger (6) moves to the left, section (II) opens and hydraulic oil passes through the circuit in section (II) and
the opening around plunger (6), and the entire flow drains out to port A.
• When the supply of hydraulic oil is cut, plunger (6) is returned to the neutral position by the force of the 2 springs
(1).
1 2 3 6 5
A B
a
b
(1) (II) (2)
Figure 3
AQ27002-003
3 Disassembly and Assembly

1 General Precautions
• Hydraulic valves all consist of precision components. Disassemble and assemble them in a clean area that is free
of dust. Use clean tools and solvent.
• After disassembly, clean parts and apply a corrosion inhibitor.
• During disassembly, number each part to ensure that it is reassembled into its original position.
• When reassembling, clean each part well, remove foreign substances, and verify that parts have no burrs or
dents. If burrs/dents are found, remove them with an oil stone.
• Replace all seals with new ones each time the hydraulic valve is disassembled.
• When reassembling, apply hydraulic oil to sliding parts and a thin coating of grease to all seals.
• Never attempt to forcibly hit or pry parts when they cannot be moved easily.
2 Disassembling procedures
(Reassembly is done in the reverse order of disassembly.)
[1] See figure 4
• Remove snap ring (10).
• Remove sleeve (5).
• Remove O-rings (13). (x 2)
13 5 10
Figure 4
AQ27002-004
ASM-17-24-002 Issued 08-2008

Copyright ©
8016-6
[2] See figure 5
• Disconnect connector (4).
Tightening torque of connector (4): 24.5 ± 2.9 Nm
• Remove O-ring (11).
11 4
Figure 5
AQ27002-005
[3] See figure 6

• Remove the plunger assembly (15). [Orifice (2) and ring (8) cannot be disassembled.]
• Remove O-ring (12).
Plunger assembly (15) must be oriented correctly at reassembly. (Install so that ring (8) is visible when viewed
from the port A side.)
1 15 1 12 3
Figure 6
AQ27002-006
3 Troubleshooting

Scratches on O-ring seal surfaces at
Repair or replace
External oil leak each port.
O-ring breakage. Replace
Spring (1) is fatigued or breakage. Replace spring (1)
Foreign substance lodged in plunger Disassemble to clean and repair or
Unstable flow rate at A -> B
assembly (15). replace.
Foreign substance blocking in orifice (2). Disassemble and clean.
Oil flow of B -> A blocked
Foreign substance lodged in plunger
from running its entire vol- Disassemble to clean and repair or replace.
assembly (15).
ume
ASM-17-24-002 Issued 08-2008

Copyright ©
Section
8018
DISASSEMBLY AND REASSEMBLY

OF THE HYDRAULIC SWIVEL
8018

Printed in France
Copyright ©
8018-2
TABLE OF CONTENTS
ROTATING JOINT ................................................................................................................................................... 3
COMPONENT DIAGRAM .......................................................................................................................................... 3
TOOLS AND JIGS ................................................................................................................................................... 4
DISASSEMBLY INSTRUCTIONS ................................................................................................................................ 5
ASSEMBLY INSTRUCTIONS ..................................................................................................................................... 7
ASSEMBLY DRAWINGS ........................................................................................................................................... 9

Copyright ©
8018-3
ROTATING JOINT
1 Component diagram
2
5
3
4
10
11
6
7,8
9 AQ17002-001
1. Axle 7. Hexagon socket head bolt

2. V-ring 8. Loctite
3. O-ring 9. Snap ring
4. Paking ring 10. Thrust ring
5. Rotor 11. O-ring
6. Cover
ASM-17-17-002 Issued 08-2008

Copyright ©
8018-4
2 Tools and jigs
1. Tools
1) Hexagon bar wrench
2) Torque wrench
3) Box wrench
4) Flash light
5) Inspection mirror
6) Brush (vinyl made)
AQ17002-002
2. Jigs
Jig for pushing out axle
M16-M20 Fully threaded bolt

L = 350-400 mm
Hexagon socket head bolt

M16-M20 Female (7) x 25
Cover (6) fitting

size
AQ17002-003
ASM-17-17-002 Issued 08-2008

Copyright ©
8018-5
Prior to disassembly
[1] As this is a hydraulic device, follow the cautions below.
- Rough handling should be avoided (e.g. forcedly prying and hitting).
- Be careful when handling parts; do not drop or hit against other parts.
- Do not allow foreign substances such as dirt or moisture to enter into the parts.
[1] Always use jigs when disassembling axles and rotors.
[1] Use a strongly-built, stable workbench which has enough space. The workspace should be clean and free of dirt
and moisture. Remove all dirt and moisture before starting work.
[1] Inspect the tools and jigs before starting work. Remove dirt and moisture to make them clean.
[1] Use suitable tools and jigs which meet requirements for the job.
[1] Follow the procedure below to disassemble rotating joints..
Disassembling procedure
1. Remove the cover (6) together with the bolt (7).
AQ17002-004
2. Remove the O-ring (11).

11
AQ17002-005
3. Remove the shaft snap ring (9), then remove thrust ring
(10). 9
10
AQ17002-006
ASM-17-17-002 Issued 08-2008

Copyright ©
8018-6
4. Push out the axle (1) from the rotor (5) using a jig.
NOTE: Do not hit the parts with a hammer while carrying out this
operation.
5
AQ17002-007
5. Remove the V-ring (2) from the axle (1).
AQ17002-008
6. Remove the O-ring (3) and packing rings (4) from the rotor
(5).
4
AQ17002-009
ASM-17-17-002 Issued 08-2008

Copyright ©
8018-7
Prior to assembly
[1] Clean all the parts.
Polish scratches, flashes or burrs using oil stone.
Change sealing parts such as O-rings and packing ring with new ones.
[1] Prior to the disassembly described in the Section 3-(1), perform the same cautions and measures mentioned in
this section.
1.
1) Clean the rotor (5) using cleaning liquid or com-
pressed air.
2) After cleaning, check for scratches, flashes, burrs
or dents on the inner sides or grooves of the rotor.
NOTE: Do not reuse back-up ring (2) and O-ring (3).

5
AQ17002-010
2. Check the number of packing rings (4) and the O-rings (3).
Apply grease and install them following the steps shown
below. 4
1) Set one packing rings (4) in each groove up to the
second from the top. 3
2) Set the O-ring (3) in the top groove.

NOTE: Do not reuse packing rings (4). Do not reuse O-ring (3).
3 4
AQ17002-011
3. After installing O-ring and packing ring, check for extrusions

or twists using a mirror. Also check for installation errors.
After the check is complete, apply grease.
After the grease application, check again for extrusion.
AQ17002-012
ASM-17-17-002 Issued 08-2008

Copyright ©
8018-8
4. Install the V-ring (2) to the axle (1), and apply plenty of
grease.
Ensure that no water or dirt mixes into the grease
2
NOTE: Do not reuse V-ring (2).
AQ17002-013
5. Install the axle (1) to the rotor (5).

NOTE: Be careful not to cause any cuts or damage to the V-ring
(2) while setting.
5
AQ17002-014
6. Install thrust ring (10) and snap ring (9) onto axle (1).
9
10
AQ17002-015
ASM-17-17-002 Issued 08-2008

Copyright ©
8018-9
5 Assembly drawings
Apply grease before

assembly
Max gap 10.04 Max gap 0.90

Min gap 8.30 Min gap 0.24
NOTE: Need treatment free from dust & rust.

NOTE: Do not paint M marked surface and port machine surface.
1. Axle (1) 8. Loctite (-)
2. V-ring (1) 9. Snap ring (1)
3. O-ring (1) 10. Thrust ring (1)
4. Paking ring (9) 11. O-ring (1)
5. Rotor (1) 12. Drive screw (2)
6. Cover (1) 13. Trade mark plate (1)
7. Hexagon socket head bolt (4)
ASM-17-17-002 Issued 08-2008

Copyright ©
8018-10
NOTES
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ASM-17-17-002 Issued 08-2008

Copyright ©
Section
8019

SWING MOTOR
8019

Printed in France
Copyright ©
8019-2
TABLE OF CONTENTS
SWING UNIT............................................................................................................................................................ 3
MAINTENANCE INSTRUCTIONS ................................................................................................................................ 3
Motor function ................................................................................................................................................. 3
Function of valves integrated in motor ............................................................................................................ 5
Parking brake function / hydraulic timer function ............................................................................................ 8
Tools used....................................................................................................................................................... 10
Disassembly .................................................................................................................................................... 13
Removing the anti-reverse valve................................................................................................................... 13
Separating the motor and the reduction gears.............................................................................................. 14
Disassembling the motor section .................................................................................................................. 14
Disassembling the reduction gears ............................................................................................................... 19
Assembling the motor section ....................................................................................................................... 23
Assembling the reduction gears.................................................................................................................... 29
Reassembling the entire motor assembly ..................................................................................................... 34
Installing the anti-reverse valve..................................................................................................................... 34
Checking Quality after Assembly .................................................................................................................... 35
Check for air leaks in the motor section ........................................................................................................ 35
Inspection before and after operation ........................................................................................................... 35
Maintenance Standards .................................................................................................................................. 36
Motor section................................................................................................................................................. 36
Reduction gear section ................................................................................................................................. 37
Valve section................................................................................................................................................. 37
Other ............................................................................................................................................................. 37
Exploded views ............................................................................................................................................... 38
Stracture drawing ............................................................................................................................................ 40
ANTI-REVERSE VALVE.......................................................................................................................................... 42
Troubleshooting .............................................................................................................................................. 42
Tools used....................................................................................................................................................... 43
Disassembling instructions.............................................................................................................................. 43
Precautions prior to disassembly .................................................................................................................. 43
Disassembly.................................................................................................................................................. 43
Precautions prior to reassembly.................................................................................................................... 44
Assembly....................................................................................................................................................... 44
Anti-reverse valve: Exploded view .................................................................................................................. 46

Copyright ©
8019-3
SWING UNIT
1 Troubleshooting
If any problems occur in the swing motor, as a general rule, replace the entire assembly.
Problems, causes and remedies are described below for reference and understanding.
1 Motor function

1. Malfunction of something other than Check to see if the oil pressure at the entry side of
the piston motor, valves (integrated in the motor is correct. Then inspect/repair each
motor) or reduction gears. device.
Replace parts with abnormal wear. Clean all parts
2. Escaping hydraulic oil due to abnor- completely and remove surface burrs and
mal wear on motor sliding sections. scratches. Reassemble, taking care to keep for-
eign substances out of parts.
1. Motor does not 3. Malfunction due to breakage of major After disassembly, replace damaged parts. Clean
rotate. motor components. In this case, the all parts completely and reassemble, taking care
motor itself makes abnormal sounds. to keep foreign substances from getting into parts.
4. Malfunction due to breakage of major
After disassembly, replace damaged parts. Clean
reduction gear components. In this
all parts completely and reassemble, taking care
case, the reduction gears make abnor-
to keep foreign substances out of parts.
mal sounds.
5. Too much load on the motor activates Check load and run motor with a load that
the relief valve. matches relief set pressure.
1. Insufficient motor revolutions due to
Check to see if the amount of oil supplied to the
lack of oil supply to motor, caused by
entry side of the motor is correct. Then inspect/
2. Motor rpms are problems related to hydraulic pump,
repair each device.
insufficient. pressure control valves, etc.
2. Motor rpms are reduced due to Disassemble and check sliding sections for
decreased motor volumetric efficiency. abnormal wear, then repair or replace.
1. Wear on sliding sections causes a
large amount of highly-pressurized
After disassembly, replace parts that show abnor-
hydraulic oil to leak and flow out from
3 .Large variation in mal wear. Clean all parts completely and reas-
the drain port, reducing rpms signifi-
motor rotation. semble. Take measures to prevent foreign
cantly and causing rotation to vary. Vari-
substances from getting into parts.
ation in rotation is also caused by wear
on shaft bearings.
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8019-4

Replace damaged oil seal or O-ring with new one.
Special care should be taken when inserting oil
seals so that lips will not be damaged.
Maximum temperature for safe use of oil seals
1. Damaged oil seal or O-ring causes oil
and O-rings is 80 °C.
to leak.
If the hydraulic oil temperature is likely to be
higher than 80 °C, measures such as installation
of a cooling system in the hydraulic circuit are
required.
2. A broken oil seal, caused by
increased pressure inside the motor
case from the causes listed in 1.2 and Repair motor according to instructions in 1.2 and
3.1, results in oil leakage. 3.1 and then replace oil seal with new one. Spe-
4. Oil leak.
- Oil seal cial care should be taken when inserting oil seals
- Withstand pressure: 3 kgf/cm2 (instan- so that lips will not be damaged.
taneous maximum)
- Normal use:1 kgf/cm2 or less
3. Drain pipe is blocked by foreign sub-
stances, or long narrow piping causes Clean drain pipe.
increased back pressure, leading to oil Recheck piping system to reduce resistance.
seal breakage and oil leakage. After taking these measures to ensure that the pres-
- Oil seal sure on the oil seals does not exceed 3 kgf/cm2,
- Withstand pressure: 3 kgf/cm2 (instan- replace oil seal with new one.
taneous maximum) Special care should be taken when inserting oil
seals so that lips will not be damaged.
- Normal use:1 kgf/cm2 or less
1. Increased drain volume due to low
Take measures described in 2.2 and 3.1.
motor efficiency.
5. Abnormal noises,
fluctuation in rotation/ Take measures described 1.4 under Valve func-
2. Makeup valve malfunction.
pressure due to cavita- tions.
tion.
3. Insufficient pressure on makeup valve Check makeup supply pressure and oil level, then
due to lack of supply flow. reset to defaults.
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8019-5
2 Function of valves integrated in motor

1. Malfunction of something other than Check to see if the oil pressure at the entry side of
the piston motor, valve the motor is correct. Then inspect/repair each
(integrated in motor), or reduction gears. device.
2. Increased internal leakage due to O-
Replace O-rings and backup rings with new ones.
ring seal breakage in relief valve.
3. Increased leakage due to bad seal in Repair, or replace piston and rear cover with new
valve and piston section. ones.
4. Faulty seat or malfunction in makeup
valve.
1) Foreign substances present. 1) Remove foreign substances completely
and repair where damaged. Clean and
reassemble. Replace if scratches are deep
and leak is large.
2) Roughness or breakage on slid- 2) Repair sliding faces or replace part with
ing faces of check valve. new one.
3) Damaged spring. 3) Replace spring. Then remove foreign sub-
1. Motor does not
stances completely and repair valve where
rotate or rotational
damaged. Clean and reassemble. Replace
speed is low.
if scratches are deep and leak is large.
5. Faulty seat in relief valve.
and leak is large.
2) Damaged spring. 2) Replace relief valve assembly.
Cracking pressure on relief valve is
reduced.
1) Spring fatigue. 1) Replace relief valve assembly.
2) Poppet and orifice are blocked. 2) Clean with mineral oil, then reassemble.
6. Increased leakage.
1) Increased internal leakage due
1) Take measures described in 1.2 and 1.3 to
to broken O-ring in valve.
solve problem.
2) Increased leakage caused by
2) Replace relief valve assembly.
faulty seal on valve or piston.
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8019-6

1. Faulty seat or malfunction in makeup
valve.
and leak is large.
2) Roughness or breakage on slid- 2) Repair sliding faces or replace part with
ing faces of check valve. new one.
damaged. Clean and reassemble. Replace
if scratches are deep and leak is large.
2. Motor does not stop, 2. Faulty seat in relief valve.

or does not stop imme- 1) Foreign substances present. 1) Remove foreign substances completely
diately. and repair where damaged. Clean and
and leak is large.
2) Damaged spring. 2) Replace relief valve assembly.
3. Cracking pressure on relief valve is
reduced.
1) Spring fatigue. 1) Replace relief valve assembly.
2) Poppet and orifice are blocked. 2) Clean with mineral oil, then reassemble.
4. Increased leakage.
1) Increased internal leakage due
1) Take measures described in 1.2 and 1.3 to
to broken O-ring in valve.
solve problem.
2) Increased leakage caused by
2) Replace relief valve assembly.
faulty seal on valve or piston.
1. Make-up valve malfunction.
and leak is large.
3. Abnormal noises.
damaged. Clean and reassemble. Replace if
scratches are deep and leak is large.
2. Insufficient pressure/oil flow to Check makeup pressure and oil flow and reset to
makeup valve. specified values.
3. Relief valve set pressure changes,
Readjust relief valve set pressure.
causing resonance in other relief valves.
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8019-7

1. Shockless feature does not operate.
1) Foreign substances present. 1) Remove foreign substances completely.
Clean damaged parts and repair, then
and leak is large.
2) Hydraulic oil is not supplied to 2) Clean relief valve assembly and remove for-
4. Greater than usual piston chamber. eign substances blocking orifice section.
shock at swing stops. 3) Increased leakage due to abnor- 3) Repair or replace sliding part.
mal wear on piston sliding part.
2. Relief valve set pressure is increased. Readjust relief valve set pressure.
3. Relief valve does not operate. Remove foreign substances completely. Clean
Foreign substances present in sliding damaged parts and repair, then reassemble.
section. Replace if scratches are deep and leak is large.
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8019-8
3 Parking brake function / hydraulic timer function
(References to models with parking brake/hydraulic timer specifications only are indicated in parentheses).

1. Release pressure PB (PG) and
valve switching signal pressure SH
(models with hydraulic timer specifica-
tions only) are not generated, or pres- Adjust PB (PG) and SH pressure to specified val-
sure supplied is low (not meeting ues.
specified values) As a result, brake
piston does not operate. Timer valve
does not switch over.
Measure motor drain pressure, inspect drain cir-
2. Valve does not operate because cuit for blockage and repair.
motor drain pressure is high. If motor drain volume is abnormally large, inspect
and repair motor.
3. Timer valve does not switch over
1. Motor does not (models with hydraulic timer specifica-
rotate. tions only).
1) Malfunction due to wear or dam- 1) Inspect and repair damaged parts. Replace
Parking brake does not age to sliding section of valve if damage to sliding section is serious.
release. body.
2) Malfunction due to foreign sub- 2) Clean sliding section and remove foreign
stances engaged in sliding sec- substances.
tion of valve body.
3) Damaged spring. 3) Replace spring.
4. Brake piston does not operate.
1) Hydraulic oil escapes due to 1) Inspect damaged parts and repair.
abnormal wear or breakage of
O-ring in brake piston.
2) Piston malfunction due to wear 2) Replace if damage to sliding section is seri-
or damage to brake piston or ous.
sliding section.
3) Malfunction due to foreign sub-
stances lodged in piston sliding 3) Clean sliding section and remove foreign
section. substances.
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8019-9

1. Worn abrasive material on disks. Replace disks with new ones.
2. Fatigue or breakage of springs in pis-
Replace springs with new ones.
ton section.
3. Faulty sliding section or warping in Repair sliding face, or replace parts if damage is
brake piston, or deformation of abrasive serious. Surfaces of abrasive material cannot be
face of disk. repaired.
4. Timer valve does not switch over
and pressure cannot be released from
cylinder chamber (models with
hydraulic timer specifications only).
2. Poor braking power.
1) Valve spring fatigue. 1) Replace spring.
No braking power.
2) (Models with hydraulic timer 2) Check pressure in SH signal system. If

specifications only:) Signal pres- back pressure is high, take measures to
sure SH is supplied or signal sys- reduce to specified value.
tem back pressure is high.
3) For other problems, 3) For other problems, see 1.3. 1) - 3).
see 1.3. 1) - 3).
5. Pressure cannot be released from
cylinder chamber because of block- Clean filter and orifice, or replace with new ones.
ages in orifice and filter.
1. Brake piston rubs on disk because
release pressure PB (PG) is low.
2. Decreased pressure in cylinder
chamber due to abnormal wear or
breakage of O-ring in brake piston.
3. For malfunctioning timer valve, see
2.4. 1) - 3).
3. Parking brake does
not release completely, 4. Faulty hydraulic timer section.
generating noises, (Models with hydraulic timer specifica-
vibratory shocks, tions only:) Parking brake operates as
abnormalities and heat. a dynamic brake because timer is set
too early.
1) Orifice is not positioned cor- 1) Disassemble to inspect valve, then assem-
rectly. ble orifice correctly.
2) Faulty valve seat. 2) If abnormal damage is found on seat surface,
repair or replace with new one.
3) Foreign substances engaged in 3) Clean new parts and remove foreign sub-
the above valve seat. stances.
4) Spring fatigue or breakage. 4) Replace spring with new one.
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8019-10
2 Tools used
No Name Description and remarks

Plastic hammer
1
Hexagon wrench
2 Screwdriver (flathead)
3 Snap ring pliers (internal)
4 Snap ring pliers (external)
5 Hand press
6 Vise
Width across flats
2.5 mm
3 mm
7 Hexagonal wrenches 5 mm
6 mm
8 mm
12 mm
Troque settings
2.45 Nm
15.7 Nm
24.5 Nm
32.4 Nm
8 Torque wrench
39.2 Nm
70 Nm
157 Nm
177 Nm
373 Nm
Width across flats
2.5 mm
3 mm
9 Bits for torque wrench 5 mm
6 mm
8 mm
12 mm
10 Socket Width across flats: 27
11 Tweezers
12 Needle nose pliers
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8019-11
Tool name............................................................................................................................... Configurations for reference
1. Ball bearing press fitting jig (2-3).
AQ22002-001
2. Ball bearing press fitting jig (2-28).
AQ22002-002
3. Oil seal press fitting jig (1-7).
AQ22002-003
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8019-12
Tool name............................................................................................................................... Configurations for reference
4. Collar press fitting jigs (1-10).
AQ22002-004
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8019-13
3 Disassembly
WARNING: Precautions prior to disassembly

!
1 Remove mud and dirt from exterior surfaces completely.
2 Remove mud and dirt from exterior surfaces completely.
3 Drain hydraulic oil from the piston motor case and the port oil passages.
4 Select a dirt-free area for work. Use caution to prevent any mud or dirt from getting on parts.
5 Handle parts carefully to avoid dropping them, or denting or scratching them by contact.
6 Do not disassemble more than what is necessary.
[1] Disassembly
Disassemble the valve following the procedure below:
WARNING: Notation in this manual:

!
1) Part numbers in the text correspond to numbers shown in the Sectional Parts Listing and Exploded View.
2) Parts marked (*1) apply only to models with anti-reverse valve specifications only.
3) Parts marked (*2) apply only to models with parking brake specifications only.
4) Parts marked (*3) apply only to models with hydraulic timer specifications only.
1 Removing the anti-reverse valve
*1, anti-reverse valve specifications only
2-38
Remove socket head bolts (2-39), and remove anti- 2-36
reverse valve (2-34) and O-ring (2-38). See the Anti-
reverse Valve Instruction.
2-34 2-39
AQ22002-006
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8019-14
2 Separating the motor and the reduction gears
[1] Secure the entire motor assembly firmly in a vise or the
like, then remove socket head bolts (3). 3
AQ22002-007
3 Disassembling the motor section

1 Secure the motor assembly firmly in a vise or the
like. 2-33 2-33
Remove socket head bolts (2-33) and separate off
cover assembly (2-27).
NOTE: Handle carefully so that valve plate (2-30) does not fall
when cover assembly (2-27) is separated off.
2-33 2-33
2-30 2-27
AQ22002-008
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8019-15
2 Remove valve plate (2-30) and pins (2-32, 2-29).
2-30 2-29 2-32
WARNING: Valve plate (2-30) may remain on the
! motor side.
3 Remove bearing (2-28).
WARNING: Do not disassemble unless absolutely

necessary. 2-28
! Bearings, once removed, cannot be reused.
AQ22002-010
4 Disassemble the check valve.

1) Loosen and remove plug (2-27-3). 2-27-3
AQ22002-011
2) Remove check valve (2-27-2) and spring (2-27-5).
2-27-5 2-27-2
AQ22002-012
5 Remove the relief valve.

1) Loosen plug (2-27-6-6) and remove relief valve
assembly (2-27-6). 2-27-6-13 2-27-6-3
WARNING: Do not touch set screws and nuts (2-27-

6-13 and 14). 2-27-6-14
Doing so will change the pressure settings.
! Relief valve assembly (2-27-6) is a functional
component and should not be disassembled.
2-27-6-6
AQ22002-013
WARNING: When removing the relief valve
assembly, poppet sheet (2-27-6-3) may remain on
! the cover side.
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8019-16
6 Remove pin (2-31) and O-ring (2-24).
WARNING: Pin (2-31) may remain on the cover 2-31 2-24

! assembly side.
AQ22002-014
7 (*2, parking brake specifications only)

[1] Remove springs (2-22, 2-23), then remove parking pilot
brake piston (2-19) using the pilot port on case (2-1). 2-23 2-22 2-19
WARNING: Use caution in this operation: air

pressure may cause the piston to fly out.
! Also, set air pressure low at the beginning of the
operation and adjust it while watching the piston.
Pilot port
AQ22002-015
8 Cover collar (2-17)

(*2, parking brake specifications only)
2-17 2-15
WARNING: Removing one disk (2-15) first makes
! this procedure easier.
NOTE: Be careful not to deform the friction plate while remov-

ing the collar.
AQ22002-016
9 Remove the cylinder block and related parts:

Cylinder block (2-6), etc.
- Pin (2-11) 2-11 2-6 2-14
- Retainer holder (2-13)
- Retainer plate (2-12) 2-16
- Piston assembly (2-14)
(*2, parking brake specifications only)
Remove disk (2-15) and friction plate (2-16).
2-15
2-12 2-13
AQ22002-017
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8019-17
10 Remove retainer plate (2-12) and piston assembly
2-12 2-14
(2-14).
AQ22002-018
11 Remove pin (2-11) and retainer holder (2-13).

2-13 2-11
AQ22002-019
12 Remove snap ring (2-10) while pressing down on

washer (2-9). 2-9 2-10

necessary.
! As a general rule, rotary parts (B1) should be replaced
as a cylinder block assembly.
AQ22002-020
13 Remove collar (2-7), spring (2-8) and washer (2-

9). 2-9 2-7 2-8

necessary.
! As a general rule, rotary parts (B1) should be replaced
as a cylinder block assembly.
AQ22002-021
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8019-18
14 Remove thrust plate (2-5). 2-5
AQ22002-022
15 Remove shaft (2-4) by tapping the end of the shaft 2-4

lightly with a plastic hammer.
AQ22002-023
16 Disassemble shaft (2-4) and ball bearing (2-3).

2-4
2-3
necessary.
! Bearings, once removed, cannot be reused.
AQ22002-024
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8019-19
4 Disassembling the reduction gears
1-23 1-21 1-25
1) Remove:
- O-ring (1-37)
- Thrust plate (1-24) 1-20 1-22 1-24 1-37
- Drive gear (1-25)
- Planetary gear (1-23)
- Needle bearing (1-22)
- Inner race (1-21)
- Thrust washer (1-20)
- Holder (1-19)
1-19
AQ22002-025
2) Remove planetary gear (1-18).
1-18
AQ22002-026
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8019-20
3) Remove holder (1-11) etc. 1-11
AQ22002-027
4) Loosen screw (1-17) and remove thrust plate (1-16).
WARNING: This screw may be hard to remove

because Loctite is used in the assembly. 1-16 1-17
! In this case, heating the screw section with a dryer
facilitates its removal.
1-11
AQ22002-028
5) Remove:
- Planetary gear (1-15)
- Needle bearing (1-14) 1-13 1-14 1-15
- Inner race (1-13)
1-12
AQ22002-029
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8019-21
1-1 1-7 1-8 1-9 1-10

WARNING: About disassembling parts related to
the pinion shaft:
Parts related to the pinion shaft will require
adjustments when disassembled.
Disassembling procedures described below are for
reference only.
Do not disassemble parts unless absolutely
! necessary.
Housing (1-1), tapered roller bearings (1-6, 1-8),
plate (1-9), pinion shaft (1-2), collar (1-3) and plates
(1-4, 1-5) shown to the left cannot be replaced as 1-5
single parts.
Always replace these parts as a housing assembly
(B6).
1-6
1-4
6) Remove collar (1-10) and plate (1-9).
1-2 1-3
AQ22002-030
7) Remove pinion shaft (1-2).

1-2
NOTE: When removing the shaft, be careful not to let it fall. If
it is hard to remove, tap it lightly with a plastic hammer.
AQ22002-031
8) Remove the inner race of tapered roller bearing

(1-8).
1-8
AQ22002-032
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8019-22
9) Break oil seal (1-7) and remove.
NOTE: Oil seals that have been removed cannot be reused.
Be careful not to damage the outer races of tapered roller
bearings (1-6, 1-8) during removal.
1-7 AQ22002-033
10) Remove plug (1-35).
1-35
AQ22002-034
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8019-23
WARNING: Precautions prior to assembly

!
1 Clean each part with clean mineral oil and dry with air.
2 Handle cleaned parts carefully to keep them from getting dirty, dented or scratched.
3 Replace all seals.
4 Fasten all tightened parts to specified torques.
5 Apply lithium grease in advance to oil seals and O-rings.
6 There are many small parts. Be careful not to lose them (especially not to let them fall into holes).
[1] Assembly
Assemble the motor following the procedure below:
1 Assembling the motor section
1 Install collar (2-7), spring (2-8) and washer (2-9) 2-9 2-7 2-8 2-6
into cylinder block (2-6).
NOTE: Be careful to orient collars (2-7) correctly.
Tapered face
Cylinder block
AQ22002-036
AQ22002-035
2 Install snap ring (2-10) while pressing on washer (2-

9).
2-9 2-10
NOTE: Make sure that the snap ring is firmly secured.
AQ22002-037
3 Apply grease to pins (2-11) and install them in cyl-

inder block (2-6).
2-13 2-11
4 Install retainer holder (2-13). 2-6
AQ22002-038
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8019-24
5 Place retainer plate (2-12) on piston assembly (2-14) 2-12 2-14
and install on cylinder block (2-6).
Coat sliding sections thoroughly with hydraulic oil
before installing.
2-6
NOTE: Be careful to orient the retainer plate correctly.
AQ22002-039
6 Press fit ball bearing (2-3) onto shaft (2-4).

(Reference jig No.21) 2-4
2-3
AQ22002-040
7 Press fit shaft (2-4) and ball bearing (2-2) into

case (2-1). 2-4
AQ22002-041
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8019-25
8 Apply grease to back surface of thrust plate (2-5)
2-5
and install.
NOTE: Thrust place must be oriented correctly.
Please tapered side on motor case side
AQ22002-043
AQ22002-042
9 Apply grease to front surface of thrust plate (2-5)

and install cylinder block ASSY.
Cylinder block ASSY 2-6
- Cylinder block (2-6)
- Pin (2-11)
- Retainer holder (2-13)
- Retainer plate (2-12)
- Piston ASSY (2-14)
AQ22002-044

Install disk (2-15) and friction plate (2-16).
NOTE: Disk and friction plate must be oriented correctly. 2-15
2-16
WARNING: Assemble by aligning disks in the

! locations on the spline without teeth.
AQ22002-045

Apply grease to O-ring (2-18) and install on collar (2-
17). 2-17 2-18
WARNING: Always press fit using a press or the like.

If hit with a plastic hammer or the like, the cylinder
! block will bounce and cause the disk plate and
friction plate to fall off.
AQ22002-046
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8019-26
Apply grease to O-rings (2-20, 2-21) and install on
brake piston (2-19). 2-19

Install brake piston (2-19) into case (2-1).
WARNING: Press fit brake piston positioned as

shown in the figure to the left. (Otherwise, the pin will
not connect with the cover). Always press fit using a
! press, etc. If hit with a plastic hammer or the like, the
2-20 2-21
cylinder block will bounce and cause the disk plate AQ22002-047
and friction plate to fall off.
Install so that pin hole (DIA 8.5) is

positioned at this location
AQ22002-048
14 Apply grease to 12 large springs (2-22), 8 small

springs, (2-23) and O-ring (2-24), then install.
2-23 2-22 2-19 2-24
AQ22002-049
Pin hole
WARNING: Install small springs (2-23) in the
! locations shown below.
Pin hole
AQ22002-050
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8019-27
15 Install greased O-rings (2-27-6-7, 15, 17) and
backup rings (2-27-6-16, 18) on relief valve (2-27-6), 2-27-6-7 2-27-6-18 2-27-6-16 2-27-6-3
and then install it on cover (2-27-1).
Tightening torque: 37±20 Nm (Width across flats: 27)
NOTE: Poppet sheet (2-27-6-3) may remain inside the cover.
2-27-6-17 2-27-6-15
AQ22002-051
16 Attach check valve (2-27-2) and spring (2-27-5)

onto cover (2-27-1). Install plug on cover (2-27).
Tightening torque: 157±10 Nm (Width across flats: 12) 2-27-5 2-27-2
AQ22002-052
17 Apply grease to O-ring (2-27-4) and install onto

2-27-4
plug (2-27-3). Install plug on cover (2-27).
2-27-3
AQ22002-053
18 Press fit ball bearing (2-28).

(Reference jig No. 22) 2-27-7
Install pins (2-31, 32) onto cover (2-27-1) and then 2-31 2-28 2-32
screw in orifice (2-27-7).
NOTE: After orifice (2-27-7) is screwed in, crimp it around the
perimeter.
2-27-1
AQ22002-054
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8019-28
19 Install pin (2-29) and attach valve plate (2-30).
Apply grease to back face to keep it from falling off.
2-31 2-30 2-29
AQ22002-055
NOTE: After installing pin (2-29), crimp the following locations

using a punch: 6 (range crimped with punch
2-29 Crimp one location with punch

(center side of motor)
Pin (2-29) crimping location
AQ22002-056
20 Install cover assembly (2-27) on case (2-1), keep-

2-31 2-30 2-27 2-32
ing an eye on the locations of pins (2-31, 2-32).
NOTE: Be careful not to drop the pin or the valve plate.
NOTE: Refer to notes in section 1-13: Installing Brake Piston
for location of pin (2-32).
AQ22002-057
21 Finger tighten socket head bolt (2-33), then

tighten to specified torque. 2-33 2-33

NOTE: Parts related to the pinion shaft should be replaced as
a housing assembly (B6). Description below is for reference
purposes only.
2-33 2-33
AQ22002-058
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8019-29
2 Assembling the reduction gears
(reference)
Dimension of oil seal after press fitting: 4.25

1 Press fit oil seal (1-7).
Press fitting dimension: 4.25 (shown in the figure to 1-7
the left).
Prior to press fitting, apply grease to the mounting
site of the oil seal in the housing and the outer sur-
face of the oil seal. (Reference jig No. 23).
AQ22002-059
2 Apply grease to the inner race of tapered roller

1-2 1-6
bearing (1-6), which is installed in pinion shaft (1-2).
Amount of grease packed: 80 to 90 cm2 (approx. 66
to 75 g).
AQ22002-060
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8019-30
3 Install pinion shaft (1-2), etc. Install inner race of
1-7 1-2 1-8
tapered roller bearing (1-8).
Apply grease to lip of oil seal (1-7) before installing
pinion shaft (1-2), etc.
Before installing pinion shaft, verify that plug (1-35) is
not attached.
Installing the pinion shaft with the plug attached
increases the air pressure inside, and this may cause
damage to oil seal (1-7).
AQ22002-061
4 Install collar (1-10) while applying load 1177ON to

the inner race of tapered roller bearing (1-8). 1-1 1-8 1-9 1-10
(Reference jig No. 24)
Apply grease to O-ring (1-36) and install on plug (1-35).
Install plug in housing (1-1).
Tightening torque: 15.7±0.8 Nm (Width across flats: 5)
1-35
1-36
AQ22002-062
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8019-31
5 Install thrust washer (1-12), inner race (1-13), nee-
dle bearing (1-14) and planetary gear (1-15) onto 1-13 1-14 1-15
holder (1-11).
1-11 1-12
AQ22002-063
6 Install thrust plate (1-16) and screw (1-17) onto

holder (1-11).
Apply Loctite 242 to screw before fastening.
1-16 1-17
Tightening torque: 24.5±4.9 Nm (Width across flats)
1-11
AQ22002-064
7 Install holder (1-11), etc.

1-11
AQ22002-065
8 Install snap ring (1-26) on sun gear (1-18).
1-26 1-18
Install snap ring with side marked with R facing this way.
AQ22002-066
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8019-32
9 Install sun gear (1-18).
1-18
AQ22002-067
10 Install holder (1-19).
1-19
AQ22002-068
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8019-33
11 Install
1-23 1-21 1-25
- Inner race (1-21)
- Needle bearing (1-22)
1-20 1-22 1-24 1-37
- lanetary gear (1-23)
- Thrust plate (1-24)
- Drive gear (1-25)
- O-ring (1-37)
AQ22002-069
WARNING: When replacing any component part of

the reduction gear, measure the dimensions shown
! below and select one thrust plate (1-24) from thrust
plate kit (B5) according to the selection table.
Thrust Plate Selection Table (1-24) (Reference)

Dimension E
(Between inner rance and housing)
(Measured dimen- 5.3 to <5.8 5.8 to <6.5 6.5 to 7.0
sion)
Part No.
(plate thickness) B0841-23031 B0841-23030 B0841-23029
For thrust plate 2.8 ± 0.14 2.3 ± 0.12 1.8 ± 0.10
(1-24)
Dimension F
(Measured dimen- 7.96 to 8.74 7.98 to 8.72 8.2 to 8.9
sion)
AQ22002-070
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8019-34
3 Reassembling the entire motor assembly
1 Place the reduction gear assembly on the motor 3
assembly, verify its orientation, finger tighten socket
head bolt (3), and then tighten to the specified torque.
Tightening torque: 177±10 Nm (Width across flats: 12).
AQ22002-071
4 Installing the anti-reverse valve

2-27-1 2-38
(*anti-reverse valve specifications only)
1 Install O-ring (2-38) on cover (2-27-1).
2 Place valve assembly (2-34) on cover (2-27-1) and
fasten socket head bolt (2-39).
Tightening torque: 32.4±2.0 Nm (Width across flats: 6)
NOTE: (Refer to the Anti-reverse Valve Instruction (40 page)
for instructions for disassembling and reassembling anti-
reverse valves.) Remove deep groove ball bearing (149) from
shaft (102) by pressing on the shaft end with press.
2-34 2-39
AQ22002-072
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Copyright ©
8019-35
5 Checking Quality after Assembly
WARNING: Check the following before and after

! operation.
1 Check for air leaks in the motor section

Fill the motor case with compressed air (0.3 MPa) through the drain port, and verify that no bubbles are given off
in water for a period of two minutes.
2 Inspection before and after operation
1 Prior to starting the motor, fill the piston motor case with clean hydraulic oil.
2 Bleed air at each piping section.
3 Operate at low speed at first, and then increase the engine rotations and apply load after confirming that
there are no abnormal sounds or vibrations.
4 Check the following after operation:
1) Is there any oil leakage?
2) Are the rpm and direction of rotation correct?
3) Is the oil temperature abnormally high?
4) Is the temperature of the piston motor case abnormally high?
5) Are there any abnormal sounds or vibrations?
6) Are there any other abnormalities?
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Copyright ©
8019-36
6 Maintenance Standards
Replace each part according to the table below.
1 Motor section
Name of part Maintenance standards

1. If there are deep scratches on the sliding section, or the sliding section is rough.
2. If the gap between the cylinder block bore and the piston assembly is too large.
Piston assembly Upper limit of diameter clearance: 0.04 mm
3. If the shoe ball section is too loose.
Maximum play (distance): 0.4 mm
Thrust plate
Retainer holder
If there are deep scratches on the sliding sections, or the sliding sections are rough.
Retainer plate
Valve plate
Brake piston ( *2. parking brake specifications only)
1. If there are deep scratches on the sliding section, or the sliding section is rough.
Cylinder block
2. If there is abnormal wear or breakage on the engaging surfaces.
( *2. parking brake specifications only)
Disk 1. If there are deep scratches or peeling on the disk (abrasive material).
2. If there is abnormal wear or breakage on the engaging surfaces.
1. If there is flaking or peeling on the rolling surfaces.
Ball bearing 2. If there are impressions on the rolling surfaces.
3. If bearing rotations are abnormal (noises, irregular rotations).
Spring If there is breakage or serious deformation.
If there are scratches causing oil leakage, scratches compromising seal performance, or
O-ring
it is permanently deformed.
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Copyright ©
8019-37
2 Reduction gear section

If there is abnormal damage, wear or flaking on gear tooth surfaces.
Pinion shaft
*Always replace as a housing assembly.
Plate If there is abnormal damage or wear.
1. If there are scratches, impressions or flaking on the roller or race section.
Tapered roller bearing 2. If it does not rotate smoothly without unusual noise.
*Always replace as a housing assembly.
1. If there is damage, deformity or abnormal wear on the lips.
Oil seal
2. If lips have become hard.
Housing
Holder If there are scratches, wear or flaking on gear tooth surfaces.
Drive gear *Always replace as a housing assembly.
Sun gear
Inner race If there are scratches, wear or flaking on the rolling surfaces of the needle bearing.
Needle bearing If there are scratches, wear or flaking on the rolling surfaces of the needle bearing.
1. If there are scratches, wear or flaking on gear tooth surfaces.
Planetary gear
2. If there are scratches, wear or flaking on rolling surfaces of the needle bearing.
Thrust plate If there are scratches, wear or seizure on sliding surfaces.
3 Valve section

1. If there are deep scratches or roughness on the sliding section.
Piston (relief valve section)
2. If the clearance between the piston and the case hole is too large.
Case
Upper limit of diameter clearance: 0.04 mm
(*3. hydraulic timer specifications only)
Valve body
1. If there are deep scratches or roughness on the sliding section.
Spool
If the clearance between the spool and the valve body hole is too large.
(Hydraulic timer valve)
2. Upper limit of diameter clearance: 0.04 mm
Spring If there is breakage or serious deformation.
Plug
Check valve If there are scratches causing oil leakage, scratches compromising seal performance, or
O-Ring it is permanently deformed.
Backup ring
4 Other

If there are scratches causing oil leakage, scratches compromising seal performance, or
Other plugs and O-rings
it is permanently deformed.
ASM-17-22-002 Issued 08-2008

Copyright ©
8019-38
7 Exploded views
1-1
1-38
1-6
1-8
1-5
1-7
1-4
1-3
1-2
1-36 1-26
1-18
1-35
1-17
1-16
1-15
1-14
1-13
1-12
1-11
1-10
1-9
1-37
A
1-24
1-23
1-22
1-21
1-20
1-19
1-25
AQ22002-073
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8019-39
2-12 2-13
2-14
2-5
2-4
2-3
2-24
2-1
2-19
2-21
2-20
A 2-17
2-18
2-22
2-23
2-15
2-10
2-9
2-8
2-7
2-6 2-16 2-34
2-11 -7
-5
-8
-3 -8 2-34
-2 -6
-1 2-39
2-27
-3 2-34
-4
-5 -9 -4 2-34
-2 10 11 -10 -2
-11
-1 -3
2-46 -8
-13 -5
-6 2-38
2-27 2-34
2-29 2-45 -12
2-32 2-33
2-27
-2
2-27 -7 -5
-4
-3
-15
2-31 -16 2-27
2-28 -3
-2 -6
2-30 -18
-17 -10
-1 -9
-4 -10
-5
-8
-6 -11
-12
-7
2-27 -13
-14
AQ22002-074
ASM-17-22-002 Issued 08-2008

2 1 8019-40
-32 -24 -21 -20 -5 -1 -4 -3 -24 -25 -14 -15 -13 -12 -11 -8
2-27
ASM-17-22-002
2 -6 -1 1
-1 -2 -5 -4 -3 -6 -29
2-27-7 -7
-8
2-31
-10
8 Stracture drawing
2-45 2-46
10 -2
11
-7
2 -9
-28
-34
-38
-39 -3
-4
-11
-5
3 2-33 2-31
-30
-6
-23
-22 -9
-19 -17 -18 -16 -41 -40 -13 -14 -12 -37 -22 -21 -23 -20 -19 -16 -17 -26 -18 -35 -36 -10
2 1
2-34
-3 -2 -6 -7 -4 -8 -1 2-1
-15 -16 -8 -10 -9 -10 -7 -6 -12

-11
-3
-9 -11
-13
2-27-6
-14
-10
-2 -1 -18 -17 -4 -5
-5 -8 2-3 -12 -13 2-2 2-4
AQ22002-075
Issued 08-2008
Copyright ©
Copyright ©
8019-41
1 Reduction gear 1 2-10 Snap ring 1 2-28 Ball bearing 1
1-1 Housing 1 2-11 Pin 3 2-29 Pin 1
1-2 Pinion shaft 1 2-12 Retainer plate 1 2-30 Valve plate 1
1-3 Coller 1 2-13 Reainer holder 1 2-31 Pin 2
1-4 Plate 1 2-14 Piston assembly 9 2-32 Pin 2
1-5 Plate 1 2-16 Friction plate 1 2-33 Hex. socket bolt 4
1-6 Taper roller bearing 1 2-17 Coller 1 2-34 Valve assembly 1
1-7 Oil seal 1 2-18 O-ring 1 2-34-1 Body 1
1-8 Taper roller bearing 1 2-19 Brake piston 1 2-34-2 Check valve assembly 2
1-9 Plate 1 2-20 O-ring 1 2-34-2-1 Check valve 1
1-10 Coller 1 2-21 O-ring 1 2-34-2-2 Valve 1
1-11 Holder 1 2-22 Spring 12 2-34-2-3 Spring 1
1-12 Thrust washer 4 2-23 Spring 8 2-34-2-4 Plug 1
1-13 Inner race 4 2-24 O-ring 1 2-34-3 Spring 2
1-14 Needle bearing 4 2-27-1 Cover 1 2-34-4 Sleeve 1
1-15 Planetary gear 4 2-27-2 Poppet 2 2-34-5 Plug 2
1-16 Thrust plate 1 2-27-3 Plug 2 2-34-6 Orifice 2
1-17 Screw 4 2-27-4 O-ring 2 2-34-7 Plug 2
1-18 Sun gear 1 2-27-5 Spring 2 2-34-8 O-ring 4
1-19 Holder 1 2-27-6 Relief valve assembly 2 2-34-9 Filter 1
1-20 Thrust washer 3 2-27-6-1 Relief housing 1 2-34-10 Washer 1
1-21 Inner race 3 2-27-6-2 Poppet 1 2-34-11 Orifice 1
1-22 Needle bearing 3 2-27-6-3 Poppet seat 1 2-34-12 Plug 2
1-23 Planetary gear 3 2-27-6-4 Spring seat 1 2-34-13 O-ring 2
1-24 Thrust plate 1 2-27-6-5 Spring 1 2-38 O-ring 3
1-25 Drive gear 1 2-27-6-6 Plug 1 2-39 Hex. socket bolt 3
1-26 Snap ring 1 2-27-6-7 O-ring 1 2-40 Disk 4
1-35 Plug 1 2-27-6-8 Piston 1 2-41 Friction plate 2
1-36 O-ring 1 2-27-6-9 O-ring 1 2-45 Plug 1
1-37 O-ring 1 2-27-6-10 Backup ring 2 2-46 O-ring 1
2 Piston motor 1 2-27-6-11 Spring guide 1 3 Hex. socket bolt 4
2-1 Case 1 2-27-6-12 O-ring 1
2-3 Ball bearing 1 2-27-6-13 Set screw 1
2-4 Shaft 1 2-27-6-14 Nut 1
2-5 Thrust plate 1 2-27-6-15 O-ring 1
2-6 Cylinder block 1 2-27-6-16 Backup ring 1
2-7 Coller 1 2-27-6-17 O-ring 1
2-8 Spring 1 2-27-6-18 Backup ring 1
2-9 Coller 1 2-27-7 Orifice 1
ASM-17-22-002 Issued 08-2008

Copyright ©
8019-42
2 Anti-reverse valve
1 Troubleshooting
If any problems occur during operation, refer to the troubleshooting table shown below to determine the cause of the
problem and measures for remedying it.
Troubleshooting table

1. Malfunction in something other than Check to see if the oil pressure at the entry side of
the piston motor, valve unit or anti- the valve is correct. Then inspect/repair each
reverse valve. device.
2. Faulty seat in check valve assembly.
1) Foreign substances present. Remove foreign substances completely and repair
where damaged. Clean and reassemble.
1. Motor does not Replace if scratches are deep and leak is large.
rotate or rotates slowly.
2) Excessive torque on anti-reverse Fasten bolts to specified torque.
valve bolts.
3. Faulty sleeve
Replace if scratches are deep and leak is large.
1. Faulty seat in check valve assembly.
2) Excessive torque on anti-reverse Fasten bolts to specified torque.
valve bolts.
2. Faulty valve inside check valve
assembly.
2. Motor does not stop,
or takes a while to stop. 1) Foreign substances present. Remove foreign substances completely and repair
Replace if sliding section is scratched
2) Valve orifice is blocked with dirt or Remove dirt or dust completely. Clean and reas-
dust. semble.
3. Faulty sleeve
1. Faulty valve inside check valve
assembly.
1) Foreign substances present. Remove foreign substances completely. Clean and
reassemble. Replace if sliding section is scratched
2) Valve orifice is blocked with dirt or Remove dirt or dust completely. Clean and reas-
3. Greater than usual dust. semble.
shock at swing stops
2. Orifice is blocked with dirt or dust.
1) Orifice section of anti-reverse Remove all dirt or dust. Clean and reassemble.
valve is blocked with dirt or dust.
2) Orifice on valve unit side is Remove all dirt or dust. Clean and reassemble.
blocked with dirt or dust.
ASM-17-22-002 Issued 08-2008

Copyright ©
2 Tools used 8019-43
No Name Location used Remarks

1 Orifice (-7) Torque setting: 2.45 Nm
2 Orifice (-22) Torque setting: 4.9 Nm
Torque wrench
Plug (-5)
3 Torque setting: 61.8 Nm
Plug (-8)
4 Orifice (-7) Width across flats: 2.5 mm
5 Hexagonal bits Orifice (-22) Width across flats: 3 mm
6 Plug (-8) Width across flats: 8 mm
7 Socket for socket wrench Plug (-5) Width across flats: 22
3 Disassembling instructions
1 Precautions prior to disassembly
1 Remove mud and dirt from exterior surfaces completely. (Wash exterior surfaces thoroughly.)
2 Drain hydraulic oil from the valve unit body and the port oil passages.
3 Select a dirt-free area for work. Use caution to prevent any mud or dirt from getting on parts.
4 Handle parts carefully to avoid dropping them, or denting or scratching them by contact.
2 Disassembly
Disassemble the valve following the procedure below:
1 Removing the anti-reverse valve
Loosen socket head bolts and remove the anti-
reverse valve from the motor. (See the instruc-
tion manual for the motor.)
2 Disassembling the anti-reverse operating section
1) Remove plug (-5) and pull out spring (-3). Tools
required -5 -3
- Socket (No. 6)
- Torque wrench (No. 3)
AQ22002-076
2) Remove check valve assembly (-2).

-2
AQ22002-077
ASM-17-22-002 Issued 08-2008

Copyright ©
8019-44
3) Remove check valve assembly (-4). -4
AQ22002-078
3 Removing the orifice

-7 -8
Remove plug (-8) and orifice (-7).
Tools required:
- Hexagonal bits (No. 4, 6)
- Torque wrench (No. 1, 3)
AQ22002-079
1 Precautions prior to reassembly
1 Clean each part with clean mineral oil and dry with air.
2 Handle cleaned parts carefully to keep them from getting dirty, dented or scratched.
3 Replace all seals with new ones.
4 Fasten all tightened parts to the specified torque.
5 Apply grease to seals before installing.
6 Once filters are removed, they cannot be reused. They must be replaced with new filters.
2 Assembly
Reassemble the valve following the procedure below:
1 Installing the orifice
1) Install filter (-20) and washer (-21)
Fasten orifice (-22) to the specified torque.
Tools required:
- Hexagonal bits (No. 5)
- Torque wrench (No. 2)
NOTE: Once filters are removed, they cannot be reused.
-20
-21
-22
AQ22002-080
ASM-17-22-002 Issued 08-2008

Copyright ©
8019-45
2) Fasten orifice (-7) and plug (-8) to the specified
-7 -8
torque.
Tools required:
- Hexagonal bits (No. 4, 6)
- Torque wrench (No. 1, 3)
AQ22002-081
2 Reassembling the anti-reverse operating section

1) Install sleeve (-4). -4
AQ22002-082
2) Install check valve assembly (-2).

-2
AQ22002-083
3) Attach O-ring (-13) to plug (-5).

Insert spring (-3) into plug and fasten to specified -5 -13 -2 -3
torque.
Tightening Torque: 61.8 N·m (6.3 kgf·m)
NOTE: Handle carefully so that the spring does not fall out
during installation of the plug.
Tools required:
Socket (No. 7)
Torque wrench (No. 3)
Reassembly of the anti-reverse valve has now been com-
AQ22002-084
pleted. Refer to the instruction manual of the motor for motor
installation procedures.
ASM-17-22-002 Issued 08-2008

Copyright ©
8019-46
5 Anti-reverse valve: Exploded view
-8
-13
-22
-7
-21
-20
-1
-5
-4
-13
-2
-3
-2
-3
-13
-5
AQ22002-085
ASM-17-22-002 Issued 08-2008

Copyright ©
Section
8020
HYDRAULIC FUNCTIONS
8020

Printed in France
Copyright ©
8020-2
TABLE OF CONTENTS
HYDRAULIC FUNCTIONS.............................................................................................................................................. 3
List of functions ........................................................................................................................................................... 3
HYDRAULIC COMPONENTS LIST ................................................................................................................................ 5
CONTROL VALVE CONFIGURATION TABLE............................................................................................................... 6
Overview .................................................................................................................................................................... 6
TRAVEL CIRCUITS ....................................................................................................................................................... 8
1. Travel Low-speed Circuit ....................................................................................................................................... 8
2. Travel High Speed Circuit .................................................................................................................................... 10
3. Straight Travel Circuit (Boom-up and Travel Forwar) .......................................................................................... 12
SWING CIRCUITS ....................................................................................................................................................... 14
1. Swing Parking Circuit ........................................................................................................................................... 14
Swing Override Throttle Circuit ................................................................................................................................ 16
BUCKET CIRCUIT (CX80) ........................................................................................................................................... 18
1. Bucket Opening Circuit ........................................................................................................................................ 18
2. Bucket Closing Circuit .......................................................................................................................................... 19
BOOM CIRCUITS ........................................................................................................................................................ 20
1. Boom-up 2-speed Circuit ..................................................................................................................................... 20
2. Boom-down Load Holding Valve Circuit ............................................................................................................... 22
BOOM SWING CIRCUIT (CX80) ................................................................................................................................. 24
Boom-Swing Circuit .................................................................................................................................................. 24
BLADE CIRCUITS (CX80) ........................................................................................................................................... 26
Blade Circuits ........................................................................................................................................................... 26
ARM CIRCUITS ........................................................................................................................................................... 28
1. Arm-in / Arm-out 2-speed Circuit .......................................................................................................................... 28
BACKUP CIRCUITS ..................................................................................................................................................... 30
Breaker and Crusher Circuit (2-speed confluence crusher circuit) .......................................................................... 30
Breaker and Crusher Circuit (backup line holding valve) ......................................................................................... 32
Breaker and Crusher Circuit (breaker circuit) Ultra Small Tail Swing Hydraulic Excavator ..................................... 34
Backup Reciprocating Circuit (ultra small swing hydraulic excavator) ..................................................................... 36
Secondary Backup Reciprocating Circuit (ultra small tail swing hydraulic excavator) ............................................. 38

Copyright ©
8020-3
HYDRAULIC FUNCTIONS
List of functions
Functions Description Pages
Travel Circuits
Low-speed Low speeds can be achieved by setting the two-stage incline angle of the travel
Page 8-9
Travel circuit motor to the larger angle.
High speeds can be achieved by setting the two-stage incline angle of the travel
High-speed motor to the smaller angle.
Page 10-11
Travel circuit The load pressure for travel motor will automatically switch speeds to low when nec-
essary.
Straight-travel
Straight travel is maintained in spite of attachment/swing operations during travel. Page 12-13
circuit
Swing Circuits
1.While the swing lever is positioned at neutral, the swing parking will be activated
to fully hold the swing.
2.Shifting through the swing lever will release the mechanical brake to start the
Swing parking 3.normal swing operation. The swing parking will also stay released if attach-
Page 14-15
circuit ments such as boom, arm and bucket were operated following the swing opera-
tion.
The swing parking will be activated 5 s after the swing lever is put in neutral or the
attachment movement is stopped.
Swing override Swing pushing is obtained by the swing override throttle integrated in the control
Page 16-17
throttle circuit valve.
The valve is installed in the swing motor. It is designed to moderate shocks at
Super shockless
start-ups and stops by the two-stage relief valve that comes with a time-lag fea-
relief valve
ture.
An anti-reverse valve is installed in the swing motor.
Swingback The valve works to reduce the backlash occurrences when the swing brake is
applied.
Cushion valves work to moderate shocks.
Cushion Valve
They are equipped on the swing pilot line.
Bucket Circuits (CX80)
Bucket-opening Opens the bucket by switching the bucket spool Page 18
Bucket-closing Closes the bucket by switching the bucket spool Page 19
Boom Circuits
Boom-up Switch-over of boom (2) spools enables the internal confluence, thus achieving
Page 20-21
2-speeds circuit higher speeds.
Boom-down load 1.The boom-down movement will be enabled by releasing the load holding valve
holding valve integrated in the control valve. Page 22-23
circuit 2.The bleed-off circuit works to control high pressures. It also reduces windage..
Boom Swing Circuits (CX80)
Boom Swing Swing the boom by switching the boom swing spool Page 24-25
Blade Circuits (CX80)
Blade Operation Operating the blade by switching the blade spool Page 26-27
Arm Circuits
Arm-in/arm-out 1. Switch-over of arm (2) spools enables the internal confluence, thus achieving
Page 28-29
2-speeds circuit higher speeds.

Copyright ©
8020-4
Functions Description Pages

Backup circuits
Breaker and
Page 30-31
Crusher circuit
Backup circuit
A backup section is provided in the main control valve as a standard feature to
(small tail swing Page 34-35
accommodate special attachments such as a breaker and a crusher.
excavator)
Backup circuit
An additional backup section can be added as an option to accommodate special
(ultra small swing Page 36-37
attachments such as a slide arm
excavator)
Secondary circuit
A secondary backup section can be added as an option to accommodate special
(small tail swing Page 38-39
attachments such as a rotating fork.
excavator)
Other
Cushion valves work to moderate shocks.
Cushion Valve
They are installed on the boom pilot line.
NOTE: See the tables page 6 for the relationship between each specification and the optional equipment.

Copyright ©
8020-5
HYDRAULIC COMPONENTS LIST
NOTE: See hydraulic schematic at the end of this document.
1. HYDRAULIC RESERVOIR
2. BREATHER
4. BY-PASS VALVE
5. SCREEN FILTER
6. RETURN FILTER
10. MAIN HYDRAULIC PUMP
15. MAIN CONTROL VALVE
16. HYDRAULIC SWIVEL
21. TRAVEL MOTOR
22. SWING MOTOR
23. TRAVEL MOTOR BRAKE
27. DIPPER CYLINDER
28. BUCKET CYLINDER
29. BOOM SAFETY VALVE
30. DIPPER SAFETY VALVE
32. BOOM LOAD HOLDING VALVE
38. HBCV DOZER BLADE
42. OIL COOLER
44. OIL COOLER BY-PASS VALVE
51. ACCUMULATOR
53. BOOM & BUCKET CONTROL LEVER
54. SWING & DIPPER CONTROL LEVER
55. TRAVEL CONTROL PEDAL
60. PILOT SYSTEM MANIFOLD
72. CONTROL PEDAL (OPTIONAL)
75. FLOW RE-INJECTION BLOCK (OPTIONAL)
76. 3-WAY SELECTOR (OPTIONAL)
78. RETURN FILTER (OPTIONAL)
79. CONTROL SHUTTLE BLOCK (OPTIONAL)
82. PILOT CIRCUIT FILTER
83. SHUT-OFF VALVE (OPTIONAL)
85. HAND/FOOT CONTROL PILOT FILTER
86. PILOT FILTER BY-PASS VALVE
93. PILOT CIRCUIT SUPPLY MANIFOLD
94. PILOT CIRCUIT RETURN MANIFOLD
95. BOOM/DIPPER PILOT CIRCUIT MANIFOLD
96. SWING PILOT CIRCUIT CUSHION VALVE
97. HYDRAULIC BREAKER FOOT CONTROL
98. OFFSET BACKHOE FOOT CONTROL
99. DOZER BLADE HAND CONTROL
100. DOZER BLADE CYLINDER
101. OFFSET BACKHOE CYLINDER
102. 3 ELECTROVALVE BLOCK
103. BOOM CYLINDER
104. BOOM PILOT CIRCUIT CUSHION VALVE
114. BOOM FOOT DIRECTION CONTROL PEDAL
115. BOOM FOOT POSITIONING PILOT SHOCK ABSORBER
116. BOOM FOOT STEERING CYLINDER
B22. SWING PILOT PRESSURE SWITCH
B26. UPPER PILOT PRESSURE SWITCH (YELLOW BAND)
B27. TRAVEL PILOT PRESSURE SWITCH
B45. OVERLOAD INDICATOR PRESSURE SWITCH
Y2. PILOT PRESSURE SOLENOID VALVE (BLUE BAND)
Y3. SWING BRAKE SOLENOID VALVE (PINK BAND)
Y4. 2 STAGE TRAVEL SOLENOID VALVE (RED BAND)
Y9. CRUSHER/BREAKER OPTION TWO FLOW SOLENOID
VALVE
Y25. OPTION 2 SOLENOID VALVE (RED BAND)
Y26. OPTION 2 SOLENOID VALVE (BLUE BAND)

Copyright ©
8020-6
CONTROL VALVE CONFIGURATION TABLE
Overview
Control valves are configured as follows according to model and specification.
OFFSET BOOM
MONO BOOM MONO BOOM
with BLADE (CX75SR)
with BLADE (CX75SR) with BLADE (CX80)
(Specification for Europe)
Blade Blade
Blade
PT PT
Standard Boom Swing PT
Buckup
Offset
Buckup
Secondary Secondary
backup backup
Blade
Blade Blade
PT
PT PT
Optional Buckup
Boom Swing
Option Offset
Buckup

Copyright ©
8020-7
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Copyright ©
8020-8
Travel Circuits
1. Travel Low-speed Circuit
The travel patterns are normal. Turning the key OFF once and switching it back ON during high-speed travel will
always set the speed back to low.
The oil discharged from A1 enters port P1 of the control valve entry, while the oil from A2 enters into port P2 of the
control valve entry. Each flow goes into the travel motor through the switch-over of the left and right travel spool. By
these flows, the machine travels forward and backward. The 2-speed travel solenoid valve will be turned OFF and the
hydraulic oil in port P of the travel motor will be connected to the pilot tank line.
21. TRAVEL MOTOR
51. ACCUMULATOR
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-9
Travel Low-speed Circuit
21 21
16
15
55
51
INTERNAL CHANGE-
OVER SWITCH IN PANEL
60
MONITOR 102
SWITCH PANEL
10

Copyright ©
8020-10
2. Travel High Speed Circuit
With High-Speed Travel, high speeds can be achieved by setting the two-stage incline angle of the travel motor to the
smaller angle.
The circuit has a travel motor, which 5 switches over to lower speeds by utilizing load pressure on the travel motor
while traveling at high speeds.
The oil discharged from A1 enters port P1 of the control valve entry, while the oil from A2 enters port P2 of the control
valve entry. Each flow goes into the travel motor through the switch-over of the left and right travel spool. By these
flows, the machine travels forward and backward. To obtain high speeds, electronic signals are sent to the switch
panel through the travel change-over switch. Then electronic signals are sent from the switch panel to the solenoid
valve for 2-speed travel in the assembly valves to switch the assembly valves. This enables the original pilot pressure
(4.2 MPa) {609 psi} from port C1 of the assembly valves to be connected with port P of the left and right travel motors
through the rotating joint. The original pressure (4.2 MPa) {609 psi} that entered port P of the left and right travel
motors positions the incline angle of the travel motor to the smaller angle, enabling faster speeds.
21. TRAVEL MOTOR
51. ACCUMULATOR
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-11
Travel High Speed Circuit
21
16
21
15
55
51
INTERNAL CHANGE-
OVER SWITCH IN PANEL
102
60
MONITOR
SWITCH PANEL
10

Copyright ©
8020-12
3. Straight Travel Circuit (Boom-up and Travel Forwar)
The following applies when travel and boom-up operations are conducted at the same time.
The hydraulic oil that entered the pilot pump from PP, which was connected to the tank via travel spool, becomes
blocked off by the switch-over of travel spool. Also, the switch-over of the spool to the boom blocks off the branch
channels from PP via all spools for attachments (boom, arm, bucket, swing, including offset if equipped with this),
which were connected to the tank. Therefore, the hydraulic oil from the pilot pump entering through PP cannot flow
any further, and the circuit pressure rises up to the original pressure of (4.2 MPa) {609 psi} . This original pressure
acts on the pilot chamber of the straight travel valve and switches over the straight travel valve. The switch-over of the
straight travel valve enables P1 to achieve travel and P2 to drive attachments. The left and the right pressures are
equal for travel because one pump drives those motors, thus enabling straight travel. In addition, extra hydraulic oil
from P2 is supplied to the travel side through a check with travel confluence throttle to keep the speed loss to a mini-
mum.
This also applies when travel and the upper actuators other than boom are operated at the same time.
1 HYDRAULIC RESERVOIR
21. TRAVEL MOTOR
51. ACCUMULATOR
103. BOOM CYLINDER
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-13
Straight Travel Circuit (Boom-up and Travel Forward)
21
16
21
1
103
55
15
51
104
INTERNAL CHANGE-
OVER SWITCH IN 60
PANEL 102
MONITOR
SWITCH PANEL 10

Copyright ©
8020-14
Swing Circuits
1. Swing Parking Circuit
Once the engine is turned on and the swing lever is positioned in neutral, the swing brake solenoid valve will be turned
ON (SH75: 12V, SH135: 24 V) and the swing parking brake will be activated.
When the swing pressure switch is turned ON by the shifting of the lever, the output to the swing brake solenoid valve
from the switch panel will be turned OFF. This releases the swing parking brake and enables the swing operation. In
another case, if an attachment such as an arm is moved within 5 s after the swing lever was returned to neutral, a lat-
eral force will be generated for the swing movement. In order to prevent the dragging caused by braking, the parking
bake will also be released.
Once the signals from attachment pressure switch (2.0 MPa {290 psi} : ON, 1.5 MPa {218 psi} : OFF) are sent to the
switch panel and the output to swing brake solenoid valve from switch panel is turned OFF, the swing parking brake
will be released.
5 s after the swing pressure switch and the attachment pressure switch are turned OFF, the solenoid valve will be
turned ON, enabling the swing parking brake to operate.
Swing Attachment Swing motor

Key Swing brake
pressure pressure mechanical Remarks
switch solenoid valve
switch switch brake
OFF OFF OFF OFF ON* Key Switch OFF
ON OFF OFF ON ON Key Switch ON
ON OFF ON ON ON Attachment operations
Independent operation of
ON ON ON OFF OFF
swing
Attachment + swing opera-
ON ON ON OFF OFF
tion
ON
ON OFF OFF ON Attachment in neutral
(in 5 s)
Notes:
• The attachment pressure switch will be ON when the spool is switched over for either boom, arm,
bucket or swing (including offset if equipped with this) and activates the original pilot pressure.
• When an asterisk (*) accompanies the “swing motor mechanical brake ON” statement, it indicates
that the swing parking release pressure automatically returns to the tank pressure because all else is
OFF, which in turn activates the mechanical brake.
22. SWING MOTOR
51. ACCUMULATOR
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-15
Swing Parking Circuit (independent operation of swing)
22
15
MONITOR
SWITCH PANEL
51
102 60
96
SWING BRAKE
SOLENOID VALVE
10

Copyright ©
8020-16
Swing Override Throttle Circuit
Providing an override throttle on the parallel circuit enables the pressure to rise at combined operation of arm and
swing, thus securing the swing force for press digging operation.
22. SWING MOTOR
27. DIPPER CYLINDER
51. ACCUMULATOR
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-17
Swing Override Throttle Circuit
22
27
1
SWING
OVERRIDE
FIXED
THROTTLE
15
000
51
102 60
96
SWING BRAKE
SOLENOID VALVE
10

Copyright ©
8020-18
Bucket Circuit (CX80)
1. Bucket Opening Circuit
When the bucket control lever is moved to the opening side, the pilot pressured oil is supplied to Port pb7 of the con-
trol valve.
The bucket spool will be in a preparation state.
The hydraulic pressured oil delivered from the hydraulic pump A1 is supplied to a bucket spool through a center
bypass oil circuit also it is supplied to the rod side of a bucket cylinder.
Accordingly, the bucket opens by contraction of the rod of the bucket cylinder.
The returned oil from the bucket cylinder bottom runs into the tank oil circuit through a bucket spool.
28. BUCKET CYLINDER
51. ACCUMULATOR
53. BOOM & BUCKET CONTROL LEVER
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-19
2. Bucket Closing Circuit
28
102
51
15
53
10

Copyright ©
8020-20
Boom Circuits
1. Boom-up 2-speed Circuit
The oil discharged from A1 is supplied to the boom (2) spool through the parallel oil passage via the right travel spool
or the straight travel valve, and merges at the downstream of the boom (1) spool.
The oil discharged from A2 merges with the oil discharged from boom (2) by way of parallel oil passage and the boom
(1) spool, and flows into the bottom side of the boom cylinder via holding valve.
51. ACCUMULATOR
103. BOOM CYLINDER
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-21
Boom-up 2-speed Circuit
103
15
104
51
60
102
10

Copyright ©
8020-22
2. Boom-down Load Holding Valve Circuit
The boom-down pilot pressure goes into port Pb8 of the control valve and the main control valve spool moves to the
left.
Also, the pilot pressure enters Port Pc2 and moves the load holding valve spool to the left. Through this movement,
the oil in the spring chamber of the load holding valve check passes the load holding valve spool, creating a connec-
tion to the tank. As a result, the pressure on the spring chamber decreases and the load holding valve check will be
released.
The pressurized oil on the boom cylinder bottom side returns to the tank line as the load holding valve opens. As a
result, the boom cylinder rod retracts and the boom is lowered.
Also, the bleed-off circuit controls high pressures, which in turn reduces windage.
32. BOOM LOAD HOLDING VALVE
51. ACCUMULATOR
60. BOOM & DIPPER CONTROL SHOCK ABSORBER
103. BOOM CYLINDER
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-23
Boom-down Load Holding Valve Circuit
TO TANK LINE LOAD HOLDING

VALVE SPOOL
32
BOOM-DOWN PILOT LINE
BOOM CYLINDER
BOTTOM SIDE DETAIL
BLEED-OFF
CIRCUIT
1 103
15
104
51
102 60
10

Copyright ©
8020-24
Boom Swing Circuit (CX80)
Boom-Swing Circuit
As the boom swing remote control valve is switched over, the pilot oil enters Port prb1 or pra1.
The oil at P2 from the hydraulic pump then flows into the boom swing cylinder via Port BR1 or AR1 through the boom
swing valve. The returning oil flows into the tank through Port AR1 or BR1.
51. ACCUMULATOR
114. BOOM FOOT DIRECTION CONTROL PEDAL
115. BOOM FOOT POSITIONING PILOT SHOCK ABSORBER
116. BOOM FOOT STEERING CYLINDER
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-25
Boom-Swing Circuit
116
103
1
115
114
15
104
51
102
60 15
102
10
51
10

Copyright ©
8020-26
Blade Circuits (CX80)
Blade Circuits
As the blade remote control valve is switched over, the pilot oil enters Port prb2 or pra2.
The oil at PR5 from the gear pump then flows into the blade cylinder through the Parallel passage.
The returning oil flows into the tank through Port AR2 or BR2.
51. ACCUMULATOR
100. DOZER BLADE CYLINDER
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-27
Blade Circuit
100
103
15
104
51
99
60
102
10 15
102 51
10

Copyright ©
8020-28
Arm Circuits
1. Arm-in / Arm-out 2-speed Circuit
The oil discharged from A1 is supplied to the arm (1) spool via parallel oil passage through central bypass oil passage
or straight travel spool.
TheArm-in / Arm-out 2-speed circuit has a configuration where the discharged oil from A2 is supplied to the arm (2)
spool through the central bypass oil passage or parallel oil passage to merge at the upstream of the arm (1) spool.
The returning oil from the cylinder will be allowed to merge with the oil on the supply side through self regeneration
only when the arm is in (when the pressure of oil on the supply side becomes lower than the pressure of oil returning).
27. DIPPER CYLINDER
51. ACCUMULATOR
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-29
Arm-in / Arm-out 2-speed Circuit
Arm-In Self
Regeneration
27
15
51
102 60
10
NOTE: INDICATES THAT AN ARM-OUT OPERATION IS TAKING PLACE

Copyright ©
8020-30
Backup Circuits
Breaker and Crusher Circuit (2-speed confluence crusher circuit)
The solenoid valve will be turned ON by turning the switch inside the cab toward the crusher side.
By stepping on the backup pedal, the pilot pressure from the remote control valve passes through the solenoid valve
via shuttle valve and enters Port P of the holding valve and Port Pb2 of the backup (2) spool.
The backup (2) spool moves to the right and shuts off the central bypass.
The pilot pressure from the solenoid valve acts on Port pcc of the confluence spool and moves the spool to the left to
shut off the central bypass.
The oil in Port P2 thus flows into the holding valve through Port P3 of the control valve.
The holding valve acts on the holding valve release spool by communicating the pilot pressure from the solenoid valve
to Port P. The valve thus returns the oil in the spring chamber to the tank and releases the check in the holding valve.
The oil at Port P3 of the control valve enters Port P4, which is upstream of the control valve backup spool, through the
holding valve check. It then merges with the oil from P1.
51. ACCUMULATOR
75. HAMMER/CRUSHER SELECTOR
Y9. CRUSHER/BREAKER OPTION TWO FLOW SOLENOID VALVE
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-31
Breaker and Crusher Circuit (2-speed confluence crusher circuit)
72
85
Y9
79
75
SWITCH
LOCKER
15
51
76 60
102
78
10

Copyright ©
8020-32
Breaker and Crusher Circuit (backup line holding valve)
Hold-Release Spool
Holding Valve Check

Copyright ©
8020-33
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Copyright ©
8020-34
Breaker and Crusher Circuit (breaker circuit) Ultra Small Tail Swing Hydraulic Excavator
By turning the switch in the cab to the breaker side and stepping on the pedal, the pilot pressure, which entered Pb2
in the control valve, switches over to the backup spool. As a result, the pressurized oil from A1 will be supplied to the
breaker through the direction valve.
51. ACCUMULATOR
Y9. CRUSHER/BREAKER OPTION TWO FLOW SOLENOID VALVE
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-35
Breaker and Crusher Circuit (breaker circuit) Ultra Small Tail Swing Hydraulic Excavator
72
1 85
79
Y9
15
51
76 60
102
78
10

Copyright ©
8020-36
Backup Reciprocating Circuit (ultra small swing hydraulic excavator)
As the back up remote control valve is switched over, the pilot oil enters Port pra1 or Port prb1. The oil at P2 then
flows into the backup valve AR1 or Port BR1 through the parallel passage.
The returning oil flows into the tank through Port BR1 or Port AR1.
51. ACCUMULATOR
98. OFFSET BACKHOE FOOT CONTROL
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-37
Backup Reciprocating Circuit (ultra small swing hydraulic excavator)
98
85
15
83
51
60
102
10

Copyright ©
8020-38
Secondary Backup Reciprocating Circuit (ultra small tail swing hydraulic excavator)
As the backup remote control valve is switched over, the pilot oil enters Port prb3 or Port pra3. The oil at PR5 from the
gear pump then flows into the backup valve BR3 or Port AR3 through the parallel passage. The returning oil flows into
the tank through Port AR3 or Port BR3.
Drain lines are pre-installed in the secondary backup section to accommodate special attachments such as a rotating
fork.
51. ACCUMULATOR
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-39
Secondary Backup Reciprocating Circuit (ultra small tail swing hydraulic excavator)
99
85
15
83
51
102
60
10

Copyright ©
8020-40
NOTES
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Copyright ©
Section
8030
HYDRAULIC COMPONENT FUNCTIONS
8030

Printed in France
Copyright ©
8030-2
TABLE OF CONTENTS
HYDRAULIC PUMP ................................................................................................................................................. 3
Configuration and Principle of Operation ......................................................................................................... 3
Flow Control..................................................................................................................................................... 5
CONTROL VALVE ................................................................................................................................................... 7
Operation with All Spools in Neutral ................................................................................................................ 7
Independent Operation .................................................................................................................................... 9
Combined Operations .................................................................................................................................... 19
Relief Valve.................................................................................................................................................... 20
SWING UNIT .......................................................................................................................................................... 23
Functional and Operational Description......................................................................................................... 23
Overview ........................................................................................................................................................ 31
TRAVEL UNIT (CX75SR)....................................................................................................................................... 35
External Dimensional Drawing....................................................................................................................... 35
Basic Structure and Drawings........................................................................................................................ 36
Operational Description ................................................................................................................................. 39
TRAVEL UNIT (CX80)............................................................................................................................................ 51
External Dimensional Drawing....................................................................................................................... 51
Basic Structure and Drawings........................................................................................................................ 52
Operational Description ................................................................................................................................. 55

Copyright ©
8030-3
HYDRAULIC PUMP
Configuration and Principle of Operation
The pump consists of a main pump (1), a blade pump (2) and a pilot pump (3), which are connected in
series.
The main pump is a swash-plate type variable displacement piston pump, which delivers two equal vol-
umes using one cylinder block. The cylinder block has ten pistons inside. Those pistons divert and alter-
nately deliver the oil to Delivery Ports (5 and 6).
Each group of 5 pistons works as one pump.

Copyright ©
8030-4
When the drive shaft (10), which is connected to the engine, rotates, the cylinder block (11) connected
to the shaft via spline and the piston section (12) rotates.
Since the piston section (12) is pushed towards the swash plate (14) via retainer (13), it rotates on the
inclined plane of the swash plate (14) and reciprocates within the cylinder block (11) according to the
incline angle of the swash plate (14).
The piston (12) draws in oil while going down the inclined plane of the swash plate (14) and discharges
oil while coming up.
The oil from the tank is taken from the inlet port (9), which is shared by all the pumps, and is divided
inside the cover (4) into the main pump (1), the blade pump (2) and the pilot pump (3). The oil to the
main pump (1) passes the control plate (15) and is drawn in by the piston (12) in cylinder block (11). The
oil delivered from the piston (12) is alternately divided into the passages (20, 21) in the control plate
(15), and will be discharged from the delivery ports (5, 6) of each group of 5 pistons.
The discharge volume of the pump fluctuates according to the changes in piston stroke in conjunction
with the changes in the incline angle of the swash plate (14). The operation of the swash plate (14) is
regulated by the discharge pressure in the main pump and the discharge pressure in the blade pump.
(See below for details).

Copyright ©
8030-5
Flow Control
1) Constant controlling of simultaneous output
The pump output will be maintained at a certain level by increasing / decreasing the flow
according to the pump discharge pressure.
The force generated by the discharge pressure acts on the swash plate (14) via the piston
section (12).
The force of the discharge pressure generates a moment (return moment) to decrease the
incline angle by using the difference between the center of piston and the center of incline
rotation in swash plate.
The return moment varies according to the discharge pressure and the incline angle.

Copyright ©
8030-6
Before the incline
When the discharge pressure is low, the return moment is also small and the spring (16) is not
bent.
Thus the swash plate (14) is at a maximum incline angle to maintain maximum discharge.
After the incline
When the discharge pressure increases, the return moment also increases. As a result the
spring (16) is bent and the incline angle of the swash plate (14) will move to the position where
the return moment and the spring force become balanced, reducing the discharge volume.
As the discharge volume further increases, the incline angle decreases accordingly. The spring
(17) will also start to bend to keep the volume decreasing.
2) Power-down control by discharge pressure of blade pump (blade shift)
An over-torque condition of the input shaft due to the simultaneous high-pressure operations of
the main pump and the blade pump is prevented by changing the output characteristics of the
main pump through the discharge pressure of the blade pump.
The discharge pressure on the blade pump acts on the shift piston (18) via passage (19).
When the discharge pressure on the blade pump increases, the force on the shift piston
increases and the moment counteracting the springs (16, 17) is generated on the swash plate
(14).
The moment acting on the swash plate (14) increases because extra moment generated by the
shift piston force is added to the return moment which is generated by the main pump discharge
pressure.
Therefore, when the discharge pressure on the blade pump is high, the swash plate (14) starts
its incline even if the discharge pressure on the main pump is low.
Thus, an over-torque on the input shaft will not take place because the main pump output
becomes low when the pressure on the blade pump is high.

Copyright ©
8030-7
CONTROL VALVE
Operation with All Spools in Neutral
1) Main passage
The oil supplied from Port P1 passes the neutral passage (2) via passage (1) and flows through
Travel (Right), Backup, Boom 2 and Arm 1 sequentially. The oil passed through Arm 1 flows into
the tank passage through passage (3) to be discharged into the tank ports (T1, T2).
Also, the oil supplied from Port P1 through passage (4) is directed into the parallel passage (7)
through passage (6) by way of the bridge (5) and travel straight valve. Then, Backup, Swing,
Boom 2, and Arm 1 sections will be communicated via each check valve and the flow will be
stopped by the spools in each section. However, because the parallel passage (7) is connected
with the neutral passage (2) via passage (8) and check valve, the oil will flow into the parallel
passage (7) from Port P1 without passing the travel straight valve when Travel (Right) is not
taking place.
In the same manner, the oil supplied from Port P2 flows into the neutral passage (10) via
passage (9). It then returns to the main body via the inlet section through passage (11), and
flows into the tank passage through neutral cut spool via passage (12).
Also, the oil supplied from Port P2 is communicated with Travel (Left), Bucket, Boom 1 and Arm
2 sections via the parallel passage (13) and check valve. The flow is stopped by the spools in
each section.
The oil supplied from Port PR5 (the third pump) flows in the neutral passage (27) through the
inlet section passage (26). The oil passing the blade section (add-on) flows into tank 1 passage
through passage (28) via the outlet section.
Also, the oil supplied from Port PR5 is communicated with the blade section via parallel passage
(29) and check valve, and the flow is stopped by the spool.
2) Signal passage
Front control signals
The oil from the hydraulic power source for signals, which enters Port PP, is directed into Port PA
(Front signal) through throttle (13). It also flows into the 5-way valve side of the front control
section through passage (14). It then passes passage (15), inlet section, passage (16) and the
4-way valve side of the front section, and will be discharged from passage (17) into Port DR
(Drain Port).
Travel control signals
The oil from the hydraulic power source for signals, which enters Port PP, is directed into Port
PT (Travel signal) through throttle (18). It also will be discharged from passage (17) into Port DR
(Drain Port) by way of passage (20) and Travel left spool.
Travel straight valve switch-over signals
The oil from the hydraulic power source for signals which enters Port PP, flows from passage
(22) into the travel right spool passing throttles (13, 21) to be discharged from the neck part of
the spool into the tank passage. At the same time, it flows into the travel left spool through
passage (23), and will be discharged from the neck part of the spool into tank passage. At this
time, the oil which flows into passage (23), will be directed through the annular passage (24)
into the pressure chamber (25) for switching over travel straight valve.

8030-8
BLADE
ARM 1
ARM 2
BOOM 1
BOOM 2
SWING
BUCKET
BACKUP
TRAVEL
(LEFT)
TRAVEL
(RIGHT) TRAVEL
(STRAIGHT
Issued 03-08
Copyright ©
Copyright ©
8030-9
Independent Operation
1) Travel spool switch-over (Figure 1)
Because switching the travel right spool by adding pressure to Port Pa1 (Pb1) closes the neutral
passage (A) and shuts off the downstream flow, the oil supplied from Port P1 will pass the neck
of the travel right spool through neutral passage (A) and will flow into cylinder Port A1 (B1).
The returning oil from cylinder Port B1 (A1) passes the neck of the travel right spool and flows
into the tank passage.
In the same manner, because switching the travel left spool by adding pressure to Port Pa6
(Pb6) closes neutral passage (B) and shuts off the downstream flow, the oil supplied from Port
P2 flows into cylinder Port A6 (B6) by way of neutral passage (B), passage (C) and the neck of
the travel left spool.
The returning oil from cylinder Port B6 (A6) passes the neck of the travel left spool and flows
into the tank passage.
TRAVEL
(RIGHT)
TRAVEL
(LEFT)
2) Backup spool switch-over (Figure 2)

If this section is to be used, first remove the stopper plugs on the cylinder port and on the pilot
cap. Additionally, replace the shut off valve with an overload release valve and remove the
stopper plug on Port P4 if necessary. Because switching the backup spool by adding pressure to
Port Pa2 (Pb2) closes neutral passage (A) and shuts off the downstream flow, the oil supplied
from Port P1 pushes up the check valve (1) through parallel passage (B) and flows into cylinder
Port A2 (B2) by way of passage (C) and the neck of backup spool. The returning oil from
cylinder Port B2 (A2) passes the neck of the backup spool and flows into the tank passage. This
section can also be merged with an external source through Port P4.

Copyright ©
8030-10
3) Swing spool switch-over (Figure 3)

Because switching the swing spool by adding pressure to Port Pa3 (Pb3) closes neutral passage
(A) and shuts off the downstream flow, the oil supplied from Port P1 pushes up the check valve
(1) through parallel passage (B) and flows into cylinder Port A3 (B3) by way of passage (C) and
the neck of the swing spool.
The returning oil from cylinder Port B3 (A3) passes the neck of the swing spool and flows into
the tank passage.
4) Bucket spool switch-over (Figure 3)
Because switching the bucket spool by adding pressure to Port Pa7 (Pb7) closes neutral
passage (D) and shuts off the downstream flow, the oil supplied from Port P2 pushes up the
check valve (2) through parallel passage (E) and flows into cylinder Port A7 (B7) by way of
passage (F) and the neck of the bucket spool. The returning oil from cylinder Port B7 (A7)
passes the neck of the bucket spool and flows into the tank passage.

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5) Boom spool switch-over
1] Neutral Position (Figure 4)
The valve has an anti-drift valve installed on the cylinder bottom side of Boom 1.
In the neutral position, the poppet (1) is firmly seated by the pressure on Port A7, which was
directed to the spring chamber (C) through passage (A), poppet (2) and passage (B).
2] Boom-up (2-pump confluence) (Figure 5)
Because switching the boom 1 spool by adding pressure to Port Pa8 closes neutral passage (A)
and shuts off the downstream flow, the oil supplied from Port P2 pushes up the check valve (1)
through parallel passage (B), passes passage (C) and the neck of the boom 1 spool, then
pushes open the poppet (2) in the anti-drift valve and flows into cylinder Port A7. Because switch-
ing the boom 2 spool and adding pressure to Port Pa4 at the same time will close neutral pas-
sage (D) and shut off the downstream flow, the oil supplied from Port P1 pushes up the check
valve (3) through parallel passage (E) and flows into cylinder port A7, by way of passage (F),
neck of the boom 2 spool and passage (G). The returning oil from cylinder Port B7 passes the
neck of the boom 1 spool and flows into the tank.
3] Boom-down (Figure 6)
Because switching the boom 1 spool by adding pressure to Port Pb8 closes neutral passage (A)
and shuts of the downstream flow, the oil supplied from Port P2 pushes up the check valve (1)
through parallel passage (B) and flows into cylinder Port B7 by way of passage (C) and the neck
of the boom 1 spool. Switching the boom 1 spool and adding pressure to Port pc2 at the same
time in order to switch poppet (3) in the anti-drift valve will reduce the pressure in spring chamber
(D) to open poppet (2). The returning oil from cylinder Port A7 will pass the neck of the boom 1
spool and flow into the tank passage.

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6) Arm spool switch-over
1] Dump (2-pump confluence) (Figure 7)
Switching the arm 1 spool by adding pressure to Port Pa5 closes the neutral passage (A). The oil
supplied from Port P1 pushes up the tandem check valve (1) through neutral passage (A) and
flows into cylinder Port A5 by way of passage (C) and the neck of the arm 1 spool. At the same
time, part of the oil supplied from Port P1 will flows into cylinder Port A5 by way of parallel pas-
sage (B), annular restriction (D), parallel check valve (2) and passage (C). Switching the arm 1
spool and adding pressure to Port Pa9 at the same time in order to switch the arm 2 spool will
close the neutral passage (E). The oil supplied from Port P2 pushes up the tandem check valve
(3) through neutral passage (E) and flows into cylinder Port A5 by way of passage (G), neck of
the arm 2 spool and passage (I). At the same time, part of the oil supplied from Port P2 will flow
into cylinder Port A5 by way of parallel passage (F), annular restriction (H), parallel check valve
(4), passage (G) and passage (I).
The returning oil from the cylinder Port B5 flows into the tank passage through the neck of the
arm 1 spool and also flows into the tank passage by way of passage (J) and the neck of the arm
2 spool.
The annular restriction (D) works as a primary restriction for a simultaneous operation with swing
movements. The annular restriction (H) works as a primary restriction for a simultaneous opera-
tion with boom.
2] Crowd (2-pump confluence) (Figure 8)
Switching the arm 1 spool by adding pressure to Port Pb5 will close the neutral passage (A), and
the oil supplied from Port P1 pushes up the tandem check valve (1) through neutral passage (A)
and flows into cylinder Port B5 by way of passage (C) and the neck of arm 1 spool. At the same
time, part of the oil supplied from Port P1 flows into cylinder Port B5 by way of parallel passage
(B), annular restriction (D), parallel check valve (2) and passage (C).
Switching the arm 1 spool and adding pressure to Port Pb9 at the same time in order to switch
the arm 2 spool will close the neutral passage (E). The oil supplied from Port P2 pushes up the
tandem check valve (3) through neutral passage (E) flows into cylinder Port A5 by way of pas-
sage (G), neck of the arm 2 spool and passage (I). At the same time, part of the oil supplied from
Port P2 flows into cylinder Port B5 by way of parallel passage (F), annular restriction (H), parallel
check valve (4), passage (G) and passage (I).
The returning oil from cylinder Port B5 flows into the tank by way of the neck of the arm 1 spool,
passage (K) and annular restriction (L). At this time, part of the returning oil pushes the check
valve (5) with restriction and flows into passage (C) via passage (M), increasing the supply vol-
ume fed to cylinder Port B5 (Regenerative circuit).

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7) Blade spool switch-over (Add-on) (Figure 9)
Because switching the blade spool by adding pressure to Port Pra2 (Prb2) closes the neutral
passage (A) and shuts off the downstream flow, the oil supplied from Port PR5 pushes up the
check valve (1) through parallel passage (B) and flows into cylinder Port AR2 (BR2) by way of
passage (C) and neck of the blade spool.
The returning oil from cylinder Port BR2 (AR2) passes the neck of the blade spool and flows into
the tank passage.
8) Boom Swing spool switch over (Add-on) (Figure 9A)

Because switching the boom swing spool by adding pressure to Port Pra1 (Prb1) closes the
neutral passage (A) and shuts off the downstream flow, the oil supplied from Port PR5 pushes
up the check valve (1) through parallel passage (B) and flows into cylinder Port AR1 (BR1) by
way of passage (C) and neck of the boom swing spool.
The returning oil from cylinder Port BR1 (AR1) passes the neck of the boom swing spool and
flows into the tank passage.
9) Relief valve
1] Main relief valve (Figure 10)
The oil in Port P1 is directly connected with the inlet passage (A) of the main relief valve via com-
mon check valve (1), while the oil in Port P2 is directly connected with the inlet passage (A) of the
main relief valve via common check valve (2).
The main relief valve prevents the maximum pressure in pumps P1 and P2 from exceeding their
programmed values. (The operational description for main relief valve is provided separately).
2] Overload relief valve
In each cylinder port of Boom 1, Arm 1, Bucket and Offset, an overload relief valve is installed to
prevent abnormal boosts of pressure on the actuator due to external forces.
The maximum pressure will also be regulated if the programmed pressure is lower than the pres-
sure on main relief valve.
The overload relief valve also prevents cavitation by drawing oil in from the tank when the pres-
sure on cylinder port becomes negative.

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(The operational description for the overload relief valve is provided separately).
10)Anti-drift valve (Boom section)

The anti-drift valve is installed on the boom bottom side of cylinder port A7 to prevent the natural
drop of boom cylinder.
1] Neutral Status (Figure 11)
The pressure on cylinder Port A7 passes the hollow cavity in poppet (1) via passage (A) and will
be directed to the spring chamber (C) through passage (B).
The force of the spring and the pressure acting on the area differences in the poppet (2) areas
work to firmly seat poppets (1, 2).
2] Up (Figure 12)
The oil supplied from the pump pushes open poppet (1) and flows out from cylinder Port A7.
3] Down (Figure 13)
Switching poppet (1) by adding pressure to Port Pc2 will direct the oil in spring chamber (C) to
the drain Port dr2 by way of passage (B), the hollow cavities in poppet (1) and spool (3). This
opens poppet (2) and the returning oil from cylinder Port A7 flows into the tank passage through
the boom 1 spool.
The function can also be added to the cylinder port on the arm rod side.

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Combined Operations
1) Additional operation with travel (Figure 14)
Operating the frontal control (in any section other than Travel) during traveling straight forward/
backward or during a spin turn (simultaneous operation of travel right/left), or traveling straight
forward/backward or spin-turning during the operation of the frontal control will switch over the
travel straight valve (1) due to the oil from the hydraulic power source for signals, which entered
from Port PP. Therefore, the oil supplied from Port P2 (shown by arrows) is shut off from the
neutral passage (C) on the 4-way valve side and will flow into parallel passage (D) on the 4-way
valve side. It will also flow into parallel passage (B) on the 5-way valve side by way of the neck of
travel straight valve and passage (E). Thus, the actuator for the frontal control is operated by the
oil supplied from Port P2.
At this time, the oil supplied from Port P1 (shown by arrows) is shut off from parallel passage (B)
on the 5-way valve side and flows into cylinder Ports (A1, B1) in Travel Right Section through
neutral passage (A) on the 5-way valve side. It also flows into the neutral passage (C) on the 4-
way valve side past passage (F) and the neck of travel straight valve, then flows into cylinder
Ports (A6, B6) in the Travel Left Section through the hollow cavity in sleeve. Thus, travel is
operated by the oil supplied from Port P1 and straight travel is maintained.
Part of the oil supplied from Port P2 passes annular restriction (G), pushes up poppet (3) to be
supplied to the travel controls. This helps eliminate the decelerating shocks at the time of travel
straight valve (1) switch-over.

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Relief Valve
1) Main relief valve
1] Operation of main relief valve
1- The relief valve is incorporated between the neutral passage “HP” and the tank passage
“LP”. The oil will flow through the throttle of main poppet (1) to fill in the internal cavity (C).
Also, the sleeve (2) and the main poppet (1) act on different areas “A, B” to ensure secure
seating.
2- When the pressure on neutral passage “HP” reaches the programmed pilot spring force,
the pilot poppet (3) opens. The oil flows around the peripheral of pilot poppet (3) and is
directed into tank passage “LP” by way of drilled hole (D) and annular space (E).
3- As the pilot poppet (3) opens, the pressure in the internal space (C) decreases. As the
main poppet (1) opens, the oil in “HP” flows directly into passage “LP”.

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2) Overload relief valve
1] Relief valve operation
1- The relief valve is incorporated between the cylinder Port “HP” and the low-pressure
passage “LP”. The oil passes the hole on piston (C) and fills the internal space (G). It then
acts on different areas <A> and <B> to make sleeve (K) and main poppet (D) securely
seated.
2- When the pressure on neutral passage “HP” reaches the programmed pilot poppet spring
force, the pilot poppet (E) opens. The oil flows around the peripheral of poppet and is
directed into the low pressure side “LP” through the drilled hole (H).
3- As poppet (E) opens, the flow of oil passing the throttle (I) in piston (C) is generated, and a
difference in pressure grows between the passage “HP” and the back side of piston (C).
The piston (C) then moves and becomes securely seated with the poppet (E).
4- The oil flow from passage “HP” to the back side of poppet (D) will be restricted to the area
(F) only, which is the annular space between poppet (D) and piston (C) and the throttle. As
a result, the difference in pressure grows larger. Consequently, the poppet (D) opens and
the oil flows directly into passage “LP”.

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5- Intake
An anti-void unit is installed to supply oil when cavitation takes place in cylinder Port “HP”.
When the pressure on cylinder port “HP” is lower than the pressure on the low pressure side
“LP”, the sleeve (K) opens due to the area difference between <A> and <B>. The oil enters the
cylinder Port “HP” from the low pressure side “LP” to prevent cavitation.

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SWING UNIT
Functional and Operational Description
1) Swash Plate Motor
Refer to Structural Drawing Figure 1.
The cylinder block has 9 pistons installed. Also, the end of the cylinder block contacts the valve
plates, which have two crescent-shaped ports A and B.
Principle of torque generation

When high pressure oil (Pressure P) is introduced into Port B, the oil pushes the swash plate by
force per one piston (F = P x Ap, where Ap is the sectional area of a piston). The piston receives
the reaction corresponding to the force from the swash plate. As a result, a component is
generated in the rotational direction of the reaction. Then, rotational force is generated on the
cylinder block by the collection of forces in the rotational direction of the piston on the high
pressure side. The torque then is transferred to the shaft via spline for rotation. On the other
hand, when the high pressure oil is introduced to Port A, the rotational direction will be reverse
to the case described above. The output torque and the number of revolutions are calculated
according to the following equations:

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Figure 1. Structural Drawing of Motor

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2) Parking Brake (for models equipped with parking brakes)
The parking brake is a hydraulic release type, wet multiple disc structure, having a shaft lock
mechanism where brake ON/OFF is switched by external signal pressure.
1] When parking brake is ON
See Figure 2-1: Structural drawing. When the hydraulic oil for brake release is shut off, the disc is
connected to the peripheral of the cylinder block via splines. The brake piston (secured to prevent
its rotation) is pushed by the force of spring, and the cylinder block and the case are secured by
the force of friction. The shaft, therefore, will be locked.
2] When parking brake is OFF
See Figure 2-2: Structural drawing. When the hydraulic oil for brake release is introduced to the
brake cylinder chamber (C) through Port PB (Port PG for models with parking brake), the brake
piston starts moving due to release pressure against the force of spring. The shaft then will be
free to rotate since there is no friction.

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3) Principle of Relief Valve Operation
The relief valve determines the driving force and the braking force at the time of hydraulic shovel swing.
They are installed on lines A and B of the main port. It also has a circuit which forces the returning oil
from relief valve to go back to the opposing main low pressure line via makeup valve. Also, it is designed
to reduce shocks at start of acceleration / deceleration. The relief valve structure has two components:
1] Area difference direct acting relief valve
2] Shockless piston
as shown in Figure 3-1.
Shockless type relief valves help eliminate shocks and stresses generated on intensified compo-
nents.
• Pressure Setting of Relief Valve versus Adjustment Volume of Relief Valve (for reference)
Per one time: Approximate 9.7 MPa {1406 psi}
Do not attempt to make adjustments as long as there are no problems.

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The relief valve operates in two steps as follows:
• Initial stage (see Figure 3-2)
At the beginning of the operation, the shockless pin moves to maintain low pressure in the
spring chamber. Thus, the area for receiving pressure on poppet will be the area of poppet seat
(S1). This is considerably large compared to the area for receiving pressure at the normal relief
setting (S1-S2). The relief operating pressure, therefore, will be held low until the shockless spin
has completely moved.
The duration for which the pressure is held low will be determined according to the orifice
diameter between poppet and piston, the area of free piston for receiving pressure, and the free
piston stroke.

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• Second stage (see Figure 3-3)
By the time the shockless piston has moved completely, the pressure in the spring chamber has
risen, and the front and the back pressures of the poppet have become equal. The relief valve,
therefore, operates on the pressure setting for normal operation.
Figure 4 compares the pressure waveforms between the conventional type and the shockless type.

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4) Makeup Valve
The makeup valve functions in two ways as described below:
First it keeps the swing body from overrunning by preventing cavitation, which is caused by swing body
overrun. If the motor had pumped due to inertia of the swing body and the motor revolutions have
exceeded the adequate number of revolutions suitable for the oil inflow to motor, the shortage of oil will
be supplemented into the main motor circuit via the makeup valve. Thus, the generation of vacuum in
the circuit will be prevented. Secondly, it maintains the normal circuit conditions for braking by prevent-
ing the generation of vacuum in the circuit. The situation applies at the time of braking, for example,
when a closed circuit was formed between the control valve and the motor. The makeup valve supple-
ments the amount of the motor drainage and the valve leakage to prevent the circuit from being vacuu-
mized.

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5) Reduction Gear (2-stage planetary gear)
See the sectional drawing below.
The motor shaft (1) is spline-jointed to the drive gear (2). The driving force from the hydraulic motor is
transferred to the planetary gear (3), which engages with the drive gear (2). The planetary gear (3)
engages with the ring gear in the reduction gear housing (4). The planetary gear thus revolves along the
gear ring while it rotates. The planetary gear (3) is held by the holder (5) via a bearing. The holder trans-
fers the orbital motion of the planetary gear (3) to the sun gear (6), which is spline jointed to the holder.
The sun gear (6) engages with the planetary gear (7) and transfers orbital motion to the planetary gear
(7) in the same manner as in the first step. The planetary gear (7) revolves as it rotates because it
engages with the ring gear in housing (4). Since the planetary gear (7) is held by holder (8) via a bear-
ing, the holder (8) transfers the orbital motion of the planetary gear (7) to the pinion shaft (9), which is
spline jointed to the holder.

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Overview
1) Features
1- The valve enhances operability by reducing the number of reverse rotations when the
swing body stops.
2- As the valve has few components and is structurally simple, maintaining the valve is easy.
2) Operational Description
The anti-reverse valve prevents reverse rotational motion caused by entrapped pressure at the
time the swing body is stopped. This is achieved by directly connecting the motor’s main line to
the makeup line for a certain period of time when the motor stops.
The anti-reverse valve consists of the following parts as shown in Figure 1.
1- Check valve
2- Flow control valve (integrated in check valve)
3- Sleeve (Combined with check valve to form a high pressure selection valve).
4- Orifice A
5- Orifice B

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When control valve is in neutral

(Ports P1, P2 on the motor at the same pressure). The check valve will be balanced at the center with
the spring force.
When the swing body is activated, the check valve on high pressure side is pushed and the check valve
will be seated.
At the time of applying the brake, the check valve is stroked by the brake pressure and will be seated.

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After the motor has been stopped by the braking action of the valve unit, it will try to move in the reverse
direction due to the entrapped pressure in the main line. This reverse pressure will seat the shuttle valve
(sleeve) in check valve onto the check valve on low pressure side. An oil passage is thus formed
between the port on which reverse pressure is applied (Port Pv2) and the port which is connected to the
main makeup line (Port Cv). Through this oil passage, the reverse pressure will be released into Port Cv.
At the same time, the reverse pressure pushes the check valve in the direction opposite of the direction
of braking. The flow control valve integrated into the check valve, which now is the low pressure side,
releases oil in the damper chamber 1 at a fixed volume. The check valve, therefore, starts stroking at a
speed.
In the end, the check valve becomes seated and the oil passage formed between Port Pv2 and Port Cv
is blocked.

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TRAVEL UNIT (CX75SR)
External Dimensional Drawing

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Basic Structure and Drawings
1) Basic structure of GM motor
• Reduction gears
The reduction gears are composed of a spur gearbox (referred to as “primary reduction gears”)
and a differential gearbox (referred to as “secondary reduction gears”) in which pericycloid tooth
profiles are adopted. The gears work to reduce the high-speed rotational motion from the
hydraulic motor and to convert it into a low speed rotation with high torque.
• Hydraulic motor
The hydraulic motor is a swash plate type axial piston motor. The motor converts the force of
pressurized oil delivered from the pump into a rotational movement.
• Brake valve
The brake valve consists of various types of valves. It stops the hydraulic motor smoothly,
prevents the motor from overrunning, and also prevents extreme high pressure from being
generated at the time the motor is stopped abruptly.
• High/low 2-step switching mechanism
The valve consists of a switching valve and a piston. It switches the piston displacement of the
hydraulic motor in two different steps.
• Parking brake
The parking brake has a friction-plate type braking mechanism and is integrated into the
hydraulic motor section.

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2) Parts list
PART NAME SYM QTY PART NAME SYM QTY PART NAME SYM QTY
Hub 1 1 Oil seal 132 1 Plug 383 1
Spindle 2 1 O-ring 135 1 O-ring 392 1
Carrier 3 1 O-ring 139 1 Name plate 399 1
Sun gear(1) 4 1 Snap ring 145 1
Planetary gear(1) 5 3 Ball bearing 149 1
Sun gear(2) 6 1 Ball bearing 150 1
Planetary gear(2) 7 4 Roller 151 3
Thrust coller(1) 9 1 Piston 161 1
Thrust washer(1) 10 4 Shoe 162 1
Thrust washer(2) 11 4 Pivot 167 2
Thrust washer(3) 12 3 Parallel pin 171 2
Cover 13 1 Spring 190 1
Ring nut 22 1 Valve seat 201 2
Ball bearing 24 2 Valve 202 2
Needle roller bearing 27 3 Sleeve 203 2
Needle roller bearing 28 4 Coller 204 2
Inner ring 29 3 Plug 205 2
Inner ring 30 4 Spring 206 2
Floating seal 31 2 O-ring 207 2
Plug 33 1 Backup ring 208 4
O-ring 35 1 O-ring 211 2
Socket plug 39 2 Shim 213 2
Hex.head bolt 40 3 Piston 214 2
Steel ball 41 1 O-ring 215 2
Parallel pin 42 2 Backup ring 216 4
O-ring 43 2 Rear flange 301 1
O-ring 44 1 Plug 321 1
Ring 45 1 Spool 323 1
Hex.socket set screw 47 2 Plug 324 2
Retainning ring 50 1 Spring retainer 325 2
Hex.head bolt 51 4 Valve 327 2
Shaft 102 1 Spring 328 2
Swash plate 103 1 Spring 330 2
Cylinder block 104 1 O-ring 336 2
Piston 105 9 O-ring 338 3
Shoe 106 9 Pallalel pin 342 1
Retainning plate 107 1 Hex.socket bolt 345 8
Thrust ball 108 1 Hex.socket plug 352 5
Timing plate 109 1 Spool 363 1
Washer 110 2 Spring 366 1
Washer 111 1 Steel ball 368 1
Piston 112 1 Hex.socket plug 375 4
Spring 113 10 Orifice 377 2
Spring 114 1 Filter 379 1
Friction plate 115 2 Orifice 380 1
Mating plate 116 3 Plug 382 3

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1) Reduction gears
1] Functions
The reduction gears are composed of a spur gearbox (referred to as “primary reduction gears”)
and a differential gearbox (referred to as “secondary reduction gears”) in which pericycloid tooth
profiles are adopted. The gears work to reduce the high-speed rotational motion from the hydrau-
lic motor and to convert it into a low speed rotation with a high torque.
2] Operational description
1- Primary reduction gears section
1)The rotational movement of the hydraulic motor is output from shaft (102). The rotation is
transferred onto the input gear (6) which is spline jointed with the shaft G (15). The input
gear (6) is engaged with three spur gears (7).
The spur gears (7) are reduced to lower speed and will rotate in the reverse direction. The
reduction gears section with input gear (6) and spur gears (7) is called the primary reduction
gears section. The reduction ratio (i1) of this section is as follows:

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2- Secondary reduction gears section
1)Each of the three spur gears (7) is connected to the crankshaft (9). When the spur gear
(7) rotates, the crankshaft (9) rotates in the same direction and for the same number
revolutions. This rotational movement causes the eccentric body sections A and B of the
crankshaft (9) to start their eccentric movement (orbital motion). This eccentric movement
(orbital motion) is transferred to the RV gears A (4) and B (5) via the needle roller bearing
(23). In this manner, the RV gears A (4) and B (5) engage in eccentric movement in the
same direction and for the same number of revolutions as the spur gears and crankshaft.

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2) The faces of teeth on RV gear A (4) and RV gear B (5) are always engaged with the pins
(17) (number of pins: Zp). When the RV gear A and the RV gear B start their eccentric
movements, the mesh point shifts on the faces of teeth sequentially while rolling. During
one turn of eccentric movement, the pin (17) rotates together with the hub (1) for the
difference value (Zp – Zr), which is equal to the difference between Zr (the total gear teeth
number of RV gears A and B) and Zp (the number of pins). The rotational direction of hub
(1) is the same as the direction of eccentric movement on RV gear. The rotation of hub (1)
is the output rotation. The secondary reduction gears section is where the reduction takes
place through crankshaft, RV gear, pin and hub.
The reduction ratio (i2) in the secondary reduction gears section is as follows:
3) The entire reduction gear

The reduction gears will operate at the product ratio of the primary reduction gears section and
the secondary reduction gears section.
Therefore, the number of output revolutions (reduction ratio i) for the reduction gears after the
hydraulic motor shaft has made one complete turn will be as follows:

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2) Hydraulic drive section
This section describes the hydraulic motor, brake valve, parking brake, which are driven by hydraulic oil,
and the high/low 2-step switching mechanism of the hydraulic motor.
1] Functions
1- Hydraulic motor
The hydraulic motor is a swash plate type axial piston motor. The motor converts the force of
pressurized oil delivered from the pump into a rotational movement.
2- Brake valve
1) The valve controls the inertial force at the time the hydraulic motor is stopped to enable a
smooth stopping of the motor.
2) The valve also keeps the hydraulic motor from overrunning when an external force causes the
motor to rotate.
This, in other words, will prevent hydraulic oil cavitation.
3) It also prevents the generation of extreme high pressure when the hydraulic motor is stopped
abruptly.
3- High/low 2-step switching mechanism
This switches the hydraulic motor in two steps: the high-speed rotation with a low-torque out-
put and the low-speed rotation with a high-torque output.
4- Parking brake
The parking brake works when the hydraulic motor is being stopped and prevents the motor
from rotating due to an external force. It has a friction-plate type braking mechanism and is
integrated into the hydraulic motor section.

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2] Principle and operational description
1- Hydraulic Motor
The pressurized oil supplied from the hydraulic pump enters the rear flange (201) in the GM
motor. The pressurized oil is directed into the cylinder block (104) through the brake valve and
the timing plate (109).
The oil will be directed into one side only of the area divided by the Y1-Y2 line drawn from the
top to the bottom dead centers of the piston (105) stroke.
The pressurized oil pushes each of the pistons (105) and generates a force F (= P x A). The
force will act on the inclined surface of the swash plate (103). Due to the angle° of this inclined
surface, the force F will be divided into component forces F2 and F3. Of these component
forces, the radial component force F3 generates a torque (= F3 x ri).
The resultant force T (= Σ [F3 x ri]) of each piston (105) is the rotational force for the hydraulic
motor. The rotational force will rotate the cylinder block (104) and the shaft (102) via piston
(105).

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2- Brake valve
The ports A and B are the inlet/outlet for the hydraulic oil. The following describes the case in
which the hydraulic oil (pressurized oil) is supplied to Port A.
The flow and the operation will be reversed when the oil is supplied to Port B. The rotational
direction of the motor will also be reversed in this case.
1) During normal operation
The hydraulic motor will start rotating when the pressurized oil is supplied to Port A from the
pump. The details will be described as follows.
The pressurized oil supplied from the pump first enters Port A and opens the valve (227). The
pressurized oil which has passed the valve (227) and entered the hydraulic motor via Port C
will give the rotational force to the hydraulic motor.
Pressurized oil also enters Port A, passes the passage (a) through a small hole in spool (223)
and enters the chamber (b). The spool (223) slides from the neutral position to the left by the
force of the pressurized oil in chamber (b). At this time, a hydraulic oil passage is formed
between the Ports D and B due to the grooves in the spool. The hydraulic oil discharged from
the hydraulic motor flows in Port B from Port D. In this manner, the hydraulic motor rotates
and the hydraulic oil returns to the oil tank. On the other hand, the pressurized oil enters Port
E when the spool (223) slides to the left, and the oil in Port E flows into the parking brake and
the 2-step switching valve.

Copyright ©
8030-45
2) Stopping (by applying the brake)
The hydraulic motor will stop rotating when the supply of pressurized oil is stopped. The
details will be described as follows.
When the supply of pressurized oil to Port A is discontinued, the pressure in Port A and
chamber b decreases. As the pressure decreases, the spool (223) starts moving towards the
right from the left position to the neutral position by the force of spring (228).
In conjunction with the movement of spool (223), the passage area between the Ports D and
B becomes smaller. When the spool reaches the neutral, the passage will be shut off.
The hydraulic motor, on the other hand, keeps rotating due to inertial force even after the sup-
ply of pressurized oil stopped. The hydraulic oil discharged from the hydraulic motor thus
loses its passage to flow out from Port D. In this manner, the hydraulic oil on Port D increases
its pressure. The hydraulic oil with the boosted pressure passes the throttle of a valve (287)
on the right-hand side and enters chamber (g) through chamber (f). Because of the hydraulic
oil entering chamber (g), the piston (286) on the right-hand side will shift to the left portion to
keep the pressure from rising. During the movement, the pressures in the chambers (r) and
(g) stay lower than the pressure in Port D through the effect of the orifice in valve (287).
At the same time, the valve (287) on the right-hand side stays open due to the difference in
pressures. The hydraulic oil flows into Port C from Port D. When the piston (286) reaches the
end of its stroke, the pressures in the chambers (g) and (f) rise and become equal to the
pressure in Port D. The valve (287) on the right-hand side then closes again. As the oil dis-
charged from Port D loses its next flow passage, the pressure continues to rise.
The valve (287) on the left-hand side then opens and the hydraulic oil in Port D flows into Port
C. In time, the pressure in Port D decreases along with the decrease in inertial force, and
valve (287) on the left side closes again. The hydraulic motor will also stop its rotation.
In this manner, the hydraulic motor will be stopped smoothly by the brake through controlling
the pressure in Port D in two separate steps.

Copyright ©
8030-46
3) Anti-overrun features
When the hydraulic motor is forced to rotate by external forces during its normal operation, an
overrunning will occur. This occurs, for instance, when an excavator is traveling down a steep
slope at the same time as working the travel motor for a power shovel. The mechanism
against the overrun phenomenon is described below.
The hydraulic motor, during its normal operation, is forced to rotate by an external force. The
pressure of the hydraulic oil (supplied to Port A or Port B) decreases.
The spool (223) starts moving toward the center as the pressure reaches the level that
causes the motor to overrun. In conjunction with the movement of spool (223), the area of the
passage between Port D, which is at the outlet side of the hydraulic motor, and Port B
becomes smaller. The hydraulic oil flow discharged into Port B from Port D also becomes lim-
ited.
At the same time, the pressure on Port D (back pressure) also increases.
The overrunning will be prevented in this manner by controlling the oil flow/pressure at the
outlet port of the hydraulic motor.

Copyright ©
8030-47
3- High/low speed 2-step changing mechanism (during 2-speed manual switch)
1) Low-speed
At low speed, the pilot pressure is not supplied from Port P. At this time, the spool (271) is
pushed to the left by the force of spring (281) and the pressurized oil in Port F is being shut
off.
The hydraulic oil in chamber S is released into the drain (motor case) via spool (271). The
thrust of the piston (161) is small at this stage. The swash plate (103) is positioned along the
surface Y. The swash plate (103), then, reaches its maximum incline angle of 1°.
In other words, the hydraulic motor reaches its maximum piston displacement and rotates at
low speeds.

Copyright ©
8030-48
2) High speed
At high speed, 3.92 MPa {568 psi} of pilot pressure is supplied from Port P. At this time, the
spool (271) is pushed to the right, overcoming the force of spring (281). The pressurized oil in
Port F is introduced into chamber S via spool (271).
The thrust of the piston (161) becomes stronger because of the pressurized oil in chamber S.
The piston (161) pushes the swash plate (103) until it hits the surface X, then holds the plate
there. The swash plate (103) is at its minimum incline angle of 2°.
In other words, the hydraulic motor is at its minimum piston displacement and rotates at high
speeds.

Copyright ©
8030-49
4- Parking brake
1) During operation
The pressurized oil is supplied from the pump to Port A or Port B.
The spool (223) in the brake valve then moves towards the left or right. By the time the spool
has moved all the way, the Port E opens. The pressurized oil is thus introduced into the cylin-
der chamber (c) from Port E. When the oil pressure reaches 0.47 MPa {68 psi} or above, the
thrust of piston (112) becomes larger than the force of spring (113). The piston (112) moves
toward the rear flange (201). The force that has been pushing the counterpart plate (116) and
the friction plate (115) from the piston, therefore, ceases to exist, allowing the friction plate
(115) to rotate freely here.
Because the friction plate (115) engages with the cylinder block (104) in the hydraulic motor
section, the braking force on the cylinder block (104) will also be released, and the hydraulic
motor will also be free to rotate.

Copyright ©
8030-50
5- When applying the brake to stop
The supply of pressurized oil to Port A or Port B is stopped.
The spool (223) in the brake valve then moves to the neutral position. Port E shuts off. The
pressure in the cylinder chamber (c) decreases. When the pressure drops to 0.47 MPa {68 psi}
or below, the hydraulic force of piston (112) becomes smaller than the force of spring (113).
The piston pushes the counterpart plate (116) and the friction plate (115) with the force of the
spring (113). This pressing force generates a friction force, which will be used for braking.
The friction plate (115) engages with the cylinder block (104) in the hydraulic motor section.
The cylinder block (104) engages with the shaft (102) of the hydraulic motor section.
In this manner, the braking torque will be applied to the hydraulic motor at the time the machine
is stopped.

Copyright ©
8030-51
TRAVEL UNIT (CX80)
External Dimensional Drawing

Copyright ©
8030-52
Basic Structure and Drawings
1) Basic structure of GM motor
1st stage Reduction
2nd stage Reduction
High-Low 2-Speed
Switching Mechanism
Parking Brake
Brake Valve
Hydraulic Motor
Reduction Gear
AO13001 016

Copyright ©
8030-53
AO13001-017

Copyright ©
8030-54
2) Parts list
PART NAME SYM QTY PART NAME SYM QTY PART NAME SYM QTY
Hub 1 1 Mating plate 116 3 Plug 383 1
Spindle 2 1 Oil seal 132 1 O-ring 392 1
Carrier 3 1 O-ring 135 1 Name plate 399 1
Sun gear(1) 4 1 O-ring 139 1
Planetary gear(1) 5 3 Snap ring 145 1
Sun gear(2) 6 1 Ball bearing 149 1
Planetary gear(2) 7 4 Ball bearing 150 3
Thrust coller(1) 9 1 Roller 151 1
Thrust washer(1) 10 4 Piston 161 1
Thrust washer(2) 11 4 Shoe 162 2
Thrust washer(3) 12 3 Pivot 167 2
Cover 13 1 Parallel pin 171 1
Ring nut 22 1 Spring 190 2
Ball bearing 24 2 Valve seat 201 2
Needle roller bearing 27 3 Valve 202 2
Needle roller bearing 28 4 Sleeve 203 2
Inner ring 29 3 Coller 204 2
Inner ring 30 4 Plug 205 2
Floating seal 31 2 Spring 206 2
Plug 33 1 O-ring 207 2
O-ring 35 1 Backup ring 208 4
Plug 39 2 O-ring 212 2
Hex.head bolt 40 3 Shim 213 2
Steel ball 41 1 Piston 214 2
Parallel pin 42 2 O-ring 215 2
O-ring 43 2 Backup ring 216 4
O-ring 44 1 Rear flange 301 1
Ring 45 1 Plug 321 1
Hex.socket set screw 47 2 Spool 323 1
Retainning ring 50 1 Plug 324 2
Hex.head bolt 51 4 Spring retainer 325 2
Washer 52 1 Valve 327 2
Shaft 102 1 Spring 328 2
Swash plate 103 1 Spring 330 2
Cylinder block 104 1 O-ring 336 2
Piston 105 9 O-ring 338 3
Shoe 106 9 Pallalel pin 342 1
Retainning plate 107 1 Hex.socket bolt 345 8
Thrust ball 108 1 Hex.socket plug 352 3
Timing plate 109 1 Spool 363 1
Washer 110 2 Spring 366 1
Washer 111 1 Steel ball 368 1
Piston 112 1 Hex.socket plug 375 4
Spring 113 10 Filter 379 1
Spring 114 1 Orifice 380 1
Friction plate 115 2 Plug 382 3

Copyright ©
8030-55
1) Reduction gears
1] Functions
This reduction gear unit is composed of two stage planetary gear mechanism.
The reduction gear reduces the high seed of hydraulic motor and converts it low-speed, high-
torque rotation.
2] Operational description
The rotation of hydraulic motor shaft is transmitted to sun gear [4] of the first stage which is linked
with shaft [102] in spline.
Sun gear [4] is meshed with three planetary gears [5], and three planetary gears [5] mesh with
hub [1] while rotating on their axis.
At that time, the hub is rotated by the rotation of the planetary gears [5].
The hub rotation is transmitted to carrier [3] which connected to planetary gears [5], and that
causes sun gear [6] rotation of the second stage.
The rotation of sun gear [6] is transmitted to the hub via four planetary gears [7] of the second
stage.
The generated rotation of reduction gear is output rotation.
Planetary gear [7]

Hub [1]
Planetary gear [5]

Spindle [2]
Shaft [102]
In put Out put
Sun gear [6]
Sun gear [4]
Carrier [3]
AO13001-018

Copyright ©
8030-56
2) Hydraulic drive section
This section describes the hydraulic motor, brake valve, parking brake, and high-low 2-speed switching
mechanism of the hydraulic motor.
1] Functions
1- Hydraulic motor
Hydraulic motor is referred to as a swash plate type axial piston motor which converts the pres-
sure oil power fed by pump into rotary motion.
2- Brake valve
1) Travel motor controls the force of rotational inertia of the body to brake and stop the rotation
smoothly.
2) Check valve function to prevent hydraulic motor from cavitation.
3) Open the port to release the parking brake force at travel motor operation, and close the port
at a standstill.
3- Relief valve
1) Softens the shock when starting the hydraulic motor, softens the shock when stopping the
hydraulic motor, and prevents cavitation through the relief operation (reduction of the stop
brake sound).
2) When sudden pressure operates on the hydraulic motor, the relief valve keeps the pressure to
a predetermined level or less to prevent damage to the hydraulic motor.
4- High-low 2-speed switching mechanism
Switches the hydraulic motor between high speed rotation with low torque, and low speed rota-
tion with high torque.
5- Parking brake
The parking brake is used the prevent machine from running away or slipping while parking on
a slope using the friction plate type brake mechanism, and it installed on the hydraulic motor.

Copyright ©
8030-57
2] Principle and operational description
1- Hydraulic Motor
Hydraulic fluid fed by pump enters rear flange [301] of travel motor, and is led from timing plate
[109] to cylinder block [104] through brake valve mechanism. This pressure oil is led to only
the one side of (Y1)-(Y2) tied between top dead point and bottom dead point of piston [105]
stroke. And the pressure led to one side of cylinder block pushes 4 or 5 pistons [105], generat-
ing the power (F1 kgf = P kgf/cm2 x A cm2). This power enters on swash plate [103], but swash
plate is fixed having an angle (x) against axis of drive shaft [102], and divided into component
of force (F2, F3). And the radial component of force (F3) generated various torque (T= F3 x ri)
against line. The total torque T [= Σ (F3 x ri)] is connected turning effort, and rotates cylinder
block [104] through piston [105].
The cylinder block [104] is connected with drive shaft [102] with spline, and rotates drive shaft
[102] to transmit torque.
301 104 105
Y1
109 102 103
F3
F3
ri
F1
P A F3
F3
F2 F3
x
Y2
AO13001-019

Copyright ©
8030-58
2- Brake valve
Port (A) and Port (B) are the input and output ports for the working fluid. The following
description assumes that the working fluid (hydraulic) is fed through port (A).
If the fluid is fed through port (B), the flow and motion are reversed. The direction of Rotation
of the motor is also reversed.
1) During normal operation
Hydraulic fluid is fed from the pump to port (A), causing the hydraulic motor to rotate. The
details are as follows.
First, the hydraulic fluid fed from the pump enters at port (A) and opens the valve [327].
The fluid oases through the valve [327], enters the hydraulic motor through port (C) and
applies rotary force to the hydraulic motor.
At the same time, hydraulic fluid enters at port (A) and passes through small holes in the
spool [323] and through channel (a) to chamber (b).
The hydraulic pressure in chamber (b) causes the spool [323] to move from the central posi-
tion to the left. At this time a groove in the spool [323] forms a channel for hydraulic fluid to
pass between port (D) and port (B).
Hydraulic fluid ejected from the hydraulic motor flows from port (D) to port (B), and the
hydraulic motor rotates. The hydraulic fluid returns to the oil tank.
Also, as the spool [323] oscillates to the left, hydraulic fluid enters port (E). The hydraulic fluid
at port (E) flows to the parking brake and 2-speed switching valve.
Parking brake
323 a b
323 327
D C
D B A C
328
B A
AO13001-020

Copyright ©
8030-59
2) Stopping (by applying the brake)
If pressurized oil supply through the port (A) is suspended while traveling, the hydraulic force
to push up the spool is lost, and the spool [323] which is slid to left side, tries to return to the
neutral position through the spring retainer [325] due to the spring [328] force. At that time,
through the oil in the chamber (b) tries to flow out to the port (A) side through the passage (a)
in the spool [323], its flow is restricted and some back pressure is generated by the throttle
effect in the passage (a) controlling the return speed of the spool [323]. At the same time, the
hydraulic motor tries to rotate with its inertia force even though the pressurized oil is sus-
pended, and the return oil from the hydraulic motor tries to return to the port (B) side from the
port (D) through the passages on spool groove and rear flange.
When the spool [323] entirely return to neutral position, the passage on the hydraulic motor of
the oil return side is completely closed by the spool [323], and the hydraulic motor ceases its
rotation. While machine working, the brake valve smoothly stops rotation of the hydraulic
motor which tries to rotate with its inertia force, by means of throttling the return side passage
of the hydraulic motor, generating back pressure due to shape of the spool groove and con-
trolling the return speed of the spool [323].
On the other hand, when braking is operated, the hydraulic motor tries to rotate with its inertia
force and to intake oil with its pumping function.
However, because the intake side is closed its passage with the spool [323], the oil supply is
suspended. This causes cavitation in the hydraulic motor. To prevent the cavitation, the valve
[327] is operated by very slight negative pressure to open the passages of port (A) side and
intake port (C) of the hydraulic motor.
And when pressurized oil is supplied through the port (B), each motion of the mentioned
parts above becomes symmetrical right and left to stop the hydraulic motor.
Parking brake
301 323
a b
325
323 327
D C
D B C A
328
B A
AO13001-021

Copyright ©
8030-60
3) Anti-racing function
During normal operation, when a hydraulic motor is rotated by an outside force, a condition
called racing runaway can occur. For example when used as the drive motor for a excavator,
racing can occur when the vehicle moves down a steep slope.
This section describes the mechanism used to prevent this condition.
During normal operation, the hydraulic motor is rotated by an outside force. The pressure of
the hydraulic fluid feed (at port (A) or port (B)) falls.
As the pressure approaches the level at which racing begins, the spool [323] begins moving
to the center towards the central position. The movement of the spool [323] reduces the size
of the flow channel from port (D) to port (B) on the output side of the hydraulic motor. This
restricts the amount of hydraulic fluid ejected from port (D) to port (B). At the same time the
pressure at port (D) (back pressure) increases.
Thus racing is prevented by controlling the flow rate and pressure at the escape port from the
hydraulic motor.
Parking brake
301 323
a b
323 327
D C
D B A C
328
B A
AO13001-022

Copyright ©
8030-61
3- Operation description of relief valve
1) Starting
The pressurized oil supplied from the pump is led to port (C) from port (A). Port (C) is con-
nected with the hydraulic pressure motor. Therefore, the hydraulic motor can give torque with
the pressurized oil led to port (C). At this time, the valve [202-a] of the relief valve(R/V) «A» is
not opened for the pressurized oil of port (C). The piston [214-a] moves to the stroke end of
the direction of an arrow with the pressurized oil. The oil of chamber (x) is led to port (D)
through the orifice (c) of the sleeve [203-a], the orifice (b) of the valve [202-a]. The pressur-
ized oil of port (C) opens the valve [202-b] (b) of the relief valve «B» with set pressure, and
pressurized oil is led to port (D). The pressurized oil from port (C) is led to the chamber (y)
through the orifice (f) of the valve [202-b], the orifice (g) of the sleeve [203-b]. If the piston
[214-b] reaches the stroke end, the pressure between the orifice (f) of the valve [202-b] and
the orifice (g) of the sleeve [203-b] will rise. The cracking pressure of the valve [202-b] turns
into more than the system pressure of the excavator with the pressure during two orifices,
and the valve [202-b] is closed.
The pressure of port (C) rises by the operation of the relief valve (R/V) «A» and «B», and the
hydraulic motor can obtain torque.
chamber(y)
214 a
orifice(f)
202 b
203 a
orifice(c)
R/V "B"
D
C
R/V "A"
203 b
orifice(g)
chamber(x)
214 b 202 a
B A
orifice(b)
AO13001-023

Copyright ©
8030-62
The pressure of the port (C) at starting is as follows.
Pressure
Time
Relief valve "B" is opened
AO13001-024
However, when the piston [214-b] position has reached the stroke end in the case of the last
stop, the valve [202-b] of the relief valve (R/V) «B» is not opened.
The pressure of the port (C) in this case is as follows.
Pressure
Time
AO13001-025
The pressure of the port (C) at starting changes with the piston [214-b] positions.
NOTE: When the pressurized oil supplied from the pump is led to port (D) from port (B), operation explanation
becomes what replaced the relief valve (R/V) «A» and relief valve (R/V) «B».

Copyright ©
8030-63
2) Stopping
If supply of pressurized oil in Port (A) is lost, the counter balance valve will return to neutrality.
Port (D) will be intercepted if the counter balance valve returns to neutrality.
However, since the hydraulic motor rotates according to inertia, the pressure is generated in
port (D).
The pressurized oil of port (D) is led to the chamber (x) through the orifice (b) of the valve
[202-a], the orifice (c) of the sleeve [203-a].
The piston [214-a] moves to the stroke end of the direction of an arrow with the pressurized
oil led to the chamber (x).
While the piston [214-a] is moving, the pressure in the chamber (x) does not rise.
The pressurized oil of port (D) opens the valve [202-a] of the relief valve (R/V) «A» with set
pressure, and pressurized oil flows into port (C). (Pressure under piston movement : Primary
relief pressure)
The pressure of port (D) is controlled by the operation of the relief valve (R/V) «A», and the
cavitation is prevented by supplying oil to port (C).
If the piston [214-a] reaches the stroke end, the pressure of chamber (x) and the pressure
between the orifice (b) of the valve [202-a] and the orifice (c) of the sleeve [203-a] will rise,
and the valve [202-a] is closed.
At this time, the relief valve (R/V) «A» is relieved above the system pressure of the excavator,
and stops the hydraulic motor. (Pressure at the time of the completion of a piston move : Sec-
ondary relief pressure)
The piston [214-b] of the relief valve (R/V) «B» moves to the direction of an arrow with the
pressurized oil of port (D).
The oil of chamber (y) is led to port (C) through the orifice (g) of the sleeve [203-b], the orifice
(f) of the valve [202-b].
chamber(y)
214 a
orifice(f)
202 b
203 a
orifice(c)
R/V "B"
D C
R/V "A"
203 b
orifice(g)
chamber(x)
B
214 b 202 a
A
orifice(b)
AO13001-026

Copyright ©
8030-64
The pressure of the port (D) at stopping is as follows.
Pressure
Time
Piston [214-a] is moving
Relief valve "A" is opened.
AO13001-027
Pressure under piston movement : Primary relief pressure
Pressure at the time of the completion of a piston move : Secondary relief pressure

Copyright ©
8030-65
4- High-low 2-speed switching mechanism
1) Low-speed
When the pilot pressure is shut off from port (P), the GM motor is low speed level.
At this time the spool [363] is pressed the left side by the force of the spring [366], the pres-
surized oil supply at port (F) is shut off.
The oil in chamber (S) is released into the motor case through the spool [363].
The force of the piston [161] is small. The swash plate [103] is parallel to side (Y).
At this time the swash plate [103] is tilted at a maximum angle (1). thus leading to lowspeed
operation.
363 161
P chamber S
drain 1
F
366
fulcrum
side Y
A or B
103
B A
AO13001-028

Copyright ©
8030-66
2) High speed
When the pilot pressure supplied to port (P), the GM motor is high speed level. At this time
the pressure overcomes the force of the spring [366] and the spool [363] is pressed the right
side. The pressurized oil supply from port (F) is then introduced into chamber (S) through the
spool [363] . The force of the piston [161] is increased by the pressurized oil of chamber (S).
The piston [161] pushes the swashl plate [103] up until it touches side (X) and keeps it. At this
time the swash plate [103] is tilted at a minimum angle (2), thus leading io high-speed opera-
tion.
363 161
P chamber S
366 F
fulcrum
A or B
side X
103
B A
AO13001-029

Copyright ©
8030-67
3) Automatic switching from high speed to low speed
As the load on the hydraulic motor increases, the pressure at port (A) or (B) Increases. While
operating at the high speed level, when the pressure at port (A) or (B) reaches setting pres-
sure, the spool [363] is pressed leftwards. From this point, the operation is as described for '
Low Speed Level '. The force of piston [161] is reduced, and the hydraulic fluid of chamber (S)
is opened to drain (motor case) through the spool [363]. The swash plate [103] is positioned
along side (Y).
At this time the swash plate [103] has its maximum angle (1). Thus in this state the hydraulic
motor has maximum displacement with low rotary speed.
363 161
P chamber S
drain 1
F
366
fulcrum
side Y
A or B
103
B A
AO13001-030

Copyright ©
8030-68
5- Parking brake
1) Travering
Hydraulic fluid is fed from the pump to port (A) or port (B), causing the brake valve spool [323]
to move to the left or right. The movement of the spool [323] opens port (E). The hydraulic oil
is fed from port (E) to cylinder chamber (c). When the hydraulic pressure reaches 0.63 MPa
(6.42 kgf/cm2), the force of the piston [112] exceeds the force of the spring [113]. The piston
[112] moves in the direction of the rear flange [301]. The pressure from the piston [112] on the
mating plates [116] and the friction plates [115] disappears, and the friction plates [115] is
able to rotate freely.
The friction plate [115] is locked to the cylinder block [104] of the hydraulic motor. Thus the
braking force of the cylinder block [104] is released, and the hydraulic motor is able to rotate
freely.
104 112 116 115
Parking brake
323 a b
301
328
113
C B A
AO13001-031

Copyright ©
8030-69
2) Stopping
The supply of hydraulic fluid to port (A) or (B) is Stopped. The brake valve spool [323] moves
to the center position, shutting off port (E). The pressure in cylinder chamber (c) falls. When
this pressure falls below 0.63 MPa (6.42 kgf/cm2), the hydraulic force of the piston [112]
becomes less than the force of the spring [113]. The spring [113] causes the piston [112] to
press against the mating plates [116] and friction plates [115].
This pressure creates the friction that serves as the braking force. The friction plate [115] is
locked to the cylinder block [104] of the hydraulic motor.
The cylinder block [104] is Iocked with the shaft [102] of the hydraulic motor.
Thus brake torque is applied to the hydraulic motor while stopped.
104 112 116 115 102
301
113
C
AO13001-032

Copyright ©
8030-70
NOTES
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Copyright ©
Section
9007
AIR CONDITIONING UNIT
9007

Printed in France
Copyright ©
9007-2
TABLE OF CONTENTS
AIR CONDITIONER ................................................................................................................................................. 3
DISASSEMBLING THE CASE .................................................................................................................................... 3
Removing the switch box: ................................................................................................................................. 3
Removing the upper case: ................................................................................................................................ 3
REPLACING THE BLOWER MOTOR........................................................................................................................... 4
REPLACING THE EVAPORATOR ............................................................................................................................... 4
REPLACING THE EXPANSION VALVE........................................................................................................................ 5
REPLACING THE HEATER CORE .............................................................................................................................. 6
REPLACING THE MOTOR ACTUATOR ....................................................................................................................... 6

Copyright ©
9007-3
AIR CONDITIONER
1 Disassembling the case
Switch box
Top of case
Filter A
Heater core
Evaporator
To remove clamps
Retainers
Retainers
Filter C
Clamp
Blower motor
Filter B
Figure 2
Figure 1 MQ18001-001
1 Removing the switch box:

1. Remove 6 screws (M4 x 10) and pull out the switch box.
2 Removing the upper case:
1. Remove filter A.
2. Remove filters B and C.
3. Remove 3 screws (M5 x 12).
4. Remove 11 clamps using a flathead screw driver.
MSM-17-18-001 Issued 08-2008

Copyright ©
9007-4
2 Replacing the blower motor
[1] When replacing the blower motor, refer to Figure 3 to Blower motor
guide the power harness and position.
Power harness
Locations of cooling hose &

power harness for blower
motor installation
Bottom of case
[1] Install the blower motor after verifying the installation

position in Figures 4 and 5.
> or = 2 mm (both side)
Clearence between fan & case for

blower motor installation
Figure 4 MQ18001-004a
Blower motor
Unit case
Align centers of blower fan & unit case
Figure 5
MQ18001-004b
3 Replacing the evaporator

1. Pull out the evaporator from under the unit case. Second row of fins from bottom
2. Pull out the thermistor together with the sensor holder.

3. Attach the sensor holder to the thermistor, then install the Thermistor
thermistor on the new evaporator in the location shown in
Figure 6.
Sensor holder
ASM-17-24-002 Issued 08-2008

Copyright ©
9007-5
4. Position the thermistor cord as shown in Figure 7, then
Place thermistor cord
install the evaporator at under the unit case. along groove
4 Replacing the expansion valve

1. Remove the pipe at the expansion valve inlet and the nut at
the evaporator inlet.
2. Peel off the insulation from the temperature sensor, remove
the sensing tube, then remove the expansion valve from the
evaporator.
3. Install the new expansion valve on the evaporator to the
specified torque.
Tightening torque for the expansion valve inlet:
13.2 ± 1.5 Nm.
Tightening torque for the evaporator inlet:
17.7 ± 2.0 Nm.
Fan motor side
NOTE: When installing the expansion valve, be careful not to
put too much pressure on the O-ring.
After sensing tube is Evaporator side

installed Applying insulation to temper-
ature sensor
Figure 8
MQ18001-007
MSM-17-18-001 Issued 08-2008

Copyright ©
9007-6
5 Replacing the heater core
1. Pull the heater core out from the unit case.
2. Remove the bolts (5x12) from the pipe retainer and install it on the new heater core.
Then install it under the unit case.
6 Replacing the motor actuator
1. Push rod clamp A on the actuator lever in the direction of the
arrow to remove it from the lever.
2. Remove the 4 screws that hold the actuator in place.
3. Install the lever on the new actuator, insert the rod into rod
clamp and lock.
ASM-17-24-002 Issued 08-2008

Copyright ©
115 MULTI-PURPOSE + 3WAY VALVE
21 15 72 NOTES
1) UPPER VALUES IS MARK , SHOW THE CONNECTIVE POINTS

AND LOWER VALUES SHOW THE ZONE NUMBER OF THIS DRAWING.
16 115 85 : OPTION PARTS

100
xx For components description see section 8020
114 85
21
79
38 Y9
22
B32 75
B45
116
29
103
28
W1 W2
22 83
22
DOUBLE ACTING CIRCUIT

83
83 75
78 76
1 4 44 SINGLE ACTING CIRCUIT
SECOND DOUBLE ACTING CIRCUIT
B27
B26 83
MULTI-PURPOSE + 3WAY VALVE
78
97
102
51
104 60
95
10
55 85
85
99
85
94 93
Y26 Y25
96
53 96
B22
B22
54
85 CX80 TIER3 EXCAVATOR
85 85 85
HYDRAULIC SCHEMATIC
Pub. Number KAJ11600-E00 EN
Copyright ©
F34
K48 A11
F3 F1 F27 F33
K47
M20
G2
M10
E51 P4 M1
P5
K7
R1
G1
P10 Y2 K8 Y45
S51 K34
Y3
Y4
S1
Y22
H2 X2
B41
B81
K19 K4 K21 K20 K3 K49
K18
E8 B47
M4
Y25 B1
Y26
E2
S16 B1
E3 P2 R3
E4
S33
S34 X8
W1 B51
M14
P3
M3
S15
B21
B26
H4
R5 B27 NOTES
H5 1) THE MARKS ARE INDICATED AS BELOW IN THIS DRAWING.

S35
: OPTION PARTS
: FOR LBX
B22 : FOR CASE NORD AMERICA
X15
U1 : FOR CASE EUROPA
B22
S13 2) EARTH LINE SYMBOLS AND CROSS POINT OF LINES IN THIS DRAWING
S6 B22 SHOWS THE FOLLOWING.
S28 K5
CONNECTED NOT CONNECTED
B22 EACH OTHER EACH OTHER
H3 A7
BODY EARTH EARTH WITH CABLE
B2 HARNESS
SINGLE WIRE CONNECTOR
3) THE SYMBOL AT EACH LINE SHOWS COLOR OF CABLE.

M7 M6 M5 THE FIGURE BEFORE THE SYMBOL SHOWS THE AREA OF CABLE.
THE AREA OF CABLE NOT INDICATED IS 0,5 mm²
P6 THE FIGURE AFTER THE SYMBOL SHOWS CIRCUIT N°.
K25 K24 K23 K22
B45 60 B 001
AREA CIRCUIT NUMBER

COLOR
S52 4) THE SYMBOL OF CONNECTOR IN THIS DRAWING SHOS THE FOLLOWING:
CONNECTOR (MALE) CONNECTOR (FEMALE)
Y8
CONNECTOR' S NAME
YAZAKI
E52 SWP CONNECTOR. No
(CN. xx)
x For components description see section 4020
M8 R7 R4 A9
CX80 TIER3 EXCAVATOR
ELECTRICAL SCHEMATIC
Pub. Number KAR11060-E00 EN

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CRAWLER EXCAVATOR CX75SR/CX80 TIER 3

* Consult the Engine Service Manual

Copyright © 2008 CNH France S.A.

DIVISION/SECTION SECTION N° REFERENCE N°

Lep SM75SRTOC-0EN Issued 03-08

SAFETY, GENERAL INFORMATION

Copyright © 2006 CNH France S.A.

Lep 7-27691EN Issued 02-06

Lep 7-27691EN Issued 02-06

To prevent injury always follow the Warning, Caution

WARNING: If you wear clothing that is too

WARNING: When working in the area of the

WARNING: When doing checks and tests

WARNING: When putting the hydraulic

Lep 7-27691EN Issued 02-06

WARNING: When the battery electrolyte is

WARNING: Use suitable floor (service)

Lep 7-27691EN Issued 02-06

STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS

Lep 7-27691EN Issued 02-06

Copyright @ 2008 CNH France SA

TYPE, SERIAL NUMBER

Lep SC75SRCX80-1002-0EN Issued 03-08

Lep SC75SRCX80-1002-0EN Issued 03-08

Lep SC75SRCX80-1002-0EN Issued 03-08

(1) Type .......................................................................................................................................................................

Serial numbers of the components

Lep SC75SRCX80-1002-0EN Issued 03-08

Transmission component oil

Lep SC75SRCX80-1002-0EN Issued 03-08

Oil viscosity / Oil range

1) With mineral base

Lep SC75SRCX80-1002-0EN Issued 03-08

Applicable Standard Recommendation

JIS (Japanese Industrial Standard) NO.2

DIN (Deutsche Industrie Normen) DIN 51601

SAE (Society of Automotive Engineers)

Based on SAE-J-313C NO. 2-D

Based on BS/2869-197 Class A-1

Lep SC75SRCX80-1002-0EN Issued 03-08

Lep SC75SRCX80-1002-0EN Issued 03-08

Plastic and resin parts

Lep SC75SRCX80-1002-0EN Issued 03-08

Main body dimensions

Lep SC75SRCX80-1002-0EN Issued 03-08

Capacity of coolant and lubricants

Hydraulic oil filter

Lep SC75SRCX80-1002-0EN Issued 03-08

Lep SC75SRCX80-1002-0EN Issued 03-08

Lep SC75SRCX80-1002-0EN Issued 03-08

Lep SC75SRCX80-1002-0EN Issued 03-08

Secondary pressure (MPa)

Foot control valve (for travel)

Secondary pressure (MPa)

Operating torque (Nm) (lbf-ft)

Operating angle (deg.)

Push rod stroke (mm) (in)

Lep SC75SRCX80-1002-0EN Issued 03-08

Operating torque (Nm) (lbf-ft)

Operating angle (deg.)

Push rod stroke (mm) (in)

Lep SC75SRCX80-1002-0EN Issued 03-08