Case CX225SR EN

CX225SR Crawler excavator
Table of contents
REFERENCE N°
SERVICE MANUAL ..................................................................................................................................9-40691GB

ENGINE SERVICE MANUAL (BB - 6BG1T)............................................................................................................. *
LARGE FORMAT HYDRAULIC AND ELECTRICAL SCHEMATICS.............................................................9-43710
* Consult the Engine Service Manual
Configurations contained in this Service Manual:

CX225SR NA (North Model América)
CX225SR WE (Model Europe)
NOTE: CNH Company reserves the right to make changes in the specifi-
cation and design of the machine without prior notice and without incur-
ring any obligation to modify units previously sold.
The description of the models shown in this manual has been made in
accordance with the technical specifications known as of the date of
design of this document.
Copyright © 2004 CNH France S.A.

Printed in France
Case Cre 9-88321GB December 2004
REPAIR MANUAL
CX225SR
9-40691 1 02/12/2004
Contents
INTRODUCTION
DISTRIBUTION SYSTEMS A
POWER PRODUCTION B
TRAVELLING D
BODY AND STRUCTURE E
FRAME POSITIONING F
WORKING ARM H
TOOLS AND COUPLERS J
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INTRODUCTION
9-40691 1 02/12/2004
1
Contents
INTRODUCTION
Foreword ( - A.10.A.40) 3
CX225SR
Safety rules ( - A.50.A.10) 4

CX225SR
Basic instructions ( - A.90.A.05) 6

CX225SR
Torque ( - A.90.A.10) 7
CX225SR
Torque ( - A.90.A.10) 8
CX225SR
Dimension ( - A.92.A.30) 11
CX225SR
Weight ( - A.92.A.40) 12
CX225SR
Consumables ( - A.92.A.55) 13
CX225SR
Hydraulic contamination ( - A.92.A.60) 16

CX225SR
Product identication ( - A.80.A.10) 18

CX225SR WE
Product identication ( - A.80.A.10) 19

CX225SR NA
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INTRODUCTION
Foreword ( - A.10.A.40)
CX225SR
INTRODUCTION TO THE REPAIR MANUAL

This manual has been designed so that in the near future it can be made available on CD and in a database
via a computer network.
This will allow fast and targeted search and navigation between the various information modules.
Information search
CRIL03J033E01 1
This manual is organised according to types of function and information.
• The function and information types are codied and appear in parentheses after the title and separated by a dash:
(1) Function
(2) Information type.
• Only the rst letter (A) and the rst number (B) of the function need to be used for the information search.
The rst letter (A) corresponds to the sections of the repair manual.
The rst number (B) corresponds to the chapters of the repair manual.
The rst part of the (A.B) code is reected in the page numbering.
THE REST OF THE CODING IS NOT LISTED IN ALPHA-NUMERIC ORDER IN THIS MANUAL.
• You will nd a table of contents at the beginning and end of each section and chapter.
You will nd an alphabetical index at the end of each chapter.
• Therefore it is the rst part of the (A.B) coding, then the tables of contents and index (page numbers) which will allow you to
quickly nd the information you are looking for.
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INTRODUCTION
Safety rules ( - A.50.A.10)

CX225SR
CAUTION
M171C - THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL.
WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO
THE POSSIBILITY OF DEATH OR SERIOUS INJURY.
ATTENTION: To avoid injury, always observe the Safety Notices, CAUTION and ATTENTION, contained in this
section and throughout the manual.
Place a “Do not start the machine” warning notice on the starter switch key before all maintenance or repair
operations.
CAUTION
M489 - Read the operators manual to familiarize yourself with the correct control functions.
CAUTION
M490 - Operate the machine and equipment controls from the seat position only. Any other method could
result in serious injury.
CAUTION
M265A - A frequent cause of personal injury or death is persons falling off and being run over. Do not
permit anyone to ride on the machine.
CAUTION
SB055 - Before starting engine, study operators manual safety messages. Read all safety signs on machine.
Clear the area of other persons. Learn and practice safe use of controls before operation. It is your
responsibility to understand and follow manufacturers instructions on machine operation, service, and to
observe pertinent laws and regulation. Operators and service manuals can be obtained from your dealer.
ATTENTION: You risk injury if you wear loose clothing or if you do not use safety equipment for your work. Always
wear clothes which are unlikely to become caught in the machinery. Other safety equipment may be required, in
particular: hard hat, safety boots, ear protectors, safety goggles or mask, thick gloves and reective clothing.
CAUTION
M124A - Rotating machine parts, stay clear, keep shields installed to help protect from clothing
entanglement and injury. Wear close-tted clothing.
CAUTION
SB071 - Rotating fan and belts: Contact will cause injury. Keep clear.
ATTENTION: Follow the procedures exactly when carrying out checks or inspections on the vehicle’s hydraulic
systems. DO NOT CHANGE the procedures.
ATTENTION: Before running the hydraulic cylinders in this vehicle through the cycles necessary for checking their
functioning or for draining a circuit, warn people nearby to move away.
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INTRODUCTION
CAUTION
SM121A - Always wear heat protective gloves to prevent burning your hands when handling heated parts.
CAUTION
M132B - Lower or block elevated implements and other attachments before servicing or when leaving the
equipment.
CAUTION
R149C - Hydraulic oil or diesel fuel leaking under pressure can penetrate the skin and cause infection
or other injury. To Prevent Personal Injury: Relieve all pressure, before disconnecting uid lines or
performing work on the hydraulic system. Before applying pressure, make sure all connections are tight
and components are in good condition. Never use your hand to check for suspected leaks under pressure.
Use a piece of cardboard or wood for this purpose. If injured by leaking uid, see your doctor immediately.
ATTENTION: To remove a hardened pin, such as a pivot pin, or a hardened shaft, use a soft-headed hammer
(brass or bronze) or a brass or bronze peg and a steel-headed hammer.
CAUTION
M428 - Always wear safety glasses when using a drill, hammer, saw, or other tools that may cause chips
to y.
ATTENTION: Use suitable servicing jacks or a chain hoist for raising the wheels or tracks. Always chock the
vehicle in place with suitable safety supports.
ATTENTION: When carrying out maintenance or repair operations on the vehicle, keep the workshop oor, the
driving position and the steps free from oil, water, grease, tools, etc... Use an oil absorbent material and/or workshop
cloths as necessary. Always use sound methods.
ATTENTION: Some parts of this vehicle are very heavy. Use lifting devices or additional assistance recommended
in the Operator’s Manual.
CAUTION
M532 - Do not operate the engine in a closed building. Proper ventilation is required under all circumstances.
CAUTION
M503 - When the battery electrolyte is frozen, the battery can explode if (1), you try to charge the battery, or
(2), you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the
battery at full charge. If you do not follow these instructions, you or others in the area can be injured.
CAUTION
M244A - BATTERIES CONTAIN ACID AND EXPLOSIVE GAS. EXPLOSION CAN RESULT FROM SPARKS,
FLAMES, OR WRONG CABLE CONNECTIONS. TO CONNECT JUMPER CABLES OR CHARGER, SEE
MANUAL(S) FOR THE CORRECT PROCEDURE. FAILURE TO FOLLOW THE ABOVE INSTRUCTIONS CAN
CAUSE SERIOUS PERSONAL INJURY OR DEATH.
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INTRODUCTION
Basic instructions ( - A.90.A.05)

CX225SR
GENERAL
Cleaning
Clean all metal parts except the bearings with white spirit or steam. Do not use caustic soda for steam cleaning.
After each cleaning, dry and oil all parts. Clean the oil ducts with compressed air. Clean the bearings with parafn,
then dry them completely and lubricate them.
Inspection
Check all the parts when they are disassembled. Replace all parts that show signs of wear or damage. Supercial
scratches and grooves can be removed with an oil stone or with a cloth dipped in red oxide. A complete visual
inspection is necessary to detect wear and pitting, and replacing parts as soon as it becomes necessary will help to
avoid premature breakdowns.
Bearings
Check that the bearings turn freely. Replace them if their adjustment is too free or if their functioning is irregular.
Wash the bearings with a good solvent or parafn and allow them to air dry.
DO NOT DRY THE BEARINGS WITH COMPRESSED AIR.
Needle bearings
Before pushing needle bearings into a cylinder bore, always remove all metallic projections from the bore and its
edges. Before pushing in bearings with a press, coat the inside and edges of the bearings with Vaseline.
Gears
Check all the gears and ensure that they do not show any signs of wear or damage. Replace the worn out
or damaged gears.
Gaskets, O-rings and at seals

Always install new gaskets, O-rings, and at seals. Coat the gaskets and O-rings with Vaseline.
Shaft
Check all shafts showing wear or damage. Enusre that the surface of a shaft carrying a bearing or gasket is
not damaged.
Spare parts
Always use CASE spare parts. To order these, refer to the Spare Parts Catalogue and indicate the correct reference
number of the CASE spare parts.
Breakdowns caused by the use of parts other than CASE spare parts are not covered by the warranty.
Lubrication
Use only the oils and lubricants specied in the Operator’s Manual or the Service Manual.
Breakdowns caused by the use of oils and lubricants not specically listed are not covered by the warranty.
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INTRODUCTION
Torque ( - A.90.A.10)
CX225SR
STANDARD TIGHTENING TORQUE
Order of tightening nuts and cap screws.

Tighten alternately so that torque remains uniform. Cap screws which are tted with Loctite (look for traces of a
white residue on the thread after removal), must be cleaned with a thin oil or a suitable solvent, then dried.
Add two or three drops of Loctite to the cap screw thread, then t the screw.
CRIL03H012E01 1
The numbers in the diagrams represent the order of tightening.
Tightening torque
Where there are no special instructions, tighten cap nuts screws to the torques given in the table below.
Standard torque setting table.

Designation of cap screws M6 M8 M10 M12 M14 M16 M18 M20
(dimensions)
Cap screw Spanner in mm 10 13 17 19 22 24 27 30
Torque setting in 6.9 19.6 39.2 58.8 98.1 157.2 196 274
Nm
Socket head Wrench in mm 5 6 8 10 12 14 14 17
screw Torque setting in 8.8 21.6 42.1 78.4 117.6 176.4 245 343
Nm
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INTRODUCTION
Torque ( - A.90.A.10)
CX225SR
SPECIAL TORQUE SETTINGS

No. Component Screw Wrench Tightening torque
diameter in mm
(1)* Travel motor and reduction gear assembly M16 24 267 - 312 Nm
(2)* Sprocket M16 24 267 - 312 Nm
(3)* Idler wheel M16 24 267 - 312 Nm
(4)* Upper roller M20 30 521 - 608 Nm
(5)* Lower roller M18 27 371 - 432 Nm
(6) Chain guide M18 27 380 - 443 Nm
(7) Track pad M20 30 300 Nm+120 °
(8) Counterweight M36 55 2750 - 2940 Nm
(9) Turntable (chassis) M20 30 468 - 545 Nm
(10) Turntable (upperstructure) M20 30 468 - 545 Nm
(11)* Swing motor and reduction gear assembly M20 30 521 - 608 Nm
(12)* Engine M16 24 265 - 313 Nm
(13)* Engine mounts M10 17 64 - 74 Nm
(14) Radiator M16 24 147 - 176 Nm
(15)* Hydraulic pump M10 17 64 - 74 Nm
M20 30 367 - 496 Nm
(16)* Hydraulic reservoir M20 30 412 - 471 Nm
(17)* Fuel tank M20 30 412 - 471 Nm
(18)* Control valve M16 24 267 - 312 Nm
(19)* Hydraulic swivel M12 19 109 - 127 Nm
(20) Cab M16 24 78 - 80 Nm
(21) Batteries M10 17 20 - 29 Nm
Use Loctite 262 or an equivalent on mounting screws marked with an asterisk (*).
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INTRODUCTION
CRIL04B072H01 1
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INTRODUCTION
CRIL04B073H01 2
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INTRODUCTION
Dimension ( - A.92.A.30)
CX225SR
Machine tted with monobloc boom 5.70 m
CRPH04B001F00 1
Dippers 1.90 m 2.40 m 3.00 m

(A) 3.08 m 3.14 m 2.90 m
(B) 2.97 m
(C) 8.97 m 8.93 m 8.85 m
(D) 6.74 m 6.70 m 6.62 m
(E) 2.80 m
(F) 1.40 m
(G) 1.68 m
(H) 4.46 m
(I) 3.66 m
(J) 2.39 m
(K) 0.60 m
(L) with track pads 600 mm 2.99 m
(M) 0.46 m
(N) 1.40 m
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INTRODUCTION
Weight ( - A.92.A.40)
CX225SR
Weight of machine
Conguration Weight Ground
pressure
With track pads 600 mm, monobloc boom 5.70 m, dipper 2.40 m, 760 kg 22 700 kg 0.47 bar
backhoe, driver and full fuel tank
Weight of components
Engine 487 kg
Hydraulic pump 125 kg
Attachment control valve 187 kg
Swing moto-reduction gear 223 kg
Travel moto-reduction gear 250 kg
Boom cylinder 200 kg
Dipper cylinder 257 kg
Bucket cylinder 151 kg
Counterweight 5880 kg
Cab kg
Turntable 244 kg
Upperstructure with equipment (counterweight and turntable) 11770 kg
Hydraulic swivel 27 kg
Undercarriage with equipment EUROPE
7020 kg
NA
7730 kg
Machine without equipment EUROPE
18840 kg
NA
19550 kg
Attachment 3870 kg
Boom with equipment 2200 kg
Dipper with equipment 3.00 m 910 kg
Dipper without equipment 3.00 m 599 kg
Radiator and oil-cooler assembly 55 kg
Fuel tank 160 kg
Hydraulic reservoir 145 kg
Idler wheel 82 kg
Upper roller 17 kg
Lower roller 35 kg
Tension shock absorber 142 kg
Track 600 mm 1350 kg
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INTRODUCTION
Consumables ( - A.92.A.55)
CX225SR
FLUIDS AND LUBRICANTS

Lubricants must have the correct properties for each application.
ATTENTION: You must respect the operating conditions for the different ingredients.
Hydraulic uid
CASE AKCELA hydraulic uid is specially designed for high pressure applications and for the CASE hydraulic
system.
The type of uid to be used depends on the ambient temperature.
• TEMPERATE COUNTRIES - 20 °C to + 40 °C
CASE AKCELA HYDRAULIC EXCAVATOR FLUID
(MS 1230. ISO VG 46. DIN 51524 PART 2 HV)
• HOT COUNTRIES 0 °C to + 60 °C
CASE AKCELA HYDRAULIC EXCAVATOR FLUID "HOT CLIMATE"
• COLD COUNTRIES - 40 °C to + 20 °C
CASE AKCELA HYDRAULIC EXCAVATOR FLUID "COLD CLIMATE"
• BIODEGRADABLE FLUID - 30 - +40 °C
This yellow uid can be mixed with standard uid.
If this liquid is used, it is advisable to completely drain the hydraulic circuit .
CASE AKCELA HYDRAULIC EXCAVATORS FLUID BIO
Transmission component oil

Extreme pressure oil used in transmission components inside sealed housings.
CASE AKCELA 135H EP GEAR LUBE SAE 80W-90
(SAE 80W-90. API GL 5. MIL-L-2105 D. MS 1316. ZF TE-ML 05A)
Grease
"Extreme Pressure" multi-purpose grease
• CASE AKCELA MOLY GREASE 241H EP-M (251H EP-M NLGI2)
with lithium and molybdenum bisulphide soap.
• CASE AKCELA 251H EP MULTI-PURPOSE GREASE (251H EP. NLGI 2)
with lithium and calcium soap.
• CASE AKCELA PREMIUM GREASE EP-2 (NLGI 2)
with lithium soap.
HYDRAULIC HAMMERS
Use only CASE AKCELA PREMIUM GREASE EP-2 (NLGI 2) grease with lithium soap.
Engine oil
CASE AKCELA NO. 1 ENGINE OIL is recommended for the engine.
This oil provides correct lubrication for your engine in all working conditions.
If CASE AKCELA NO. 1 ENGINE OIL Multigrade cannot be obtained, use oil corresponding to one of the following
categories: ACEA E5. MS 1121. API CH-4.
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INTRODUCTION
CRIL03H015F01 1
OIL USE RANGE
1. Mineral-based
2. Semi-synthetic based
3. Synthetic based
Fuel
Use fuel that is compliant with ASTM (American Society for Testing and Materials) standard D975.
• Use Grade No 2 fuel. The use of other types of fuel can result in a loss of power and may cause high fuel
consumption.
• When the temperature is very cold, the use of a mixture of No 1 and No 2 fuel is permitted. See your fuel
vendor for winter fuel requirements in your area.
• If the temperature falls below the fuel cloud point (point at which wax begins to form) the wax crystals will
cause power loss or will prevent the engine from starting.
IMPORTANT: In cold weather, ll the fuel tank at the end of the day’s work to prevent condensation from forming.
FUEL STORAGE
Long storage can lead to the accumulation of impurities and condensation in the fuel tank. Engine trouble can
often be traced to the presence of water in the fuel.
The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible.
Drain off water and impurities regularly.
Anti-freeze/Anti-corrosion
Use anti-freeze in all seasons to protect the cooling system from corrosion and all risk of freezing.
CASE AKCELA PREMIUM ANTI-FREEZE LRD -25°C
For environments with temperatures falling to - 25 °C, do not mix with water.
CASE AKCELA PREMIUM ANTI-FREEZE (MS 1710)
For environments with temperatures falling to - 38 °C, use with water in a proportion of 50/50.
IMPORTANT: Do not mix products of a different origin or a different make.
The system must be topped up with the same product.
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INTRODUCTION
Environment
Before carrying out any servicing operation on this machine and before disposing of used uids or lubricants, always
think of the environment. Never throw uid or oil on the ground and never keep them in leaking receptacles.
Contact your local ecological recycling centre for information on appropriate ways to dispose of these substances.
Components made from plastic or resin

When cleaning plastic parts, (the console, the instrument panel, the indicators etc...) avoid using petrol, parafn,
paint solvents etc.
Use only water, soap and a soft cloth. The use of petrol, parafn, paint solvents, etc, will cause discoloration,
cracking or deformation of these components.
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INTRODUCTION
Hydraulic contamination ( - A.92.A.60)

CX225SR
CLEANING THE HYDRAULIC SYSTEM
General
Contamination of the hydraulic system is a major cause of incorrect operation of hydraulic components.
Contamination is indicated by the presence of foreign particles in the hydraulic uid.
Contamination of the hydraulic system can occur in any of the following situations:
1. When draining the uid or disconnecting a hydraulic line.
2. When disassembling a component.
3. Due to normal component wear.
4. Due to damaged or worn seals.
5. Due to a damaged component in the hydraulic system.
All hydraulic systems can function even if they are slightly contaminated. The components of the hydraulic system
are designed to support slight contamination. Any increase in the degree of contamination can cause serious
problems in the hydraulic system.
The following is an incomplete list of these problems:

1. The cylinder rod seals leak.
2. Control valve spools do not return to the neutral position.
3. Control valve spools do not move easily.
4. Hydraulic uid is too hot.
5. Hydraulic components wear quickly.
6. Safety valves or check valves do not close due to contamination.
7. Repaired components break down soon.
8. Cycles are slow; the machine does not have enough power.
If any of the above situations occurs, it is an indication of excessive contamination of the hydraulic system.
To eliminate contamination, effectively, refer to PRIMARY HYDRAULIC POWER SYSTEM - Decontaminating
(A.10.A - F.30.A.60).
Types of contamination
Contamination exists basically in two forms: microscopic or visible.
We speak of microscopic contamination when very small particles of foreign bodies are in suspension in the
hydraulic uid. These particles are too small to be seen or felt. Microscopic contamination can be detected by
identifying the problems relating to microscopic contamination or by laboratory tests.
The following are a few examples of problems caused by microscopic contamination:

• The cylinder rod seals leak.
• Control valve spools do not return to the neutral position.
• The operating temperature of the hydraulic system is too high.
• Components wear quickly.
We speak of visible contamination when the presence of foreign bodies can be detected visually, by touch or by
smell. Visible contamination can cause the sudden failure of a component.
The following are a few examples of problems caused by visible contamination:
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INTRODUCTION
• The uid contains metal or other fragments.

• The uid contains air. The uid is dark and thick.
• There is a smell of burning in the uid. The uid contains water.
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INTRODUCTION
Product identication ( - A.80.A.10)

CX225SR WE
NOTE: For all parts orders, requests for information or assistance, always specify the type and the serial number of
the machine to your CASE dealer.
Fill out the following lines with the required information: type, year of manufacture, serial number of the machine
(manufacturer’s plate), mark, type and serial number of the engine, and serial numbers of hydraulic components.
Manufacturer’s plate
CRIL03H001E01 1
(1) TYPE (2) YEAR OF MANUFACTURE (3) SERIAL NUMBER
Engine
MAKE TYPE SERIAL NUMBER
Serial numbers of hydraulic components

COMPONENTS SERIAL NUMBER
Hydraulic pump
Swing reduction gear
Travel reduction gear
Travel control valve
Attachment control valve
Swing control valve
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INTRODUCTION
Product identication ( - A.80.A.10)

CX225SR NA
NOTE: For all parts orders, requests for information or assistance, always specify the type and the serial number of
the machine to your CASE dealer.
Fill out the following lines with the required information: type, year of manufacture, serial number of the machine
(manufacturer’s plate), make, type and serial number of the engine and serial numbers of hydraulic components.
Manufacturer’s plate
CRIL03I175E01 1
(1)TYPE (2)YEAR OF MANUFACTURE (3)SERIAL NUMBER
Engine
MAKE TYPE SERIAL NUMBER
Serial numbers of hydraulic components

COMPONENTS SERIAL NUMBER
Hydraulic pump
Swing reduction gear
Travel reduction gear
Travel control valve
Attachment control valve
Swing control valve
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INTRODUCTION
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REPAIR MANUAL
DISTRIBUTION SYSTEMS
CX225SR
26019 1 02/12/2004
A
Contents
DISTRIBUTION SYSTEMS - A
PRIMARY HYDRAULIC POWER SYSTEM A.10.A

CX225SR
HYDRAULIC COMMAND SYSTEM A.14.A

CX225SR
ELECTRICAL POWER SYSTEM A.30.A

CX225SR
LIGHTING SYSTEM A.40.A

CX225SR
26019 1 02/12/2004
A
PRIMARY HYDRAULIC POWER SYSTEM - 10.A
CX225SR
26020 1 02/12/2004
A.10.A / 1
Contents
TECHNICAL DATA
PRIMARY HYDRAULIC POWER SYSTEM - General specication (A.10.A - D.40.A.10) 5
CX225SR

CX225SR
PRIMARY HYDRAULIC POWER SYSTEM - Special tools (A.10.A - D.20.A.40) 9

CX225SR WE

CX225SR NA
PRIMARY HYDRAULIC POWER SYSTEM - Seed rates (A.10.A - D.50.A.60) 13

CX225SR
Hydraulic pump
Hydraulic pump - Special tools (A.10.A.20 - D.20.A.40) 15
CX225SR
Hydraulic pump - Service limits (A.10.A.20 - D.20.A.20) 18

CX225SR
FUNCTIONAL DATA
PRIMARY HYDRAULIC POWER SYSTEM - Static description (A.10.A - C.30.A.20) 19
CX225SR
PRIMARY HYDRAULIC POWER SYSTEM - Dynamic description (A.10.A - C.30.A.10) 20

CX225SR
Stack valve
Stack valve - External view (A.10.A.18 - C.10.A.40) 23
CX225SR
Stack valve - Sectional view (A.10.A.18 - C.10.A.30) 26

CX225SR
Stack valve Inlet section - Sectional view (A.10.A.18.10 - C.10.A.30) 31

CX225SR
Stack valve Outlet section - Sectional view (A.10.A.18.20 - C.10.A.30) 32

CX225SR
Hydraulic pump
Hydraulic pump - Sectional view (A.10.A.20 - C.10.A.30) 33
CX225SR
Compensator
Compensator - Sectional view (A.10.A.23 - C.10.A.30) 37
CX225SR
Sensing system
Sensing system Temperature sensor - Electronic schema (A.10.A.95.90 - C.20.A.50) 38
CX225SR
Powerboost system
26020 1 02/12/2004
A.10.A / 2
Powerboost system - Electronic schema (A.10.A.10 - C.20.A.50) 39
CX225SR
SERVICE
PRIMARY HYDRAULIC POWER SYSTEM - Warm up (A.10.A - F.35.A.40) 40
CX225SR
PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A - F.35.A.51) 41

CX225SR
PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20) 42

CX225SR
PRIMARY HYDRAULIC POWER SYSTEM - Bleed (A.10.A - F.35.A.25) 43

CX225SR
PRIMARY HYDRAULIC POWER SYSTEM - Pressure test (A.10.A - F.40.A.30) 44

CX225SR
PRIMARY HYDRAULIC POWER SYSTEM - Decontaminating (A.10.A - F.30.A.60) 46

CX225SR
Stack valve
Stack valve - Remove (A.10.A.18 - F.10.A.10) 48
CX225SR
Stack valve - Overhaul (A.10.A.18 - F.10.A.40) 49

CX225SR
Stack valve Outlet section - Disassemble (A.10.A.18.20 - F.10.A.25) 50

CX225SR
Stack valve Inlet section - Disassemble (A.10.A.18.10 - F.10.A.25) 51

CX225SR
Stack valve - Visual inspection (A.10.A.18 - F.40.A.10) 52

CX225SR
Stack valve Inlet section - Assemble (A.10.A.18.10 - F.10.A.20) 53

CX225SR
Stack valve Outlet section - Assemble (A.10.A.18.20 - F.10.A.20) 54

CX225SR
Stack valve - Install (A.10.A.18 - F.10.A.15) 55

CX225SR
Relief valve
Relief valve - Disassemble (A.10.A.16 - F.10.A.25) 56
CX225SR
Relief valve - Assemble (A.10.A.16 - F.10.A.20) 57

CX225SR
Relief valve - Pressure test (A.10.A.16 - F.40.A.30) 58

CX225SR
Relief valve - Pressure setting (A.10.A.16 - F.45.A.70) 59

CX225SR
Powerboost system
Powerboost system Electrovalve - Electrical test (A.10.A.10.15 - F.40.A.50) 60
CX225SR
Hydraulic pump
Hydraulic pump - Remove (A.10.A.20 - F.10.A.10) 61
CX225SR
Hydraulic pump - Disassemble (A.10.A.20 - F.10.A.25) 63

CX225SR
Hydraulic pump - Assemble (A.10.A.20 - F.10.A.20) 70

CX225SR
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Hydraulic pump - Install (A.10.A.20 - F.10.A.15) 80
CX225SR
Hydraulic pump - Bleed (A.10.A.20 - F.35.A.25) 82

CX225SR
Hydraulic pump - Pressure test (A.10.A.20 - F.40.A.30) 83

CX225SR
Reservoir
Reservoir - Remove (A.10.A.22 - F.10.A.10) 84
CX225SR
Reservoir - Install (A.10.A.22 - F.10.A.15) 85

CX225SR
Compensator
Compensator - Disassemble (A.10.A.23 - F.10.A.25) 86
CX225SR
Compensator - Assemble (A.10.A.23 - F.10.A.20) 87

CX225SR
Oil lter
Oil lter - Remove (A.10.A.24 - F.10.A.10) 89
CX225SR
Oil lter - Install (A.10.A.24 - F.10.A.15) 90

CX225SR
Sensing system
Sensing system Temperature sensor - Electrical test (A.10.A.95.90 - F.40.A.50) 91
CX225SR
DIAGNOSTIC
PRIMARY HYDRAULIC POWER SYSTEM - Troubleshooting (A.10.A - G.40.A.10) 92
CX225SR
Stack valve
Stack valve - Troubleshooting (A.10.A.18 - G.40.A.10) 92
CX225SR
Relief valve
Relief valve - Troubleshooting (A.10.A.16 - G.40.A.10) 93
CX225SR
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
PRIMARY HYDRAULIC POWER SYSTEM - General specication

(A.10.A - D.40.A.10)
CX225SR
Capacities
Total hydraulic circuit 206 L
Hydraulic uid reservoir 120 L
Coolant only 6.1 L
Main hydraulic pump

Variable ow twin pump, with axial pistons.
Maximum ow 2 x 190 L/min

Displacement 2 x 96.7 cm³
Hydraulic control pump

Fixed ow pump
Maximum ow 22 L/min

Displacement 11 cm³
Calibration pressure
Pilot circuit main relief valve (± 1 bar) 39 bar
Main relief valve (standard) (± 3 bar) 343 bar
Main relief valve (power boost) (± 5 bar) 373 bar
Secondary relief valve (boom, dipper and bucket) ( ± 5 bar) 392 bar
Secondary relief valve (swing) (± 4 bar) 304 bar
Secondary relief valve (travel) (± 5 bar) 343 bar
Secondary relief valve (boom and dipper) (± 5 bar) 392 bar
Boom cylinder
Barrel diameter 125 mm
Rod diameter 90 mm
Stroke 1284 mm
Dipper cylinder
Rod diameter 95 mm
Stroke 1474 mm
Bucket cylinder
Rod diameter 80 mm
Stroke 1012 mm
Cylinder leakage - attachment lowering (without load)

Boom cylinders (rod retraction) 5 mm/5 mn
Dipper cylinder (rod extension) 5 mm/5 mn
Bucket cylinder (rod extension) 7 mm/5 mn
Full (at the end of the attachment) 200 mm/10 mn
Cylinder speed
Boom raising (bucket open and on the ground) 3.5+/-0.6 s
Boom lowering (bucket open) 2.9+/-0.6 s
Arm opening 2.7+/-0.6 s
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Arm closing 3.7+/-0.6 s

Bucket opening 2.3+/-0.6 s
Bucket closing 4+/-0.6 s
Control valve
Five-section control valve for dipper, boom acceleration, swing, option and right travel.
Four-section control valve for dipper acceleration, bucket, boom and left travel.
Load holding relief valve for boom and dipper.
Swing motor
Fixed ow motor with axial pistons.
Automatic disk brakes.
Chassis upperstructure swing speed 11.2 RPM

Working ow 155 L/min
Reduction ratio 16.757
Braking torque 857 Nm
Minimum brake release pressure 32 bar
Acceptable motor leakage 16 L/min
Travel motor
Two-speed motor with axial pistons.
Automatic disk brakes.
Slow speed 3.1 km/h

High speed 5 km/h
Gradeability 70 % (35°)
Tractive effort 19 100 daN
Displacement 168.9 cm³
100.3 cm³
Working ow 212 L/min
Reduction ratio 43.246
Braking torque (excluding reduction gear) 483 Nm
Permissible deviation in travel over a distance of 20 m (full speed) 1m
Acceptable motor leakage 13 L/min
Attachment
Breakout force 13000 daN
Breakout force (dipper 3 m) 9530 daN
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PRIMARY HYDRAULIC POWER SYSTEM - General specication

(A.10.A - D.40.A.10)
CX225SR
CRIL04B040H01 1
Location of secondary relief valves
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Calibration pressure
Item Description Secondary Nominal Pressure For pressure setting
relief pressure with one procedures,
pressure read on the turn of the refer to:
setting machine screw
(* or for a
shim)
(A) Main relief valve(standard 343 bar to 346 bar 217 bar Relief valve - Pressure setting
pressure) 120 L/min (A.10.A.16 - F.45.A.70)
Main relief valve (power boosted 373 bar to 373 bar 290 bar Relief valve - Pressure setting
pressure) 108 L/min (A.10.A.16 - F.45.A.70)
(B) Boom raising port secondary 392 bar to 405 bar 212 bar Relief valve - Pressure test
relief 20 L/min (H.20.B.16 - F.40.A.30)
(B1) Boom cylinder safety valves 392 bar to 405 bar - Safety valve - Pressure
(B2) secondary relief 20 L/min setting (H.20.B.15 - F.45.A.70)
(C) Boom lowering port secondary 392 bar to 407 bar 212 bar Relief valve - Pressure test
relief 20 L/min (H.20.B.16 - F.40.A.30)
(D) Dipper out port secondary relief 392 bar to 400 bar 212 bar Relief valve - Pressure test
20 L/min (H.25.B.16 - F.40.A.30)
(D1) Dipper cylinder safety valves 392 bar to 400 bar - Safety valve - Pressure
secondary relief 20 L/min setting (H.25.B.15 - F.45.A.70)
(E) Dipper in port secondary relief 392 bar to 400 bar 212 bar Relief valve - Pressure test
20 L/min (H.25.B.16 - F.40.A.30)
(F) Bucket open port secondary 392 bar to 408 bar 212 bar Relief valve - Pressure test
relief 20 L/min (H.30.C.16 - F.40.A.30)
(G) Bucket close port secondary 392 bar to 408 bar 212 bar Relief valve - Pressure test
relief 20 L/min (H.30.C.16 - F.40.A.30)
(H) Pilot circuit main relief 39 bar 43 bar 30 bar Relief valve - Pressure test
(A.14.A.16 - F.40.A.30)
(I) RH swing port secondary relief 304 bar to 325 bar 5 bar* Relief valve - Pressure test
122 L/min (F.40.C.16 - F.40.A.30)
(J) LH swing port secondary relief 304 bar to 325 bar 5 bar* Relief valve - Pressure test
122 L/min (F.40.C.16 - F.40.A.30)
(K) Forward travel secondary relief 343 bar 343 bar 60 bar Relief valve - Pressure test
(F.10.F.16 - F.40.A.30)
(L) Reverse travel secondary relief 343 bar 343 bar 60 bar Relief valve - Pressure test
(F.10.F.16 - F.40.A.30)
(N1) Negative pressure of pump 25.5 bar Hydraulic pump - Pressure
(N2) bodies (P1) and (P2) test (A.10.A.20 - F.40.A.30)
Pilot accumulator check Accumulator - Check
(A.14.A.30 - F.40.A.11)
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PRIMARY HYDRAULIC POWER SYSTEM - Special tools (A.10.A -

D.20.A.40)
CX225SR WE
Digital tester assembly
CRIL03G253E00 1
DESCRIPTION QUANTITY CODE
Tester assembly for Multi-Handy 2051 - E54444449
Multi-Handy 2051 tester 1 D5444448
Pressure sensor (0 bar to 600 bar) 2 V5344460
Straight union for sensor 2 W5344461
Elbow union for sensor 1 X5344462
Engine speed sensor 1 Z5344463
Cable (length 5 m) 3 E3144472
Electric plug 220 volts 50 Hz 1 D5344467
Cigarette lighter cable 1 E5344468
Instruction Sheet 1 -
Carrying case 1 N5344476
The Multi-Handy tester is used to:

Check pressure (two pressure scales)
Check differential pressure (delta P)
Check temperature
Check engine rpm
Check the ow
600 litre turbine
CRIL03G254E00 2
DESCRIPTION QUANTITY CODE
Turbine 1 RE3 Z5344486
Plates M45x2 2 D4323359
Flange diameter 24 mm 2 B8230183
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Semi-ange 4 D4024267
Screw M12 length 75 mm 8 Z1232983
Union assembly for testing pressure and ow
CRIL03G258E00 3
DESCRIPTION CODE
Union assembly for testing pressure and ow CAS30038
Set of high pressure hoses
CRIL03G259E00 4
DESCRIPTION CODE
Set of high pressure hoses CAS30036
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PRIMARY HYDRAULIC POWER SYSTEM - Special tools (A.10.A -

D.20.A.40)
CX225SR NA
Digital tester assembly for pressure measurement
CRIL03G255E00 1
DESCRIPTION CODE
Digital tester assembly for pressure measurement OEM1652
Digital tester assembly for pressure and temperature measurement
CRIL03G256E00 2
DESCRIPTION CODE
Digital tester assembly for pressure and temperature measurement OEM1653
Flowmeter
CRIL03G257E00 3
DESCRIPTION CODE
Flowmeter for a ow of < 75 GPM CAS10280
Flowmeter for a ow of > 75 GPM OEM1240
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Union assembly for testing pressure and ow
CRIL03G258E00 4
DESCRIPTION CODE
Union assembly for testing pressure and ow CAS40023A + CAS40035
Set of high pressure hoses
CRIL03G259E00 5
DESCRIPTION CODE
Set of high pressure hoses CAS30036
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PRIMARY HYDRAULIC POWER SYSTEM - Seed rates (A.10.A -

D.50.A.60)
CX225SR
CRIL04B043G01 1
Main pumps ow curve and pressure
VARIABLE POWER
• Two pumps under load at equal pressure
• Engine speed 2000 RPM
• Maximum displacement 96.7 cm³.
• Torque consumed pilot pump 9.0 Nm.
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CRIL04B043G02 2
Main pumps ow curve and pressure
VARIABLE POWER
• One pump under load
• Torque consumed pilot pump 9.0 Nm.
CRIL04B043G03 3
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Main pumps ow curve and pilot pressure

"Negative ow control" diagram
Hydraulic pump - Special tools (A.10.A.20 - D.20.A.40)

CX225SR
NOTE: The tools listed below are to be manufactured locally.

NOTE: Numbers in parentheses refer to Hydraulic pump - Sectional view (A.10.A.20 - C.10.A.30)
CRIL04B006E01 1
Used to install piston (69) and (70).

(A) 20 mm
(B) G1
(C) diameter 23 mm
(D) 56 mm
(E) diameter 4 mm
(F) Number of coils: 7
CRIL04B007E01 2
Used to install pusher bracket (47).

(A) 50 mm
(B) M12
(C) M12
(D) G3/4
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CRIL04B008E01 3
Used to install outer ring of taper roller bearing (4) on take-off shaft (3).
(A) 125 mm
(B) 105 mm
(C) diameter 46 mm
(D) diameter 56 mm
CRIL04B009E01 4
Used to protect seal (37) when reinstalling on seal holder (45).

(A) M8
(B) 95 mm
(C) 70 mm
(D) diameter 44 mm
(E) diameter 46 mm
(F) 69 mm
(G) 18 °
CRIL04B010E01 5
Used to install seal (37) on seal holder (45).
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(A) 53 mm
(B) 10 mm
(C) 12 mm
(D) 2 mm
(E) diameter 30 mm
(F) diameter 45 mm
(G) diameter 82 mm
(H) 30 °
CRIL04B011E01 6
Bushing (1)
Used to calculate the thickness of shims (2).
(A) diameter 11 mm
(B) diameter 116.5 mm
(C) 120 °
(D) 18 mm
(E) diameter 101 mm
(F) diameter 134.5 mm
CRIL04B012E01 7
Bushing (2)
Used to calculate the thickness of shims (2).
(A) 20.5 mm
(B) diameter 84 mm
(C) diameter 99.4 mm
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Hydraulic pump - Service limits (A.10.A.20 - D.20.A.20)

CX225SR
Description of parts Wear Limit Control Action

instrument
Clearance between the piston and 0.04 mm or less Micrometer Replace the cylinder assembly
the cylinder bore
Valve plate (sliding contact surface 0.8 Ra Gauge Polish the surface with a stone
roughness)
Cylidner barrel (sliding contact 0.4 Ra Gauge Polish the surface with a stone
surface roughness)
Swash plate (roughness) 0.8 Ra Gauge Polish the surface with a stone
Piston assembly (roughness on 0.8 Ra Gauge Polish the surface
contact surface of shoes)
Clearance between pistons and 0.4 mm or less Gauge Replace the parts
shoes
Scratches on the sliding surface of 0.4 mm or more Gauge Replace the parts
the shoes
Inspection of barrel, pistons and bearings

Cylinder bores Replace the cylinder barrel if the bores show signs of
scratches or seizing.
Pistons Replace any pistons showing signs of scratches or
seizing.
Taper roller bearings and needle bearings Replace any interior or exterior bearing rings showing
signs of scratching.
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PRIMARY HYDRAULIC POWER SYSTEM - Static description (A.10.A

- C.30.A.20)
CX225SR
The hydraulic diagram is available as a poster at the end of this manual.

For easier understanding, the same legend is used for components appearing in the hydraulic sections and on
the poster.
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PRIMARY HYDRAULIC POWER SYSTEM - Dynamic description

(A.10.A - C.30.A.10)
CX225SR
TRAVEL
Functions Description Refer to
HIGH SPEED High speed is obtained by changing the travel motors TRAVELLING Travel - Hydraulic
from large displacement to small displacement. schema (F.10.F - C.20.A.20)
When the pressure increases too much, the motors
automatically change to low speed.
When the pressure drops below 39 bar, the motors
automatically change to high speed.
LOW SPEED Low speed is obtained when the travel motors are TRAVELLING Travel - Hydraulic
changed to high displacement. schema (F.10.F - C.20.A.20)
STRAIGHT-LINE If you want to use the attachment or the swing during TRAVELLING Travel - Hydraulic
TRAVEL travel, the machine will continue in a straight line without schema (F.10.F - C.20.A.20)
zig-zagging.
SWING
BRAKING When the swing control is in the neutral position, the SWINGING Circular swing -
motor and reduction gear assembly is braked. Hydraulic schema (F.40.C -
When the swing is operated, the motor and reduction C.20.A.20)
gear assembly brake is released.
The swing is braked 5 seconds after putting the control
into neutral or when the attachment is no longer
operated.
PRIORITY The swing torque is maintained by the priority valve SWINGING Circular swing -
incorporated in the control valve. Hydraulic schema (F.40.C -
When working in a trench, the swing variable priority C.20.A.20)
valve is activated to provide sufcient ow to the dipper.
ANTI-REBOUND This function reduces the number of rebounds when the SWINGING Circular swing -
swing is stopped. Hydraulic schema (F.40.C -
A protective valve is mounted on the swing motor. C.20.A.20)
ATTACHMENT
BOOM LIFTING An internal spool is used to provide two ows when BOOM Lift - Hydraulic schema
raising the boom. (H.20.B - C.20.A.20)
BOOM LOWERING, Boom lowering is made possible by unlocking the load BOOM Lift - Hydraulic schema
LOAD HOLDING holding system which is incorporated in the control valve. (H.20.B - C.20.A.20)
BOOM LOWERING, Acceleration and ow reduction pressure information BOOM Lift - Hydraulic schema
ADDITIONAL are controlled via the fuel return circuit in the boom (H.20.B - C.20.A.20)
SUPPLY valve spool and the continuous connection between the
supply and the return.
BOOM LOWERING, The pressure points are controlled by the circuit which BOOM Lift - Hydraulic schema
VIBRATION keeps part of the supply ow for the free passage. This (H.20.B - C.20.A.20)
PREVENTION is used to reduce vibration.
DIPPER OUT An internal spool provides two ows for the dipper. DIPPER Lift - Hydraulic schema
(H.25.B - C.20.A.20)
DIPPER IN, LOAD Dipper in is made possible by unlocking the load holding DIPPER Lift - Hydraulic schema
HOLDING system that is incorporated in the control valve. (H.25.B - C.20.A.20)
DIPPER IN, The additional supply cancellation valve makes DIPPER Lift - Hydraulic schema
ADDITIONAL combined movements quicker. (H.25.B - C.20.A.20)
SUPPLY
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CUSHION VALVE Shocks experienced when the attachment stops moving
are reduced by the cushion valve which incorporates
pilot heating.
BUCKET OPENING ARM TOOL ATTACHMENT Tilt
AND CLOSING - Hydraulic schema (H.30.C -
C.20.A.20)
OPTION An option section incorporated in the control valve can DIGGING Hammer - Hydraulic
be used as a breaker or a grab, for example. schema (J.20.E - C.20.A.20)
OTHERS
PUMP FLOW Is used to reduce power consumption by decreasing the See following page
REDUCTION INFO pump ow when the machine is not under load or the
controls are in neutral.
CRIL04A070G01 1
Controls in neutral position
(1) Pressure limiter (2) Pressure limiter
(3) Calibrated port (4) Calibrated port
(15) Main control valve (B26) Upper pilot pressure switch
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(B27) Travel pilot pressure switch (P1) Pump D2 outlet ow

(P2) Pump D1 outlet ow 1 (PP) Flow at pilot pump outlet D3
• In neutral with the engine running, some of the ow from the low pressure pump (D3) fed to (PP) is divided by
a calibrated restrictor bridge. One part passes through the two travel spools, and the other passes through all
the other spools before rejoining the general return circuit. When the spools are moved, these circuits will be
locked, which will close upper pilot (B26) and travel pilot (B27) pressure switches.
• Pump outlet (D2) enters (P1) on the control valve, while pump (D1) enters in (P2), passing through the control
valve via the free passages. They are controlled by two pressure limiters (1) and (2) set to 25.5 bar under
50 L/min and two restrictors (3) and (4). Both these pressures are sent to the HP pumps via ports (Ps1)
and (Ps2) to set them at minimum ow.
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Stack valve - External view (A.10.A.18 - C.10.A.40)

CX225SR
CRIL04A071G01b 1
Control valve block - Identication of ports
Port Description Port Description

(A1) RH forward travel (A2) Option circuit
(A3) Swing left (A5) Arm opening
(A6) LH forward travel (A7) Bucket closing
(A8) Boom raising (B1) RH reverse travel
(B2) Option circuit (B3) Swing right
(B5) Arm closing (B6) LH reverse travel
(B7) Bucket opening (B8) Boom lowering
(Dr) Leak-off return (P1-P2) Main pump pressure
(P3-P3) Flow reinjection (option) (PA) Attachment and swing pressure switch
(PT) Travel pressure switch (PP) Pilot pump pressure
(Pbu) Swing priority cancellation (Pc1) Dipper load holding
(Pc2) Boom load holding (Pc3) Priority to swing
(Ph) Main relief valve power boost (Ps1-Ps2) Negative pressure
(T1-T2) Return (T3) Swing return
(T4) By-pass return (T5) Towards cushion valve - heating
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CRIL04A88H01 2
Control valve block - description
Description of control valve block

(1) Control valve block (P1) (13) Control valve block (P2)
(32) Valve (33) Spring
(37) Flange (43) Flange
(52) Flange (57) Spacer
(68) Main safety valve (69) Secondary relief valve
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(72) Plug (74) Spool cap screw

(75) Screw (76) Load holding valve xing screws
(77) Control valve block xing screws (78) Swing priority cap xing screws
(81) Washer (87) Plug
(88) Cap (89) Seal
(92) Plug (93) Plug
(96) Plug (A-A) Refer to Stack valve - Sectional view
(A.10.A.18 - C.10.A.30)
(B-B) Refer to Stack valve - Sectional view (A.10.A.18 - (M-M) Refer to Stack valve - Sectional view
C.10.A.30) (A.10.A.18 - C.10.A.30)
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Stack valve - Sectional view (A.10.A.18 - C.10.A.30)

CX225SR
CRIL04A089G01 1
Section A-A - Control valve block (P1)
(5R) Spool assembly - RH travel (7) Seal

(8) Large cap with pilot port (9) Large cap
(10) Small cap (12) Small cap with pilot port
(14) Spool assembly - dipper 1 (15) Spool assembly - boom 2
(16) Spool assembly - swing (17) Spool assembly option (grab/hammer)
(41) Load holding valve watertight seal (42) Load holding valve watertight seal
(63) Port plug (70) Negative pressure valve
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CRIL04A090G01 2
Section B-B - Control valve block (P2)
(1) Control valve block (P2) (2) Spool assembly - dipper 2

(3) Spool assembly - boom 1 (4) Spool assembly - bucket
(5L) Spool assembly - LH travel (6) Straight-line travel spool assembly
(7) Seal (8) Large cap with pilot orice
(9) Large cap (10) Small cap
(12) Small cap with pilot orice (41) Load holding valve watertight seal
(42) Load holding valve watertight seal (70) Negative pressure valve
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CRIL04A103G01 3
Section M-M - Watertight seal between the two control valve blocks
(65) Seal (66) Seal
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CRIL04A102G01 4
Other sections
Section Description Refer to

(C-C) Output section with swing priority spool and dipper Stack valve Outlet section - Sectional view
recycling valve (A.10.A.18.20 - C.10.A.30)
(D-D) Dipper section 1 and 2 Control valve - Sectional view (H.25.B.14 -
C.10.A.30)
(E-E) Boom 1 and 2 section Control valve - Sectional view (H.20.B.14 -
C.10.A.30)
(F-F) Swing and bucket section Control valve - Sectional view (F.40.C.14 -
C.10.A.30)
Control valve - Sectional view (H.30.C.13 -
C.10.A.30)
(G-G) Option and LH travel section Control valve - Sectional view (J.20.E.14 -
C.10.A.30)
Control valve - Sectional view (F.10.F.14 -
C.10.A.30)
(H-H) RH travel and straight-line spool section Control valve - Sectional view (F.10.F.14 -
C.10.A.30)
(I-I) Inlet section with main relief valve and check valves Stack valve Inlet section - Sectional view
(A.10.A.18.10 - C.10.A.30)
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(J-J) Restrictor bridge (60) on port (PP) (pilot pressure)

and port (PT) (upper pilot pressure switch)
CRIL04A104A01 5
(K-K) Union (61) on port (PA) (travel pilot pressure switch)
CRIL04A105A01 6
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Stack valve Inlet section - Sectional view (A.10.A.18.10 - C.10.A.30)

CX225SR
CRIL04A109G01 1
Section I-I
(34) Valve
(35) Spring
(53) Spacer
(54) Seal
(55) Back-up ring
(68) Main relief valve
(92) Plug
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Stack valve Outlet section - Sectional view (A.10.A.18.20 - C.10.A.30)

CX225SR
CRIL04A110G01 1
Section C-C - Swing priority spool and dipper recycling valve.
(18) Cap (19) Swing priority spool

(20) Spring seat (21) Spring
(22) Spool end (23) Seal
(24) Plug (25) Seal
(26) Spring (27) Recycling spool
(30) Seal (31) Back-up ring
(72) Plug
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Hydraulic pump - Sectional view (A.10.A.20 - C.10.A.30)

CX225SR
CRIL04A181H01 1
(1) Support (2) Shim

(3) Take-off shaft (4) Taper roller bearing
(5) Screw (6) Support
(7) Body (8) Swash plate
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(9) Retaining plate (10) Piston

(11) Snap ring (12) Pinion
(13) Seal (14) Cylinder barrel
(15) Valve plate (16) Centring stud
(17) Screw (18) Needle roller bearing
(19) Screw (20) Seal
(21) Coupling (22) Control pump
(23) Spring (24) Bushing
(25) Ring (26) Screw
(27) Seal (28) Plate
(29) Seal (30) Cover
(31) Seal (32) Valve plate
(33) Centring stud (34) Spring
(35) Spherical bushing (36) Seal
(37) Seal (38) Screw
(39) Driving shaft (40) Regulator block
(41) Regulator cartridge (42) Safety valve
(43) Safety block (44) Regulator cartridge
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CRIL04A182H01a 2
(45) Seal carrier (46) Pusher bracket

(47) Pusher (48) Piston
(49) Spring seat (50) Spring
(51) Stop (52) Seal
(55) Body (56) Screw
(57) Nut (58) Spring
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(59) Bushing (60) Seal

(61) Body (62) Screw
(63) Nut (64) Stop
(67) Spring (68) Seal
(69) Piston (70) Piston
(71) Sleeve (72) Regulator block
(73) Pusher (74) Swash plate
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Compensator - Sectional view (A.10.A.23 - C.10.A.30)

CX225SR
CRIL04A100G01 1
(1) Control lever (2) Spring

(3) Centring stud (4) Spring
(5) Nut (6) Washer
(7) Stop (8) Spring guide
(9) Cover (10) Seal
(11) Spring seat (12) Liner
(13) Spool (14) Piston
(15) Body (16) Seal
(17) Cover (18) Screw
(19) Piston
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Sensing system Temperature sensor - Electronic schema

(A.10.A.95.90 - C.20.A.50)
CX225SR
CRIL03K145F01 1
Circuit layout
(1) Coolant temperature indicator (2) Coolant or hydraulic oil overheating indicator
lamp
(3) Audible alarm device (A2) Engine electronic control box
(B1) Coolant solution temperature sensor (B9) Coolant solution temperature sensor
(B10) Hydraulic oil temperature thermo-switch (P1) Instrument panel
CRIL03G094E03 2
Timing diagram
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Powerboost system - Electronic schema (A.10.A.10 - C.20.A.50)

CX225SR
CRIL04B074F01 1
Circuit layout
(K28) Power boost solenoid valve relay

(P1) Instrument panel
(S29) Power boost switch
(Y5) Power-up solenoid valve (yellow band)
CRIL04B075F01 2
Timing diagram
(1) Operational power boost
OPERATION
• When the power boost switch (S29) is operated, a signal is sent to instrument panel (P1). This activates
relay (K28) and thus also power boost solenoid valve (Y5) for about 8 seconds. During these 8 seconds,
the main relief valve is overcalibrated.
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PRIMARY HYDRAULIC POWER SYSTEM - Warm up (A.10.A -

F.35.A.40)
CX225SR
1. Start the engine. The engine takes 10 to 15 minutes

to warm up.
2. With the engine running at full speed, operate the
bucket and dipper controls in one direction (against
the cylinder stops) for 30 seconds.
3. Actuate the bucket and dipper control in the other
direction (against the cylinder stops) for 30 seconds.
4. Repeat steps 2 and 3 until the hydraulic temperature
reaches 44 - 55 °C.
5. Operate the boom, swing and travel controls in both
directions to warm up all the circuits to 44 - 55 °C.
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PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A -

F.35.A.51)
CX225SR
DANGER
M252A - Hydraulic uid escaping under pressure can have enough force to penetrate the skin. Hydraulic
uid may also infect a minor cut or opening in the skin. If injured by escaping uid, see a doctor at
once. Serious infection or reaction can result if medical treatment is not given immediately. Make sure
all connections are tight and that hoses and lines are in good condition before applying pressure to the
system. Relieve all pressure before disconnecting the lines or performing other work on the hydraulic
system. To nd a leak under pressure use a small piece of cardboard or wood. Never use hands.
IMPORTANT: This operation must be carried out before any work is done on the hydraulic circuit.
1. Park the machine on hard, at ground.
2. Open the bucket until the cylinder rod is completely
retracted.
3. Extend the dipper until the cylinder rod is completely
retracted.
Lower the boom so that the end of the dipper is
resting on the ground.
Lower the tool to the ground.
4. Slow the engine speed to idle for 30 seconds, then

switch off the engine.
5. Turn the starter switch key to "ON" without starting
the engine.
6. Lower the pilot control cancellation lever.
7. Operate each control more than 10 times in both
directions to release all pressure in the circuits.
8. Press button (1) located on the hydraulic reservoir
breather to release pressure in the reservoir.
CRIL04B099A01 1
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PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A -

F.35.A.20)
CX225SR
Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A - F.35.A.51)

Prior operation: Fuel ller aid - Remove (B.20.A.20 - F.10.A.10)
NOTE: It is recommended to install the vacuum pump before carrying out any work on the hydraulic circuit which
requires opening the circuit.
Installing this pump prevents uid loss when the circuit is opened.
This chapter describes the procedure for installing vacuum pump CAS-10193.
1. Remove plate (A) from the top of the hydraulic
reservoir.
Do not remove the reservoir seal.
CRIL04B100A01 1
2. To install the adapter plate with elbow union, refer

to PRIMARY HYDRAULIC POWER SYSTEM -
Special tools (A.10.A - D.20.A.40).
3. Connect the vacuum pump to the adapter plate
elbow union.
Connect the vacuum pump harness to the batteries.
4. Start the pump before carrying out any work on the
circuit.
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PRIMARY HYDRAULIC POWER SYSTEM - Bleed (A.10.A - F.35.A.25)

CX225SR
IMPORTANT: A hydraulic component and the circuit must be bled after the component has been replaced.
It is essential to ll the pump and motor housings and hydraulic components with oil before starting the machine.
Failure to comply with these two recommendations may damage the component (overheating and seizing).
IMPORTANT: Having bled the components, stop the engine for ve minutes and check for air bubbles in the
hydraulic uid in the reservoir.
1. To ll the housing and drain the hydraulic pump,
refer to Hydraulic pump - Bleed (A.10.A.20 -
F.35.A.25)
2. To bleed the attachment cylinders, extend and
retract each cylinder rod four or ve times without
bringing them up against the stops.
Repeat the operation three or four times, this time
bringing all the cylinder rods up against the stops.
3. To ll the housing and bleed the hydraulic swing
motor, refer to Hydraulic motor - Bleed (F.40.C.28
- F.35.A.25)
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PRIMARY HYDRAULIC POWER SYSTEM - Pressure test (A.10.A -

F.40.A.30)
CX225SR
CRIL04B065G01 1
Port identication marks
Description of ports and insertion diameters, adjusting screws

Port Description Location
Screw
(D1) Pump output (P2) SAE 6000 psi 1"
(D2) Pump output (P1) SAE 6000 psi 1"
(D3) Pilot pump output to Din3 G 1/2
(D4) Option pump output G 1/4
(S1) Main pump and pilot pump suction SAE 2000 psi 3"
(S2) Option pump intake G 3/4
(Pp) Pilot pump output G 1/2
(Din3) Pilot pump output from D3 G 1/2
(Dr) Leak-off circuit G 3/4
(Pd1) Plugged - Pressure test point G 1/4
(Pi1) Negative pressure G 1/4
(Pi2) Negative pressure G 1/4
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Port Description Location

Screw
(H) Pilot pressure adjusting screw (main relief valve)
(2) Pump bleed screw
(3) Adjusting screw on large pump adjustment spring
(4) Adjusting screw on small pump adjustment spring
(5) Adjusting screw on large pump adjustment spring
(6) Adjusting screw on small pump adjustment spring
(7) Adjusting screw on retaining spring for maximum plate tilt on pump 1
(8) Adjusting screw on retaining spring for maximum plate tilt on pump 2
(9) Maximum stop adjusting screw pumps P1 and P2
(M1) Working pressure (port (Pd1) on main pump (D1))
• LH travel
• Boom
• Bucket
(M2) Working pressure (port (Pd2) on main pump (D2))
• R.H. travel
• Swing
• Dipper
(M3) Pilot pressure (port (Pd3) on pilot pump (D3) or port (P2) on the pilot circuit lter)
For pressure setting values, refer to PRIMARY HYDRAULIC POWER SYSTEM - General specication (A.10.A -
D.40.A.10)
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PRIMARY HYDRAULIC POWER SYSTEM - Decontaminating (A.10.A

- F.30.A.60)
CX225SR

Prior operation: To remove the electric pump for lling with fuel, refer to Fuel ller aid - Remove (B.20.A.20
- F.10.A.10)
Prior operation: To remove the protective panel from the hydraulic reservoir, refer to Upper shield - Remove
(E.20.A.71 - F.10.A.10)
Prior operation: To remove the lower access panel to the hydraulic reservoir, refer to Protective shield - Remove
(E.20.A.73 - F.10.A.10)
1. Prepare portable lter CAS10162A as follows:

Expel all hydraulic uid from the portable lter inlet
and outlet hoses.
Remove the portable lter cartridge.
Expel all hydraulic uid from the portable lter.
Clean the interior of the cartridge housing.
Install a new lter cartridge.
CRIL03I082A 1
2. Drain the hydraulic uid from the reservoir and clean

the reservoir, see the Operator’s Manual.
NOTE: Do not re-install the drain plug on the hydraulic
reservoir.
3. Replace the breather element and the return lter
and clean the intake lter, see the Operator’s
Manual.
NOTE: Do not install the plate and the breather.
4. Replace the pilot circuit lter, see the Operator’s
Manual.
5. Replace the Ultra Clean lter, see the Operator’s
Manual.
6. Install the valve from union kit (CAS 10508) on the
reservoir drain port.
Make sure that the valve is closed.
CAS10508-3 2
7. Fill the hydraulic reservoir with clean hydraulic uid,

see the Operator’s Manual.
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8. Install the inlet hose from the portable lter on the

valve under the hydraulic reservoir.
9. Install the long pipe from union kit (CAS 10508) on
the portable lter return hose.
10. Pass the long pipe into the hydraulic reservoir via
the breather port.
Move the intake lter long pipe as far away as
possible.
11. Open the valve under the hydraulic reservoir.
12. Install the portable lter on the upperstructure so
that the machine can be operated.
Attach the portable lter securely to the machine.
13. Connect the portable lter electric cable to the
battery.
Make sure that the electric cable is away from all
moving parts.
14. Start the portable lter.
15. Start the engine, run it at half speed for 10 minutes.
During those ten minutes, stir the hydraulic uid in
the hydraulic reservoir with the long pipe.
16. Bring the hydraulic uid to its operating temperature,
refer to PRIMARY HYDRAULIC POWER SYSTEM
- Warm up (A.10.A - F.35.A.40)
17. With the engine idling, stir the hydraulic uid in the
hydraulic reservoir for 10 minutes with the long pipe.
18. Shut down the portable lter and the engine.
19. Close the valve under the hydraulic reservoir.
20. Remove the inlet pipe from the valve under the
hydraulic reservoir.
21. Remove the long pipe from the hydraulic reservoir.
22. Disconnect the portable lter’s electric cable from
the battery.
Remove the portable lter from the machine.
23. Install a vacuum pump on the hydraulic reservoir,
refer to PRIMARY HYDRAULIC POWER SYSTEM
- Drain uid (A.10.A - F.35.A.20)
Start the vacuum pump.
24. Remove the valve from underneath the reservoir
and install the drain plug.
25. Stop and remove the vacuum pump.
26. Replace the return lter and clean the intake lter,
see the Operator’s Manual.
27. Replace the pilot circuit lter, see the Operator’s
Manual.
28. Replace the Ultra-Clean lter, see the Operator’s
Manual.
29. Check the hydraulic uid level.
Top up as necessary, see the Operator’s Manual.
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Stack valve - Remove (A.10.A.18 - F.10.A.10)

CX225SR
Prior operation: To remove the side protection panels from the hydraulic control valve, refer to Side shield -
Remove (E.20.A.70 - F.10.A.10)
Prior operation: To remove the valve bank hood, the front protection panels from the hydraulic control valve and
the valve bank hood bracket, refer to Upper shield - Remove (E.20.A.71 - F.10.A.10)
Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20)
1. Remove bracket xtures (5), then remove the

bracket.
2. Mark the position of the hoses (1) and electrical
connectors (2) on control valve block (3).
CRIL04C134B01 1
3. Disconnect the electrical connectors (2) from the

pressure switches.
4. Disconnect and plug hoses (1).
5. Plug the unions on control valve block (3).
6. Attach a suitable lifting device to the control valve
block (3).
7. Remove screws and (4) control valve block (3).
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Stack valve - Overhaul (A.10.A.18 - F.10.A.40)

CX225SR
NOTE: This section relates only to the control valve components not dealt with under functionalities. To nd the
functionalities, refer to Stack valve - Sectional view (A.10.A.18 - C.10.A.30) Other sections
IMPORTANT: Clean and check parts before assembling, refer to Stack valve - Visual inspection (A.10.A.18 -
F.40.A.10).
1. To separate components (1) and (13), remove
screws (77) and washers (81).
Replace seals (65) and (66), refer to Stack valve
- Sectional view (A.10.A.18 - C.10.A.30) section
(M-M).
When reassembling, tighten screws (77) to a torque
of 167 - 177 Nm.
2. Negative pressure valves (70) are not removable.
Only the seals should be replaced.
When reassembling, tighten valves (70) to a torque
of 103 - 113 Nm.
3. Tightening torques for the other components:
Restrictor bridge (60) - 103 - 113 Nm.
Plug (61) - 39 - 44 Nm.
Plug (63) - 14 - 18 Nm.
Plug (72) - 73 - 79 Nm.
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Stack valve Outlet section - Disassemble (A.10.A.18.20 - F.10.A.25)

CX225SR
1. SWING PRIORITY SPOOL

Remove plug (72) and discard the seal.
Remove spring (33) and valve (32).
Remove screws (78) and cap (18). Discard seal
(23).
Remove complete spool (19).
Remove screws from spool (22).
Remove springs (21) and seats (20).
NOTE: To avoid abrasion of the spoolvsurface during
dismantling of the spool assembly, use a soft-jawed vice
and clamp the spool as closely as possible to the head
in order to avoid any deformation. If the threaded part
of the screw is coated with locking uid, heat the screw CRIL04B004A01 1
head with an industrial drier until it can be removed easily
(usually the temperature should be 200 - 250 °C). If the
spring is damaged (impaired functioning) during this
operation, replace the spring.
2. DIPPER RECYCLING VALVE
Remove plug (24) and discard seal (25).
Remove spring (26) and spool/liner assembly (27).
Discard seals (30) and back-up rings (31).
CRIL04B005A01 2
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Stack valve Inlet section - Disassemble (A.10.A.18.10 - F.10.A.25)

CX225SR
CRIL04A109G02 1
Input section - cross-sectional view
1. Remove plugs (72) and (92). Discard seals.

2. Remove screws (75) and anges (52).
Extract spacers (53), springs (35) and valves (34).
Discard seals (54) and back-up rings (55).
3. Remove main relief valve (68).
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Stack valve - Visual inspection (A.10.A.18 - F.40.A.10)

CX225SR
NOTE: Clean all parts with a suitable light oil based product. Allow to air dry and place each part on a clean sheet
of paper or vinyl for inspection.
NOTE: Inspect the surface of each part for scratches, abrasion and other damage.
1. Check for scratches and dents on the check valve
seats in the control valve body and for traces of rust
and foreign matter.
2. Check for scratches and dents on the outer surface
of the spool. Remove small scratches with a piece
of cloth soaked in an abrasive product.
3. Check that all sliding surfaces move freely. Check
for the absence of foreign matter in passages and
grooves.
4. Check for deformed or worn springs.
5. Replace all seals and backup rings with new original
parts.
6. After removing the caps and plugs, make sure that
there is no trace of paint on the body ports or the
plug rims. (any trace of residual paint might lead
to contamination, which could cause the system to
malfunction and result in possible leaks).
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Stack valve Inlet section - Assemble (A.10.A.18.10 - F.10.A.20)

CX225SR
Prior operation: To clean and check parts before assembling, refer to Stack valve - Visual inspection (A.10.A.18
- F.40.A.10).
CRIL04A109G02 1
Input section - cross-sectional view
Torque settings
Valve (68) 78 - 88 Nm
Plug (72) 73 - 79 Nm
Screw (75) 39 - 44 Nm
Plug (92) 206 - 226 Nm
1. Install plugs (72) and (92) with new seals.
Tighten the plugs to the specied torque.
2. Install valves (34) and springs (35).
Install spacers (53) tted with seals (54) and new
back-up rings (55).
Install anges (52) with screws (75). Tighten the
screws to the required torque.
3. Install main relief valve (68) tted with a new seal.
Tighten the valve to the required torque.
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Stack valve Outlet section - Assemble (A.10.A.18.20 - F.10.A.20)

CX225SR
- F.40.A.10).
1. SWING PRIORITY SPOOL

Install spring (33) and check valve (32).
Install plug (72) with a new seal.
Tighten the plug (72) to a torque of 73 - 79 Nm.
Coat the threaded parts of spool (19) with thread
locking uid.
Clamp the end of the spool (spring side) in a
soft-jawed vice.
Install spring (21) and seats (20) on screw (22).
Install and tighten screws (22) to a torque of 19 -
22 Nm.
Fit complete spool (19) in the control valve.
Fit a new seal (23) on cap (18).
Install cap (18) with screws (78). CRIL04B004A01 1
Tighten screws (78) to a torque of 8.8 - 10.8 Nm.
2. DIPPER RECYCLING VALVE
Fit new seals (30) and (31) on liner (27B).
Install piston (27C) and spool (27A) on liner (27B).
CRIL03L049A02 2
3. Fit spring (26) and spool/liner assembly (27).

Install the plug (24) tted with a new seal (25).
Tighten the plug to a torque of 103 - 113 Nm.
CRIL04B005A01 3
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Stack valve - Install (A.10.A.18 - F.10.A.15)

CX225SR
1. Using a lifting device, position control valve block

(3) on its bracket.
CRIL04C134B01 1
2. Coat xing screws (4) with thread locking uid and

tighten them to a torque of 267 - 312 Nm.
Remove the lifting device.
3. Install and tighten supply and pilot hoses (1) on
control valve block (3) following the marks made
during removal.
4. Attach electrical connectors (2) to the pressure
switches following the marks made during removal.
5. Mount bracket (5).
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Relief valve - Disassemble (A.10.A.16 - F.10.A.25)

CX225SR
CRIL04A200F01 1
Main relief valve
(1) Nut (2) Adjusting screw for standard pressure

(3) Seal (4) Piston
(5) Spring (6) Awl
(7) Nut (8) Adjusting screw for power boost pressure
(9) Seal (10) Valve body
(11) Seal (12) Check valve seat
(15) Valve tip (16) Spring
(17) Valve
1. The valve is removed in the order of the marks on
the parts.
NOTE: Valve seat (12) should not be removed. It is

crimped to body (10).
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Relief valve - Assemble (A.10.A.16 - F.10.A.20)

CX225SR
CRIL04A200F01 1
Main relief valve
Refer to the disassembly process for a description of the parts.
1. Clean the parts, coat the threads with hydraulic oil

and replace the seals during assembly.
The valve is re-assembled in the reverse order of
the marks on the parts.
When installing body (10) on the control valve,
tighten it to a torque of 78 - 88 Nm.
Next operation: Relief valve - Pressure setting (A.10.A.16 - F.45.A.70)
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Relief valve - Pressure test (A.10.A.16 - F.40.A.30)

CX225SR
Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Warm up (A.10.A - F.35.A.40)

Prior operation: Check the pressure on pilot valve (H) and adjust it if necessary, refer to Relief valve - Pressure
setting (A.14.A.16 - F.45.A.70).
1. Connect a 0 - 600 bar pressure gauge to pressure

test point (M2).
2. With the engine at full speed, operate the dipper
retraction control (as far as the cylinder stop) and
hold it in this position.
Read the pressure gauge: the reading should be
343 ± 1 bar (34.3 ± 0.1 MPa).
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Relief valve - Pressure setting (A.10.A.16 - F.45.A.70)

CX225SR
1. SETTING THE POWER BOOST PRESSURE

Disconnect and plug the power boost pilot hose
from the main relief valve in (PH).
Using a wrench, hold adjusting screw (3) in position
and loosen lock nut (4).
Tighten adjusting screw (3) up to the stop. Tighten
lock nut (4).
Start the engine and run it at maximum speed,
select mode "N".
CRIL04B002A01 1
2. Operate the dipper retraction control (cylinder stop)

and hold it in this position.
Loosen lock nut (2) and turn adjusting screw (1)
until the power boost pressure is reached. Read the
pressure gauge: the reading should be 373 ± 1 bar
(37.3 ± 0.1 MPa).
Using a wrench, hold adjusting screw (1) and tighten
lock nut (2).
NOTE: Tighten screw (1) to increase the pressure.
Loosen screw (1) to reduce the pressure..
3. Check the pressure again. If the required pressure
is not reached, repeat step 2.
4. STANDARD PRESSURE ADJUSTMENT
and loosen lock nut (4).
Start the engine and run it at maximum speed,
select mode "N".
5. Operate the dipper retraction control (cylinder stop)

and hold it in this position.
Turn adjusting screw (3) until standard pressure is
reached.
Read the pressure gauge: the reading should be
343 ± 1 bar (34.3 ± 0.1 MPa).
and tighten lock nut (4).
6. Check the pressure again. If the required pressure
is not reached, repeat step 5
7. Shut down the engine.
Reconnect the power boost pilot hose to the main
relief valve in (PH).
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Powerboost system Electrovalve - Electrical test (A.10.A.10.15 -

F.40.A.50)
CX225SR
To carry out this test, use the solenoid valve electrical connector and a multimeter, refer to ELECTRICAL POWER
SYSTEM - Special tools (A.30.A - D.20.A.40).
1. Disconnect connector (1) from pilot pressure

solenoid valve (Y5).
CRIL04D002A03 1
2. Connect electrical connector on solenoid valve (3)

to connector (1) of solenoid valve (Y5) then install
multimeter (2).
CRIL03I078A05 2
3. The solenoid resistance reading for solenoid valve

(Y5) on multimeter (2) should be 45 ohms at a
temperature of 20 °C.
NOTE: The resistance value will vary depending on the
temperature.
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Hydraulic pump - Remove (A.10.A.20 - F.10.A.10)

CX225SR
Prior operation: Rear ballasting - Remove (F.20.B.61 - F.10.A.10)
Prior operation: Silencer - Remove (B.40.A.36 - F.10.A.10)
1. Remove the exhaust protection panel.

2. Remove xing screws (1) and washers (2) from
silencer bracket (3), then remove silencer bracket
(3).
CRIL04C149A01 1
3. Mark, remove and plug all the hoses connected to

the main pump and the control pump.
Remove and plug the suction and feed pipe on the
main pump.
CRIL04C150A00 2
4. Attach a suitable lifting device to the lifting rings to

support ange and pump assembly (1).
Do not leave any slack so that the lifting device
supports ange and pump assembly (1) as soon as
it is removed.
Remove screws (2) and washers (3) that secure
ange and pump assembly (1) to the engine.
CRIL04C151A01 3
5. Gently pull the ange and pump assembly

horizontally away from the exible coupling attached
to the engine ywheel.
Place the ange and pump assembly on a clean
bench.
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6. Remove splined sleeve (1) from the shaft of

main pump (2), refer to Drive system - Remove
(B.90.A.42 - F.10.A.10)
CRIL03J012A01 4
7. Remove xing screws and washers (1), then

remove main pump and control pump assembly (3)
from ange (2).
CRIL04C152A01 5
8. To remove the hydraulic control pump, refer to

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Hydraulic pump - Disassemble (A.10.A.20 - F.10.A.25)

CX225SR
1. Remove screws (1) and washers (2), then remove

control pump (3).
Remove bushing (4), coupling (5) and discard seal
(6).
If the main pump is equipped with a secondary
pump, remove screws (7), washers (8), secondary
pump (9), coupling (10) and discard seal (11).
CRIL04A074B01 1
2. If the main pump is not equipped with a secondary

pump, remove plate (1), screws (2) and discard the
seal.
CRIL04A075A01 2
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3. Remove screws (1) and safety block (2) from pump

body (3).
Discard seals.
Remove the safety valve.
CRIL04A076B01 3
4. Remove screws (1) and regulator block (2).

Remove sleeve (4) from cover (5).
NOTE: The regulator block can be hard to remove
because of the centring studs (3).
CRIL04A077B01 4
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5. Mark and remove regulator cartridge (1) and spring

(2).
Mark and remove regulator cartridge (3), spring (4),
spring seat (5), piston (6) and spool (7).
NOTE: Do not loosen nuts (8) on the regulator cartridges
(1) and (2) as this will change the ow.
CRIL04A078B01 5
6. Remove screws (1), seal holder (2), shims (3) and

discard seal (4).
CRIL04A079B01 6
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7. Mark and remove seal (1) from seal holder (2).
CRIL04A080A01 7
8. Fix the pump on an output shaft bracket pointing

downwards.
Remove screws (4) and (3) that attach cover (1) to
body (2).
Fix two screws (4) temporarily to hold cover (1) on
body (2).
Turn the pump output shaft so that it points upwards.
Remove the two screws (4).
NOTE: Fix two lifting rings with diameter 18 mm in the
orices of body (2).
CRIL04A065B01 8
9. Attach a suitable lifting device to the lifting rings on

cover (1) and remove it.
CRIL04A082A01 9
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10. Remove swash plate assembly (1).

Remove shaft (2).
Remove shaft (3) complete with bearing (4).
CRIL04A083B01 10
11. Remove retaining plate (1) with pistons (2).

Mark and remove cylinder barrel (3), spherical
bushing (4), springs (5), snap ring (7) and pinions
(6).
Mark and remove valve plates (8) and (9), bushings
(10), and discard seals (11).
Mark and remove rods (12) and pistons (13) and
(14).
CRIL04A081B01 11
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12. Discard seal (1).

Remove rings (2), bushings (3) and springs (4) and
(5) from body (6).
CRIL04A053B01 12
13. With an extractor, remove inner ring (1) from the

taper rolling bearing on shaft (2).
NOTE: Only remove the inner ring from the taper rolling
bearing on the other shaft if this is considered necessary.
CRIL04A084B01 13
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14. Remove screws (5).

Mark and remove brackets (3) and (4).
Remove outer rings from taper roller bearing (2).
Mark and remove shims (1).
CRIL04A057B01 14
Next operation: Refer to Hydraulic pump - Service limits (A.10.A.20 - D.20.A.20)
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Hydraulic pump - Assemble (A.10.A.20 - F.10.A.20)

CX225SR
1. Fit springs (5) in cover (6).
Fit springs (4), bushings (3) and rings (2) in cover

(6).
Fit seal (1).
CRIL04A053B01 1
2. Fit seals (1) on valve plate (2) and (3).

Coat bushings (4) with grease and t them in the
original orices on valve plates (2) and (3).
Position the valve plates in cover (5) following the
marks made during removal.
CRIL04A054B01 2
3. Fit pistons (1) and (2) in cover (3) following the

CRIL04A055A01 3
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4. Install on cylinder barrel (3) pinion (1) using snap

rings (2).
Install springs (4) and spherical bushing (5).
Install in barrel (2) retaining plate (6) tted with
pistons (7) following the marks made during
removal.
CRIL04A056B01 4
5. Install shims (1), outer ring (2) of the taper roller

bearing.
Install brackets (3) and (4) following the marks
made during removal.
Tighten screws (5) by hand.
Coat the brackets with clean hydraulic oil. Mount the
swash plate temporarily on the brackets to position
them correctly.
Remove the swash plate.
Tighten screws (5) to a torque of 5.9 Nm.

NOTE: If an inspection reveals that one of the following
parts needs replacing - the shaft, the cylinder barrel, the
valve plate, the taper roller bearing or housing - it will
be necessary to add or remove shims according to the
following procedure.
CRIL04A057B01 5
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6. Measure the exact distance between L1 and L2,

use the formula below to determine the shimming
thickness required.
L = (L1 + L2 + thickness of seal (B) 0.3 mm) - (L3 +
thickness of bearing (A) 27.25 mm)
Thickness of one shim = 0.4 mm
Fit the required number of shims in body (6).
CRIL04A072B01 6
7. Coat the contact surface of the valve plate and the

cylinder barrel with clean hydraulic oil.
Fit barrel assembly (1) in cover (2).

Coat the sliding contact surface of pistons (A) and
swash plate (3) with clean hydraulic oil.
Fit swash plate assembly (3).

Install shaft (4) and shaft (5).
CRIL04A058B01 7
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8. Fit to brace against pistons (1) and (2) spring (3)

and plug (4), refer to Hydraulic pump - Special
tools (A.10.A.20 - D.20.A.40).
Install pusher (5) between piston (1) and swash
plate (6).
NOTE: Coat the spherical parts of the pushers with
grease to prevent them from falling.
CRIL04A059B01 8
9. Using a suitable lifting device, raise cover (1), lower

it slowly to position it on body (2).
Fix it temporarily with two screws.
CRIL04A060B01 9
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10. Using special tool (A), refer to Hydraulic pump -

Special tools (A.10.A.20 - D.20.A.40), install inner
ring (1) of the taper roller bearing on shaft (2).
CRIL04A061B01 10
11. Install outer ring (1) of the taper roller bearing.
CRIL04A062A01 11
12. Using special tool (A), refer to Hydraulic pump

- Special tools (A.10.A.20 - D.20.A.40), position
seal (1) on seal holder (2) following the marks made
during removal.
Fit seal (3).
CRIL04A063A01 12
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13. Install the same number of shims (1) as removed,

bracing against the outer ring of the bearing.
Fit seal protector (A) on shaft (2), refer to Hydraulic
pump - Special tools (A.10.A.20 - D.20.A.40)
then install seal holder assembly (3) in pump body
housing (4).
NOTE: If an inspection reveals that one of the following
parts needs replacing - shaft, cylinder, valve plate, taper
roller bearing or housing - it will be necessary to adjust the
number of shims by carrying out the following instruction.
CRIL04A064B01 13
14. Prepare the necessary tools, refer to Hydraulic

pump - Special tools (A.10.A.20 - D.20.A.40).
Install bushing (2) on outer ring of taper roller
bearing (3).
Install bushing (1) in body housing (4).
Install seal holder (5) on top of bushing (1), secure it
using three screws (M10 x 35), tighten to a torque
of 1.5 Nm.
Using a feeler gauge, measure the distance (A)
between the top of bushing (1) and the bottom of
seal holder (5), which corresponds to the thickness
of shimming required.
Remove bushings (1) and (2) and t the necessary

number of shims on the outer ring of the taper roller
bearing.
CRIL04A073B01 14
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15. Fix the pump on an output shaft bracket pointing

downwards.
Mount cover (1) on body (2) using screws (3) and
(4).
Tighten to a torque of 284.2 Nm.
CRIL04A065B01 15
16. Remove special tools (1) and (2).

Fit spring (3) and regulator cartridge (4).
Tighten to a torque of 343 Nm.
NOTE: When removing special tools (1) and (2), take care
that the pistons do not become misaligned as this would
cause the pushers to fall.
CRIL04A066B01 16
17. Install pusher (1), piston (2) and using special tools
(3) and (4), refer to Hydraulic pump - Special
tools (A.10.A.20 - D.20.A.40), tighten screw (3) so
that pistons (5) and (6) are moved and come into
contact with stop (7).
NOTE: Swash plate (8) is tilted to its maximum.
CRIL04A067A01 17
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18. Remove the special tools.

Install spring seat (1), spring (2) and regulator
cartridge (3).
Tighten to a torque of 235 Nm.
CRIL04A068A01 18
19. Check that the pump is assembled correctly.

Protect the splines on shaft (1).
Turn the shaft by hand or with a tool, make sure the
shaft turns freely.
CRIL04A069A01 19
20. Check that the grooves on pistons (69) and (70) are
orientated correctly.
Fit the two sleeves (71) via the orices in cover
(30) on the grooves of pistons (69) and (70), refer
to Hydraulic pump - Sectional view (A.10.A.20 -
C.10.A.30)
21. Using the centring studs, position regulator (40) on
cover (30), making sure that both ends of control
lever (A) are correctly mounted on pins (B) of
pistons (69) and (70), refer to Hydraulic pump -
Sectional view (A.10.A.20 - C.10.A.30).
Install the regulator xing screws and tighten them
to a torque of 64.7 Nm.
CRIL04B013A01 20
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22. Using screws (1), install safety valve block (2) with
new seals on body (3), tighten to a torque of 32.3
Nm.
Install the safety valve on block (2), tighten to a
torque of 29.4 Nm
CRIL04A076B01 21
23. Fit seal (6) and bushing (4) on the cover.

Install the coupling (5) on the end of the take-off
shaft.
Install control pump (3) using washers (2) and
screws (1), tighten to a torque of 39.2 Nm.
If the main pump is equipped with a secondary
pump, t seal (11) on cover.
Mount coupling (10) on the end of the drive shaft.
Install secondary pump (9) using washers (8) and
screws (7), tighten to a torque of 39.2 Nm
CRIL04A074B01 22
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24. If the main pump is not equipped with a secondary

pump, install plate (1) tted with a seal and tighten
screws (2) to a torque of 39.2 Nm.
CRIL04A075A01 23
25. Check again that the pump is assembled correctly.

Protect the splines on shaft (1), turn the shaft by
hand or with a tool, make sure that the shaft and
the gears on the secondary and control pumps turn
freely.
CRIL04B027A01 24
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Hydraulic pump - Install (A.10.A.20 - F.10.A.15)

CX225SR
1. To install the hydraulic control pump, refer to

2. Install main pump and control pump assembly (3) on
ange (2), then install xing washers and screws (1).
Apply locking uid to retaining screws (1) and
tighten to a torque of 367 - 496 Nm
CRIL04C152A01 1
3. Install splined sleeve (1) on the shaft of main pump

(2), refer to Drive system - Install (B.90.A.42 -
F.10.A.15).
CRIL03J012A01 2
4. Using a sling and a suitable lifting device, carefully

engage ange and pump assembly (1) horizontally
on the exible coupling attached to the engine
ywheel. Fit screws (2) and washers (3) that secure
ange and pump assembly (1) to the engine.
CRIL04C151A01 3
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5. Mount silencer bracket (3) using xing screws (1)

and washers (2).
tighten to a torque of 62.8 - 72.6 Nm
CRIL04C149A01 4
6. Install all the hoses that are connected to the main

pump and the control pump following the marks
Install the suction and feed pipe on the main pump.
CRIL04C150A00 5
7. Install the exhaust protection panel.
Next operation: Silencer - Install (B.40.A.36 - F.10.A.15)

Next operation: Rear ballasting - Install (F.20.B.61 - F.10.A.15)
Next operation: Hydraulic pump - Bleed (A.10.A.20 - F.35.A.25)
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Hydraulic pump - Bleed (A.10.A.20 - F.35.A.25)

CX225SR
IMPORTANT: After bleeding the components, shut down the engine for ve minutes, then check for the absence
of air bubbles in the hydraulic uid in the reservoir.
1. Remove the bleed plug (1) after cleaning the
surrounding area.
Fill the pump with hydraulic uid via that port.
Install and tighten air bleed plug (1).
Start the engine in idle mode.
Gradually loosen bleed plug (1) on the pump.
Tighten the plug when air-free uid ows out of the
bleed plug hole.
Check the reservoir level and top up as necessary.
CRIL04A085A01 1
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Hydraulic pump - Pressure test (A.10.A.20 - F.40.A.30)

CX225SR
1. NEGATIVE PRESSURE CHECK

Install a T-piece equipped with a pressure test tting
between port (Pi2) on the primary pump and the
negative pressure hose (1).
Connect the pressure controller or a 0 - 25 bar
pressure gauge to the pressure test tting.
Start the engine and run it at maximum speed.
The reading on the pressure gauge should be 25.5
bar (2.55 MPa).
CRIL04B066B01 1
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Reservoir - Remove (A.10.A.22 - F.10.A.10)

CX225SR
Prior operation: Fuel tank - Remove (B.20.A.22 - F.10.A.10)

Prior operation: Remove lower protective panel (4), refer to Protective shield - Remove (E.20.A.73 - F.10.A.10)
1. Using a suitably-sized container, drain the hydraulic

reservoir, by removing plug (1).
Re-insert and tighten plug (1).
CRIL04B195A01 1
2. Remove connecting brackets (1) from between the

reservoirs.
CRIL04B196A01 2
3. Attach identication tags and remove the hoses and

hydraulic hoses.
Remove connectors.
Plug the ports and hoses.
4. Remove xing screws (1) from beneath the
NOTE: Check that the hydraulic reservoir is free at the
clamping point.
CRIL04B195A02 3
5. Install lifting rings on the hydraulic reservoir.

Using a sling and a lifting device, carefully remove
the hydraulic reservoir from the machine.
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Reservoir - Install (A.10.A.22 - F.10.A.15)

CX225SR
1. Using a sling and a lifting device, position the

hydraulic reservoir on the machine.
Remove the lifting rings.
Install the washers on screws (1), coat with locking
uid and tighten to a torque of 412 - 471 Nm
CRIL04B195A02 1
2. Install and tighten the unions on the hydraulic

reservoir.
Install the hydraulic hoses following the marks made
during removal.
Install connecting brackets (1) between the
reservoirs.
CRIL04B196A01 2
3. Fill the hydraulic reservoir.

Check for leaks.
Install lower protective panel (4).
Next operation: Fuel tank - Install (B.20.A.22 - F.10.A.15)

Next operation: PRIMARY HYDRAULIC POWER SYSTEM - Bleed (A.10.A - F.35.A.25)
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Compensator - Disassemble (A.10.A.23 - F.10.A.25)

CX225SR
NOTE: Cover (11) includes adjusting screws (15) and nuts (13), do not loosen these screws and nuts, failure to
comply with this instruction will cause loss of pressure and ow.
CRIL04A170G01 1
1. Remove screws (1), cover (2), piston (3) and seals (4).
Use a magnet to remove piston assembly (5) tted with pistons (6) and (7).
Mark and remove pistons (6) and (7).

Remove slide valve (8) tted with piston assembly (9).
Remove as single unit cover (11) tted with spring guide (12), stop (14), adjusting screw (15), the washer and nut (13).
Remove seal (16).
Remove springs (17) and (18) and spring seat (19).
3. Discard seals (20) and (21).
Remove centring studs (29).
4. Remove retaining ring, (22) plug (23), and discard seal (24).
Remove control lever (25) tted with pin (26).
Remove liner (27) from body (28).
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Compensator - Assemble (A.10.A.23 - F.10.A.20)

CX225SR
1. Install in body (28) on the spring side, liner (27).

NOTE: Fit liner (27) into body (28) making sure orices
(A) are aligned correctly.
CRIL04A108B01 1
2. Install control lever (25) in body (28) on orice (A) of

liner (27) using pin (26).
Install plug (23) tted with a new seal (24) in its
original orice.
Install retaining ring (22).
Install seals (20), (21) and (30).
Install centring studs (29).
CRIL04A106B01a 2
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3. Following the markings made during removal, install

in body (28) slide valve (8) tted with piston (9).
Install piston (5) tted with pistons (6) and (7) in
body (28).
Fit seal (4) in body (28).
Install in body (28) cover (2) tted with piston (3).
CRIL04A107B01 3
4. Install spring seat (19), springs (17) and (18) on the

other end of body (28).
Install seal (16) on cover (11).
Install in body (28) cover (11) tted with stop, spring
guide (12), adjusting screws (15) and nuts (13).
CRIL04A171B01 4
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Oil lter - Remove (A.10.A.24 - F.10.A.10)

CX225SR
1. Open the hood of swing reduction gear (1).
CRIL04C108A01 1
2. Mark, disconnect and plug hoses (1) and (2).

Plug lter ports (4).
Remove screws (3).
Remove lter (4).
CRIL04C109A01 2
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Oil lter - Install (A.10.A.24 - F.10.A.15)

CX225SR
1. Place lter (4) on its bracket.

Install lter and bracket assembly and tighten
screws (3).
Remove the plugs from hoses (1) and (2).
Remove the plugs from the lter ports.
Install and tighten hoses (1) and (2) following marks
CRIL04C109A01 1
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Sensing system Temperature sensor - Electrical test (A.10.A.95.90 -

F.40.A.50)
CX225SR
1. Disconnect connector (1) from thermo-switch (B10).
CRIL03K190A01 1
2. Remove thermo-switch (B10).

3. Connect the appropriate electrical test connector (3)
to connector (1) on thermo-switch (B10) then install
multimeter (4), refer to ELECTRICAL POWER
CRIL03I081A01 2
4. Install thermo-switch (B10) in a container of water

(2) and place everything on tripod (6).
5. Using a spirit lamp (7), gradually heat the water in
container (2).
6. Using multimeter (4), check the contact position
on thermo-switch (B10) against the temperature
reading on the thermometer (1), refer to
ELECTRICAL POWER SYSTEM - General
specication (A.30.A - D.40.A.10).
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PRIMARY HYDRAULIC POWER SYSTEM - Troubleshooting (A.10.A

- G.40.A.10)
CX225SR
NOTE: This table summarises the main symptoms relating to the hydraulic circuit in general.
Problem Possible Cause Correction
The hydraulic system Oil level in reservoir too low Rell the tank
is not operating or is
operating incorrectly.
Insufcient pilot pressure Refer to HYDRAULIC COMMAND
SYSTEM - Troubleshooting (A.14.A -
G.40.A.10)
Pump faulty Check the pressures
Test the pump
Main relief valve faulty Refer to Relief valve - Troubleshooting
(A.10.A.16 - G.40.A.10)
Cylinder faulty Check for leaks, traces of aking or
scratches on the cylinder rods.
Pump charge pressure too high Check the pressure
Valves or control valve cracked Replace cracked components
Spool stroke incomplete Refer to Stack valve - Troubleshooting
(A.10.A.18 - G.40.A.10)
Filter clogged in the circuit Clean and replace lters
Blockage in the system Locate and remove the cause of the
blockage
Stack valve - Troubleshooting (A.10.A.18 - G.40.A.10)

CX225SR
NOTE: This table summarises the main symptoms relating to the control valve block in general.
The spool does not move Abnormal rise in oil temperature (ow is Eliminate the cause of the ow resistance
encountering resistance in the lines)
Contaminated hydraulic oil Clean the circuit and replace the hydraulic
oil
Lines with over-tightened port unions Loosen and retighten the unions to the
required torque
Control valve body deformed during Loosen the xing screws and inspect
installation
Excessive pressure Check the inlet (pump side) and supply
pressures
Spool not straight Replace the control valve assembly
Return spring damaged Replace the spring
Spring or cap deformed Loosen the cap xing screws and retighten
them to the required torque
Uneven temperature distribution in the Warm up the oil by operating all the
control valve controls
Control valve obstructed by oil pollution Clean out the control valve and the
hydraulic circuit
Insufcient pilot pressure Check the pilot circuit main relief valve
Does not hold the load Oil leak in the spool Check the spool
Leak in the main relief valve Remove the valve and clean the seats of
the valve and the control valve
Leak in the load holding valve Remove the valve and clean the seats,
replacing them if necessary
Leak in the cylinder Check that the cylinder rings are not
leaking
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Charge drops when Contaminated check valve Remove and clean the valve
moving from neutral to
the Raise position
Damaged check valve or seat Replace the valve or repair the valve and
its seat.
Relief valve - Troubleshooting (A.10.A.16 - G.40.A.10)

CX225SR
NOTE: This table summarises the main symptoms relating to the valve block.
No rise in pressure Main valve, sleeve or pilot valve jammed Replace the valve
open or contamination of seat
Pressure is unstable The pilot valve seat is damaged Replace the valve
Piston or main valve seized Replace the valve
Pressure is incorrect Seat worn by contamination Replace the valve
Lock nut on adjusting device is loose Set and tighten the nut again correctly
Oil leak Damaged valve seat Replace the valve
Components seized by contamination Replace the valve
Damaged seals Replace the seals
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Index

Compensator - Assemble (A.10.A.23 - F.10.A.20) 87
CX225SR
Compensator - Disassemble (A.10.A.23 - F.10.A.25) 86
CX225SR
Compensator - Sectional view (A.10.A.23 - C.10.A.30) 37
CX225SR
Hydraulic pump - Assemble (A.10.A.20 - F.10.A.20) 70
CX225SR
Hydraulic pump - Bleed (A.10.A.20 - F.35.A.25) 82
CX225SR
Hydraulic pump - Disassemble (A.10.A.20 - F.10.A.25) 63
CX225SR
CX225SR
Hydraulic pump - Pressure test (A.10.A.20 - F.40.A.30) 83
CX225SR
CX225SR
Hydraulic pump - Sectional view (A.10.A.20 - C.10.A.30) 33
CX225SR
Hydraulic pump - Service limits (A.10.A.20 - D.20.A.20) 18
CX225SR
Hydraulic pump - Special tools (A.10.A.20 - D.20.A.40) 15
CX225SR
Oil lter - Install (A.10.A.24 - F.10.A.15) 90
CX225SR
Oil lter - Remove (A.10.A.24 - F.10.A.10) 89
CX225SR
Powerboost system - Electronic schema (A.10.A.10 - C.20.A.50) 39
CX225SR
Powerboost system Electrovalve - Electrical test (A.10.A.10.15 - F.40.A.50) 60
CX225SR
PRIMARY HYDRAULIC POWER SYSTEM - Bleed (A.10.A - F.35.A.25) 43
CX225SR
PRIMARY HYDRAULIC POWER SYSTEM - Decontaminating (A.10.A - F.30.A.60) 46
CX225SR
PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A - F.35.A.51) 41
CX225SR
PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20) 42
CX225SR
PRIMARY HYDRAULIC POWER SYSTEM - Dynamic description (A.10.A - C.30.A.10) 20
CX225SR
CX225SR
CX225SR
PRIMARY HYDRAULIC POWER SYSTEM - Pressure test (A.10.A - F.40.A.30) 44
CX225SR
PRIMARY HYDRAULIC POWER SYSTEM - Seed rates (A.10.A - D.50.A.60) 13
CX225SR
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CX225SR WE
CX225SR NA
PRIMARY HYDRAULIC POWER SYSTEM - Static description (A.10.A - C.30.A.20) 19
CX225SR
PRIMARY HYDRAULIC POWER SYSTEM - Troubleshooting (A.10.A - G.40.A.10) 92
CX225SR
PRIMARY HYDRAULIC POWER SYSTEM - Warm up (A.10.A - F.35.A.40) 40
CX225SR
Relief valve - Assemble (A.10.A.16 - F.10.A.20) 57
CX225SR
Relief valve - Disassemble (A.10.A.16 - F.10.A.25) 56
CX225SR
CX225SR
CX225SR
Relief valve - Troubleshooting (A.10.A.16 - G.40.A.10) 93
CX225SR
Reservoir - Install (A.10.A.22 - F.10.A.15) 85
CX225SR
Reservoir - Remove (A.10.A.22 - F.10.A.10) 84
CX225SR
Sensing system Temperature sensor - Electrical test (A.10.A.95.90 - F.40.A.50) 91
CX225SR
Sensing system Temperature sensor - Electronic schema (A.10.A.95.90 - C.20.A.50) 38
CX225SR
Stack valve - External view (A.10.A.18 - C.10.A.40) 23
CX225SR
Stack valve - Install (A.10.A.18 - F.10.A.15) 55
CX225SR
Stack valve - Overhaul (A.10.A.18 - F.10.A.40) 49
CX225SR
Stack valve - Remove (A.10.A.18 - F.10.A.10) 48
CX225SR
Stack valve - Sectional view (A.10.A.18 - C.10.A.30) 26
CX225SR
Stack valve - Troubleshooting (A.10.A.18 - G.40.A.10) 92
CX225SR
Stack valve - Visual inspection (A.10.A.18 - F.40.A.10) 52
CX225SR
Stack valve Inlet section - Assemble (A.10.A.18.10 - F.10.A.20) 53
CX225SR
Stack valve Inlet section - Disassemble (A.10.A.18.10 - F.10.A.25) 51
CX225SR
Stack valve Inlet section - Sectional view (A.10.A.18.10 - C.10.A.30) 31
CX225SR
Stack valve Outlet section - Assemble (A.10.A.18.20 - F.10.A.20) 54
CX225SR
Stack valve Outlet section - Disassemble (A.10.A.18.20 - F.10.A.25) 50
CX225SR
Stack valve Outlet section - Sectional view (A.10.A.18.20 - C.10.A.30) 32
CX225SR
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HYDRAULIC COMMAND SYSTEM - 14.A
CX225SR
26022 1 02/12/2004
A.14.A / 1
Contents
SERVICE
Relief valve
CX225SR

CX225SR
Hydraulic pump
CX225SR

CX225SR
Accumulator
Accumulator - Check (A.14.A.30 - F.40.A.11) 7
CX225SR
DIAGNOSTIC
HYDRAULIC COMMAND SYSTEM - Troubleshooting (A.14.A - G.40.A.10) 8
CX225SR
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DISTRIBUTION SYSTEMS - HYDRAULIC COMMAND SYSTEM
Relief valve - Pressure test (A.14.A.16 - F.40.A.30)

CX225SR
1. With the engine switched off, connect a 0 - 100 bar

(0 - 10 MPa) pressure gauge to the pressure test
point (M3).
CRIL04B109A01 1
2. With the engine at full speed, move the pilot control

cancellation lever to the low position.
3. With the attachment, swing and travel controls in
neutral, take the reading from the pressure gauge.
The reading should be 39 ± 1 bar (3.9 ± 0.1 MPa).
4. To adjust main relief valve (H) if necessary, refer
to Relief valve - Pressure setting (A.14.A.16 -
F.45.A.70)
5. Disconnect the pressure gauge.
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Relief valve - Pressure setting (A.14.A.16 - F.45.A.70)

CX225SR
Prior operation: Relief valve - Pressure test (A.14.A.16 - F.40.A.30)
1. Loosen the lock nut and turn valve adjusting screw

(H) until the standard pressure is reached.
Tighten the screw to increase the pressure.
Loosen the screw to reduce the pressure.
2. Tighten the lock nut while holding the adjusting
screw in position.
3. When adjusting screw has been tightened, check
the pressure again and make sure there are no
leaks.
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A.14.A / 4

CX225SR
1. Open the rear RH side door.

2. Mark, disconnect and plug hoses (1).
Remove screws (2) and remove hydraulic control
pump (3).
CRIL04C135A01 1
3. Remove bushing and coupling and discard the seal

on the main pump.
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A.14.A / 5

CX225SR
1. Fit the seal and bushing on the main pump.

Install the coupling on the shaft.
2. Mount hydraulic control pump (3) on the main
hydraulic pump using screws (2), tighten to a torque
of 39.2 Nm.
Install the hose (1) following the marks made during
removal.
CRIL04C135A01 1
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Accumulator - Check (A.14.A.30 - F.40.A.11)

CX225SR
1. Start the engine.

Raise the boom completely and extend the dipper.
Shut down the engine.
2. Turn the starter switch key to the "ON" position
without starting the engine.
3. Operate the boom lowering or dipper retracting
control several times in succession.
4. The pressure in the accumulator should enable the
boom lowering or dipper retracting function to be
performed about six times.
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HYDRAULIC COMMAND SYSTEM - Troubleshooting (A.14.A -

G.40.A.10)
CX225SR

No movement on any Incorrectly adjusted pilot control Adjust the lever or replace the switch
function cancellation lever or defective electrical
switch
Insufcient pilot pressure at pump outlet Adjust the main relief valve, refer to Relief
valve - Pressure setting (A.14.A.16 -
F.45.A.70)
Insufcient pilot pressure at solenoid valve Test the electrical circuit, refer to Hydraulic
outlet lock-out Electrovalve - Electrical test
(E.50.B.13.10 - F.40.A.50)
Repair or replace the faulty components
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Index

Accumulator - Check (A.14.A.30 - F.40.A.11) 7
CX225SR
HYDRAULIC COMMAND SYSTEM - Troubleshooting (A.14.A - G.40.A.10) 8
CX225SR
CX225SR
CX225SR
CX225SR
CX225SR
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ELECTRICAL POWER SYSTEM - 30.A
CX225SR
26023 1 02/12/2004
A.30.A / 1
Contents
TECHNICAL DATA
ELECTRICAL POWER SYSTEM - General specication (A.30.A - D.40.A.10) 4
CX225SR
ELECTRICAL POWER SYSTEM - Special tools (A.30.A - D.20.A.40) 5

CX225SR

CX225SR
Battery
Battery - General specication (A.30.A.83 - D.40.A.10) 16
CX225SR
FUNCTIONAL DATA
ELECTRICAL POWER SYSTEM - Static description (A.30.A - C.30.A.20) 18
CX225SR
ELECTRICAL POWER SYSTEM - Overview (A.30.A - C.10.A.10) 19

CX225SR

CX225SR
Fuse and relay box

Fuse and relay box - Overview (A.30.A.80 - C.10.A.10) 23
CX225SR

CX225SR
Fuse and relay box Fuse - Overview (A.30.A.80.81 - C.10.A.10) 25

CX225SR
Alternator
Alternator - Electronic schema (A.30.A.82 - C.20.A.50) 26
CX225SR
SERVICE
Battery
Battery - Visual inspection (A.30.A.83 - F.40.A.10) 27
CX225SR
Battery - Disconnect (A.30.A.83 - F.10.A.11) 28

CX225SR
Battery - Remove (A.30.A.83 - F.10.A.10) 30

CX225SR
Battery - Check (A.30.A.83 - F.40.A.11) 31

CX225SR
Battery - Charging (A.30.A.83 - F.60.A.30) 32

CX225SR
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A.30.A / 2
Battery - Overhaul (A.30.A.83 - F.10.A.40) 33
CX225SR
Battery - Install (A.30.A.83 - F.10.A.15) 34

CX225SR
Battery - Connect (A.30.A.83 - F.10.A.16) 35

CX225SR
DIAGNOSTIC
Alternator
Alternator - Testing (A.30.A.82 - G.40.A.20) 36
CX225SR
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A.30.A / 3
DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
ELECTRICAL POWER SYSTEM - General specication (A.30.A -

D.40.A.10)
CX225SR
General voltage of electrical system: 24 volts, negative earth
Battery
Number of batteries 2
Voltage for each battery 12 volts
Rated capacity 92 Ah
Reserve 160 min
Cold starting capacity at 17 °C 800 amps
Load for load control 400 amps
Starter motor
Voltage 24 volts
Power 4.5 kW
Alternator
Built-in voltage regulator, without adjustment
Alternator current 50 amps
Attachment working light and cab working light

Voltage 24 volts
Power 55 watts
Coolant temperature sensor (B1)

Temperature -10 °C 20 °C 80 °C
Resistance measured between wires (75) and (27) 20260 ohms 6004 ohms 8949 ohms
Coolant temperature sensor (B9)

Temperature 50 °C 95 °C 115 °C
Resistance 153.9 ohms 32.3 ohms 18.4 ohms
Hydraulic uid temperature thermo switch (B10)

Contact closed 98 °C
Contact open 91 °C
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A.30.A / 4
ELECTRICAL POWER SYSTEM - Special tools (A.30.A - D.20.A.40)

CX225SR
Test electrical connector kit
CRIL03G248E00 1
DESCRIPTION CODE
Test electrical connector kit CAS-30039
CONTENTS OF TEST ELECTRICAL CONNECTOR KIT CAS-30039

Test electrical connector.- not used
CRPH03I027A 2
Test electrical connector.- not used
CRPH03I028A 3
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Test electrical connector for emergency stop motor,

motor side.
CRPH03I029A 4
emergency stop motor harness side.
CRPH03I030A 5
Test electrical connector for solenoid and fuel level
sensor.
CRPH03I031A 6
Test electrical connector for hydraulic pump proportional
valve.
CRPH03I032A 7
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A.30.A / 6

valve.
CRPH03I033A 8
Test electrical connector for pressure switch, pressure
switch side.
CRPH03I034A 9
switch harness side.
CRPH03I035A 10
Test electrical connector for air conditioning compressor
clutch contact switch.
CRPH03I036A 11
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Test electrical connector not used.
CRPH03I037A 12
CRPH03I038A 13
CRPH03I039A 14
CRPH03I040A 15
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Test electrical connector for hydraulic uid temperature

sensor and coolant temperature sensor.
CRPH03I041A 16
Test electrical connector for engine rpm sensor.
CRPH03I042A 17
Test electrical connector for pressure detector.
CRPH03I043A 18
Test electrical connector for electronic acceleration
module (RED4).
CRPH03I044A 19
26023 1 02/12/2004
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module (RED4).
CRPH03I045A 20
module (RED4).
CRPH03I046A 21
Digital multimeter
CRIL03G249E00 22
DESCRIPTION CODE
Digital multimeter CAS-1559
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ELECTRICAL POWER SYSTEM - Special tools (A.30.A - D.20.A.40)

CX225SR
Electrical connector test kit
CRIL03G248E00 1
DESCRIPTION CODE
Electrical connector test kit CAS-40041
CONTENTS OF ELECTRICAL CONNECTOR TEST KIT CAS-40041

Test electrical connector-not used.
CRPH03I027A 2
Test electrical connector-not used.
CRPH03I028A 3
26023 1 02/12/2004
A.30.A / 11

motor side.
CRPH03I029A 4
emergency stop motor harness side.
CRPH03I030A 5
Test electrical connector for solenoid and fuel level
sensor.
CRPH03I031A 6
valve.
CRPH03I032A 7
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A.30.A / 12

valve.
CRPH03I033A 8
switch side.
CRPH03I034A 9
switch harness side.
CRPH03I035A 10
Test electrical connector for air conditioning compressor
clutch contact switch.
CRPH03I036A 11
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CRPH03I037A 12
CRPH03I038A 13
CRPH03I039A 14
CRPH03I040A 15
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Test electrical connector for hydraulic uid temperature

sensor and coolant temperature sensor.
CRPH03I041A 16
Test electrical connector for engine rpm sensor.
CRPH03I042A 17
Test electrical connector for pressure sensor.
CRPH03I043A 18
module (RED4).
CRPH03I044A 19
26023 1 02/12/2004
A.30.A / 15

module (RED4).
CRPH03I045A 20
module (RED4).
CRPH03I046A 21
Digital multimeter
CRIL03G249E00 22
DESCRIPTION CODE
Digital multimeter OEM-1414
Battery - General specication (A.30.A.83 - D.40.A.10)

CX225SR
Discharge test
Discharge test at -15 °C
Discharge current 300 amps
Discharge time at 6 volts 5.2 minutes
Voltage after testing for 30 seconds 10 volts
Cross-reference table between the acidimeter oat graduations and degrees Baumé at 26°C
Density of the electrolyte below Density of the electrolyte at minimum Normal density of the electrolyte
minimum
Float graduation Degrees Baumé Float graduation Degrees Baumé Float graduation Degrees Baumé
26023 1 02/12/2004
A.30.A / 16
1100 14 1160 20 1250 29

1110 15 1170 21 1260 30
1120 16 1180 22 1275 31
1130 17 1190 23 1290 32
1140 18 1200 24 1305 33
1150 19 1210 25 1320 34
1220 26 1335 35
1230 27 1350 36
1240 28
16 ° Baumé = 25 % of load
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ELECTRICAL POWER SYSTEM - Static description (A.30.A -

C.30.A.20)
CX225SR
The electrical diagram is available as a poster at the end of this manual.

For easier understanding, the same legend is used for components appearing in the electrical sections and on
the poster.
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ELECTRICAL POWER SYSTEM - Overview (A.30.A - C.10.A.10)

CX225SR
CRIL04B113H01 1
GENERAL LOCATION OF COMPONENTS (OUTSIDE THE CAB)

(A3) Electronic acceleration
(B1) Coolant temperature sensor
(B9) Coolant temperature sensor
(B10) Hydraulic oil temperature thermo -switch
(B21) Pressure switch for engine oil pressure
(B22) Swing pilot pressure switch
26023 1 02/12/2004
A.30.A / 19
(B26) Upper pilot pressure switch

(B27) Travel pilot pressure switch
(B41) Engine speed detector
(B45) Overload indicator pressure sensor
(B81) Horn
(E2) Working light (attachment)
(E3) Working light (cab)
(F22) Fuse 20 amps; main protection for circuits F11 and F12
(F23) Fuse 65 amps; main protection for circuits F1 to F10 and F13 to F20
(G1) Batteries
(G2) Alternator
(H2) Audible travel alarm (North American model)
(K7) Battery relays
(M1) Starter motor
(M2) Engine emergency stop motor
(M4) Windscreen washer motor
(M14) Filler pump motor
(R1) Glow plugs
(R2) Fuel ow adjustment resistor
(R5) Fuel level sensor
(S52) Air conditioning compressor clutch switch
(X2) Rotating beacon connector
(Y2) Pilot pressure solenoid valve
(Y3) Swing brake solenoid valve
(Y4) 2nd gear solenoid valve
(Y5) Power boost solenoid valve
(Y8) Air conditioning compressor magnetic clutch
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ELECTRICAL POWER SYSTEM - Overview (A.30.A - C.10.A.10)

CX225SR
CRIL03G085H01 1
GENERAL LOCATION OF COMPONENTS (INSIDE THE CAB)

(E4) Cab lighting
(E52) Air conditioner
(M3) Windscreen wiper motor
(P6) Air conditioner control panel
(P8) Heater control panel
(R3) Engine throttle control
(S1) Starter switch
(S6) Rotating beacon switch
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(S9) Engine emergency stop switch

(S13) Overload indicator switch
(S14) Hammer/grab switch
(S15) Audible warning device switch
(S16) Engine idler switch
(S28) Travel alarm switch (North America)
(S29) Power boost switch
(S30) N/E working mode switch
(S51) Hydraulic control cancellation lever switch
(X8) Radio connector
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Fuse and relay box - Overview (A.30.A.80 - C.10.A.10)

CX225SR
CRIL04B111F01 1
Main relays and fuses
(1) Battery cables

(F22) Fuse 20 amps; main protection for circuits F11 and F12
(F22) Fuse 65 amps; main protection for circuits F1 to F10 and F13 to F20
(K7) Battery relays
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Fuse and relay box - Overview (A.30.A.80 - C.10.A.10)

CX225SR
CRIL04B112G01 1
Relays, fuses, electronic control box (operator’s compartment)
(1) Memory erasing connector (A2) Engine electronic control box

(A7) Overload indicator electronic control box (A8) Engine mode selector
(F21) Fuse box (H3) Overload indicator audible alarm device
(K1) Engine emergency stop relay (K2) Glow plug relay
(K4) Working light relay (K5) Rotating beacon relay
(K18) Travel gear relay (K19) Swing brake relay
(K20) Windscreen wiper motor relay (K21) Windscreen washer pump relay
(K22) Air conditioning compressor magnetic clutch (K23) Slow air conditioning fan motor relay
relay
(K24) Medium air conditioning fan motor relay (K25) Fast air conditioning fan motor relay
(K27) Travel alarm relay (North America) (K28) Power boost solenoid valve relay
(U1) DC-DC converter 24 volts - 12 volts (X4) Engine test point connector
(X11) Overload indicator pressure check connector (X13) Engine fault code erasing connector
(X14) Engine fault code detection connector
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Fuse and relay box Fuse - Overview (A.30.A.80.81 - C.10.A.10)

CX225SR
CRIL03G222F01 1
Secondary fuse box

(1) Spare fuses (F1) 15 amps Engine electronic control box, engine
mode selector
(F2) 10 amps Main instrument panel lighting and air (F3) 10 amps Travel gear relay
conditioner
(F4) 10 amps Cancellation of hydraulic controls (F5) 10 amps Swing brake relay
(F6) 10 amps Rotating beacon relay (European (F7) 20 amps Fuel ller pump
model)
(F8) 15 amps Engine emergency stop motor (F9) 30 amps Glow plugs
(F10) 10 amps Overload indicator electronic control (F11) 10 amps Memory
box
(F12) 10 amps Starter switch (F13) 20 amps Air conditioning, heating
(F14) 10 amps Travel audible alarm device (North (F15) 15 amps Working lights
American model)
(F16) 15 amps Dual ow hammer/grab option (F17) 10 amps DC-DC converter (24 volts - 12
volts)
(F18) 15 amps Windscreen wiper and washer (F19) 10 amps Horn
(F20) 15 amps Cigarette lighter, adjustable cab seat
compressor
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Alternator - Electronic schema (A.30.A.82 - C.20.A.50)

CX225SR
CRIL03G200E01 1
Circuit layout
(1) Starting (2) Battery charge indicator lamp

(3) Audible alarm device (G2) Alternator
(P1) Instrument panel (S1) Starter switch
CRIL03G201E02a 2
Timing diagram
(A) Starting (B) Test
OPERATION
• When the alternator (L) output voltage falls to 6 volts, battery charge indicator lamp (2) lights up and the
audible alarm device (3) sounds.
26023 1 02/12/2004
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Battery - Visual inspection (A.30.A.83 - F.40.A.10)

CX225SR
DANGER
SA046 - Before you service a battery, always wear face protection, protective gloves and protective clothing.
Battery acid or battery explosion can cause serious injuries.
DANGER
D38-14A - Batteries produce explosive gases. Keep sparks, ame and cigarettes away. Ventilate when
charging or using in enclosed space. Always shield eyes when working near batteries.
1. Check that the battery cables are correctly

connected (tightness, insulation, grease on
terminals) and that the battery terminals are free
of salt.
2. Check the battery retaining bracket, inspecting also
for any damage caused by overtightening of the
bracket.
3. Check the battery tray for impacts and cracks.
4. Check the electrolyte level in each battery cell:
If the battery is "maintenance-free", check the
electrolyte level after every 1000 hours of use or
every 6 months, whichever comes rst.
For other types of battery, check the electrolyte level
after every 250 hours of use.
26023 1 02/12/2004
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Battery - Disconnect (A.30.A.83 - F.10.A.11)

CX225SR
DANGER
DANGER
1. Remove thumb screw (1), washers (2) and

protective mat (3).
DANGER
M145B - When working around storage batteries,
remember that all of the exposed metal parts are
"live". Never lay a metal object across the terminals
because a spark, short circuit, explosion or personal
injury may result.
CRIL04B144A01 1
2. Remove the terminal connection covers from the

negative and positive connections.
3. Disconnect the battery cable (1) (0 volts) from the
NEGATIVE terminal, indicated by (-) on the battery
(A).
DANGER
47-55A - Disconnect the ground cable rst when the
battery cables are disconnected from the battery.
Connect the ground cable last when the battery
cables are connected to the battery.
CRIL03K003A02 2
4. Disconnect the battery cable (2) (+24 volts) from

the POSITIVE terminal, indicated by (+) on the
battery (A).
5. Having disconnected both cables from the battery,
keep them well away from the battery’s negative
and positive terminals.
6. Disconnect the battery cable (3) (0 volts) from the
NEGATIVE terminal, indicated by (-) on the battery
(B).
7. Disconnect the battery cable (4) (+12 volts) from
the POSITIVE terminal, indicated by (+) on the
battery (B).
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8. Having disconnected the battery connecting (5)

cable, keep it well clear of the battery’s negative and
positive terminals.
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Battery - Remove (A.30.A.83 - F.10.A.10)

CX225SR
Prior operation: Battery - Disconnect (A.30.A.83 - F.10.A.11)
1. Remove screws (1), washers (2) and frame (3).
CRIL04B145A01 1
2. Remove screws (1), washers (2) and elbow (3).
CRIL04B146A01 2
3. Remove the batteries.
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Battery - Check (A.30.A.83 - F.40.A.11)

CX225SR
Prior operation: Battery - Remove (A.30.A.83 - F.10.A.10)
NOTE: Use an acidimeter to check the density of the battery electrolyte. A thermometer graduated to at least 52 °C
must be used to check the temperature of the electrolyte.
NOTE: If the density of the electrolyte cannot be checked without adding water to the battery cell, after adding the
water charge the battery for 15 minutes between 15 amps and 25 amps to mix the water and the electrolyte properly.
1. Using the acidimeter, remove sufcient electrolyte
to allow the oat to move freely in the acidimeter’s
glass tube.
2. Keep the acidimeter upright and read the value
reached by the liquid, as indicated by the oat.
3. Repeat operations 1 and 2 for each battery cell.
Note the values taken from the acidimeter oat and
convert them to degrees Baumé. Refer to Battery -
General specication (A.30.A.83 - D.40.A.10).
4. The minimum density of the electrolyte should
be the 1.24 graduation 1240 on the oat, which
corresponds to 28 ° Baumé.
5. Read the electrolyte temperature on the
thermometer.
6. If the temperature of the electrolyte is above 26
°C add 1/2 ° Baumé to the gure read from the
acidimeter for every 6 °C above 26 °C.
If the temperature of the electrolyte is below 26 °C
subract 1/2 ° Baumé from the gure read from the
acidimeter for every 6 °C below 26 °C.
7. The charge level for each battery cell must be at
least 75 %, corresponding to a corrected density
of 28 ° Baumé.
8. If the difference between the high and low values
for the electrolyte density is less than 5 ° Baumé
and the charge level for each battery cell is at least
75 %, check the charge.
9. If the difference between the high and low values
for the electrolyte density is less than 5 ° Baumé
but the charge level for the battery cell is less
than 75 %, replace the battery, refer to Battery
- Remove (A.30.A.83 - F.10.A.10) and Battery -
Install (A.30.A.83 - F.10.A.15), then check again.
Next operation: Battery - Install (A.30.A.83 - F.10.A.15)
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Battery - Charging (A.30.A.83 - F.60.A.30)

CX225SR
Prior operation: Battery - Visual inspection (A.30.A.83 - F.40.A.10)

Prior operation: Battery - Remove (A.30.A.83 - F.10.A.10)
DANGER
47-83A - Never try to charge the battery if the electrolyte in the battery is frozen.
IMPORTANT: The battery must only be charged using a self-regulating charger with constant voltage and variable
current.
1. Using a charge tester or voltmeter, measure the
battery charge level. For this measurement, the
battery must not have been charged or recharged
for at least one hour.
Refer to Battery - Check (A.30.A.83 - F.40.A.11)
2. Use the following data to decide on the charging
time:
- For a charge level below 20 % or a voltage below
12 volts, the charging time is 24 hours.
- For a charge level between 20 % and 60 % or
a voltage between 12 volts and 12.3 volts, the
charging time is 12 hours.
- For a charge level above 60 % or a voltage above
12.3 volts, the charging time is 6 hours.
3. Connect the charger. Since the device supplies

a constant voltage, the current will be adjusted
automatically according to the discharge status and
rated capacity of the battery.
4. Before reinstalling the battery in the machine, carry
out a rapid discharge test using a battery tester.
5. After installing the battery, refer to Battery - Install
(A.30.A.83 - F.10.A.15), inspect the charge circuit
on the machine and check that there are no rogue
consumers.
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A.30.A / 32
Battery - Overhaul (A.30.A.83 - F.10.A.40)

CX225SR
DANGER
DANGER
1. Carry out regular visual inspections of the battery,

refer to Battery - Visual inspection (A.30.A.83 -
F.40.A.10).
2. If the battery is damaged and leaking, it must be
replaced, refer to Battery - Remove (A.30.A.83
- F.10.A.10) and Battery - Install (A.30.A.83 -
F.10.A.15).
3. If the battery requires cleaning, remove it, refer
to Battery - Remove (A.30.A.83 - F.10.A.10).
Use a product specically intended for cleaning
batteries, in accordance with the manufacturer’s
recommendations.
If a product specically intended for cleaning
batteries is not available, use bicarbonate of soda
and water, making sure that no cleaning solution
gets into the battery cells.
4. After cleaning, install the battery, refer to Battery -
Install (A.30.A.83 - F.10.A.15).
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Battery - Install (A.30.A.83 - F.10.A.15)

CX225SR
1. Clean the battery compartment.

Position the batteries making sure the negative and
positive terminals are in the correct position.
Install elbow (3), washers (2) and screws (1).
CRIL04B146A01 1
2. Install retaining frame (3) for the batteries and mat.

Install washers on screws (1) and (2) tighten.
CRIL04B145A01 2
Next operation: Battery - Connect (A.30.A.83 - F.10.A.16)
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A.30.A / 34
Battery - Connect (A.30.A.83 - F.10.A.16)

CX225SR
1. Clean the battery connections and cables.

2. Clean and grease the negative and positive
terminals on batteries (A) and (B).
CRIL03K003A02 1
3. Connect battery connecting cable (5) (+12 volts) to

the POSITIVE terminal, indicated by (+) on battery
(A).
4. Connect battery connecting cable (5) (0 volts) to the
NEGATIVE terminal, indicated by (-) on battery (B).
5. Connect battery cable (+24 volts) to the POSITIVE
terminal, indicated by (+) on battery (B).
6. Connect battery cable (0 volts) to the NEGATIVE
terminal, indicated by (-) on battery (A).
7. Install the terminal sleeves on the battery cable
connections, taking care to match the polarity
colours.
8. Fold back the protective mat.
26023 1 02/12/2004
A.30.A / 35
Alternator - Testing (A.30.A.82 - G.40.A.20)

CX225SR
N° Test Point Expected Result Other Result (Possible Cause)

1 Hourmeter (P5) works. The voltage is greater than or equal The voltage is below 10 volts
Measure the voltage between to 10 volts. Go to test 2
path10 on connector (CNM1A) and Poor connection on connector
the earth. (CNM1A) or faulty instrument panel.
Clean connector terminals or
replace instrument panel (P1).
2 Hourmeter (P5) does not work. The voltage is greater than or equal The voltage is below 10 volts
Measure the voltage between the to 10 volts. Go to test 3
male terminal (wire (BrR)) of at Repair the cut wires between
connector (3) and the earth. connector (CNM1A) and connector
(3).
3 Disconnect connector (CN4) and The voltage is greater than or equal The voltage is below 10 volts
measure the voltage between the to 10 volts. Go to test 4
male terminal (wire (BrR)) of at Clean the terminals or repair cut
connector (3) and the earth. wire (BrR) between connector
(CN4) and connector (3).
4 Disconnect connector (4) and The voltage is greater than or equal The voltage is below 10 volts
measure the voltage between the to 10 volts. Repair or replace alternator (G2)
male terminal (wire (G2)) of at Clean the terminals or repair cut
connector (L) and the earth. wire (BrR) between connector
(CN4) and connector (4).
CRIL04C007F01 1
Faulty charge circuit - Wiring schematic
(1) Battery charge indicator (2) Controlled 24 V

(3) Connector (4) Alternator connector
(A2) Engine electronic control box (G2) Alternator
(K7) Battery relays (M1) Starter motor
(P1) Instrument panel (P5) Hourmeter
(S1) Starter switch
26023 1 02/12/2004
A.30.A / 36
Index

Alternator - Electronic schema (A.30.A.82 - C.20.A.50) 26
CX225SR
Alternator - Testing (A.30.A.82 - G.40.A.20) 36
CX225SR
Battery - Charging (A.30.A.83 - F.60.A.30) 32
CX225SR
Battery - Check (A.30.A.83 - F.40.A.11) 31
CX225SR
Battery - Connect (A.30.A.83 - F.10.A.16) 35
CX225SR
Battery - Disconnect (A.30.A.83 - F.10.A.11) 28
CX225SR
Battery - General specication (A.30.A.83 - D.40.A.10) 16
CX225SR
Battery - Install (A.30.A.83 - F.10.A.15) 34
CX225SR
Battery - Overhaul (A.30.A.83 - F.10.A.40) 33
CX225SR
Battery - Remove (A.30.A.83 - F.10.A.10) 30
CX225SR
Battery - Visual inspection (A.30.A.83 - F.40.A.10) 27
CX225SR
ELECTRICAL POWER SYSTEM - General specication (A.30.A - D.40.A.10) 4
CX225SR
CX225SR
CX225SR
CX225SR
CX225SR
ELECTRICAL POWER SYSTEM - Static description (A.30.A - C.30.A.20) 18
CX225SR
CX225SR
CX225SR
Fuse and relay box Fuse - Overview (A.30.A.80.81 - C.10.A.10) 25
CX225SR
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LIGHTING SYSTEM - 40.A
CX225SR
26024 1 02/12/2004
A.40.A / 1
Contents
FUNCTIONAL DATA
Front work light
Front work light - Electronic schema (A.40.A.16 - C.20.A.50) 3
CX225SR
26024 1 02/12/2004
A.40.A / 2
DISTRIBUTION SYSTEMS - LIGHTING SYSTEM
Front work light - Electronic schema (A.40.A.16 - C.20.A.50)

CX225SR
CRIL03G205F01 1
Circuit layout
(1) Instrument panel lighting (2) Air conditioner control panel lighting
(E2) Attachment working light (E3) Working light (cab)
(K4) Working light relay (P1) Instrument panel
(P6) Air conditioner control panel (S10) Working light switch
CRIL03G206E02 2
Timing diagram
OPERATION
• Pressing working light switch (S10) once controls instrument panel lighting (1) and (2) and relay excitation (K4), which
switches on working lights (E2) and (E3).
• Pressing a second time turns off all the lit components.
26024 1 02/12/2004
A.40.A / 3
Index

Front work light - Electronic schema (A.40.A.16 - C.20.A.50) 3
CX225SR
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A.40.A / 4
26024 1 02/12/2004
A.40.A / 5
CNH France S.A.- FRANCE
SERVICE
PRINTED IN FRANCE
COPYRIGHT BY CNH France S.A
All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH France S.A. company reserves the right to modify without prior notice the characteristics and the design of the
machine without any obligation to carry out those modications on machines already sold.
The description of the models shown in this manual has been made using the technical specications known at the
date on which this document was designed.
26019 1 02/12/2004
REPAIR MANUAL
POWER PRODUCTION
CX225SR
26026 1 02/12/2004
B
Contents
POWER PRODUCTION - B
ENGINE B.10.A
CX225SR
FUEL AND INJECTION SYSTEM B.20.A

CX225SR
AIR INTAKE SYSTEM B.30.A

CX225SR
EXHAUST SYSTEM B.40.A

CX225SR
ENGINE COOLANT SYSTEM B.50.A

CX225SR
LUBRICATION SYSTEM B.60.A

CX225SR
STARTING SYSTEM B.80.A

CX225SR
PTO POWER IN B.90.A

CX225SR
26026 1 02/12/2004
B
ENGINE - 10.A
CX225SR
26027 1 02/12/2004
B.10.A / 1
Contents
ENGINE - 10.A
TECHNICAL DATA
ENGINE - General specication (B.10.A - D.40.A.10) 3
CX225SR
ENGINE - Engine horse power (B.10.A - D.50.A.20) 4

CX225SR
FUNCTIONAL DATA
ENGINE - Electronic schema (B.10.A - C.20.A.50) 5
CX225SR
Electronic control
Electronic control - Electronic schema (B.10.A.92 - C.20.A.50) 7
CX225SR
SERVICE
ENGINE - Remove (B.10.A - F.10.A.10) 11
CX225SR
ENGINE - Install (B.10.A - F.10.A.15) 15

CX225SR
Sensing system
Sensing system Speed sensor - Electrical test (B.10.A.95.80 - F.40.A.50) 18
CX225SR
DIAGNOSTIC
ENGINE - Problem solving (B.10.A - G.40.A.30) 19
CX225SR
Sensing system
Sensing system Speed sensor - No signal (B.10.A.95.80 - G.30.B.21) 21
CX225SR
26027 1 02/12/2004
B.10.A / 2
POWER PRODUCTION - ENGINE
ENGINE - General specication (B.10.A - D.40.A.10)

CX225SR
Manufacturer Isuzu
Model BB-6BG1T
Type
Four-stroke, water-cooled with overhead valves, direct injection, in-line cylinders (electronic control) with
turbocharger
Number of cylinders 6 in line
Bore and stroke 105 x 125 mm
Operating conditions
Idle 900 tr/min
Max. rpm 1950 tr/min
"Normal" N mode 2000 tr/min
"Economical" E mode 1800 tr/min
ECC 1289 Power 103 kW (140 cv)
Max. torque 527 Nm to 1600 tr/min
Capacities
Engine oil 24 L
Engine cooling circuit 23 L
Radiator alone 8L
Fuel tank 265 L
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B.10.A / 3
ENGINE - Engine horse power (B.10.A - D.50.A.20)

CX225SR
CRIL04B147G01 1
Power and consumption curves
(rpm) engine rpm (g/kWh) fuel consumption in grams per kilowatt hour
(kW) engine power in kilowatts (Nm) engine torque in Newton metres
(A)Fuel consumption (B)Engine power (C)Engine torque

(A1) Less than 249 g/kWh (B1) 2000 tr/min (C1) 461 Nm to 1000 tr/min
(B2) 103 kW to 1950 tr/min (C2) 526.6 Nm to 1600 tr/min
(B3) 95.5 kW to 1980 tr/min
(B4) 100.6 kW to 2000 tr/min
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B.10.A / 4
ENGINE - Electronic schema (B.10.A - C.20.A.50)

CX225SR
CRIL03K121H01 1
Engine control
Circuit layout
(1) Engine (2) Rack sensor
(3) Control circuit (4) Linear motor control circuit
26027 1 02/12/2004
B.10.A / 5
(5) Electronic acceleration circuit (A2) Engine electronic control box

(A3) Electronic acceleration (B1) Coolant solution temperature sensor
(B41) Engine speed detector (R2) Fuel ow adjustment resistor
(R3) Engine throttle control (S1) Starter switch
FUEL CONSUMPTION CONTROL

1. The engine electronic control box (A2) calculates the target speed based on:
• voltage signals of throttle control (R3),
• voltage signals from coolant temperature sensor (B1),
• voltage signals (starter switch (S1)) powering the engine electronic control box..
2. Engine electronic control box (A2) calculates the fuel ow by analysing the difference between the target
speed (electronic acceleration tachometric sensor) and the actual speed (engine rpm sensor (B41).
3. Engine electronic control box (A2) converts the fuel ow at the target position of electronic acceleration rack
(A3) and corrects that target position in accordance with regulating resistance (R2).
ENGINE CHECK AT START-UP

1. When contact switch (S1) is in the starting position, the starting signal is sent simultaneously to the starter
motor and engine electronic control box (A2).
2. Engine electronic control box (A2) determines the fuel ow injection. This ow is determined from the water
temperature data and the real number of revolutions of the engine.
3. Once the start signal is switched off, engine electronic control box (A2) goes from start fuel control to
normal ow injection control.
ENGINE CHECK ON SHUTDOWN

On receiving the engine shutdown signal (when ignition is turned off), engine electronic control box (A2)
transmits the rack "no injection" position signal to electronic acceleration (A3) and activates the engine
shutdown signal.
ELECTRONIC ASSISTANCE POWER-ASSIST ERROR AND BACK-UP MODE

1. The rack sensor signal reaches engine electronic control box (A2).
2. Engine electronic control box (A2) compares the target position and the actual position of the rack.
3. If engine electronic control box (A2) determines that the rack is not in its correct target position, it considers it
as a power-assist error and stops the engine.
4. If the back-up mode is activated during an electronic acceleration (A3) power-assist error , the engine runs
in back-up mode.
5. In back-up mode, the rack position is adjusted exclusively by the engine rpm sensor (B41).
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B.10.A / 6
Electronic control - Electronic schema (B.10.A.92 - C.20.A.50)

CX225SR
ELECTRICAL SYSTEM FAULT DETECTION
CRIL03K147F01 1
Circuit layout
(1) Engine electrical system fault indicator lamp (2) Audible alarm device
(3) Fault code detection connection (4) Fault code erasing connection
(5) Engine (A2) Engine electronic control box
(A3) Electronic acceleration (B1) Coolant solution temperature sender
(B41) Engine speed detector (P1) Instrument panel
(R3) Throttle control (X13) Fault code erasing connector
(X14) Fault code detection connector
26027 1 02/12/2004
B.10.A / 7
CRIL03K148F01 2
Timing diagram with error code 41
(1) Engine electrical system fault indicator lamp (2) Audible alarm device
(3) Fault code detection connection (5A) With the engine stopped
(5B) Engine starting (5C) Engine running
OPERATION
• When connection (3) of the fault code connector (X14) is not functioning, the engine electrical system faults
are reported by the continuous lighting up of electrical system fault indicator lamp (1).
• When connection (3) of the fault code connector (X14) is functioning, the engine electrical system faults are
reported by a series of ashes of the electrical system fault indicator lamp (1).
26027 1 02/12/2004
B.10.A / 8
CRIL03K149F01 3
Timing diagram - Error code reader
(1) Engine electrical system fault indicator lamp (3) Fault code detection connection
(5A) With the engine stopped (5C) Engine running
OPERATION
1. When connection (3) of the fault code detection connector (X14) is set up with the engine running, the
current fault code of the engine electrical system are reported by a series of ashes of the electrical system
fault indicator lamp (1).
2. When connection (3) of the fault code detection connector (X14) is set up with the engine switched off, the
current and previous fault code of the engine electrical system are reported by a series of ashes of the
electrical system fault indicator lamp (1).
3. The ashing sequence of a fault code is repeated three times before going on to the ashing sequence
of the next fault code.
CRIL03K184E00 4
The diagram above shows several simultaneous faults of the engine electrical system.
4. With the engine running or stopped, if connection (3) of fault code detection connector (X14) is set up, and if
there is no fault in the engine electrical system, the electrical system fault indicator lamp will ash at regular
intervals (once every second).
CRIL03K185E00 5
The diagram above indicates that there is no fault in the engine electrical system.
26027 1 02/12/2004
B.10.A / 9
List of fault codes

Fault code no. Description Indicator lamp
lighted
(32) Rack position detector YES
(31) Circuit inside the electronic regulator, linear servomotor YES
(41) TDC sensor YES
(42) Engine speed detector YES
(21) Acceleration sensor NO
(15) Coolant solution temperature sensor NO
(25) Resistance to fuel ow adjustment no NO
ERASING FAULT CODES

• To erase the fault code from the electronic control box memory, connect (4) the fault code erasing connector
(X13) for at least one second, then turn the start switch to the "OFF" position for at least half a second.
26027 1 02/12/2004
B.10.A / 10
ENGINE - Remove (B.10.A - F.10.A.10)

CX225SR

Prior operation: ENGINE COOLANT SYSTEM - Drain uid (B.50.A - F.35.A.20)
Prior operation: Remove the lower protection panels (1), (3) and (6), refer to Protective shield - Remove
(E.20.A.73 - F.10.A.10)
1. Remove the upper protection brackets.

2. Remove and plug the upper and lower radiator
hoses.
Remove and plug the upper and lower refrigerant
hoses.
Place identication tags on heater hoses (1) and
(2), disconnect them and plug the ports.
CRIL04C136A01 1
3. Remove the engine throttle control.

Remove and plug the fuel supply and return pipe.
CRIL04C137A01 2
4. Mark and disconnect water temperature sensors

(1) and (2).
CRIL04C138A01 3
26027 1 02/12/2004
B.10.A / 11
5. Mark and disconnect the glow plugs (1).
CRIL03J109A01 4
6. Mark and disconnect engine oil pressure switch and

engine rpm sensor (1).
CRIL04C139A01 5
7. Mark and disconnect starter motor (1).

Remove the earthing braid at the engine end.
CRIL04C140A01 6
8. Remove and plug hose (1) connecting the

turbocharger to the air lter.
CRIL04C141A01 7
26027 1 02/12/2004
B.10.A / 12
9. Mark and disconnect alternator (1).

NOTE: If the machine is tted with air conditioning,
remove the compressor mountings and place it away from
the engine.
CRIL04C142A01 8
10. Remove and plug the expansion tank hose.

Remove all mountings fastening the electrical
harnesses to the engine and place the harnesses
away from the engine.
Remove the exhaust shield.
11. Place identication labels on the hydraulic pump.
Place a container under the hydraulic pump.
Disconnect hydraulic oil temperature thermo-switch
(1).
Disconnect all hoses.
Plug the hoses and the ports
CRIL04C144A01 9
26027 1 02/12/2004
B.10.A / 13
12. Install a lifting device in the rings of engine (1) and

hydraulic pump (2).
CRIL04C145B01 10
13. Remove the engine mountings.

Mark each screw for identication purposes.
Carefully raise the engine, moving it until it is free of
the radiator shroud.
When nothing else is in the way, remove the engine.
14. Mount the engine on a repair bench.
Next operation: Hydraulic pump - Remove (A.10.A.20 - F.10.A.10)
26027 1 02/12/2004
B.10.A / 14
ENGINE - Install (B.10.A - F.10.A.15)

CX225SR
Prior operation: To connect the hydraulic pump to the engine, refer to Hydraulic pump - Install (A.10.A.20
- F.10.A.15)
1. Install a lifting device in the rings of engine (1) and

hydraulic pump (2).
CRIL04C145B01 1
2. Carefully raise and install the engine until it engages

with the radiator shroud.
3. Install new exible blocks.
Install the screws and washers following the marks
Coat with locking uid and tighten to torque 264.9
- 313.9 Nm
4. Take the electrical harnesses with all the mounting
hardware and install them.
5. Connect the cables to alternator (1).
NOTE: If the machine is tted with air conditioning, install
the compressor, refer to Compressor - Install (E.40.D.31
- F.10.A.15).
CRIL04C142A01 2
26027 1 02/12/2004
B.10.A / 15
6. Install hose (1) connecting the turbo-charger to the

air lter.
CRIL04C141A01 3
7. Connect the starter motor and earth strap (1)

following the marks made during removal.
CRIL04C140A01 4
8. Connect engine oil pressure switch and engine rpm

sensor (1).
CRIL04C139A01 5
9. Connect water temperature sensors (1) and (2)

following the marks made during removal.
CRIL04C138A01 6
10. Install the upper and lower radiator hoses.

Install the heating circuit hoses following the marks
Install the upper and lower refrigerant hoses.
26027 1 02/12/2004
B.10.A / 16
11. Install the fuel supply pipe.

Install the fuel return pipe.
Loosen screw (1) and operate priming pump (2)
until the fuel ows out without air bubbles.
Retighten the screw (1).
CRIL03I118A01 7
12. Install the engine throttle control.
CRIL04C137A01 8
13. Install the exhaust shield.

Install the upper protection brackets.

Next operation: To install the engine hood, refer to Engine hood - Remove (E.20.A.72 - F.10.A.10)
Next operation: To install lower protection panels (1), (3) and (6), refer to Protective shield - Remove (E.20.A.73
- F.10.A.10)
Next operation: ENGINE COOLANT SYSTEM - Filling (B.50.A - F.60.A.10)
26027 1 02/12/2004
B.10.A / 17
Sensing system Speed sensor - Electrical test (B.10.A.95.80 -

F.40.A.50)
CX225SR
1. Disconnect connector (1) from engine speed sensor

(B41).
CRIL04B149A01 1
2. Connect the appropriate electrical test connector (3)

to connector (1) on motor speed sensor (B41), then
install the multimeter (2), refer to ELECTRICAL
POWER SYSTEM - Special tools (A.30.A -
D.20.A.40).
CRIL03I078A04 2
3. The motor speed sensor resistance reading (B41)

on multimeter (2) should be between 700 ohms
and 25 °C.
NOTE: The resistance value will vary according to the
heat
26027 1 02/12/2004
B.10.A / 18
ENGINE - Problem solving (B.10.A - G.40.A.30)

CX225SR
OPERATION
1. Engine electrical circuit conguration
CRIL04C008G01 1
2. Component descriptions
(1) Engine (2) Fault code detection connection

(A2) Engine electronic control box (A3) Electronic acceleration
(B1) Coolant solution temperature sensor (B41) Engine speed detector
(R2) Fuel ow adjustment resistor (R3) Engine throttle control
(X14) Engine fault code detection connector
TROUBLESHOOTING
PRELIMINARY INSPECTIONS
1. Check the quantity of fuel
2. Check that fuel is not contaminated.
3. Check engine oil level.
4. Check coolant level.
5. Check air lter blockage indicator (dust)
26027 1 02/12/2004
B.10.A / 19
6. Check the battery terminals and wiring for tightness and corrosion.
7. Check the alternator terminals and wiring for tightness and corrosion.
8. Check the starter motor terminals and wiring for tightness and corrosion.
9. Check the battery voltage (with engine shut down). It should be 23 - 26 volts.
10. Check the quantity of uid in the battery.
11. Ensure that the cables are not discoloured, burnt or stripped.
12. Check for moisture on cables (especially on connectors and terminals).
13. Check fuses for condition and corrosion.
14. Check alternator voltage (with engine speed above the throttle control mid-point). The reading should be
27.5 - 29.5 volts.
When the battery charge is inadequate, only 25 volts may be generated at start up.
15. If noise is heard from the battery relay (with starter motor ON or OFF), replace the relay.
NOTE: Starter motor switch ON.
Connect (2) to fault code detection connector (X14).
The engine electrical Fault code (31) displayed. Check electronic acceleration (A3), refer to
system fault indicator Internal circuit for electronic regulator or Injection control - No signal (B.20.A.92
lamp is lit servomotor faulty. - G.30.B.21).
Fault code (32) displayed. Check electronic acceleration (A3), refer to
Faulty rack position sensor. Injection control - No signal (B.20.A.92
- G.30.B.21).
Fault code (41) displayed. Check electronic acceleration (A3), refer to
Faulty TDC sensor. Injection control - No signal (B.20.A.92
- G.30.B.21).
Fault code (42) displayed. Check engine speed sensor (B41), refer
Faulty engine speed (B41) sensor. to Sensing system Speed sensor - No
signal (B.10.A.95.80 - G.30.B.21).
Fault code (21) displayed. Check the engine throttle control (R3),
Faulty engine throttle control (R3). refer to Throttle command Electronic
throttle - Low signal (B.20.A.06.91 -
G.30.B.20).
Fault code (15) displayed. Check coolant temperature sensor
Faulty coolant temperature sensor (B1). (B1), refer to Sensing system Coolant
temperature - Low signal (B.50.A.95.90
- G.30.B.20).
Fault code (25) displayed. Check fuel ow adjustment resistor (R2),
Faulty fuel ow adjustment resistor (R2). refer to Injection control - No signal
(B.20.A.92 - G.30.B.21).
No fault displayed. Clean connector terminals, repair
Poor electronic throttle control (A3) damaged harness wires or replace
connection, damaged harness or faulty electronic control box (A2).
electronic control box (A2).
26027 1 02/12/2004
B.10.A / 20
Sensing system Speed sensor - No signal (B.10.A.95.80 - G.30.B.21)

CX225SR
42 - Capteur régime moteur défectueux
Cause:
Fault code (42) displayed.

Faulty engine speed (B41) sensor.
CRIL04C063E01 1
(A2) Engine electronic control box.

(B41) Engine speed sensor.
Possible failure modes:
1. The main symptom of this error is detection of signals that the engine ywheel speed sensor is incapable of
transmitting.
2. No information.
3. The fault code is erased automatically after repair.
If the tachometer sensor tted in the injection pump is faulty, the electronic control box will seek information
from engine speed sensor (B41)
Solution:
1. Check the resistor of engine speed sensor (B41), refer to Sensing system Speed sensor - Electrical
test (B.10.A.95.80 - F.40.A.50).
A. Correct, continue by 2
B. Incorrect, continue by 7
2. Check the connectors.
3. Check continuity of wires.
4. Check the position (gap) of speed sensor (B41).
A. Correct, replace the speed sensor.
5. Repair the connections to the connector. The fault code is no longer active.
26027 1 02/12/2004
B.10.A / 21
A. Correct, test completed.
B. Incorrect, replace speed sensor.

6. Repair or change the harness. The fault code is no longer active.
7. Adjust the speed sensor position. The fault code is no longer active.
B. Incorrect, replace speed sensor.
26027 1 02/12/2004
B.10.A / 22
Index
ENGINE - 10.A
Electronic control - Electronic schema (B.10.A.92 - C.20.A.50) 7
CX225SR
ENGINE - Electronic schema (B.10.A - C.20.A.50) 5
CX225SR
ENGINE - Engine horse power (B.10.A - D.50.A.20) 4
CX225SR
ENGINE - General specication (B.10.A - D.40.A.10) 3
CX225SR
ENGINE - Install (B.10.A - F.10.A.15) 15
CX225SR
ENGINE - Problem solving (B.10.A - G.40.A.30) 19
CX225SR
ENGINE - Remove (B.10.A - F.10.A.10) 11
CX225SR
Sensing system Speed sensor - Electrical test (B.10.A.95.80 - F.40.A.50) 18
CX225SR
Sensing system Speed sensor - No signal (B.10.A.95.80 - G.30.B.21) 21
CX225SR
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FUEL AND INJECTION SYSTEM - 20.A
CX225SR
26028 1 02/12/2004
B.20.A / 1
Contents
FUNCTIONAL DATA
Throttle command
Throttle command Electronic throttle - Functional diagram (B.20.A.06.91 - C.20.A.70) 4
CX225SR

CX225SR

CX225SR

CX225SR
Fuel shut-off
Fuel shut-off Electrical shut-off - Electronic schema (B.20.A.13.81 - C.20.A.50) 11
CX225SR
Sensing system
Sensing system Level sensor - Electronic schema (B.20.A.95.90 - C.20.A.50) 13
CX225SR
SERVICE
Fuel ller aid
Fuel ller aid - Remove (B.20.A.20 - F.10.A.10) 15
CX225SR
Fuel ller aid - Install (B.20.A.20 - F.10.A.15) 16

CX225SR
Fuel tank
Fuel tank - Remove (B.20.A.22 - F.10.A.10) 17
CX225SR
Fuel tank - Install (B.20.A.22 - F.10.A.15) 19

CX225SR
Injection control
Injection control - Electrical test (B.20.A.92 - F.40.A.50) 20
CX225SR
DIAGNOSTIC
Throttle command
Throttle command Electronic throttle - Low signal (B.20.A.06.91 - G.30.B.20) 21
CX225SR
Injection control
Injection control - No signal (B.20.A.92 - G.30.B.21) 23
CX225SR

CX225SR
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Injection control - Low signal (B.20.A.92 - G.30.B.20) 27
CX225SR

CX225SR
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POWER PRODUCTION - FUEL AND INJECTION SYSTEM
Throttle command Electronic throttle - Functional diagram

(B.20.A.06.91 - C.20.A.70)
CX225SR
THROTTLE CONTROL
CRIL03K122F01 1
Circuit layout

(A3) Electronic acceleration (R3) Engine throttle control
OPERATION
1. The engine electronic control box (A2) calculates the target position of the rack using the target rpm and
data from each sensor (actual engine rpm, actual position of the rack, fuel ow adjustment resistor), and it
transmits the signal to the electronic acceleration.
2. The electronic acceleration (A3) calculates the target position of the rack and its real position (value measured
by the rack detector) and moves the rack by turning the electric motor to adjust the quantity of fuel injected.
3. By repeating this process, the engine electronic control box (A2) controls electronic acceleration (A3) to obtain:
real number of revolutions = target number of revolutions.
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Relationship between the throttle control position and the engine rpm
CRIL03K127E01 2
(A) Throttle control position by percentage open
(B) Engine speed in rpm.
(C) Input voltage in volts
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B.20.A / 5

(B.20.A.06.91 - C.20.A.70)
CX225SR
ENGINE IDLING CHECK
CRIL03K123E01 1
Circuit layout
(1) Engine (P1) Instrument panel

(A2) Engine electronic control box (S16) Engine idle switch
(A3) Electronic acceleration
CRIL03K124F01 2
Timing diagram
OPERATION
1. If starter switch (S1) is in the "OFF" position when idle switch (S16) is in the "ON" position, starter switch (S16) will return to
the "OFF" position as soon as starter switch (S1) is turned to the "ON" position.
2. Every time idle switch (S16) is activated, engine idle will be alternately activated/deactivated.
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B.20.A / 6

(B.20.A.06.91 - C.20.A.70)
CX225SR
INJECTION PUMP ELECTRONIC REGULATOR
CRIL03K146G01 1
Circuit layout
(1) Engine (2) Hydraulic system

(3) Injection pump (4) Electronic regulator
(5) Engine speed signal (6) Rack position detector signal
(7) Rack control signal (8) Engine speed detector signal
(9) Linear motor (10) Rack
(11) Linear motor control section (12) Rack position detector
(A2) Engine electronic control box (B41) Engine speed detector
(R2) Fuel ow adjustment resistor (R3) Engine throttle control
(S1) Starter switch
OPERATION
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1. To ensure low fuel consumption and optimum productivity, the calculation section (engine electronic control
box (A2) compares the information received with the stored data, then transmits a control signal to control
section (11) of linear motor (9) through connections, (5), (6), (7) and (8).
2. Control section (11) sends a signal to linear motor (9) of regulator (4) to activate rack control (10) on injection
pump (3).
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B.20.A / 8

(B.20.A.06.91 - C.20.A.70)
CX225SR
N/E MODES CHECK
CRIL04B150F01 1
Circuit layout
(1) Engine (2) Fuel injection pump

(A2) Engine electronic control box (A8) Engine mode selector
(B26) Upper pilot pressure switch (yellow band) (B27) Travel pilot pressure switch
(S1) Starter motor switch (S30) N/E mode switch
CRIL04B151F01 2
Timing diagram
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B.20.A / 9
(3) Engine speed

(4) Engine start up, maximum engine throttle position
OPERATION
1. When N/E mode switch (S30) is in position E, the engine is set to fuel economy mode (1800 tr/min).
2. When N/E mode switch (S30) is in position N, the engine is set to working mode (2000 tr/min).
3. If the excavator is not working ((B26) and (B27) set to OFF) and N/E mode switch (S30) is in position N, the
engine speed drops to 1800 tr/min to reduce fuel consumption.
This function does not operate when N/E mode switch (S30) is in position E.
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B.20.A / 10
Fuel shut-off Electrical shut-off - Electronic schema (B.20.A.13.81 -

C.20.A.50)
CX225SR
CRIL03K141F01 1
Circuit layout
(1) Engine (A2) Electronic control box

(A3) Electronic acceleration (K1) Relay-engine emergency stop
(M2) Engine emergency stop motor (S9) Engine emergency stop switch
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B.20.A / 11
CRIL03K142F01 2
Timing diagram
EMERGENCY STOP CONTROL OPERATION
1. If engine emergency stop switch (S9) is activated, transistor output (OUT1) = 0 volts.
2. (OUT1) at 0 volts, emergency stop relay (K1) is activated, as is emergency stop motor (M2).
3. Stop signal input (IN1) on engine electronic control box (A2) falls to 0 volts, the engine electronic control box (A2) accepts
that as the emergency stop status and transmits the "stop engine" signal (OUT2) = 0 volts.
4. Electronic acceleration (A3) starts to control the engine shut down when it receives the signal (rack position = 0 mm).
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Sensing system Level sensor - Electronic schema (B.20.A.95.90 -

C.20.A.50)
CX225SR
CRIL03G087E01 1
Circuit layout
(1) Fuel level indicator (2) Minimum fuel level indicator lamp
(3) Audible alarm device (P1) Instrument panel
CRIL03G088E01 2
Fuel level indicator (1)
Sensor specication (R5)

(A) Tank full Sensor resistance 10 ohms
(B) Tank empty Sensor resistance 90 ohms
Tank half empty Sensor resistance 38 ohms
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CRIL03G089E02 3
Timing diagram
(2) Minimum fuel level indicator lamp (C) Lamp test

(3) Audible alarm device (D) Audible alarm device test
OPERATION
• When sensor resistance (R5) falls to 37 ohms or below, minimum fuel level indicator lamp (2) lights up.
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Fuel ller aid - Remove (B.20.A.20 - F.10.A.10)

CX225SR
1. Open hood (1) and prop it with strut (2).
CRIL04B152A01 1
2. Disconnect the ller pump.

Remove screws (4).
Remove casing assembly (3) with the fuel ller.
CRIL04B153A01 2
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Fuel ller aid - Install (B.20.A.20 - F.10.A.15)

CX225SR
1. Install casing assembly (3) with the fuel ller.

Fit screws (4).
Connect the ller pump.
Close the hood again.
CRIL04B153A01 1
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Fuel tank - Remove (B.20.A.22 - F.10.A.10)

CX225SR
Prior operation: Fuel ller aid - Remove (B.20.A.20 - F.10.A.10)

Prior operation: Remove the fuel tank and hydraulic reservoir protective panels, refer to Upper shield - Remove
(E.20.A.71 - F.10.A.10)
Prior operation: To remove the right guard, refer to Side shield - Remove (E.20.A.70 - F.10.A.10)
Prior operation: Remove lower panel (4) (underneath upperstructure), refer to Protective shield - Remove
(E.20.A.73 - F.10.A.10)
1. Open the fuel tank cap.

Using a suitably-sized container, drain the fuel tank
via the plug (1).
Tighten the drain plug.
CRIL04B193A01 1
2. Disconnect the fuel gauge sensor (1) and move

harness (2) to one side.
CRIL04B194A01 2
3. Remove the collar and the fuel supply hose

underneath the tank.
Remove the collar and fuel return hose located on
the side of the tank.
Plug the hoses and the ports
Remove the xing clip from the return hose.
4. Remove fuel tank xing screws (1), (2) and (3).
NOTE: Check that the fuel tank is not attached at a xing
point.
CRIL04B194A02 3
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5. Using a sling and a lifting device, remove the fuel

tank from the machine.
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Fuel tank - Install (B.20.A.22 - F.10.A.15)

CX225SR
1. Using a sling and a lifting device, install the fuel

tank in the machine.
2. Fit the washers on screws (1) coat with thread
locking uid and tighten to a torque of 412 - 471 Nm
Mount the brackets and screws (2) and (3).
CRIL04B194A02 1
3. Install the hose and the collar on the fuel supply

orice underneath the tank.
Install the hose and collar on the return port located
on the side of the fuel tank.
Install retaining clips on the hoses.
Connect harness (2) to fuel gauge sensor (1).
CRIL04B194A01 2
4. Fill the fuel tank.

Check for leaks.
5. Bleed the fuel circuit.
Loosen screw (1) and operate priming pump (2)
until the fuel ows out without air bubbles.
Retighten the screw (1).
CRIL03I118A01 3
6. Install the RH protective panel.

Install the upper protective panel.
Install the fuel ller.
Install lower panel (4).
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Injection control - Electrical test (B.20.A.92 - F.40.A.50)

CX225SR
Use a voltmeter and the electrical test connector for electronic acceleration module, refer to ELECTRICAL POWER
1. 31 - CHASSIS HARNESS DISCONNECTED

Disconnect the connectors from the servomotor.
Connect service cable (A8P) between the
servomotor connectors.
Connect the meter, red wire to (brown) wire (Br)
and black to (green/red) wire (GR).
Check the tension. It should be.0.5 - 4.5 volts.
CRIL04C014A02 1
2. 32 - DRAFT LOAD POTENTIOMETER SHORTED

TO +12V
Connect the meter, red wire to (white/blue) wire
(WL) or (white/yellow) wire (WY) and black to
(green/red) wire (GR).
Check the tension. It should be .0.5 - 4.5 volts.
CRIL04C014A01 2
3. 41 - Sonde tachymètre du servo-moteur

défectueuse
Connect the meter, red wire to (blue) wire (L) and
black to (yellow) wire (Y).
Check the resistance. It should be 2000 - 2400
ohms.
CRIL04C014A03 3
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Throttle command Electronic throttle - Low signal (B.20.A.06.91 -

G.30.B.20)
CX225SR
21 - DRAFT SENSITIVITY CONTROL VOLTAGE LOW (SHORT OR OPEN CIRCUIT)
Cause:
Faulty engine throttle control
CRIL04C064E01 1

(R3) Electronic engine throttle control
Voltage check at engine throttle control output

Engine throttle control Between (62) and (73) Between (73) and (83)
0% 5 volts 0 volts
100 % 0 volts 5 volts
1. The signal is outside the specied values.

The engine speed does not change.
2. This fault is detected when the output signal from the engine electronic control box (A2) is less than or greater
than 0 - 5.120 volts for six hundred and fty-ve seconds or more.
If the signal is invalid, the volume opening is set to 0%.
Solution:
1. Check the voltage at engine throttle control output
B. Incorrect, continue 7
2. Check the voltage uctuations at the engine throttle control output.
3. Check the connections of the wires to the connectors.
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B.20.A / 21
5. Repair connections. The fault code is no longer active.
7. Replace engine throttle control (R3). The fault code is no longer active.
8. Change electronic control box (A2). The fault code is no longer active.
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Injection control - No signal (B.20.A.92 - G.30.B.21)

CX225SR
31 - CHASSIS HARNESS DISCONNECTED
Cause:
Defective electronic regulator or servomotor internal circuit.
CRIL04C060E01 1
(A2) Engine electronic control box

(A3) Injection pump electronic acceleration.
1. The main symptom of this error is incorrect positioning of the servomotor, which cuts the supply to the engine.
2. The current rack position differs by more than 2 mm from the target position.
3. The fault code is erased when the contact switch is moved to OFF then to ON after repair.
Solution:
1. Check the servomotor voltage, refer to Injection control - Electrical test (B.20.A.92 - F.40.A.50)
2. Check the TDC sensor resistor, refer to Injection control - Electrical test (B.20.A.92 - F.40.A.50)
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8. Change injection pump.
A. Test completed.
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CX225SR
32 - DRAFT LOAD POTENTIOMETER SHORTED TO +12V
Cause:
Faulty rack position sensor.
CRIL04C061E01 1

1. The sensor cannot detect the rack position..

The servomotor cuts the engine.
2. This fault is detected when the signal from engine electronic control box (A2) is less than or greater than 0.5
- 4.5 volts for over a second.
3. The fault code is erased when the contact switch is moved to OFF then to ON after repair.
Solution:
1. Check the rack position sensor voltage, refer to Injection control - Electrical test (B.20.A.92 - F.40.A.50)
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A. Test completed..
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Injection control - Low signal (B.20.A.92 - G.30.B.20)

CX225SR
41 - 41 - Sonde tachymètre du servo-moteur défectueuse
Cause:
Tachometer sensor on servomotor faulty.
CRIL04C062E01 1

1. The sensor cannot detect the signals from the rotating sensor tted in the injection pump.
2. No information.
If the tachometer sensor tted in the injection pump is faulty, the electronic control box will seek information
from engine speed sensor (B41).
Solution:
1. Check the voltage of the servomotor tachometer sensor, refer to Injection control - Electrical test (B.20.A.92
- F.40.A.50)
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CX225SR
25 - POSITION LEVER POTENTIOMETER CONTROL VOLTAGE LOW (SHORT OR OPEN CIRCUIT)
Cause:
Faulty fuel ow adjustment resistor.
CRIL04C066E01 1

(R2) Fuel ow adjustment resistor
1. No signal from fuel ow adjustment resistor (R2) attached to the engine.
2. No information.
No signal between engine electronic control box (A2) and fuel ow adjustment resistor (R2), the engine
speed returns to idle.
Solution:
1. Check the voltage of ow adjustment resistor (R2), refer to Injection control - Electrical test (B.20.A.92 -
F.40.A.50)
2. Check the connectors.
4. Repair the connections to the connector. The fault code is no longer active.
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7. Replace fuel ow adjustment resistor (R2). The fault code is no longer active.
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B.20.A / 30
Index

Fuel ller aid - Install (B.20.A.20 - F.10.A.15) 16
CX225SR
Fuel ller aid - Remove (B.20.A.20 - F.10.A.10) 15
CX225SR
Fuel shut-off Electrical shut-off - Electronic schema (B.20.A.13.81 - C.20.A.50) 11
CX225SR
Fuel tank - Install (B.20.A.22 - F.10.A.15) 19
CX225SR
Fuel tank - Remove (B.20.A.22 - F.10.A.10) 17
CX225SR
Injection control - Electrical test (B.20.A.92 - F.40.A.50) 20
CX225SR
Injection control - Low signal (B.20.A.92 - G.30.B.20) 27
CX225SR
CX225SR
CX225SR
CX225SR
Sensing system Level sensor - Electronic schema (B.20.A.95.90 - C.20.A.50) 13
CX225SR
CX225SR
CX225SR
CX225SR
CX225SR
Throttle command Electronic throttle - Low signal (B.20.A.06.91 - G.30.B.20) 21
CX225SR
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AIR INTAKE SYSTEM - 30.A
CX225SR
26029 1 02/12/2004
B.30.A / 1
Contents
SERVICE
Air cleaner
Air cleaner - Remove (B.30.A.25 - F.10.A.10) 3
CX225SR
Air cleaner - Install (B.30.A.25 - F.10.A.15) 4

CX225SR
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B.30.A / 2
POWER PRODUCTION - AIR INTAKE SYSTEM
Air cleaner - Remove (B.30.A.25 - F.10.A.10)

CX225SR
1. Open the rear LH side door.
CRIL04B187A00 1
2. Disconnect restriction indicator (1).

Disconnect air intake hose (2).
Plug the ports.
Remove screws (3) and air lter assembly (4).
CRIL04B188A01 2
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POWER PRODUCTION - AIR INTAKE SYSTEM
Air cleaner - Install (B.30.A.25 - F.10.A.15)

CX225SR
1. Install air lter assembly in place (4).

Tighten screws (3) to a torque of 2.4 - 2.8 Nm.
Remove the plugs.
Connect restriction indicator (1).
Install air intake hose (2).
CRIL04B188A01 1
2. Close the rear LH side door.
CRIL04B187A00 2
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B.30.A / 4
Index

Air cleaner - Install (B.30.A.25 - F.10.A.15) 4
CX225SR
Air cleaner - Remove (B.30.A.25 - F.10.A.10) 3
CX225SR
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B.30.A / 5
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B.30.A / 6
EXHAUST SYSTEM - 40.A
CX225SR
26030 1 02/12/2004
B.40.A / 1
Contents
SERVICE
Silencer
Silencer - Remove (B.40.A.36 - F.10.A.10) 3
CX225SR
Silencer - Install (B.40.A.36 - F.10.A.15) 5

CX225SR
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B.40.A / 2
POWER PRODUCTION - EXHAUST SYSTEM
Silencer - Remove (B.40.A.36 - F.10.A.10)

CX225SR
Prior operation: To remove the hydraulic pump protective panel, refer to Upper shield - Remove (E.20.A.71
- F.10.A.10)
1. Open the engine hood.

Open the rear RH door.
Remove upper protective panel (1).
Remove protective brackets for upper protective
panels (2).
CRIL04D001A01 1
2. Remove nuts and lock nuts (1) from exhaust piping

(2).
CRIL04B037B01 2
26030 1 02/12/2004
B.40.A / 3
3. Remove nuts (1), then remove xing clamps (2)

from exhaust silencer (3).
Remove exhaust silencer (3).
Discard exhaust piping seal.
CRIL04B038B01 3
4. Remove screws (1) from collar (2) and separate

exhaust silencer (3) from piping (4).
Remove collar (2).
CRIL04B039A01 4
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B.40.A / 4
Silencer - Install (B.40.A.36 - F.10.A.15)

CX225SR
1. Install collar (2) on exhaust silencer (3).

Install piping (4) in collar (2).
CRIL04B039A01 1
2. Install a new seal on the turbo-charger.

Install exhaust silencer (3) on bracket (4).
Install retaining clamps (2) on silencer (3).
Install and tighten nuts (1).
CRIL04B038B02 2
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3. Install and tighten nuts and lock nuts (1).

Install and tighten screws (2) on clamp (3).
CRIL04B037B02 3
4. Install and tighten screws on protective panel (1).

Install upper protective panel brackets (2).
Close the RH rear door.
Close the engine hood.
CRIL04D001A01 4
5. Install the hydraulic pump protective panel.
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B.40.A / 6
Index

Silencer - Install (B.40.A.36 - F.10.A.15) 5
CX225SR
Silencer - Remove (B.40.A.36 - F.10.A.10) 3
CX225SR
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ENGINE COOLANT SYSTEM - 50.A
CX225SR
26031 1 02/12/2004
B.50.A / 1
Contents
FUNCTIONAL DATA
Sensing system
Sensing system Coolant temperature - Electronic schema (B.50.A.95.90 - C.20.A.50) 3
CX225SR

CX225SR
Sensing system Coolant over-temperature - Wiring schema (B.50.A.95.91 - C.20.A.45) 7

CX225SR
SERVICE
ENGINE COOLANT SYSTEM - Drain uid (B.50.A - F.35.A.20) 8
CX225SR
ENGINE COOLANT SYSTEM - Interior washing (B.50.A - F.30.A.20) 9

CX225SR
ENGINE COOLANT SYSTEM - Filling (B.50.A - F.60.A.10) 10

CX225SR
Radiator
Radiator - Remove (B.50.A.32 - F.10.A.10) 11
CX225SR
Radiator - Install (B.50.A.32 - F.10.A.15) 13

CX225SR
Sensing system
Sensing system Coolant temperature - Electrical test (B.50.A.95.90 - F.40.A.50) 15
CX225SR
DIAGNOSTIC
Sensing system
Sensing system Coolant over-temperature - Troubleshooting (B.50.A.95.91 - G.40.A.10) 16
CX225SR
Sensing system Coolant temperature - Low signal (B.50.A.95.90 - G.30.B.20) 17

CX225SR
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B.50.A / 2
POWER PRODUCTION - ENGINE COOLANT SYSTEM
Sensing system Coolant temperature - Electronic schema

(B.50.A.95.90 - C.20.A.50)
CX225SR
CRIL03K145F01 1
Circuit layout
(1) Coolant temperature indicator (2) Coolant or hydraulic oil overheating indicator
lamp
(3) Audible alarm device (A2) Engine electronic control box
(B1) Coolant solution temperature sensor (B9) Coolant solution temperature sensor
(B10) Hydraulic oil temperature thermo - switch (P1) Instrument panel
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B.50.A / 3
CRIL03G094E03 2
Timing diagram
CRIL03G093E01 3
Coolant temperature indicator specications (1)

(A) 50 °C
(B) 115 °C
Engine electronic control box overheating signal specication (A2)

Output ON 105 °C
Output OFF 92 °C
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Sensing system Coolant temperature - Electronic schema

(B.50.A.95.90 - C.20.A.50)
CX225SR
IDLE CHECKING BY BATTERY VOLTAGE AND COOLANT TEMPERATURE

• The aim of this function is to avoid the battery from being discharged or the lowering of the coolant temperature
in case of too long an idling period.
CRIL03K139F01 1
Circuit layout

(A3) Electronic acceleration (B1) Coolant solution temperature sensor
OPERATION
When the idle time is too long and either the voltage supplied to the engine electronic control box (A2) drops or the
coolant temperature (B1) is low, the idling speed increases automatically.
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CRIL03K140F01 2
Adjustment to idling speed according to battery voltage and coolant temperature.
(1) Idle speed (rpm) (2) Motor electronic control box supply voltage in
volts
(3) Coolant temperature in °C
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Sensing system Coolant over-temperature - Wiring schema

(B.50.A.95.91 - C.20.A.45)
CX225SR
CRIL04C006F01 1
(1) Coolant or hydraulic oil overheating indicator (2) Coolant temperature indicator
lamp
(A2) Engine electronic control box (B1) Coolant solution temperature sensor
(B9) Coolant solution temperature sensor (B10) Hydraulic oil temperature thermo -switch
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ENGINE COOLANT SYSTEM - Drain uid (B.50.A - F.35.A.20)

CX225SR
Prior operation: Remove lower protection panels (underneath upperstructure) (1), (7) and (8), refer to Protective
shield Guard - Remove (E.20.A.73.71 - F.10.A.10)
1. Remove the radiator cap.

ATTENTION: Do not remove the radiator cap when the
engine is hot. The circuit is still under pressure and you
could be scalded.
CRIL04B155A01 1
2. Place a container of suitable capacity under the

radiator.
Open the radiator drain valve.
CRIL04B156A01 2
3. Place a suitably-sized container under the engine.

Remove the coolant drain plug located on the
engine block.
CRIL04B157A01 3
4. Close the radiator drain valve if the coolant does

not ow.
Install the coolant drain plug on the engine block.
26031 1 02/12/2004
B.50.A / 8
ENGINE COOLANT SYSTEM - Interior washing (B.50.A - F.30.A.20)

CX225SR
1. Fill the radiator with fresh water until it overows.

Put the radiator cap back on.
CRIL04B155A01 1
2. Start the engine and let it idle for 10 mn until the

engine temperature reaches approximately 80 °C.
3. Drain the cooling circuit, refer to ENGINE
COOLANT SYSTEM - Drain uid (B.50.A -
F.35.A.20)
4. Repeat steps 1 to 3 until the water drained runs
clear.
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B.50.A / 9
ENGINE COOLANT SYSTEM - Filling (B.50.A - F.60.A.10)

CX225SR
1. Fill the radiator with coolant until it overows.

Put the radiator cap back on.
CRIL04B155A01 1
2. Open the hood of swing hydraulic motor.

Remove the expansion tank cap.
Fill the expansion tank with coolant up to the mark
(FULL).
Put the expansion tank cap back on.
CRIL04B154A01 2
3. Start the engine and let it idle for 5 minutes.

Top up the coolant in the expansion tank if the level
has dropped.
NOTE: Do not ll the expansion tank above the mark
(FULL).
26031 1 02/12/2004
B.50.A / 10
Radiator - Remove (B.50.A.32 - F.10.A.10)

CX225SR

1. Remove the expansion tank hose (1).

NOTE: If the machine is tted with air conditioning,
remove the retaining screws from the condenser and put
it to one side.
CRIL04B189A01 1
2. Remove and plug cooling radiator hoses (1) and (2).

Remove the retaining clips from the protective
sheaths (3).
3. Remove and plug cooling radiator hoses (4) and (5).
4. Remove screws (7) from retaining tie rod (8) on the
cooling radiator.
Remove wing nuts (9) and grill (10).
CRIL03J171B01 2
26031 1 02/12/2004
B.50.A / 11
5. Remove xing screws (1) from the radiator amd

extract the oating seal.
NOTE: Check that the cooling radiator is not attached
at a xing point.
CRIL04B189A02 3
6. Using a sling and a lifting device, carefully remove

the radiator and cooler assembly from the machine.
26031 1 02/12/2004
B.50.A / 12
Radiator - Install (B.50.A.32 - F.10.A.15)

CX225SR
1. Using a lifting device, carefully mount the radiator

on the machine and engage it in the oating seal.
2. Fit the washers on screws (1) and tighten to a
torque of 147 - 176 Nm.
CRIL04B189A02 1
3. Install tie rod (8), install and tighten screws (7).

4. Install hoses (4) and (5) on the oil cooler.
Tighten the clamps.
5. Install hoses (1) and (2) on the cooling radiator.
Tighten the clamps.
Install retaining clips (3) on the sheaths protecting
the heating hoses.
NOTE: If the machine is equipped with air conditioning,
install the condenser with the mountings on each side,
screw up and tighten.
CRIL03J171B01 2
26031 1 02/12/2004
B.50.A / 13
6. Install hose on expansion tank (1).
CRIL04B189A01 3

26031 1 02/12/2004
B.50.A / 14
Sensing system Coolant temperature - Electrical test (B.50.A.95.90

- F.40.A.50)
CX225SR
1. Disconnect the connectors.

Remove sensor (B1) or (B9).
CRIL03K189A01 1
2. Connect the appropriate test electrical connector (3)

to sensor (B1) or (B9) then install multimeter (4).
Refer to ELECTRICAL POWER SYSTEM - Special
tools (A.30.A - D.20.A.40)
CRIL03I081A03 2
3. Install sensor (B1) or (B9) in a container (2) full of

water and place everything on tripod (6).
4. Using a spirit lamp (7), gradually heat the water in
container (2).
5. Using a multimeter (4), check the resistance position
of sensor (B1) or (B9) according to the temperature
reading on thermometer (1). Refer to ELECTRICAL
POWER SYSTEM - General specication (A.30.A
- D.40.A.10)
26031 1 02/12/2004
B.50.A / 15
Sensing system Coolant over-temperature - Troubleshooting

(B.50.A.95.91 - G.40.A.10)
CX225SR
NOTE: Troubleshooting if the temperature indicator light remains lit (even if actual temperatures are lower than
84 °C for the hydraulic oil and 92 °C for the coolant).
NOTE: Make sure the temperature gauge needle is positioned in zone "H".
NOTE: Refer to Sensing system Coolant over-temperature - Wiring schema (B.50.A.95.91 - C.20.A.45)
Fault code 14 appears Faulty temperature (B1) sensor. Measure the resistance of sensor (B1) at
when a fault detection the terminals on connector (CN5), refer to
connection is made to Sensing system Coolant temperature -
connector X14. Electrical test (B.50.A.95.90 - F.40.A.50).
If the values are incorrect, replace sensor
(B1).
Poor connection with connector (CNA5). Measure the resistance of sensor (B1) at
the terminals on connectors (CNA0) and
(CN4).
If the values are incorrect, clean the
terminals on connector (CNA5).
Poor connection to connector (CN4). Measure the resistance of sensor (B1) at
the terminals on connectors (CNA0) and
(CN7).
terminals on connector (CN4).
terminals on connectors (CN7) and
(CNA0) or replace electronic control box
(A2).
Fault code 15 does not Poor connection or faulty thermo-switch Disconnect connector (CNH1), if the
appear when a fault (B10). overheating indicator light (1) goes out,
detection connection is clean the terminals on connector (CNH1)
made to connector X14. or replace thermo-switch (B10).
Poor connection or faulty sensor (B9). Disconnect wire (YB418) from the sensor,
if overheating indicator light (1) goes out,
clean the terminals or replace sensor (B9).
Poor connection or defective (B1) sensor. Disconnect connector (CNA5), if
overheating indicator light (1) goes out,
clean the terminals on connector (CNA5)
or replace sensor (B1).
Poor connection or faulty electronic control Disconnect connector (CN7), if overheating
(A2) box. indicator light (1) goes out, clean the
terminals on connector (CN7) or replace
electronic control box (A2).
Poor connection with connector (CNM1B), Check the voltage between track 1
fault in wiring or faulty (P1) instrument (wire WL439) on connector (CNM1B) on
panel. instrument panel (P1) and the earth.
If the voltage is less than or equal to 1
volts, replace instrument panel (P1).
If the voltage is greater than 1 volts,
replace or repair the harness.
26031 1 02/12/2004
B.50.A / 16
Sensing system Coolant temperature - Low signal (B.50.A.95.90 -

G.30.B.20)
CX225SR
15 - LOAD SENSING PIN SHORT CIRCUIT TO +12 VOLTS, FAILED OR CORRODED LOAD SENSING PIN
Cause:
Faulty coolant temperature sensor.
CRIL04C065E01 1

(B1) Coolant temperature sensor.
1. No signal is detected by the temperature sensor, or the signal exceeds the specied values.
2. This fault is detected when the engine electronic control box signal (A2) is less or greater than 0.1 - 4.8
volts after 5 seconds or more.
If the signal is faulty, the engine runs on the assumption that the temperature is 80 ° (in this conguration the
engine can be difcult to start at very low temperatures).
Solution:
1. Check the coolant sensor voltage, refer to Sensing system Coolant temperature - Electrical test
(B.50.A.95.90 - F.40.A.50)
26031 1 02/12/2004
B.50.A / 17
5. Repair or replace the harnesses. The fault code is no longer active.
7. Replace engine coolant temperature sensor (B1). The fault code is no longer active.
26031 1 02/12/2004
B.50.A / 18
Index

ENGINE COOLANT SYSTEM - Drain uid (B.50.A - F.35.A.20) 8
CX225SR
ENGINE COOLANT SYSTEM - Filling (B.50.A - F.60.A.10) 10
CX225SR
ENGINE COOLANT SYSTEM - Interior washing (B.50.A - F.30.A.20) 9
CX225SR
Radiator - Install (B.50.A.32 - F.10.A.15) 13
CX225SR
Radiator - Remove (B.50.A.32 - F.10.A.10) 11
CX225SR
Sensing system Coolant over-temperature - Troubleshooting (B.50.A.95.91 - G.40.A.10) 16
CX225SR
Sensing system Coolant over-temperature - Wiring schema (B.50.A.95.91 - C.20.A.45) 7
CX225SR
Sensing system Coolant temperature - Electrical test (B.50.A.95.90 - F.40.A.50) 15
CX225SR
CX225SR
CX225SR
Sensing system Coolant temperature - Low signal (B.50.A.95.90 - G.30.B.20) 17
CX225SR
26031 1 02/12/2004
B.50.A / 19
26031 1 02/12/2004
B.50.A / 20
LUBRICATION SYSTEM - 60.A
CX225SR
26032 1 02/12/2004
B.60.A / 1
Contents
FUNCTIONAL DATA
Sensing system
Sensing system Oil pressure - Electronic schema (B.60.A.95.91 - C.20.A.50) 3
CX225SR
Sensing system Oil pressure - Wiring schema (B.60.A.95.91 - C.20.A.45) 4

CX225SR
DIAGNOSTIC
Sensing system
Sensing system Oil pressure - Troubleshooting (B.60.A.95.91 - G.40.A.10) 5
CX225SR
26032 1 02/12/2004
B.60.A / 2
POWER PRODUCTION - LUBRICATION SYSTEM
Sensing system Oil pressure - Electronic schema (B.60.A.95.91 -

C.20.A.50)
CX225SR
CRIL03G090E01 1
Circuit layout
(1) Starting (2) Engine oil pressure indicator lamp

(3) Audible alarm device (B21) Pressure switch for engine oil pressure
CRIL03G091E02 2
Timing diagram
(A) Starting (B) Test
ENGINE OIL PRESSURE SWITCH SPECIFICATION

• Pressure switch (B21) opens at 0.4 MPa.
26032 1 02/12/2004
B.60.A / 3
Sensing system Oil pressure - Wiring schema (B.60.A.95.91 -

C.20.A.45)
CX225SR
CRIL04C005F01 1
(B21) Engine oil pressure switch (P1) Instrument panel
26032 1 02/12/2004
B.60.A / 4
Sensing system Oil pressure - Troubleshooting (B.60.A.95.91 -

G.40.A.10)
CX225SR
NOTE: Refer to Sensing system Oil pressure - Wiring schema (B.60.A.95.91 - C.20.A.45)
The oil pressure indicator The indicator light goes out when the Replace pressure switch (B21).
remains lit even if the connector is disconnected from pressure
engine oil level is correct. switch (B21).
The indicator light goes out when Short circuit on wire (LgY) between
connector (CN5) is disconnected. connector (CN5) and pressure switch
(B21).
Repair wire (LgY).
The indicator light goes out when Short circuit on wire (LgY) between
connector (CNMB1) is disconnected. connector (CN5) and connector (CNM1B).
Repair wire (LgY).
The indicator light does not go out when Faulty (P1) instrument panel.
connector (CNM1B) is disconnected. Replace instrument panel (P1).
26032 1 02/12/2004
B.60.A / 5
Index

Sensing system Oil pressure - Electronic schema (B.60.A.95.91 - C.20.A.50) 3
CX225SR
Sensing system Oil pressure - Troubleshooting (B.60.A.95.91 - G.40.A.10) 5
CX225SR
Sensing system Oil pressure - Wiring schema (B.60.A.95.91 - C.20.A.45) 4
CX225SR
26032 1 02/12/2004
B.60.A / 6
STARTING SYSTEM - 80.A
CX225SR
26033 1 02/12/2004
B.80.A / 1
Contents
TECHNICAL DATA
Engine starter
Engine starter - General specication (B.80.A.82 - D.40.A.10) 3
CX225SR
FUNCTIONAL DATA
Cold start aid
Cold start aid Pre-heating - Electronic schema (B.80.A.30.81 - C.20.A.50) 4
CX225SR
Cold start aid Pre-heating - Dynamic description (B.80.A.30.81 - C.30.A.10) 7

CX225SR
Start control
Start control Start relay - Electronic schema (B.80.A.90.80 - C.20.A.50) 8
CX225SR
DIAGNOSTIC
STARTING SYSTEM - Testing (B.80.A - G.40.A.20) 9
CX225SR
26033 1 02/12/2004
B.80.A / 2
POWER PRODUCTION - STARTING SYSTEM
Engine starter - General specication (B.80.A.82 - D.40.A.10)

CX225SR
Voltage 24 volts
Power 4.5 kW
26033 1 02/12/2004
B.80.A / 3
Cold start aid Pre-heating - Electronic schema (B.80.A.30.81 -

C.20.A.50)
CX225SR
AUTOMATIC ENGINE PRE-HEATING
CRIL03K125F01 1
Circuit layout
(1) Engine (2) Preheating indicator lamp

(A2) Engine electronic control box (A3) Electronic acceleration
(B1) Coolant solution temperature sensor (K2) Glow plug relay
(P1) Instrument panel (R1) Glow plug
(S1) Starter switch
26033 1 02/12/2004
B.80.A / 4
OPERATION
1. Once the starter switch is turned to "on" (IN1 = ON), main electronic control box (A1) calculates the preheating
time (Tp) based on the coolant temperatures (see graph).
2. Engine electronic control box (A2) activates pre-heating relay (K2) during preheating period (Tp) calculated
previously.
3. At the end of preheating period (Tp), preheating indicator lamp (1) goes out and preheating relay (K2) remains
activated for 2 seconds.
4. When starter switch (S1) is turned to "START" (ST, IN2 = ON), engine electronic control box (A2) reactivates
preheating relay (K2), without preheating indicator lamp (2) lighting up.
5. Engine electronic control box (A2) calculates the time after post-heating (Ta) based on the coolant temperature
(see graph).
6. When starter switch (S1) is moved from "START" to "ON" (IN1 = ON ; IN2 = OFF), engine electronic control
box (A2) activates preheating relay (K2) during the period after post-heating (Ta), without preheating indicator
lamp (2) lighting up.
7. The post-heating procedure helps stabilise the engine speed when starting, in order to reduce emission of
smoke from the exhaust.
8. The control system mentioned above starts immediately; as soon as the starter switch is turned to "on", the
preheating will begin, only if the preheating time is more than 3 seconds (coolant temperature less than - 5 °C).
CRIL03K135F01 2
Preheating and post-heating time graph
(T) Engine water temperature in °C (Tp) Pre-heating time in seconds

(Ta) Post-heating time in seconds
26033 1 02/12/2004
B.80.A / 5
TIMING DIAGRAM
1. If the engine is started within 2 seconds of the lighting up of preheating indicator lamp (2)
CRIL03K136E01 3
2. If the engine is started 2 seconds after the lighting up of preheating indicator lamp (2)
CRIL03K137E01 4
3. If the engine is started during the lighting up of preheating indicator lamp (2)
CRIL03K138E01 5
(A) 3 seconds (B) 2 seconds additional pre-heating

(C) Pre-heating time when engine is being (Tp) Pre-heating time
started
(Ta) Post-heating time
26033 1 02/12/2004
B.80.A / 6
Cold start aid Pre-heating - Dynamic description (B.80.A.30.81 -

C.30.A.10)
CX225SR
Flow chart
Starter switch ON
Water Pre-heating time
temperature calculation
Calculated time
Pre-heat plug Signal active
activated
Elapsed time Signal activated
Pre-heat plug
deactivated
Engine started
Pre-heat plug
activated
Water Post-heating time
temperature calculation
Calculated time
Pre-heat plug
activated
Elapsed time
Pre-heat plug
deactivated
26033 1 02/12/2004
B.80.A / 7
Start control Start relay - Electronic schema (B.80.A.90.80 -

C.20.A.50)
CX225SR
CRIL03K143E01 1
Supply cut-off delay - Circuit conguration
(G1) Battery (K7) Battery relay

CRIL03K144E01 2
Timing diagram
POWER TRANSISTOR PROTECTION
• To protect instrument panel circuits (P1) in the event of a short circuit of a solenoid valve or relay, the power transistors
turn off the electric supply.
26033 1 02/12/2004
B.80.A / 8
STARTING SYSTEM - Testing (B.80.A - G.40.A.20)

CX225SR
IMPORTANT: This problem-solving procedure is to be used if the engine refuses to start even though the
engine electrical system fault indicator lamp is out. If the indicator lamp is lit, refer to STARTING SYSTEM -
Troubleshooting (B.80.A - G.40.A.10).
NOTE: Prior checks:
Make sure there are no problems with the engine or in the fuel system.
Make sure the fuses are intact.
Make sure that the starter motor is working and turning the engine.
N° Test Point Expected Result Other Result (Possible Cause)
1 Starter switch to ON The contact switch is in position (2) The contact switch is in position (1)
Check the position of engine fuel (start up). (stop).
cut-off contact switch (M2). Problem with the engine injection Go to test 2
system.
2 Detach connector (CND6). Connect The voltage is less than 20 volts. The voltage is 20 - 30 volts.
service connector (P6) (cab side (3) Repair cut wire (LR) between Go to test 3
) and measure the voltage between connector (CND6) and fuse (F8).
the earth and the supply (wire (LR)
).
3 Starter switch on (ON) service Current continuity exists. No function (L) or (LW) wires cut or
connector (P6) still connected. Faulty engine (M2), repair or replace faulty relay.
check continuity between wires (L) engine (M2). replace relay (K1).
and (LW).
CRIL04C009F01 1
Engine does not start - Problem (N° 5)
(1) Stop position (F8) Fuse 15 amps.

engine emergency stop motor
(2) Start-up position (K1) Engine emergency stop relay
(3) Cab end (M2) Engine emergency stop motor
(4) Service connector (6P) (S9) Engine emergency stop switch
26033 1 02/12/2004
B.80.A / 9
Index

Cold start aid Pre-heating - Dynamic description (B.80.A.30.81 - C.30.A.10) 7
CX225SR
Cold start aid Pre-heating - Electronic schema (B.80.A.30.81 - C.20.A.50) 4
CX225SR
Engine starter - General specication (B.80.A.82 - D.40.A.10) 3
CX225SR
Start control Start relay - Electronic schema (B.80.A.90.80 - C.20.A.50) 8
CX225SR
STARTING SYSTEM - Testing (B.80.A - G.40.A.20) 9
CX225SR
26033 1 02/12/2004
B.80.A / 10
PTO POWER IN - 90.A
CX225SR
26034 1 02/12/2004
B.90.A / 1
Contents
PTO POWER IN - 90.A
FUNCTIONAL DATA
Drive system
Drive system - Overview (B.90.A.42 - C.10.A.10) 3
CX225SR
SERVICE
Drive system
Drive system - Remove (B.90.A.42 - F.10.A.10) 4
CX225SR
Drive system - Visual inspection (B.90.A.42 - F.40.A.10) 5

CX225SR
Drive system - Install (B.90.A.42 - F.10.A.15) 6

CX225SR
26034 1 02/12/2004
B.90.A / 2
POWER PRODUCTION - PTO POWER IN
Drive system - Overview (B.90.A.42 - C.10.A.10)

CX225SR
CRIL03J003G01 1
ENGINE-PUMP COUPLING
(1) Engine ywheel (2) Splined sleeve centring block

(3) Splined sleeve centring block xing screw (4) Roll pin
(5) Splined sleeve (6) Flexible coupling
(7) Main pump splined shaft (8) Locking screw
(9) Engine ywheel centring block xing screw (10) Engine ywheel centring block
(11) Roll pin
26034 1 02/12/2004
B.90.A / 3
Drive system - Remove (B.90.A.42 - F.10.A.10)

CX225SR
Prior operation: Hydraulic pump - Remove (A.10.A.20 - F.10.A.10)
1. Mark the swing position of the splined sleeve (1)

on the main pump splined shaft (2) and read the
distance between the face of the end of the main
pump splined shaft (2) and the outer face of the
splined sleeve (1).
Remove the locking screws (3) then remove the
splined sleeve (1).
CRIL03J009B01 1
2. Remove the exible coupling (4).

3. Remove the screws (5), the centring blocks (6) and
the roll pins (7) from the splined sleeve (1).
4. Remove the screws (8), the centring blocks (9) and
the roll pins (10) from the engine ywheel (11).
26034 1 02/12/2004
B.90.A / 4
Drive system - Visual inspection (B.90.A.42 - F.40.A.10)

CX225SR
1. Check for cracked, broken, chipped or worn splines

on the splined sleeve.
Check that the roll pins are not missing, damaged
or worn out.
If any of the above conditions exist, replace the
splined sleeve.
2. Check for cracks, ruptures and other wear and tear
on the coupling assembly.
If any of the above conditions exist, replace the
coupling assembly.
26034 1 02/12/2004
B.90.A / 5
Drive system - Install (B.90.A.42 - F.10.A.15)

CX225SR
1. Install roll pins (10) on engine ywheel (11).
CRIL03J009B01 1
2. Insert centring blocks (9) in exible coupling (4).

3. Centre exible coupling assembly (4) and centring
blocks (9) on roll pins (10) on engine ywheel (11).
4. Reinstall screws (8) on engine ywheel (11).
Coat xing screws (8) with thread locking uid and
tighten to a torque of 205.5 - 225.6 Nm
5. Reinstall roll pins (7), centring blocks (6) and screws
(5) on splined sleeve (1).
Coat screws (5) with thread locking uid and tighten
them.
6. Install locking screws (3) on splined sleeve (1).
7. In accordance with the swing position and the
distance noted during removal, refer to Drive
system - Remove (B.90.A.42 - F.10.A.10), position
splined sleeve (1) on the splined shaft of main pump
(2).
Coat locking screws with thread locking uid (3) and
Next operation: Hydraulic pump - Install (A.10.A.20 - F.10.A.15)
26034 1 02/12/2004
B.90.A / 6
Index
PTO POWER IN - 90.A

Drive system - Install (B.90.A.42 - F.10.A.15) 6
CX225SR
Drive system - Overview (B.90.A.42 - C.10.A.10) 3
CX225SR
Drive system - Remove (B.90.A.42 - F.10.A.10) 4
CX225SR
Drive system - Visual inspection (B.90.A.42 - F.40.A.10) 5
CX225SR
26034 1 02/12/2004
B.90.A / 7
SERVICE
PRINTED IN FRANCE
26026 1 02/12/2004
REPAIR MANUAL
TRAVELLING
CX225SR
26035 1 02/12/2004
D
Contents
TRAVELLING - D
WHEELS AND TRACKS Tracks D.50.B

CX225SR
26035 1 02/12/2004
D
TRAVELLING - D
WHEELS AND TRACKS Tracks - 50.B
CX225SR
26036 1 02/12/2004
D.50.B / 1
Contents
TRAVELLING - D
TECHNICAL DATA
Drive sprocket
Drive sprocket - Special tools (D.50.B.45 - D.20.A.40) 5
CX225SR
Drive sprocket - Service limits (D.50.B.45 - D.20.A.20) 6

CX225SR
Steel track
Steel track - Service limits (D.50.B.46 - D.20.A.20) 7
CX225SR
Roller
Roller Lower roller - Service limits (D.50.B.56.10 - D.20.A.20) 8
CX225SR
Roller Upper roller - Service limits (D.50.B.56.20 - D.20.A.20) 9

CX225SR
Roller Upper roller - Special tools (D.50.B.56.20 - D.20.A.40) 10

CX225SR
Roller Lower roller - Special tools (D.50.B.56.10 - D.20.A.40) 11

CX225SR
Idler wheel
Idler wheel - Special tools (D.50.B.57 - D.20.A.40) 12
CX225SR
Idler wheel - Service limits (D.50.B.57 - D.20.A.20) 13

CX225SR
FUNCTIONAL DATA
Steel track
Steel track - Exploded view (D.50.B.46 - C.10.A.20) 14
CX225SR
Track tensioning mechanism

Track tensioning mechanism Shock absorber - Exploded view (D.50.B.48.70 - 15
C.10.A.20)
CX225SR
Track tensioning mechanism Adjuster-recoil mechanism - Exploded view (D.50.B.48.65 16

- C.10.A.20)
CX225SR
Roller
Roller Upper roller - Sectional view (D.50.B.56.20 - C.10.A.30) 17
CX225SR
Roller Lower roller - Sectional view (D.50.B.56.10 - C.10.A.30) 18

CX225SR
SERVICE
26036 1 02/12/2004
D.50.B / 2
Drive sprocket
Drive sprocket - Remove (D.50.B.45 - F.10.A.10) 19
CX225SR
Drive sprocket - Install (D.50.B.45 - F.10.A.15) 21

CX225SR
Steel track
Steel track - Remove (D.50.B.46 - F.10.A.10) 22
CX225SR
Steel track - Install (D.50.B.46 - F.10.A.15) 26

CX225SR
Steel track Chain - Measure (D.50.B.46.20 - F.40.A.16) 29

CX225SR
Track tensioning mechanism

Track tensioning mechanism - Tension adjust (D.50.B.48 - F.45.A.40) 30
CX225SR
Track tensioning mechanism Shock absorber - Remove (D.50.B.48.70 - F.10.A.10) 32

CX225SR
Track tensioning mechanism Shock absorber - Disassemble (D.50.B.48.70 - F.10.A.25) 34

CX225SR
Track tensioning mechanism Shock absorber - Assemble (D.50.B.48.70 - F.10.A.20) 35

CX225SR
Track tensioning mechanism Shock absorber - Install (D.50.B.48.70 - F.10.A.15) 36

CX225SR
Track tensioning mechanism Adjuster-recoil mechanism - Remove (D.50.B.48.65 - 38

F.10.A.10)
CX225SR
Track tensioning mechanism Adjuster-recoil mechanism - Disassemble (D.50.B.48.65 - 39

F.10.A.25)
CX225SR
Track tensioning mechanism Adjuster-recoil mechanism - Assemble (D.50.B.48.65 - 40

F.10.A.20)
CX225SR
Track tensioning mechanism Adjuster-recoil mechanism - Install (D.50.B.48.65 - 41

F.10.A.15)
CX225SR
Roller
Roller - Leakage test (D.50.B.56 - F.40.A.40) 42
CX225SR
Roller Lower roller - Remove (D.50.B.56.10 - F.10.A.10) 43

CX225SR
Roller Lower roller - Disassemble (D.50.B.56.10 - F.10.A.25) 45

CX225SR
Roller Lower roller - Visual inspection (D.50.B.56.10 - F.40.A.10) 47

CX225SR
Roller Lower roller - Assemble (D.50.B.56.10 - F.10.A.20) 48

CX225SR
Roller Lower roller - Install (D.50.B.56.10 - F.10.A.15) 50

CX225SR
Roller Upper roller - Remove (D.50.B.56.20 - F.10.A.10) 51

CX225SR
Roller Upper roller - Disassemble (D.50.B.56.20 - F.10.A.25) 53

CX225SR
26036 1 02/12/2004
D.50.B / 3
Roller Upper roller - Visual inspection (D.50.B.56.20 - F.40.A.10) 55
CX225SR
Roller Upper roller - Assemble (D.50.B.56.20 - F.10.A.20) 56

CX225SR
Roller Upper roller - Install (D.50.B.56.20 - F.10.A.15) 58

CX225SR
Idler wheel
Idler wheel - Disassemble (D.50.B.57 - F.10.A.25) 59
CX225SR
Idler wheel - Assemble (D.50.B.57 - F.10.A.20) 61

CX225SR
26036 1 02/12/2004
D.50.B / 4
TRAVELLING - WHEELS AND TRACKS Tracks
Drive sprocket - Special tools (D.50.B.45 - D.20.A.40)

CX225SR
CRIL04A005F01 1
Gauge for checking sprocket wear.
Gauge to be made locally

MARKING SIZE MARKING SIZE
(A) 220 mm (B) 190 mm
(C) 84.7 mm (D) 70 mm
(E) 69.58 mm (F) 35.61 mm
(G) 4.6 mm (H) 0.52 mm
(J) radius 29.6 mm (K) radius 40.8 mm
(L) 306 mm (M) radius 322.3 mm
(N) radius 6 mm (P) 17.1 °
(Q) 12.7 ° (R) radius 36 mm
(S) radius 539.5 mm (T) radius 76.5 mm
(U) 21.46 mm
26036 1 02/12/2004
D.50.B / 5
Drive sprocket - Service limits (D.50.B.45 - D.20.A.20)

CX225SR
CRIL032G007F01 1
Sprocket
MARKING STANDARD DIMENSION WEAR LIMIT
(A) 66 mm 60 mm
(B) diameter 582.5 mm 576.5 mm
(C) diameter 659 mm 653 mm
(D) diameter 644.6 mm
(P) 190 mm
26036 1 02/12/2004
D.50.B / 6
Steel track - Service limits (D.50.B.46 - D.20.A.20)

CX225SR
CRIL03G011F01 1
Steel track

(A) 34.5 mm 21.5 mm
(B) 106 mm 101 mm
(C)
(D)
(E) bushing outside diameter 58.72 mm 57.5 mm
(F) bushing inside diameter 37.3 mm 38.3 mm
(G) pin inside diameter 36.3 mm 35.5 mm
(H) 190 mm 195 mm
26036 1 02/12/2004
D.50.B / 7
Roller Lower roller - Service limits (D.50.B.56.10 - D.20.A.20)

CX225SR
CRIL03J048F01 1
Lower roller

(A) diameter 150 mm 142 mm
(B) 15 mm
(C) 173 mm 179 mm
(D) diameter (pin) 65 mm 64.5 mm
(D) diameter (bushing) 65 mm 65.8 mm
(E) 69 mm 68.6 mm
(F) 23.3 mm 22.8 mm
26036 1 02/12/2004
D.50.B / 8
Roller Upper roller - Service limits (D.50.B.56.20 - D.20.A.20)

CX225SR
CRIL03J049F01 1
Upper roller

(B) 10 mm
(C) 85 mm 79 mm
(D) diameter (pin) 46 mm 45.5 mm
(D) diameter (bushing) 46 mm 46.8 mm
(E) 83 mm 82.6 mm
(F) 5.5 mm 5 mm
(G) 29.7 mm 29.2 mm
26036 1 02/12/2004
D.50.B / 9
Roller Upper roller - Special tools (D.50.B.56.20 - D.20.A.40)

CX225SR
CRIL04A006F01 1
Gauge for checking wear on upper roller

(A) 175 mm (B) 156 mm
(C) 85 mm (D) 78.6 mm
(E) 45 mm (F) 35 mm
(G) 17.5 mm (H) 10 mm
(I) 5.5 mm (J) radius 3 mm
(K) radius 3 mm (L) 10 mm
(M) radius 68 mm (N) 24 mm
(O) radius 16 mm (P) 11.5 °
(Q) radius 18 ° (R) 9.8 °
26036 1 02/12/2004
D.50.B / 10
Roller Lower roller - Special tools (D.50.B.56.10 - D.20.A.40)

CX225SR
CRIL04A004F01 1
Gauge for checking wear on lower roller

(A) 221 mm (B) 215 mm
(C) 184.7 mm (D) 173 mm
(E) 84 mm (F) 29 mm
(G) 25.3 mm (H) 10 mm
(J) 42 mm (K) 60 mm
(L) 13.8 mm (M) 240 mm
(N) 15 mm (P) 18 mm
(Q) 5° (R) radius 6 x 5 mm
(S) 1.5 ° (T) radius 2 x 10 mm
(U) 23 ° (V) 10 °
(W) radius 10 mm (X) radius 4 x 5 mm
26036 1 02/12/2004
D.50.B / 11
Idler wheel - Special tools (D.50.B.57 - D.20.A.40)

CX225SR
CRIL03J053F01 1
Gauge for checking idler wheel wear

(A) 180 mm (B) 159 mm
(C) 84 mm (D) 55 mm
(E) 26 mm (F) 19 mm
(G) 10 mm (H) 0.6 mm
(I) 19 mm (J) 10 °
(K) radius 42 mm (L) radius 2 x 5 mm
(M) radius 4 x 3 mm
26036 1 02/12/2004
D.50.B / 12
Idler wheel - Service limits (D.50.B.57 - D.20.A.20)

CX225SR
CRIL03J054F01 1
Idler wheel

(B) 19 mm
(C) 84 mm 80 mm
(D) pin diameter 65 mm 64.5 mm
(D) bushing diameter 65 mm 65.8 mm
(E) 69 mm 68.6 mm
(F) 12.4 mm 11.9 mm
26036 1 02/12/2004
D.50.B / 13
Steel track - Exploded view (D.50.B.46 - C.10.A.20)

CX225SR
CRIL03G115G01 1
(1) Track shoe (2) Screw

(3) Nut (4) End of chain half-link
(5) End of chain half-link (6) End of chain pin
(7) Shim (8) End of chain pin spacer
(9) Pin (10) RH standard pin half-link
(11) LH standard pin half-link (12) Standard pin
(13) Standard pin spacer (14) Seal
26036 1 02/12/2004
D.50.B / 14
Track tensioning mechanism Shock absorber - Exploded view

(D.50.B.48.70 - C.10.A.20)
CX225SR
CRIL03G207F01 1
(1) Shock absorber spring (2) Pin

(3) Slotted nut (4) Yoke
(5) Spring guide
26036 1 02/12/2004
D.50.B / 15
Track tensioning mechanism Adjuster-recoil mechanism - Exploded

view (D.50.B.48.65 - C.10.A.20)
CX225SR
CRIL03G208F01 1
(1) Screw (2) Flat washer

(3) Screw (4) Lock washer
(5) Bracket (6) Grease tting
(9) Ball (10) Check valve body
(11) Cylinder rod (12) Wiper seal
(13) Thrust ring (14) Seal
(15) Cylinder barrel (16) Valve assembly
26036 1 02/12/2004
D.50.B / 16
Roller Upper roller - Sectional view (D.50.B.56.20 - C.10.A.30)

CX225SR
CRIL04A013F01 1
Assembly dimension
(A) 114.3 - 114.7 mm
(B) 85 mm
Description
(1) Upper roller (2) Drain plug
(3) Screw (4) Cover
(5) Seal (6) Thrust plate
(7) Shaft (8) Seal
(9) Bushing (10) Support
(11) Screw
26036 1 02/12/2004
D.50.B / 17
Roller Lower roller - Sectional view (D.50.B.56.10 - C.10.A.30)

CX225SR
CRIL03J044F01 1
Assembly dimension
(A) 319 - 317.8 mm
(B) 246 mm
Description
(1) Lower roller (2) Drain plug
(3) Retaining ring (4) Gland
(5) Seal (6) Shaft
(7) Seal (8) Bushing
26036 1 02/12/2004
D.50.B / 18
Drive sprocket - Remove (D.50.B.45 - F.10.A.10)

CX225SR
Prior operation: Steel track - Remove (D.50.B.46 - F.10.A.10)
1. Move the machine so that the track is in the position

shown.
CRIL03G116A00 1
2. Rotate the upperstructure so that the cab is over

the side of the machine where the sprocket to be
removed is located.
Using the attachment, raise the side of the machine
until the sprocket teeth arefree of the chain.
CRIL03G117A00 2
3. To facilitate reassembly, make alignment marks (1)

on the sprocket and the reduction gear.
CRIL03G118A01 3
26036 1 02/12/2004
D.50.B / 19
4. Remove the screws (1) and the washers that attach

the sprocket to the reduction gear.
CRIL03G119A01 4
5. Using a soft face hammer, tap the sprocket off the

reduction gear housing and remove it.
CRIL03G120A00 5
26036 1 02/12/2004
D.50.B / 20
Drive sprocket - Install (D.50.B.45 - F.10.A.15)

CX225SR
1. Install the sprocket on the drive reduction gear

following the marks (1) made during removal.
CRIL03G118A01 1
2. If necessary, use a soft face hammer to seat the

sprocket correctly o the reduction gear housing.
CRIL03G134A00 2
3. Apply thread lock uid to the screws (1).

Install the washers and the screws, tighten to a
CRIL03G119A01 3
26036 1 02/12/2004
D.50.B / 21
Steel track - Remove (D.50.B.46 - F.10.A.10)

CX225SR
1. Park the machine on a hard, level surface.

Rotate the upperstructure of the machine so that the
cab is over the track to be removed.
2. Lower the bucket or the tool to lift the track a few

centimetres off the ground.
CRIL03G121A00 1
3. Mark the master pin (1) on the at surfaces on one

side and on the retaining pin (2) at the other end.
CRIL03G122A01 2
4. Bring the master pin to a level halfway up the

sprocket.
Operate the machine to lower the track to be
removed to the ground.
Rotate the upperstructure of the machine so that
the cab is facing forwards.
IMPORTANT: Do not remove the check valve.
DANGER
SA024 - Hydraulic uid or grease injected into
your skin can cause severe injury or death. Keep
your hands and body away from any pressurized CRIL03G123A01 3
leak. If uid is injected into your skin, see a doctor
immediately and have the uid removed.
26036 1 02/12/2004
D.50.B / 22
5. Slacken the track by gradually loosening the check

valve about two turns.
Grease will escape from an orice in the valve
thread.
CRIL03G124A00 4
6. Remove the screws (1) and the track shoe nuts

above the end of chain pin.
Remove the track shoe.
CRIL03G125A01 5
7. Straighten one of the retaining pin ends.
CRIL03G126A01 6
8. Tap the retaining pin out of the end of chain pin.
CRIL03G127A00 7
26036 1 02/12/2004
D.50.B / 23
9. Remove the screws and the track shoe nuts below

the end of chain pin.
Remove the track shoe.
CRIL03G128A00 8
10. Install the portable hydraulic press CAS-10044 on

the end of chain axle.
Drive the end of chain pin out.
CRIL03G129A00 9
11. Remove the portable hydraulic press.

12. Using a crowbar, separate the chain links.
Remove the two spacers (1).
CRIL03G130A01 10

Using the attachment, raise the chassis on the side
of the track to be removed.
Install stands under the machine to hold it in place
and lower the machine onto the stands.
Stop the engine.
CRIL03G131A00 11
26036 1 02/12/2004
D.50.B / 24
14. Attach a sling to the lower end of the track.

Start the engine.
Reverse the machine, moving the dipper out at the
same time.
When the track is free of the sprocket, stop the
machine from reversing further.
Continue moving the dipper out until the track is
pulled away from the machine.
Stop the engine, move the track to be replaced
away from the machine.
CRIL03G132A00 12
26036 1 02/12/2004
D.50.B / 25
Steel track - Install (D.50.B.46 - F.10.A.15)

CX225SR
1. Place and align the new track under the carrier

rollers.
CRIL03G136A00 1
2. Remove the stand.

Lower the machine onto the track chain.
3. Connect a lifting device to the track.
Raise the track on the idler wheel.
CRIL03G137A00 2
4. Attach the track to the attachment with a sling.

Start the engine.
Move the machine forward, moving the dipper out at
the same time to engage the track on the sprocket.
CRIL03G138A00 3
26036 1 02/12/2004
D.50.B / 26
5. Connect suitable pulling equipment to both ends

of the track chain.
Use the pulling equipment to pull the two ends of
the track chain together.
CRIL03G139A00 4
6. Install the two spacers (1) in the half links where the
end of chain pin is located.
CRIL03G130A01 5
7. Install the end of chain pin using portable hydraulic

press CAS 10044.
CRIL03G140A00 6
8. Remove the portable hydraulic press.

Install a new retaining pin (1) in the end of chain pin.
Bend the ends of the pin to secure the end of chain
pin.
CRIL03G141A01 7
9. Install the two track shoes, the screws and the nuts.
26036 1 02/12/2004
D.50.B / 27
10. Tighten screws (1) to a torque of 300 Nm +120 °
CRIL03G125A01 8
Next operation: Track tensioning mechanism - Tension adjust (D.50.B.48 - F.45.A.40)
26036 1 02/12/2004
D.50.B / 28
Steel track Chain - Measure (D.50.B.46.20 - F.40.A.16)

CX225SR
NOTE: Measure the diameter of the pins and bushings with a micrometer or an outside calliper.
1. Measure the outside diameter of the bushing (2)
using an outside caliper (1).
CRIL03G153A01 1
2. Measure the inside diameter of the bushing.

3. Measure the outside diameter of the track pin.
Refer to Steel track - Service limits (D.50.B.46 -
D.20.A.20).
Replace them if necessary.
26036 1 02/12/2004
D.50.B / 29
Track tensioning mechanism - Tension adjust (D.50.B.48 - F.45.A.40)

CX225SR
NOTE: Check the tension of the tracks as required. Adjust the tension according to the type of surface on which
the machine will be operating. Tighten the track for operation on hard surfaces and loosen the track for operation
on soft surfaces.
1. Park the machine on a hard, level surface. Rotate
the upperstructure of the machine so that the cab is
over the track to be checked.
2. Lower the attachment to raise the machine until
the track to be checked is a few centimetres off the
ground.
CRIL03G121A00 1
3. Measure the distance between the bottom of the

track frame and the top of the track shoe, which
should be:
Steel tracks 280 - 300 mm

Steel tracks with rubber pad 260 - 280 mm
CRIL03G143A00 2
4. Proceed as follows to increase the track tension:

Clean the grease tting of the track adjustment
cylinder.
Ensure that the check valve is tight.
CRIL03G124A00 3
26036 1 02/12/2004
D.50.B / 30
5. Inject grease into the track tension cylinder until the

required tension is obtained.
DANGER
your hands and body away from any pressurized
CRIL03G144A00 4
6. Proceed as follows to reduce the track tension:

Do not remove the check valve. The grease in
the track tension cylinder is under high pressure.
Slacken the track by slowly loosening the check
valve about two turns, the grease will escape from
an orice in the valve thread.
CRIL03G124A00 5
7. When the track tension is correct, tighten the check

valve.
8. Clean the grease from the check valve.
26036 1 02/12/2004
D.50.B / 31
Track tensioning mechanism Shock absorber - Remove

(D.50.B.48.70 - F.10.A.10)
CX225SR

Move the machine until the track chain is free of the
idler wheel.
CRIL03G189A00 1
2. Attach a nylon sling from the lifting device to the

idler wheel.
CRIL03G190A00 2
3. Using a crowbar, move the idler wheel and the

shock absorber/spring assembly out of the chassis
housing.
CRIL03G191A00 3
26036 1 02/12/2004
D.50.B / 32
4. Using a crowbar, move the idler wheel and shock

absorber spring away from the chassis housing
until a nylon sling can be attached to the shock
absorber-spring assembly.
Remove the screws and washers which attach the
idler wheel to the shock absorber yoke.
Remove the idler wheel.
CRIL03G192A00 4
26036 1 02/12/2004
D.50.B / 33
Track tensioning mechanism Shock absorber - Disassemble

(D.50.B.48.70 - F.10.A.25)
CX225SR
ATTENTION: The shock absorber spring is highly compressed.

1. Place the shock absorber assembly in a hydraulic
press.
Operate the hydraulic press to compress the shock
absorber spring (2).
Remove the pin (5) from the slotted nut (4).
Remove the slotted nut (4) from the spring guide (1).
Carefully operate the press to decompress the
shock absorber spring (2).
Remove the yoke (3) and the shock absorber spring
(2) from the spring guide (1).
CRIL03I148A01 1
26036 1 02/12/2004
D.50.B / 34
Track tensioning mechanism Shock absorber - Assemble

(D.50.B.48.70 - F.10.A.20)
CX225SR
ATTENTION: The shock absorber spring is highly compressed.

1. Mount spring guide (1) in a hydraulic press.
Place shock absorber spring (2) and yoke (3) on
spring guide (1).
CRIL03I148A01 1
2. Carefully operate the hydraulic press to compress

the shock absorber spring (2) to preloaded value
(A).
(A) = 556 mm
CRIL03I147A01 2
3. Install slotted nut (4) in contact with spring guide (1).

Install pin (5) in slotted nut (4) and spring guide
shaft (1).
Operate the hydraulic press to decompress the
assembly and remove the shock absorber.
26036 1 02/12/2004
D.50.B / 35
Track tensioning mechanism Shock absorber - Install (D.50.B.48.70

- F.10.A.15)
CX225SR
1. Attach a suitable lifting device to the idler wheel and

bring it into position on the shock absorber yoke.
Apply thread locking uid to the screws tted with
washers and tighten to a torque of 267 - 312 Nm
2. Attach a sling from the lifting equipment to the idler
wheel and shock absorber assembly.
CRIL03G199A00 1
3. Raise the idler wheel and shock absorber assembly

and install it in the chassis housing.
Push the idler wheel and the shock absorber into
the chassis.
Remove the lifting equipment from the idler wheel
and the back of the shock absorber.
CRIL03G196A00 2
4. Insert the lifting equipment sling into the central

orice of the shock absorber yoke.
CRIL03G197A00 3
26036 1 02/12/2004
D.50.B / 36
5. Raise the assembly and slide it into the chassis,

using a crowbar. Remove the lifting equipment.
CRIL03G198A00 4
Next operation: Steel track - Install (D.50.B.46 - F.10.A.15)
26036 1 02/12/2004
D.50.B / 37
Track tensioning mechanism Adjuster-recoil mechanism - Remove

(D.50.B.48.65 - F.10.A.10)
CX225SR

Prior operation:
Prior operation: Remove the roller located under the tension cylinder, refer to Roller Lower roller - Remove
(D.50.B.56.10 - F.10.A.10)
IMPORTANT: Do not place any part of your body under the tension cylinder.
You could be seriously injured if the cylinder falls when the screws securing it to the machine are removed.
DANGER
SA024 - Hydraulic uid or grease injected into your skin can cause severe injury or death. Keep your hands
and body away from any pressurized leak. If uid is injected into your skin, see a doctor immediately
and have the uid removed.
1. Unscrew the tension cylinder check valve.

Place wooden blocks under the tension cylinder to
prevent it from falling from the machine when the
screws securing it to the machine are removed.
Remove the screws and the at washers.
CRIL03G212A01 1
2. Using a crowbar, push the piston rod into the

cylinder barrel.
The grease will ow out of the check valve.
Remove the tension cylinder from the machine.
CRIL03G213A00 2
26036 1 02/12/2004
D.50.B / 38
Track tensioning mechanism Adjuster-recoil mechanism -

Disassemble (D.50.B.48.65 - F.10.A.25)
CX225SR
NOTE: The numbers in parentheses refer to Track tensioning mechanism Adjuster-recoil mechanism -
Exploded view (D.50.B.48.65 - C.10.A.20)
1. Remove the two screws (3) and the locking washers
(4).
Remove the bracket (5).
2. Remove the grease tting (6) from the check valve.
3. Remove the check valve from the cylinder barrel
(15).
4. If necessary, disassemble the check valve by

removing the valve (7), spring (8) and ball (9) from
the check valve body (10).
5. Remove the cylinder rod (11) from the cylinder
barrel (15).
CRIL03G220A01 1
6. With a screwdriver, remove the seal (12) from the

cylinder barrel (15).
7. Remove the ring (13) and discard the seal (14).
26036 1 02/12/2004
D.50.B / 39
Track tensioning mechanism Adjuster-recoil mechanism -

Assemble (D.50.B.48.65 - F.10.A.20)
CX225SR
NOTE: The numbers in parentheses refer to Track tensioning mechanism Adjuster-recoil mechanism -
Exploded view (D.50.B.48.65 - C.10.A.20)
1. Install the seal (14) and the ring (13) in the cylinder
barrel (15).
CRIL03G220A01 1
2. Use a centring piece (A) to insert the wiper seal

(12) into the cylinder barrel (15) until it touches the
barrel collar.
CRIL03G221A01a 2
3. Install the cylinder rod (11) in the cylinder barrel (15).

4. If the check valve has been dismantled, install the
ball (9) spring (8) and the valve (7) in the check
valve body (10).
Install the grease tting (6) in the check valve body.
5. Install the check valve assembly on the cylinder
barrel (15).
Tighten the check valve to a torque of 59 Nm.
6. Install the bracket (5) on the cylinder barrel (15).
Mount the locking washers (4) on the screws (3)
and fasten the bracket to the cylinder barrel.
26036 1 02/12/2004
D.50.B / 40
Track tensioning mechanism Adjuster-recoil mechanism - Install

(D.50.B.48.65 - F.10.A.15)
CX225SR
1. Check that the cylinder rod is inserted as far as

possible into the cylinder barrel.
CRIL03G213A00 1
2. Move the tension cylinder into position.

Apply thread lock uid to the screws.
Support the tension cylinder whilst an assistant
installs the at washers and screws to secure it.
Tighten the screws.
CRIL03G212A01 2
Next operation: Install the roller located under the tension cylinder, refer to Roller Lower roller - Install
(D.50.B.56.10 - F.10.A.15)
Next operation: Steel track - Install (D.50.B.46 - F.10.A.15)
26036 1 02/12/2004
D.50.B / 41
Roller - Leakage test (D.50.B.56 - F.40.A.40)

CX225SR
Use tools CAS-1450 and CAS-1682 for this test.
1. Connect shut-off valve (1) to pressure regulator

(2). Connect a union for the air supply hose to the
shut-off valve.
CRIL03G154A01 1
2. Install the adapter and a quick coupling on the oil

lling port. Use a sealing ring with the adapter.
3. Turn the knob anti-clockwise to close pressure
regulator (2).
4. Connect the pressure gauge pipe to the quick
coupling.
5. Make sure that shut-off valve (1) is open.
6. Adjust pressure regulator (2) until the pressure
gauge shows 1.9 bar.
7. Turn the shaft of the unit under test four revolutions.
8. Adjust the pressure regulator until the pressure
gauge shows 1 bar.
9. Close the shut-off valve. Maintain air pressure
for 10 seconds. A drop in air pressure during this
time indicates a defective component or incorrect
assembly.
26036 1 02/12/2004
D.50.B / 42
Roller Lower roller - Remove (D.50.B.56.10 - F.10.A.10)

CX225SR
1. Swing the upperstructure at right angles to the

undercarriage.
Press the attachment against the ground until the
track (1) is lifted off the gound and there is sufcient
clearance between the track frame and the track to
remove the lower roller.
Shut down the engine and remove the starter switch
key.
CRIL03G050A01 1
2. Install blocks or a suitable support under the

machine.
CRIL03I176A01 2

thread.
DANGER
CRIL03I179A01 3
4. Place wooden blocks under the track at both ends.
CRIL03I177A01 4
26036 1 02/12/2004
D.50.B / 43
5. Place a wooden block under the lower roller to

support it.
Remove the xing screws and washers.
Remove the lower rollers (A).
CRIL03I178A01 5
26036 1 02/12/2004
D.50.B / 44
Roller Lower roller - Disassemble (D.50.B.56.10 - F.10.A.25)

CX225SR
NOTE: When the lower roller is worn or leaking, it must be reconditioned or replaced with a new one. Refer to
Roller Lower roller - Service limits (D.50.B.56.10 - D.20.A.20)
1. Clean lower roller (1) using a suitable solvent.
Remove the two drain plugs (2) and drain the oil.
CRIL03G214A01 1
2. Discard the circlips (3).

Remove bearings (4).
CRIL03G215A01 2
3. Discard seals (5).

NOTE: The seal (5) has four components: two rubber
rings and two metal rings. When bearings (4) are
removed, one rubber ring and one metal ring are located
in either lower roller seal housing (1), or on shaft (6).
CRIL03G216A01 3
26036 1 02/12/2004
D.50.B / 45

Remove the shaft (6).
CRIL03G217A01 4
5. Discard seals (5) on roller (1) or shaft (6) Refer

to Roller Lower roller - Visual inspection
(D.50.B.56.10 - F.40.A.10)
CRIL03G218A01 5
6. Discard bushings (8) if necessary.
CRIL03G219A01 6
26036 1 02/12/2004
D.50.B / 46
Roller Lower roller - Visual inspection (D.50.B.56.10 - F.40.A.10)

CX225SR
1. Use cleaning solvent to clean all components.

2. Inspect the contact surfaces of the bushings on the
shaft for scoring, pitting and other damage.
Measure the diameter of the shaft at four opposing
points.
Compare the values with the specications, replace
if necessary.
NOTE: for the specications, refer to Roller Lower roller
- Service limits (D.50.B.56.10 - D.20.A.20)
3. Check that the bushings do not show any signs of
wear or damage. Measure the inner diameter and
width of the bushing.
them if necessary.
4. Check for any damage that is likely to cause leaks in
the bore in each end bearing and in the lower roller.
Replace components as necessary.
26036 1 02/12/2004
D.50.B / 47
Roller Lower roller - Assemble (D.50.B.56.10 - F.10.A.20)

CX225SR
1. If bushings (8) have been removed, install new

bushings in the roller using a centring piece and a
hydraulic press.
CRIL03G219A02 1
2. Install one of the rubber sealing rings and one of

the metal sealing rings (5) in the seal housing on
the roller (1).
NOTE: The seal (5) has four components:
Two rubber rings and two metal rings. One rubber ring
and one metal ring are tted in the seal housing on roller
(1). The two remaining rings are tted in the seal housing
of bearing (4).
CRIL03G218A01 2
3. Grease the surface of the shaft (6) and install the

shaft in the roller (1).
Install seals (7) on shaft (6).
CRIL03G217A02 3
4. Install the remaining rubber and metal sealing

rings (5) in the seal bore of bearings (4). Apply a
generous amount of clean oil to the seals.
CRIL03G216A01 4
26036 1 02/12/2004
D.50.B / 48
5. Install bearings (4) on shaft (6) and install circlips

(3).
Install one of the plugs (2).
To check for leaks, refer to Roller - Leakage test
(D.50.B.56 - F.40.A.40).
CRIL03G215A02 5
6. Fill the roller with oil.

Install the other plug (2).
CRIL03G214A02 6
26036 1 02/12/2004
D.50.B / 49
Roller Lower roller - Install (D.50.B.56.10 - F.10.A.15)

CX225SR
1. Install each lower roller (A) underneath the frame.
CRIL03I178A01 1
2. Install hardened washers on the screws.

Coat the screws with thread locking uid and tighten
them to a torque of 521 - 608 Nm
Repeat the operation for each roller.
3. Remove the wooden shims underneath each end
of the track.
CRIL03I177A01 2
4. Remove the shims or the stand.
CRIL03I176A01 3
Next operation: Track tensioning mechanism - Tension adjust (D.50.B.48 - F.45.A.40)
26036 1 02/12/2004
D.50.B / 50
Roller Upper roller - Remove (D.50.B.56.20 - F.10.A.10)

CX225SR
1. Park the machine on a hard, level surface.

Lower the tool to the ground.
CRIL03G121A00 1

thread.
DANGER
CRIL03G124A00 2
3. Install a hydraulic jack on the track frame.

Raise the track.
CRIL03G145A00 3
4. Place wooden blocks between the track and the

track frame.
CRIL03G146A00 4
26036 1 02/12/2004
D.50.B / 51
5. Unscrew the screws fastening the upper roller to

the track frame.
CRIL03G147A00 5
6. Remove the upper roller.
CRIL03G148A00 6
26036 1 02/12/2004
D.50.B / 52
Roller Upper roller - Disassemble (D.50.B.56.20 - F.10.A.25)

CX225SR
NOTE: When an upper roller is worn or leaking, it must be reconditioned or replaced with a new one; for wear limits,
refer to Roller Upper roller - Service limits (D.50.B.56.20 - D.20.A.20)
1. Clean upper roller (1) using a suitable solvent.
Remove drain plug (2) and drain the oil.
CRIL04A014A01 1
2. Secure the upper roller in a vice.

Remove screws (2) and cover (3) from upper roller
(1).
Discard seal (4).
CRIL04A015A01 2
3. Remove screws (1) and thrust plate (2).
CRIL04A016A01 3
26036 1 02/12/2004
D.50.B / 53
4. Remove roller (1) from shaft (2).
CRIL04A017A01a 4
5. Remove seal (1) from bracket (2) and roller (1).
CRIL03J039A01 5
6. Using a press, remove shaft (1) from bracket (2).

Be careful not to damage the seal bore.
CRIL03J040A01 6
7. Using a hammer and a brass punch, remove

bushings (1) and (3) from roller (2).
CRIL04A018A01 7
26036 1 02/12/2004
D.50.B / 54
Roller Upper roller - Visual inspection (D.50.B.56.20 - F.40.A.10)

CX225SR
1. Use cleaning solvent to clean all components.

2. Inspect the contact surfaces on the shaft covers for
scoring, pitting and other damage.
Measure the diameter of the shaft at four opposing
points.
if necessary.
NOTE: for the specications, refer to Roller Upper roller
- Service limits (D.50.B.56.20 - D.20.A.20).
3. Check for wear and damage to the covers.
4. Check for wear or damage to the bearings, replace
them if necessary.
5. Check for any damage that might cause leaks
between the bore in the support and the upper roller.
Replace components as necessary.
26036 1 02/12/2004
D.50.B / 55
Roller Upper roller - Assemble (D.50.B.56.20 - F.10.A.20)

CX225SR
1. Using a press, install shaft (1) in bracket (2).
CRIL03J042A01 1
2. Using a press, install bushings (1) and (3) in roller

(2).
CRIL04A018A01 2
3. Install seal (1) in bracket bore (2).

Apply a generous amount of clean oil to the seals
(1).
CRIL03J039A01 3
4. Grease shaft (2) and install it in roller (1).
CRIL04A017A01a 4
26036 1 02/12/2004
D.50.B / 56
5. Install thrust plate (2) in the roller and install screws

(1).
CRIL04A016A01 5
6. Install seal (4) on cover (3).

Using a press, install the cover on roller (3).
Install cover (3) on roller (1) and install screws (2).
CRIL04A015A01 6
7. To check for leaks, refer to Roller - Leakage test

(D.50.B.56 - F.40.A.40).
Fill the upper roller with oil and install plug (2) on
roller (1).
CRIL04A014A01 7
26036 1 02/12/2004
D.50.B / 57
Roller Upper roller - Install (D.50.B.56.20 - F.10.A.15)

CX225SR
1. Place blocks on the track frame.

Mount and support the upper roller.
CRIL03G152A00 1
2. Apply thread lock uid to the screw threads.

Install hardened washers on the screws.
Fix the upper roller support to the track frame.
Tighten the screws to a torque of 528 - 608 Nm.
CRIL03G147A00 2
3. Remove the wooden blocks between the track shoe

and the track frame.
CRIL03G145A00 3
4. Release the pressure from the hydraulic jack.

Lower the track onto the upper roller.
Remove the jack.
Next operation: .Track tensioning mechanism - Tension adjust (D.50.B.48 - F.45.A.40)
26036 1 02/12/2004
D.50.B / 58
Idler wheel - Disassemble (D.50.B.57 - F.10.A.25)

CX225SR
1. Place idler wheel (2) on supports with drain plug (1)

at the bottom.
Remove drain plug (1) from slide block (4).
CRIL04A019A01 1
2. Remove snap ring (3) at one end.

Pull slide block (4) off shaft (6).
CRIL04A020A01 2

Remove shaft (6) with slide block (4).
CRIL04A021A01 3
4. Remove snap ring (3).

Remove the slide block (4) from the shaft (6).
Discard the seal (5) on shaft (6).
CRIL04A022A01 4
26036 1 02/12/2004
D.50.B / 59
5. Discard the seal (7) on slide block (4).
CRIL04A023A01 5
6. Discard the seal on the (7) idler wheel.
CRIL03G238A01 6
7. Discard the bushings (8) if necessary.

Make sure you do not damage the idler wheel seal
bore.
CRIL03G239A01 7
26036 1 02/12/2004
D.50.B / 60
Idler wheel - Assemble (D.50.B.57 - F.10.A.20)

CX225SR
1. Place bushings (8) under a press.

Insert a driver between the bushing and press.
Activate the press.
CRIL03G240B01b 1
2. Fit a seal and a metal bushing in the idler wheel

bore.
Repeat this step to t the seal on the other side of
the idler wheel.
CRIL03G238A01 2
3. Fit the seal and the remaining metal bushing in the

seal bore of slide blocks (4).
CRIL04A023A01 3
26036 1 02/12/2004
D.50.B / 61
4. Fit the seal (5) on the shaft (6).

Fit the shaft in the hub (4).
Secure the slide and shaft with a snap ring (3).
CRIL04A022A01 4
5. Install the shaft and slide block assembly on the

idler wheel.
CRIL04A021A01 5
6. Fit the other seal (5) on shaft (6).

Mount guide block (4) on shaft.
Install a snap ring (3) to secure the slide and shaft.
CRIL04A020A01 6
7. Check for leaks, refer to Roller - Leakage test

(D.50.B.56 - F.40.A.40)
8. Fill the slide blocks (4) with oil.
Fit the drain plugs (1).
CRIL04A019A01 7
26036 1 02/12/2004
D.50.B / 62
Index
TRAVELLING - D

Drive sprocket - Install (D.50.B.45 - F.10.A.15) 21
CX225SR
Drive sprocket - Remove (D.50.B.45 - F.10.A.10) 19
CX225SR
Drive sprocket - Service limits (D.50.B.45 - D.20.A.20) 6
CX225SR
Drive sprocket - Special tools (D.50.B.45 - D.20.A.40) 5
CX225SR
Idler wheel - Assemble (D.50.B.57 - F.10.A.20) 61
CX225SR
Idler wheel - Disassemble (D.50.B.57 - F.10.A.25) 59
CX225SR
Idler wheel - Service limits (D.50.B.57 - D.20.A.20) 13
CX225SR
Idler wheel - Special tools (D.50.B.57 - D.20.A.40) 12
CX225SR
Roller - Leakage test (D.50.B.56 - F.40.A.40) 42
CX225SR
Roller Lower roller - Assemble (D.50.B.56.10 - F.10.A.20) 48
CX225SR
Roller Lower roller - Disassemble (D.50.B.56.10 - F.10.A.25) 45
CX225SR
Roller Lower roller - Install (D.50.B.56.10 - F.10.A.15) 50
CX225SR
Roller Lower roller - Remove (D.50.B.56.10 - F.10.A.10) 43
CX225SR
Roller Lower roller - Sectional view (D.50.B.56.10 - C.10.A.30) 18
CX225SR
Roller Lower roller - Service limits (D.50.B.56.10 - D.20.A.20) 8
CX225SR
Roller Lower roller - Special tools (D.50.B.56.10 - D.20.A.40) 11
CX225SR
Roller Lower roller - Visual inspection (D.50.B.56.10 - F.40.A.10) 47
CX225SR
Roller Upper roller - Assemble (D.50.B.56.20 - F.10.A.20) 56
CX225SR
Roller Upper roller - Disassemble (D.50.B.56.20 - F.10.A.25) 53
CX225SR
Roller Upper roller - Install (D.50.B.56.20 - F.10.A.15) 58
CX225SR
Roller Upper roller - Remove (D.50.B.56.20 - F.10.A.10) 51
CX225SR
Roller Upper roller - Sectional view (D.50.B.56.20 - C.10.A.30) 17
CX225SR
Roller Upper roller - Service limits (D.50.B.56.20 - D.20.A.20) 9
CX225SR
Roller Upper roller - Special tools (D.50.B.56.20 - D.20.A.40) 10
CX225SR
Roller Upper roller - Visual inspection (D.50.B.56.20 - F.40.A.10) 55
CX225SR
26036 1 02/12/2004
D.50.B / 63
Steel track - Exploded view (D.50.B.46 - C.10.A.20) 14
CX225SR
Steel track - Install (D.50.B.46 - F.10.A.15) 26
CX225SR
Steel track - Remove (D.50.B.46 - F.10.A.10) 22
CX225SR
Steel track - Service limits (D.50.B.46 - D.20.A.20) 7
CX225SR
Steel track Chain - Measure (D.50.B.46.20 - F.40.A.16) 29
CX225SR
Track tensioning mechanism - Tension adjust (D.50.B.48 - F.45.A.40) 30
CX225SR
Track tensioning mechanism Adjuster-recoil mechanism - Assemble (D.50.B.48.65 - F.10.A.20) 40
CX225SR
Track tensioning mechanism Adjuster-recoil mechanism - Disassemble (D.50.B.48.65 - F.10.A.25) 39
CX225SR
Track tensioning mechanism Adjuster-recoil mechanism - Exploded view (D.50.B.48.65 - 16
C.10.A.20)
CX225SR
Track tensioning mechanism Adjuster-recoil mechanism - Install (D.50.B.48.65 - F.10.A.15) 41
CX225SR
Track tensioning mechanism Adjuster-recoil mechanism - Remove (D.50.B.48.65 - F.10.A.10) 38
CX225SR
Track tensioning mechanism Shock absorber - Assemble (D.50.B.48.70 - F.10.A.20) 35
CX225SR
Track tensioning mechanism Shock absorber - Disassemble (D.50.B.48.70 - F.10.A.25) 34
CX225SR
Track tensioning mechanism Shock absorber - Exploded view (D.50.B.48.70 - C.10.A.20) 15
CX225SR
Track tensioning mechanism Shock absorber - Install (D.50.B.48.70 - F.10.A.15) 36
CX225SR
Track tensioning mechanism Shock absorber - Remove (D.50.B.48.70 - F.10.A.10) 32
CX225SR
26036 1 02/12/2004
D.50.B / 64
26036 1 02/12/2004
D.50.B / 65
SERVICE
PRINTED IN FRANCE
26035 1 02/12/2004
REPAIR MANUAL
BODY AND STRUCTURE
CX225SR
26037 1 02/12/2004
E
Contents
BODY AND STRUCTURE - E
SHIELD E.20.A
CX225SR
USER CONTROLS AND SEAT E.32.A

CX225SR
USER PLATFORM E.34.A

CX225SR
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning E.40.D

CX225SR
SAFETY SECURITY ACCESSORIES Safety E.50.B

CX225SR
26037 1 02/12/2004
E
SHIELD - 20.A
CX225SR
26038 1 02/12/2004
E.20.A / 1
Contents
SHIELD - 20.A
SERVICE
Side shield
Side shield - Remove (E.20.A.70 - F.10.A.10) 3
CX225SR
Upper shield
Upper shield - Remove (E.20.A.71 - F.10.A.10) 5
CX225SR
Engine hood
Engine hood - Remove (E.20.A.72 - F.10.A.10) 8
CX225SR
Protective shield
Protective shield - Remove (E.20.A.73 - F.10.A.10) 9
CX225SR
26038 1 02/12/2004
E.20.A / 2
BODY AND STRUCTURE - SHIELD
Side shield - Remove (E.20.A.70 - F.10.A.10)

CX225SR
1. CAB FLOOR PROTECTION

To reach the hardware, remove the mat on the cab
oor (screws under the foam caps).
The other hardware items are underneath the cab
oor.
CRIL04C146A01 1
2. RH REAR DOOR
This door is attached by a hinge held by hardware
(1).
CRIL04A025A01 2
3. RH FRONT DOOR
(1).
CRIL04A026A01 3
4. CONTROL VALVE SIDE PROTECTION PANEL

Remove RH front door (1).
To remove upper protective panel (2) from hydraulic
lter, refer to Upper shield - Remove (E.20.A.71 -
F.10.A.10).
Remove valve bank hood (3), refer to Upper shield
- Remove (E.20.A.71 - F.10.A.10).
To remove front protective panel (4) from hydraulic
control valve, refer to Upper shield - Remove
(E.20.A.71 - F.10.A.10).
Remove retaining screws.
Remove side protection (5) from hydraulic control
valve.
CRIL04A045A01 4
26038 1 02/12/2004
E.20.A / 3
5. SIDE TANK PROTECTION

Remove protective panel (1) held by screws (2).
The other hardware items (3) are underneath the
chassis.
CRIL04A045A02 5
6. LH REAR DOOR
(1).
CRIL04A027A01 6
7. TRAVEL MOTOR PROTECTIVE SHIELD

These panels are xed with screws (1).
CRIL03J074A01 7
26038 1 02/12/2004
E.20.A / 4
Upper shield - Remove (E.20.A.71 - F.10.A.10)

CX225SR
1. REAR PROTECTIVE PANELS

(1) Hydraulic pump protective panel.
(2) Closing panel.
CRIL04A034A01 1
2. PROTECTIVE PANELS REAR BRACKET

(1) Bracket.
(2) Bracket.
(3) Bracket.
(4) Bracket.
(5) Bracket.
(6) Bracket.
CRIL04B173A01 2
3. SWING MOTOR PROTECTIVE PANEL

(1) Swing motor protective panel.
(1) Access panel to expansion tank.
CRIL04A035A01 3
4. HYDRAULIC AND FUEL TANK PROTECTIVE

PANEL
(1) Fuel and hydraulic tank protective panel.
CRIL04A036A01 4
26038 1 02/12/2004
E.20.A / 5
5. FLOW SELECTOR VALVE HOOD

(1) Flow selector valve hood.
CRIL04A037A01 5
6. CONTROL VALVE HOOD AND FRONT

PROTECTIVE PANEL FOR HYDRAULIC
CONTROL VALVE
Control valve hood (1).
Protective panel (2) Provides access to the hoses at
the back of the control valve.
(3) Provides access to the safety rail mounting.
Protective panels (4) and (5) give access to control
valve hoses.
CRIL04A028B02 6
7. SAFETY RAIL.
Remove ow selector valve hood (4).
Remove the ow selector valve bracket.
Remove protective panel (1).
Remove upper and lower xtures (2) from the safety
rail.
Remove safety rail (3).
CRIL04A033A02 7
26038 1 02/12/2004
E.20.A / 6
8. VALVE BANK COVER SUPPORT

Remove xing screws (1), (3), (4), (5) and remove
the bracket.
CRIL04A044A01 8
26038 1 02/12/2004
E.20.A / 7
Engine hood - Remove (E.20.A.72 - F.10.A.10)

CX225SR
1. Open the hood.

Attach the hood to a suitable lifting device using
slings.
Remove support strut (2).
Remove xing screws (1) from the hinges.
Remove the hood.
CRIL04A024A01 1
26038 1 02/12/2004
E.20.A / 8
Protective shield - Remove (E.20.A.73 - F.10.A.10)

CX225SR
1. HYDRAULIC SWIVEL PROTECTIVE PANEL

(UNDERNEATH UNDERCARRIAGE)
(1) Hydraulic swivel access panel.
CRIL04C143A01 1
2. LOWER PROTECTIVE PANELS (UNDERNEATH

UPPERSTRUCTURE)
(1) Access panel to engine.
(2) Access panel cab oor.
(3) Access panel to hydraulic pump.
(4) Access panel to hydraulic reservoir.
(5) Access panel to fuel tank.
(6) Access panel to air-conditioning compressor
belt tightener.
(7) Access panel to radiator mounting.
(8) Access panel radiator drain cock.
CRIL04B174B01 2
3. CAB FLOOR PROTECTIVE PANEL

(1) Access panel to cab oor.
CRIL03I143A01 3
26038 1 02/12/2004
E.20.A / 9
Index
SHIELD - 20.A
Engine hood - Remove (E.20.A.72 - F.10.A.10) 8
CX225SR
Protective shield - Remove (E.20.A.73 - F.10.A.10) 9
CX225SR
Side shield - Remove (E.20.A.70 - F.10.A.10) 3
CX225SR
Upper shield - Remove (E.20.A.71 - F.10.A.10) 5
CX225SR
26038 1 02/12/2004
E.20.A / 10
USER CONTROLS AND SEAT - 32.A
CX225SR
26039 1 02/12/2004
E.32.A / 1
Contents
FUNCTIONAL DATA
Instrument panel
Instrument panel - Detailed view (E.32.A.81 - C.10.A.50) 3
CX225SR
26039 1 02/12/2004
E.32.A / 2
BODY AND STRUCTURE - USER CONTROLS AND SEAT
Instrument panel - Detailed view (E.32.A.81 - C.10.A.50)

CX225SR
CRIL03K120F01 1
(1) Coolant or hydraulic oil overheating indicator lamp

(2) Engine oil pressure indicator lamp
(3) Minimum fuel level indicator lamp
(4) Battery charge indicator lamp
(5) Engine electrical system fault indicator lamp
(6) Preheating indicator lamp
(7) Fuel level indicator
(8) Engine coolant temperature gauge
(P5) Hourmeter
(S2) Travel gear switch
(S10) Working light switch
(S11) Windscreen wiper switch
(S12) Windscreen washer switch
26039 1 02/12/2004
E.32.A / 3
Index

Instrument panel - Detailed view (E.32.A.81 - C.10.A.50) 3
CX225SR
26039 1 02/12/2004
E.32.A / 4
USER PLATFORM - 34.A
CX225SR
26040 1 02/12/2004
E.34.A / 1
Contents
FUNCTIONAL DATA
Wiper system
Wiper system - Electronic schema (E.34.A.65 - C.20.A.50) 3
CX225SR
Windscreen washer system

Windscreen washer system - Electronic schema (E.34.A.66 - C.20.A.50) 4
CX225SR
26040 1 02/12/2004
E.34.A / 2
BODY AND STRUCTURE - USER PLATFORM
Wiper system - Electronic schema (E.34.A.65 - C.20.A.50)

CX225SR
CRIL03G229E01 1
Circuit layout
(1) Windscreen wiper intermittent indicator lamp (2) Windscreen wiper continuous indicator lamp
(K20) Windscreen wiper motor relay (M3) Windscreen wiper motor
(P1) Instrument panel (S11) Windscreen wiper switch
CRIL03G230E02 2
Timing diagram
(A) Intermittent position (B) Continuous position
OPERATION
• The intermittent (1) and continuous (2) windscreen wiper indicator lamps do not light up when the windscreen
washer switch is operated.
26040 1 02/12/2004
E.34.A / 3
BODY AND STRUCTURE - USER PLATFORM
Windscreen washer system - Electronic schema (E.34.A.66 -

C.20.A.50)
CX225SR
CRIL03G231E01 1
Circuit layout
(K21) Windscreen washer pump relay (M4) Windscreen washer pump motor
(P1) Instrument panel (S12) Windscreen washer switch
CRIL03G232E02 2
Timing diagram
(K20) Windscreen wiper motor relay
OPERATION
• The intermittent and continuous windscreen wiper indicator lamps do not light up when windscreen washer
switch (S12) is operated.
26040 1 02/12/2004
E.34.A / 4
Index

Windscreen washer system - Electronic schema (E.34.A.66 - C.20.A.50) 4
CX225SR
Wiper system - Electronic schema (E.34.A.65 - C.20.A.50) 3
CX225SR
26040 1 02/12/2004
E.34.A / 5
26040 1 02/12/2004
E.34.A / 6
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning

- 40.D
CX225SR
26041 1 02/12/2004
E.40.D / 1
Contents
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - 40.D
TECHNICAL DATA
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Special tools 4
(E.40.D - D.20.A.40)
CX225SR
FUNCTIONAL DATA
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Dynamic 6
description (E.40.D - C.30.A.10)
CX225SR
Command
Command - Overview (E.40.D.05 - C.10.A.10) 8
CX225SR
Electronic HVAC control

Electronic HVAC control - Electrical schema (E.40.D.92 - C.20.A.40) 9
CX225SR
SERVICE
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Disassemble 10
(E.40.D - F.10.A.25)
CX225SR
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Evacuate 14

(E.40.D - F.35.A.35)
CX225SR
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Charging (E.40.D 15

- F.60.A.30)
CX225SR
Compressor
Compressor - Remove (E.40.D.31 - F.10.A.10) 16
CX225SR
Compressor - Install (E.40.D.31 - F.10.A.15) 17

CX225SR
Condenser
Condenser - Remove (E.40.D.32 - F.10.A.10) 18
CX225SR
Condenser - Install (E.40.D.32 - F.10.A.15) 19

CX225SR
Receiver/drier
Receiver/drier - Remove (E.40.D.36 - F.10.A.10) 20
CX225SR
Receiver/drier - Install (E.40.D.36 - F.10.A.15) 21

CX225SR
DIAGNOSTIC
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ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Troubleshooting 22
(E.40.D - G.40.A.10)
CX225SR
Compressor
Compressor Magnetic clutch - Troubleshooting (E.40.D.31.80 - G.40.A.10) 23
CX225SR
Ventilation system
Ventilation system - Troubleshooting (E.40.D.60 - G.40.A.10) 23
CX225SR

CX225SR

CX225SR
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E.40.D / 3
BODY AND STRUCTURE - ENVIRONMENT CONTROL Heating, ventilation and air-conditioning

- Special tools (E.40.D - D.20.A.40)
CX225SR
Tools required for air-conditioning control

Refrigerant recovery, recycling OEM-1418
and charging station
CRPH03I021A 1
Electronic leak detector OEM-1437
CRPH03I022A 2
Thermometer 0 - 250 °C CAS-1048
CRPH03I023A 3
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Belt tensioning tool CAS-10808
CRPH03I024A 4
Protective goggles CAS-10073-3
CRPH03I025A 5
26041 1 02/12/2004
E.40.D / 5

- Dynamic description (E.40.D - C.30.A.10)
CX225SR
The air conditioning system comprises ve major components: the condenser (5), the evaporator (3), the
compressor (4), the expansion valve (1) and the receiver-dryer (6). These components are connected by pipes and
hoses for closed circuit operation. The air-conditioning system runs on R-134a refrigerant.
The compressor receives the refrigerant in the form of gas. The compressor then compresses the refrigerant and,
still in its gaseous form, sends it to the condenser. The air circulates through the condenser and removes the
heat from the refrigerant. As the heat dissipates, the refrigerant becomes liquid. The liquid refrigerant circulates
from the condenser to the receiver-dryer. The receiver-dryer is a container lled with a material to extract the
moisture that accumulates in the air-conditioning circuit. The moisture must be eliminated to prevent the internal
components in the air-conditioning system from corroding. The receiver-dryer also acts as a refrigerant reservoir
for the air-conditioning system.
Still in liquid form, the refrigerant passes to the expansion valve. The expansion valve restricts the ow of the
refrigerant to the evaporator. Because of this restriction, the refrigerant is under less pressure at the expansion
valve outlet than at the inlet. As the refrigerant passes through the evaporator, it is warmed by the air surrounding
the evaporator. The combination of increased warmth and lower pressure causes the refrigerant to evaporate. The
evaporation cools the air circulating in the evaporation coil. The cooled air is then used to cool the driver’s cab.
The refrigerant, now in the gas phase again, returns to the compressor and the cycle is repeated.
26041 1 02/12/2004
E.40.D / 6
CRIL03I010G01 1
Air-conditioning circuit components
(1) Expansion valve (2) Temperature sensor

(3) Evaporator (4) Compressor
(5) Condenser (6) Receiver dehydrator
(7) Gas under low pressure (8) Gas under high pressure
(9) Liquid under low pressure (10) Liquid under high pressure
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E.40.D / 7
Command - Overview (E.40.D.05 - C.10.A.10)

CX225SR
NOTE: Refer to the Operating and Maintenance Manual for the detailed use of these controls.
CRIL03I009F01 1
Heating, ventilation and air conditioning controls.
1. System ON/OFF selector switch and indicator lamp.
2. Air conditioning ON/OFF selector switch and indicator lamp.
3. Fan speed selector switch.
4. Temperature selector switch and indicator lamp.
5. Air circulation selector switches and indicator lamps:
Top front air vent.
Top front and rear vents.
Top and bottom rear vents.
6. Windshield defroster selector switch and indicator lamp.
7. Air inlet selector switch and indicator lamp.
Outside air inlet.
Inside air inlet.
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E.40.D / 8
Electronic HVAC control - Electrical schema (E.40.D.92 - C.20.A.40)

CX225SR
CRIL03I011G01 1
Air conditioning electrical circuit diagram
Description of electrical circuit iagram

(1) Air conditioning control panel (2) Air-conditioning compressor
(3) Pressure switch (4) Compressor clutch supply
(5) Fan speed information (6) Outside or recycled air selection information
(7) Air mixture moderator control (8) Air diffuser selection control
(9) Air conditioning electronic control box (10) Solar ray sensor
(11) Evaporator thermal sensor (12) Recycled air thermal sensor
(13) Anti-frost temperature information (14) windscreen open/closed information
(15) Cab door open/closed information (16) SCM electronic control box
(17) Shutter control motor (18) Fan control
(19) Recycling air sensor
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E.40.D / 9

- Disassemble (E.40.D - F.10.A.25)
CX225SR
CRIL03L149G01 1
Air-conditioning group
(1) Case (2) Filter

(3) Cover (4) Heater body
(5) Evaporator (6) Blower motor
(7) Clamp (8) Clips
(9) Filter (10) Filter
1. Remove the six xing screws and extract case (1).
2. Remove lters (2), (9) and (10).

3. Remove clips (8) using a screwdriver.
CRIL03L150A01 2
4. Remove the eleven xing screws and extract cover

(3).
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E.40.D / 10
5. BLOWER MOTOR REPLACEMENT (6)

When assembling, follow the positioning of harness
(3) and heating hose (1) on blower motor (2) and
lower housing (4).
CRIL03L151A01 3
6. When installing a blower motor:

Check the distance between the fan and housing (
(A) more than or equal to 2 mm)
Centre motor fan (1) in housing (2).
CRIL03L152A01 4
7. EVAPORATOR REPLACEMENT (5)

Remove the evaporator from the case.
Remove thermistor (2) with sensor bracket (1).
Install bracket (1) and the sensor for thermistor (2)
on the second bank of ns (3) keeping distance (A)
= 47 - 48 mm.
CRIL03L153A01 5
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E.40.D / 11
8. Position the thermistor in groove (1) provided for

this purpose then install the evaporator in the lower
housing.
CRIL03L154B01 6
9. EXPANSION VALVE REPLACEMENT

Remove the pipe at the expansion valve inlet and
the nut at the evaporator inlet. Discard seals.
Remove insulation from the temperature sensor,
remove the detection tube then remove the
expansion valve from the evaporator.
Install the new expansion valve on the evaporator
using new seals:
Torque setting on expansion valve inlet pipe 11.7
- 14.7 Nm.
Torque setting on nut at evaporator inlet 15.7 - 19.6
Nm - Nm.
Install the temperature sensor following distance
(A) = 105 - 115 mm. CRIL03L156A01 7
10. Insulate temperature sensor (1).
CRIL03L157A01 8
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11. MOTOR CONTROL REPLACEMENT

Push clamp (A) towards the boom to remove it from
the lever.
Remove the four screws holding the control.
Install the lever on the new control.
CRIL03L155B01 9
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E.40.D / 13

- Evacuate (E.40.D - F.35.A.35)
CX225SR
CAUTION
M143B - Never attempt to service the air conditioning system unless you are completely familiar with air
conditioning and the safety precautions which must be followed when handling liquid refrigerant. Liquid
refrigerant can cause severe and painful frostbite. Contact your Dealer, who is experienced in servicing
and handling of refrigerants.
CAUTION
SM105A - Always wear safety goggles when working with liquid refrigerant. Liquid refrigerant in your
eyes could cause blindness.
CAUTION
SM109A - When refrigerant comes in contact with an open ame, it forms phosgene gas. Never breathe
these fumes.
CAUTION
M742 - Always reclaim all refrigerant prior to opening an A/C system. A drop of liquid refrigerant on your
skin may cause frostbite. Open ttings carefully and slowly when servicing the air conditioning system.
Your skin must be treated for frostbite or a physician must be seen if you get refrigerant on your skin.
CAUTION
M743 - Keep refrigerant containers in correct upright position. Always keep refrigerant containers away
from heat and sunlight. The pressure in a container will increase with heat.
ATTENTION: Service work on air-conditioning circuits must be carried out by approved service engineers.
NOTE: If possible, run the air-conditioning system for a few minutes before starting the recovery process. Shut
down the system before proceeding.
1. Remove the caps from low (1) and high pressure
(2) test points.
Connect hoses on the recovery station OEM-1418
on the pressure test points:
Low pressure on port (1) (suction),
High pressure on port (2) (discharge).
Start recovery.
CRIL04D005A01 1
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E.40.D / 14

- Charging (E.40.D - F.60.A.30)
CX225SR
1. Remove the caps from low (1) and high pressure

(2) test points.
Connect hoses on the recovery station OEM-1418
on the pressure test points:
Low pressure on port (1) (suction),
High pressure on port (2) (discharge).
Load the circuit.
Circuit capacity: 750 - 850 g.
CRIL04D005A01 1
26041 1 02/12/2004
E.40.D / 15
Compressor - Remove (E.40.D.31 - F.10.A.10)

CX225SR
Prior operation: To discharge the air-conditioning system, refer to ENVIRONMENT CONTROL Heating,
ventilation and air-conditioning - Evacuate (E.40.D - F.35.A.35)
CRIL04D006G01 1
1. Loosen and remove belt (2) by adjusting screw (1)

on the tension pulley.
2. Disconnect electric wire (3).
3. Remove screws (6) and disconnect suction (4) and
delivery (5) hoses.
Discard seal rings.
Plug hose and compressor ports
4. Remove retaining screws (7).
Remove compressor (8).
5. Remove compressor bracket and tension pulley (9)
by removing screws (10).
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Compressor - Install (E.40.D.31 - F.10.A.15)

CX225SR
CRIL04D006G01 1
Torque settings
(6) Retaining screws for suction and delivery hoses 19.8 - 29.4 Nm
(7) Compressor retaining screws 19.8 - 29.4 Nm
(10) Bracket retaining screws 53.9 - 63.7 Nm
1. Install compressor bracket and tension pulley (9)
with screws (10).
2. Install compressor (8) on its bracket using screws
(7).
3. Connect suction (4) and delivery (5) hoses to the
compressor using screws (6) and new seal rings.
4. Install belt (2).
Tighten belt by adjusting screw (1) on the tension
pulley.
NOTE: By applying pressure of around 10 kg in the
middle of the belt, the tension slack should be 8 - 10 mm.
5. Connect electric wire (3).
Next operation: ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Charging (E.40.D
- F.60.A.30)
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E.40.D / 17
Condenser - Remove (E.40.D.32 - F.10.A.10)

CX225SR
Prior operation: Air cleaner - Remove (B.30.A.25 - F.10.A.10)
CRIL04D003F01 1
1. Remove screws (1) from the connectors on supply

(IN) and outlet (OUT) hoses on the condenser.
Discard seals.
2. Remove screws (2) and xing lugs (3) holding
condenser (4) on bracket (5).
3. To remove bracket (5), remove the hose supports,
then remove screws (6).
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Condenser - Install (E.40.D.32 - F.10.A.15)

CX225SR
CRIL04D003F01 1
1. Install bracket (5), tighten using screws (6).
2. Install condenser (4) on its bracket using screws (2)

and xing lugs (3).
Tighten screws (2) to 7.8 - 11.8 Nm.
3. Connect inlet (IN) and outlet (OUT) hoses to the
condenser using screws (1) and new seals.
Tighten screws (1) to 7.8 - 11.8 Nm.
Next operation: To charge the circuit, refer to ENVIRONMENT CONTROL Heating, ventilation and
air-conditioning - Charging (E.40.D - F.60.A.30)
Next operation: Air cleaner - Install (B.30.A.25 - F.10.A.15)
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Receiver/drier - Remove (E.40.D.36 - F.10.A.10)

CX225SR
1. Detach connector (1).
CRIL04D004A01 1
2. Remove screws (2) from the unions on inlet (IN) and

outlet hoses (OUT) on receiver-drier (3)
Discard the seals.
3. Remove screws (4) and remove receiver-drier (3)
from its bracket (5).
4. Remove screws (6) and support (5).
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Receiver/drier - Install (E.40.D.36 - F.10.A.15)

CX225SR
1. Install bracket (5) using screws (6).
CRIL04D004A01 1
2. Install receiver-drier (3) on its bracket (5).

Attach screws (4).
3. Connect inlet (IN) and outlet (OUT) hoses of
receiver-drier (3) with new seals and screws (2).
Tighten screws to a torque of 7.8 - 11.8 Nm.
4. Attach connector (1).
Next operation: ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Charging (E.40.D
- F.60.A.30)
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E.40.D / 21

- Troubleshooting (E.40.D - G.40.A.10)
CX225SR
NOTE: AIR CONDITIONING CIRCUIT

The high and low Air in the circuit. Replace the receiver-drier, remove the
pressures are above There are no air bubbles even if water is water and rell with refrigerant.
normal. placed on the condenser (the receiver-drier
remains cool)
Expansion valve defective or not Adjust or replace the valve.
connected to the thermostat pipe. Repair and connect the thermostat pipe to
The low pressure piping is cold, with large the expansion valve.
quantities of water or ice on the pipes.
Defective expansion valve. Clean, repair or replace the expansion
Clogged expansion valve or low pressure valve.
circuit evaporator.
Water placed on the condenser becomes
colder (the high and low pressures return
to normal)
Clogged condenser and/or radiator vanes. Clean the condenser and/or the radiator.
Defective refrigerant fan or slack drive belt. Repair the fan or adjust the belt tension.
The volume of blown air drops when the
air conditioning has been operating for a
long time.
Variation in high and The circuit is full of water Change the receiver-drier, eliminate the
low pressures at regular The blown air does not remain cold water and rell with refrigerant
intervals (they remain
at normal level with no
change in pressure)
The high and low Gas leak from components connected by Replace the parts or the pipes.
pressures are below pipes.
normal. Air bubbles apparent in the visual gauge,
oil in the pipework or the components
(positive reaction from leak tester)
Refrigerant low or non-existent due to poor Rell with refrigerant to normal level.
maintenance.
Air bubbles apparent in the visual gauge,
no oil in the circuit or the components
(negative reaction from leak tester)
Defective or clogged expansion valve. Repair, remove dust or replace the valve.
Clogged low pressure circuit evaporator. Adjust the refrigerant to its correct level.
Excess refrigerant.
Low pressure piping is not cold
Clogged evaporator vanes or air Wash the evaporator and/or replace the
conditioner lter. lter
Thermistor wrongly positioned Adjust the thermistor position
Gas leak in the air conditioner Repair the piping
Defective electrical circuit or thermistor Repair the electrical circuit or the
Ice forms on the evaporator when the thermistor
blower is at low speed Increase the temperature or the blower
The volume of blown air drops when the speed
air conditioning has been operating for a
certain time
Incorrect high and low Defective compressor. Replace the compressor.
pressures With the compressor stopped, the high
pressure drops again to the low pressure
level.
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E.40.D / 22
Compressor Magnetic clutch - Troubleshooting (E.40.D.31.80 -

G.40.A.10)
CX225SR
NOTE: Symptom: MAGNETIC CLUTCH IS NOT FUNCTIONING

The "Frost" symbol lights No power supply to the clutch. Check the clutch fuse
up on the screen Check the air conditioning harness
Check the air conditioning control
Defective clutch or compressor Repair or replace
Pressure switch malfunction or incorrect Refer to ENVIRONMENT CONTROL
circuit pressure Heating, ventilation and air-
conditioning - Troubleshooting
(E.40.D - G.40.A.10)
The "Frost" symbol Defective evaporator connection or Repair or replace the parts
ashes and "5E°" is thermal detector
displayed on the screen
Ventilation system - Troubleshooting (E.40.D.60 - G.40.A.10)

CX225SR
NOTE: Electrical circuit fault detection table.

Symptom: THE BLOWN AIR IS NOT COLD ENOUGH
The audible alarm device Anti-overheating device activated Check that the device is functioning
sounds continuously correctly
HLE.0 to HLE.9 displayed Thermal detector or harness short-circuited Repair or replace the parts
on the screen or cut out
No contact with the thermal detector union Repair
HLE is displayed on the 1) Air mixture motor disconnected Repair motor or the electrical circuit
screen 2) Mixture motor defective connections
3) Electrical harness defective
The Frost symbol ashes Evaporator thermal detector connector Repair
on the screen disconnected or cut out
Evaporator thermal detector Replace
HLE.0 to HLE.9 displayed Cab and evaporator thermal detectors Repair or replace the parts
on the screen short-circuited at the same time
AND the Frost symbol
ashes
Defective control See electronic control box
Temperature set to 18° Cold air is reaching the thermal detector Check the conduit and correct the fault
and in rear ventilation allowing cold air to reach the thermal
mode the blown air is detector
colder than normal
Failure of controller and thermal detector Repair
Air mixture moderator in Compressor clutch control Repair the control
"Max. Cold" position
Supply circuit Refer to troubleshooting in the cooling
cycle
Motor actuator does not Defective motor actuator Repair
move and the force of the
blown air is less than 1,5
Kgf
Defective control Repair
Motor actuator does not Defective motor actuator lever Repair or replace the lever
move Clean and grease the lever
26041 1 02/12/2004
E.40.D / 23

CX225SR

Symptom: THE BLOWN AIR IS NOT HOT ENOUGH
HLE.0 to HLE.9 displayed Cab and evaporator thermal detectors Repair or replace the parts
on the screen short-circuited at the same time
AND the Frost symbol
ashes
Defective control See electronic control box
The Frost symbol ashes Evaporator thermal detector connector Repair
on the screen disconnected or cut out
Evaporator thermal detector Replace
With the temperature Hot air is reaching the thermal detector Check the conduit and correct the fault
set to 32° and in "Feet" allowing hot air to reach the thermal
ventilation mode the detector
blown air is hotter than
normal
Failure of controller and thermal detector Repair
Air mixture moderator in Hot water supply circuit Refer to troubleshooting in the cooling
"Max. Hot" position cycle
Motor actuator does not Defective motor actuator Repair
move and the force of the
blown air is less than 1,5
Kgf
Defective control Repair

CX225SR

Symptom: THE FAN SPEED CANNOT BE CHANGED (THEBLOWN AIR CANNOT BE CHANGED TO COLD OR
RECYCLED AIR)
The audible alarm device Anti-overheating device activated Check that the device is functioning
sounds continuously correctly
The ventilation system The door or windscreen are open The limiter is controlled by the door or the
only operates when the air windshield
conditioning is in "Head"
mode
The door or windshield are closed The limiter is controlled by the "Max. cold"
state
HLE.0 to HLE.9 displayed Thermal detector or harness short-circuited Repair or replace the parts
on the screen or cut out
No contact with the thermal detector union Repair
Cold air or recycled air Motor actuator union on the cold Reconnect or repair the union
indicator ashes on the or recycled air control defective or
screen disconnected
Defective motor actuator Repair or replace the actuator
Defective main harness Repair or replace the harness
26041 1 02/12/2004
E.40.D / 24
Index
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - 40.D

Command - Overview (E.40.D.05 - C.10.A.10) 8
CX225SR
Compressor - Install (E.40.D.31 - F.10.A.15) 17
CX225SR
Compressor - Remove (E.40.D.31 - F.10.A.10) 16
CX225SR
Compressor Magnetic clutch - Troubleshooting (E.40.D.31.80 - G.40.A.10) 23
CX225SR
Condenser - Install (E.40.D.32 - F.10.A.15) 19
CX225SR
Condenser - Remove (E.40.D.32 - F.10.A.10) 18
CX225SR
Electronic HVAC control - Electrical schema (E.40.D.92 - C.20.A.40) 9
CX225SR
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Charging (E.40.D - 15
F.60.A.30)
CX225SR
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Disassemble (E.40.D - 10
F.10.A.25)
CX225SR
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Dynamic description 6
(E.40.D - C.30.A.10)
CX225SR
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Evacuate (E.40.D - 14
F.35.A.35)
CX225SR
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Special tools (E.40.D - 4
D.20.A.40)
CX225SR
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Troubleshooting (E.40.D - 22
G.40.A.10)
CX225SR
Receiver/drier - Install (E.40.D.36 - F.10.A.15) 21
CX225SR
Receiver/drier - Remove (E.40.D.36 - F.10.A.10) 20
CX225SR
CX225SR
CX225SR
CX225SR
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E.40.D / 26
SAFETY SECURITY ACCESSORIES Safety - 50.B
CX225SR
26042 1 02/12/2004
E.50.B / 1
Contents
FUNCTIONAL DATA
Hydraulic lock-out
Hydraulic lock-out - Electrical schema (E.50.B.13 - C.20.A.40) 3
CX225SR
Hydraulic lock-out Electrovalve - External view (E.50.B.13.10 - C.10.A.40) 4

CX225SR
Hydraulic lock-out Electrovalve - Sectional view (E.50.B.13.10 - C.10.A.30) 5

CX225SR
SERVICE
Hydraulic lock-out
Hydraulic lock-out Electrovalve - Electrical test (E.50.B.13.10 - F.40.A.50) 6
CX225SR
Hydraulic lock-out Electrovalve - Remove (E.50.B.13.10 - F.10.A.10) 7

CX225SR
Hydraulic lock-out Electrovalve - Disassemble (E.50.B.13.10 - F.10.A.25) 8

CX225SR
Hydraulic lock-out Electrovalve - Visual inspection (E.50.B.13.10 - F.40.A.10) 9

CX225SR
Hydraulic lock-out Electrovalve - Assemble (E.50.B.13.10 - F.10.A.20) 10

CX225SR
Hydraulic lock-out Electrovalve - Install (E.50.B.13.10 - F.10.A.15) 11

CX225SR
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E.50.B / 2
BODY AND STRUCTURE - SAFETY SECURITY ACCESSORIES Safety
Hydraulic lock-out - Electrical schema (E.50.B.13 - C.20.A.40)

CX225SR
CRIL03G202F02 1
Circuit layout
(F4) Fuse 10 amps: hydraulic control cancellation

(F21) Fuse box
(F23) Fuse 65 amps: main protection for circuits (F1) to (F10) and (F13) to (F20)
(G1) Battery
(K7) Battery relay
(S51) Hydraulic control cancellation lever switch
(Y2) Pilot pressure solenoid valve (blue band)
OPERATION
• When the engine is running and the hydraulic control cancellation lever is in the working position, contact
switch (S51) is closed and pilot pressure solenoid valve (Y2) is energised. Pilot pressure is supplied to the
servo-mechanism and the machine’s hydraulic controls are operational.
26042 1 02/12/2004
E.50.B / 3
Hydraulic lock-out Electrovalve - External view (E.50.B.13.10 -

C.10.A.40)
CX225SR
CRIL04C078F01 1
(B) Pilot manifold supply

(C1) 2nd travel gear pilot
(C2) Swing brake pilot
(C3) Power boost pilot system
(P) Pilot pressure supply
(T) Return to reservoir
(Y2) Pilot pressure solenoid valve
(Y3) Swing brake solenoid valve
(Y4) 2nd travel gear solenoid valve
(Y5) Power boost solenoid valve
26042 1 02/12/2004
E.50.B / 4
Hydraulic lock-out Electrovalve - Sectional view (E.50.B.13.10 -

C.10.A.30)
CX225SR
CRIL03I138F01 1
(1) Retaining nut

(2) Coil
(3) Core
(4) Seal
(5) Spool
(6) Spring
(7) Plug
26042 1 02/12/2004
E.50.B / 5
Hydraulic lock-out Electrovalve - Electrical test (E.50.B.13.10 -

F.40.A.50)
CX225SR
1. Disconnect connector (1) from pilot pressure

CRIL04D002A01 1
2. Connect the electrical connector (3) on connector

(1) from solenoid valve (Y2) to connector of solenoid
valve (2) then install the multimeter.
CRIL03I078A01 2
3. The solenoid resistance reading for solenoid valve

(Y2) on multimeter (2) should be 45 ohms at a
temperature.
26042 1 02/12/2004
E.50.B / 6
Hydraulic lock-out Electrovalve - Remove (E.50.B.13.10 - F.10.A.10)

CX225SR
Prior operation: To remove the side cover plate in the cab oor, refer to Side shield - Remove (E.20.A.70 -
F.10.A.10).
Prior operation: To remove the access panel in the cab oor, refer to Protective shield Guard - Remove
(E.20.A.73.71 - F.10.A.10).
1. Disconnect the electrical connectors from the wiring

harness (1) taking care to mark the coloured bands.
Disconnect hose (2) from port union (C2).
Disconnect hose (3) from port union (P).
Disconnect hose (5) from port union (B).
Disconnect hose (6) from port union (T).
For port markings, refer to Hydraulic lock-out
Electrovalve - External view (E.50.B.13.10 -
C.10.A.40)
CRIL04C148A01 1
2. Disconnect the solenoid valve electrical connectors

(1) from their brackets (2).
CRIL04C147A01 2
3. Remove xing screws (1) and spacers (2) from

solenoid valve block (3).
CRIL03I163A01 3
26042 1 02/12/2004
E.50.B / 7
Hydraulic lock-out Electrovalve - Disassemble (E.50.B.13.10 -

F.10.A.25)
CX225SR
NOTE: Mark each part of every element during disassembly to make reassembly easier.
1. Remove retaining nut (1) from the coil.
Remove the coil (2) from the solenoid.
CRIL03I157A01 1
2. Remove core from the solenoid (3).

Remove and discard the O-rings (4).
3. Remove spool (1) from the solenoid valve element
Remove spring (2) from the solenoid valve element.
NOTE: The spool of solenoid valve element (Y3) differs

from the spools of solenoid valve elements (Y2), (Y4)
and (Y5).
To identify them, refer to Hydraulic lock-out Electrovalve
- External view (E.50.B.13.10 - C.10.A.40)
CRIL03I153A01 2
26042 1 02/12/2004
E.50.B / 8
Hydraulic lock-out Electrovalve - Visual inspection (E.50.B.13.10 -

F.40.A.10)
CX225SR
1. Inspect springs for cracks, distortion, or evidence

of permanent blocking.
Replace the spring(s) if any of these defects is
noted.
2. Check the spools for cracks, pitting, distortion or
other damage. Check that the spools are functioning
correctly in the bores of the solenoid valve block
body.
Replace the spool(s) or the solenoid valve block
body if any of these defects is noted.
3. Check for damage to the internal thread and for
evidence of wear in the solenoid valve block body.
Replace the solenoid valve block body if any of
these defects is noted.
4. Measure the clearance between the spools and
the bores of the solenoid valve block body. The
clearance should be approximately 0.01 mm.
If this is not the case, replace the spools and the
solenoid valve block body.
26042 1 02/12/2004
E.50.B / 9
Hydraulic lock-out Electrovalve - Assemble (E.50.B.13.10 -

F.10.A.20)
CX225SR
Prior operation: Hydraulic lock-out Electrovalve - Visual inspection (E.50.B.13.10 - F.40.A.10).
1. To reassemble the solenoid valve, follow the steps

for disassembly in the reverse order. Refer to
Hydraulic lock-out Electrovalve - Disassemble
(E.50.B.13.10 - F.10.A.25).
Tighten core (3) to a torque of 30 - 37 Nm.
Tighten nut (1) to a torque of 4.9 Nm.
CRIL03I157A01 1
26042 1 02/12/2004
E.50.B / 10
Hydraulic lock-out Electrovalve - Install (E.50.B.13.10 - F.10.A.15)

CX225SR
1. To install the solenoid valve, follow the removal

procedure steps in reverse order, refer to Hydraulic
lock-out Electrovalve - Remove (E.50.B.13.10 -
F.10.A.10).
2. Replace the access panel in the cab oor, refer to
Protective shield Guard - Remove (E.20.A.73.71
- F.10.A.10).
3. Replace the cab oor side cover plate, refer to Side
shield - Remove (E.20.A.70 - F.10.A.10).
26042 1 02/12/2004
E.50.B / 11
Index

Hydraulic lock-out - Electrical schema (E.50.B.13 - C.20.A.40) 3
CX225SR
Hydraulic lock-out Electrovalve - Assemble (E.50.B.13.10 - F.10.A.20) 10
CX225SR
Hydraulic lock-out Electrovalve - Disassemble (E.50.B.13.10 - F.10.A.25) 8
CX225SR
Hydraulic lock-out Electrovalve - Electrical test (E.50.B.13.10 - F.40.A.50) 6
CX225SR
Hydraulic lock-out Electrovalve - External view (E.50.B.13.10 - C.10.A.40) 4
CX225SR
Hydraulic lock-out Electrovalve - Install (E.50.B.13.10 - F.10.A.15) 11
CX225SR
Hydraulic lock-out Electrovalve - Remove (E.50.B.13.10 - F.10.A.10) 7
CX225SR
Hydraulic lock-out Electrovalve - Sectional view (E.50.B.13.10 - C.10.A.30) 5
CX225SR
Hydraulic lock-out Electrovalve - Visual inspection (E.50.B.13.10 - F.40.A.10) 9
CX225SR
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E.50.B / 12
26042 1 02/12/2004
E.50.B / 13
SERVICE
PRINTED IN FRANCE
26037 1 02/12/2004
REPAIR MANUAL
FRAME POSITIONING
CX225SR
26043 1 02/12/2004
F
Contents
FRAME POSITIONING - F
TRAVELLING Travel F.10.F

CX225SR
STABILISING Ballasting F.20.B

CX225SR
SWINGING Circular swing F.40.C

CX225SR
26043 1 02/12/2004
F
TRAVELLING Travel - 10.F
CX225SR
26044 1 02/12/2004
F.10.F / 1
Contents
TECHNICAL DATA
Command valve
Command valve Foot command valve - Special tools (F.10.F.12.10 - D.20.A.40) 5
CX225SR
Command valve Foot command valve - General specication (F.10.F.12.10 - D.40.A.10) 5

CX225SR
Hydraulic motor
Hydraulic motor - Torque (F.10.F.28 - D.20.A.10) 6
CX225SR
FUNCTIONAL DATA
TRAVELLING Travel - Electronic schema (F.10.F - C.20.A.50) 7
CX225SR
TRAVELLING Travel - Hydraulic schema (F.10.F - C.20.A.20) 8

CX225SR

CX225SR

CX225SR
Command valve
Command valve Foot command valve - Sectional view (F.10.F.12.10 - C.10.A.30) 14
CX225SR
Control valve
Control valve - Sectional view (F.10.F.14 - C.10.A.30) 16
CX225SR
Hydraulic motor
Hydraulic motor - Exploded view (F.10.F.28 - C.10.A.20) 18
CX225SR
Hydraulic motor - Sectional view (F.10.F.28 - C.10.A.30) 20

CX225SR
Reducer, spur gear

Reducer, spur gear - Exploded view (F.10.F.44 - C.10.A.20) 23
CX225SR
Reducer, spur gear - Sectional view (F.10.F.44 - C.10.A.30) 25

CX225SR
Sensing system
Sensing system Alarm - Electronic schema (F.10.F.95.90 - C.20.A.50) 27
CX225SR
SERVICE
Command valve
26044 1 02/12/2004
F.10.F / 2
Command valve Foot command valve - Remove (F.10.F.12.10 - F.10.A.10) 28
CX225SR
Command valve Foot command valve - Disassemble (F.10.F.12.10 - F.10.A.25) 29

CX225SR
Command valve Foot command valve - Visual inspection (F.10.F.12.10 - F.40.A.10) 35

CX225SR
Command valve Foot command valve - Assemble (F.10.F.12.10 - F.10.A.20) 36

CX225SR
Command valve Foot command valve - Install (F.10.F.12.10 - F.10.A.15) 42

CX225SR
Command valve Speed selection valve - Electrical test (F.10.F.12.15 - F.40.A.50) 43

CX225SR
Control valve
Control valve - Disassemble (F.10.F.14 - F.10.A.25) 44
CX225SR
Control valve - Assemble (F.10.F.14 - F.10.A.20) 46

CX225SR
Relief valve
Relief valve - Pressure test (F.10.F.16 - F.40.A.30) 48
CX225SR
Relief valve - Pressure setting (F.10.F.16 - F.45.A.70) 50

CX225SR
Hydraulic motor
Hydraulic motor - Leakage test (F.10.F.28 - F.40.A.40) 51
CX225SR
Hydraulic motor - Remove (F.10.F.28 - F.10.A.10) 53

CX225SR
Hydraulic motor - Disassemble (F.10.F.28 - F.10.A.25) 54

CX225SR
Hydraulic motor - Check (F.10.F.28 - F.40.A.11) 59

CX225SR
Hydraulic motor - Assemble (F.10.F.28 - F.10.A.20) 60

CX225SR
Hydraulic motor - Install (F.10.F.28 - F.10.A.15) 66

CX225SR
Reducer, spur gear

Reducer, spur gear - Remove (F.10.F.44 - F.10.A.10) 67
CX225SR
Reducer, spur gear - Disassemble (F.10.F.44 - F.10.A.25) 68

CX225SR
Reducer, spur gear - Visual inspection (F.10.F.44 - F.40.A.10) 72

CX225SR
Reducer, spur gear Bearing - Preload (F.10.F.44.10 - F.45.A.30) 73

CX225SR
Reducer, spur gear - Assemble (F.10.F.44 - F.10.A.20) 74

CX225SR
Reducer, spur gear - Install (F.10.F.44 - F.10.A.15) 78

CX225SR
DIAGNOSTIC
TRAVELLING Travel - Troubleshooting (F.10.F - G.40.A.10) 79
CX225SR
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F.10.F / 3
Command valve
Command valve Foot command valve - Troubleshooting (F.10.F.12.10 - G.40.A.10) 79
CX225SR
26044 1 02/12/2004
F.10.F / 4
FRAME POSITIONING - TRAVELLING Travel
Command valve Foot command valve - Special tools (F.10.F.12.10 -

D.20.A.40)
CX225SR
NOTE: Tool to be manufactured locally
CRIL03L111A01 1
Used for removing and installing the cover bushing.

(A) 10 mm
(B) 8 mm
(C) 20 mm
(D) 30 mm
(E) 2 mm
Command valve Foot command valve - General specication

(F.10.F.12.10 - D.40.A.10)
CX225SR
Working pressure 68 bar

Secondary pressure (max. control pressure at end of stroke) 0 - 44 bar
Authorised return pressure 2.9 bar
Rated ow 10 L/min
Operating angle ±10 ° ±12.4 °
Operating temperature range -20 - 100 °C
26044 1 02/12/2004
F.10.F / 5
Hydraulic motor - Torque (F.10.F.28 - D.20.A.10)

CX225SR
CRIL04A101G02 1
Description
(1) 112 - 124 Nm (2) 353 - 393 Nm
(3) 98 - 118 Nm (4) 1.96 - 2.98 Nm
(5) 19.6 - 21.6 Nm (6) 136 - 138 Nm
(7) 1.96 - 2.98 Nm (8) 8.8 - 10.8 Nm
(9) 1.96 - 2.98 Nm (10) 1.96 - 2.98 Nm
(11) 8.8 - 10.8 Nm
26044 1 02/12/2004
F.10.F / 6
TRAVELLING Travel - Electronic schema (F.10.F - C.20.A.50)

CX225SR
CRIL03G097E01 1
Circuit layout
(1) Travel gear indicator lamp (K18) Travel gear relay

(P1) Instrument panel (S2) Travel gear switch
(Y4) 2nd travel gear solenoid valve (red band)
CRIL03G098E02 2
Timing diagram
(A) Lamp test (B) Reset
TRAVEL GEAR OPERATION

1. When the starter switch is in the "ON" position, 1st gear is selected by default.
2. Every time travel gear switch (S2) is pressed, the travel gear changes as follows: 1 to 2, 2 to 1 and the
corresponding indicator lamp lights up.
26044 1 02/12/2004
F.10.F / 7
TRAVELLING Travel - Hydraulic schema (F.10.F - C.20.A.20)

CX225SR
CRIL04A029H01 1
High speed travel circuit - Dynamic Description
High speed travel circuit

(1) Straight-line travel valve (15) Control valve
(16) Hydraulic swivel (21) Travel motor
26044 1 02/12/2004
F.10.F / 8
(C1) 2nd gear travel pilot (Pa1/A1) RH forward travel

(Pb1/B1) RH reverse travel (Pa6/A6) LH forward travel
(Pb6/B6) LH reverse travel (P1) Pump D2 outlet ow
(P2) Pump D1 outlet ow (S2) Travel gear switch
(Y4) 2nd gear travel solenoid valve
DYNAMIC DESCRIPTION
• The travel motors are fed by two ows (21).
• At high speed, the travel motors are set to low displacement.
• The travel motors have an internal circuit which enables them to change from low to high displacement when
the supply pressure exceeds a certain value. If the pressure falls, the travel motors automatically change
back to low displacement.
• Pump outlet (D2) enters in (P1) on the control valve whilst pump (D1) enters in (P2). One ow goes directly to
the LH travel valve spool, (P2) and the other to the RH travel valve spool (P1).
• The 2nd gear solenoid valve (red band) (Y4) must be activated to change to high gear. The 2nd gear travel
pilot pressure 39 bar from the 2nd gear travel solenoid valve (Y4) passes through the hydraulic swivel (16) and
goes to control the displacement change valve spools of the travel motors (21).
26044 1 02/12/2004
F.10.F / 9

CX225SR
CRIL04A030H01 1
Low gear travel circuit - Dynamic Description
Low speed travel circuit

26044 1 02/12/2004
F.10.F / 10

(P2) Pump D1 outlet ow (S2) Travel gear switch
(Y4) 2nd gear travel solenoid valve
DYNAMIC DESCRIPTION
• Low gear is selected on travel motors (21) by default. Even if the machine is in a high gear when the engine is
switched off, low gear is automatically selected for travel motors (21) when the engine is restarted.
• Pump outlet (D2) enters in (P1) on the control valve whilst pump (15) enters in (D1) (P2). One ow goes
directly to the LH travel valve spool (P2) and the other to the RH travel valve spool (P1).
• 2nd gear travel solenoid valve (red band) is de-activated and the displacement change valve spools on travel
motors (Y4) are connected to the return circuit (21).
26044 1 02/12/2004
F.10.F / 11

CX225SR
CRIL04A031H01 1
Straight-line travel circuit - Dynamic Description
Straight-line travel circuit

26044 1 02/12/2004
F.10.F / 12

(P2) Pump D1 outlet ow
DYNAMIC DESCRIPTION
This chapter describes the situation in which the boom is raised as the machine is travelling.
• When the boom needs to be raised, boom valve spool 2 is actuated and the low pressure circuit coming from
(PP) and passing through all attachment and swing spools is closed. This circuit increases in pressure up
to 39 bar, which pilots the straight-line travel valve (1). The output from pump (D2) therefore supplies the
two travel systems at (P1) and the output ow from pump (D1) supplies the attachment at (P2). As both
travel motors (21) are supplied in parallel, their pressure is equal and the machine travels in a straight line.
In addition, if the ow is not completely expended on the attachment, the surplus from this ow is used for
travel and the loss of speed is minimal.
• If functions other than the boom are used at the same time as travel, their operation is exactly the same.
26044 1 02/12/2004
F.10.F / 13
Command valve Foot command valve - Sectional view (F.10.F.12.10

- C.10.A.30)
CX225SR
CRIL03L070G01a 1
Description
(1) Lower body (2) Spool
(3) Shim (4) Washer
(5) Recoil Spring (6) Calibrated spring
(7) Spring seat (8) Seal
(9) Plug (10) Seal
(11) Push rod guide (12) Seal
(13) Pusher (14) Cover
(15) Ball (16) Screw
(17) Shaft (18) Cam
(19) Bushing (20) Boot
(21) Piston (22) Upper body
(23) Spring (24) Spring seat
(25) Ball (26) Guard
26044 1 02/12/2004
F.10.F / 14

(29) Seal
26044 1 02/12/2004
F.10.F / 15
Control valve - Sectional view (F.10.F.14 - C.10.A.30)

CX225SR
CRIL04A163G01a 1
RH and straight-line travel section
(5R) RH travel spool (6) Straight-line travel spool

(7) Seal (8) Large cap
(12) Small cap (35) Spring
(36) Seal (37) Flange
(51) Valve (73) Plug
(74) Screw M10x1.5 L=28 (75) Screw M10x1.5 L=40
(B) Spring (C) Spring seat
(D) Spool screw
26044 1 02/12/2004
F.10.F / 16
CRIL04A169F01 2
LH travel section
(5L) RH travel spool (7) Seal

(46) Plug (47) Seal
(48) Spring (49) Valve
(74) Screw M10x1.5 L=28 (B) Spring
(C) Spring seat (D) Spool screw
26044 1 02/12/2004
F.10.F / 17
Hydraulic motor - Exploded view (F.10.F.28 - C.10.A.20)

CX225SR
CRIL04B003H01a 1
Description
(40) Shaft (41) Swash plate
(42) Cylinder barrel (43) Piston assembly
26044 1 02/12/2004
F.10.F / 18
(44) Shoe (45) Retaining plate

(46) Thrust ball (47) Bearing
(48) Washer (49) Seal
(50) Spring (51) Snap ring
(52) Friction plate (53) Intermediate plate
(54) Roller (55) Bearing
(56) Seal (57) Seal
(58) Piston (59) Seal
(60) Seal (61) Spring
(62) Piston (63) Ball
(64) Screw (65) Spring
(66) Centring stud (67) Centring stud
(68) Base plate (69) Screw
(70) Cap (71) Seal
(72) Guide washer (73) Spring
(74) Thrust washer (75) Spool end
(78) Valve (79) Spool
(80) Safety valve (81) Plug
(82) Seal (83) Throttle valve
(84) Nut (85) Screw
(86) Plug (87) Seal
(88) Spring seat (89) Seal
(90) Spring (91) Valve
(92) Piston (93) Back-up ring
(96) Valve body (97) Valve
(98) Valve seat (99) Back-up ring
(102) Plug (103) Seal
(104) Spool (105) Snap ring
(106) Spool (107) Back-up ring
(108) Seal (109) Seal
(110) Back-up ring (111) Spool
(112) Plug (113) Seal
(114) Spring guide (115) Washer
(116) Spring (117) Valve plate
(118) Seal (119) Plug
(120) Plug (121) Plug
(122) Plug (123) Plug
(124) Plug (125) Plug
(126) Plug (127) Plug
(128) Plug (129) plug
(130) Plug (131) Plug
(132) Plug (133) Seal
(134) Spring (135) Spring seat
(136) Plug
26044 1 02/12/2004
F.10.F / 19
Hydraulic motor - Sectional view (F.10.F.28 - C.10.A.30)

CX225SR
CRIL04A087H01a 1
Hydraulic motor specication
(40) Shaft (41) Swash plate

(42) Cylinder barrel (43) Piston assembly
(44) Shoe (45) Retaining plate
26044 1 02/12/2004
F.10.F / 20
(46) Thrust ball (47) Bearing

(50) Spring (51) Snap ring
(52) Friction plate (53) Intermediate plate
(54) Roller (55) Bearing
(56) Seal (57) Seal
(58) Piston (59) Seal
(62) Piston (63) Ball
(64) Screw (65) Spring
(66) Centring stud (67) Centring stud
(68) Base (117) Valve plate
CRIL04A101G01a 2
Hydraulic motor base specication
(69) Screw (70) Cap

(74) Thrust washer (75) Spool end
(76) Seal (78) Valve
(79) Spool (80) Safety valve
(81) Plug (83) Throttle valve
26044 1 02/12/2004
F.10.F / 21
(102) Plug (103) Seal

(104) Spool (106) Spool
(112) Plug (122) Plug
(123) Plug (127) Plug
(130) Throttle valve (131) Plug
(132) Plug
26044 1 02/12/2004
F.10.F / 22
Reducer, spur gear - Exploded view (F.10.F.44 - C.10.A.20)

CX225SR
CRIL04A092H01 1
Description
(1) Housing (2) Cover
(3) Shaft pinion (4) Screw
26044 1 02/12/2004
F.10.F / 23
(5) Screw (6) Plug

(7) Seal (8) Sun pinion
(9) Shim (10) Plate
(11) Screw (12) Screw
(13) Bushing (14) Roller bearing
(15) Pinion (16) Satellite carrier
(17) Plate (18) Bearing
(19) Face seal (20) Centring stud
(21) Washer (22) Washer
(23) Snap ring (24) Shim
(25) Satellite carrier (26) Spacer
(27) Pinion (28) Bushing
(29) Roller bearing (30) Plate
(31) Knuckle
26044 1 02/12/2004
F.10.F / 24
Reducer, spur gear - Sectional view (F.10.F.44 - C.10.A.30)

CX225SR
CRIL04A091G01 1
Description
(1) Housing (2) Cover
(3) Shaft pinion (4) Screw
(5) Screw (6) Plug
(7) Seal (8) Sun pinion
(9) Shim (10) Plate
(13) Bushing (14) Roller bearing
(15) Pinion (16) Spacer
(17) Plate (18) Bearing
(19) Face seal (20) Centring stud
(21) Washer (22) Plate
(23) Snap ring (24) Shim
(25) Satellite carrier (26) Thrust washer
(27) Pinion (28) Bushing
26044 1 02/12/2004
F.10.F / 25
(29) Roller bearing (30) Plate

(31) Knuckle (32) Thrust washer
26044 1 02/12/2004
F.10.F / 26
Sensing system Alarm - Electronic schema (F.10.F.95.90 - C.20.A.50)

CX225SR
CRIL04D007E01 1
Travel audible alarm device - Circuit layout
(A8) Engine mode selector (K27) Travel audible alarm relay

(B27) Travel pilot pressure switch (P1) Instrument panel
(H2) Travel audible alarm device (S28) Travel alarm switch
CRIL03G226E02 2
Timing diagram
OPERATION
• When travel is activated and travel alarm switch (S28) is open, the pilot pressure closes travel pilot pressure switch
(B27) and a signal is sent to instrument panel (P1). Travel audible alarm relay (K27) is energised and travel audible
alarm (H2) sounds.
26044 1 02/12/2004
F.10.F / 27
Command valve Foot command valve - Remove (F.10.F.12.10 -

F.10.A.10)
CX225SR
Prior operation: To remove the side guard from under the cab oor, refer to Side shield - Remove (E.20.A.70
- F.10.A.10)
1. Attach identication labels to all the control pedal

hoses.
Disconnect the hoses.
Plug the ports.
CRIL03L107A00 1
2. Remove pedals (1), brackets (2) and levers (3).
CRIL03I083A01 2
3. Remove the oor mat.

Remove screws (1) and the foot control.
CRIL03I083A02 3
26044 1 02/12/2004
F.10.F / 28
Command valve Foot command valve - Disassemble (F.10.F.12.10 -

F.10.A.25)
CX225SR
NOTE: Always handle high precision parts with the greatest care to prevent them being damaged by being knocked
or dropped.
The control pedal components may rust due to contamination and humidity if they are left without protection
after disassembly.
If work has to be interrupted, the components must be protected from contamination or corrosion.
NOTE: Mark the position and bore of all parts.
1. Tighten the control pedal in a vice with soft jaws.
Remove the boot.
CRPH03I047A 1
2. Remove the locking screw from the camshaft.
CRPH03I048A 2
3. Remove the camshaft using a drift punch.
CRPH03I049A 3
26044 1 02/12/2004
F.10.F / 29
4. Remove the cam and steel ball assembly.
CRPH03I050A 4
5. Remove the cover xing screws.
CRPH03I051A 5
6. Remove the cover.

NOTE: Repeat steps 2 to 6 for the second control pedal
body.
CRPH03I052A 6
7. Remove the upper body.
CRIL03L095A00 7
26044 1 02/12/2004
F.10.F / 30
8. Remove the spool assembly.
CRIL03L096A00 8
9. Remove the guide assembly.
CRIL03L092A00 9
10. Remove the piston.
CRIL03L093A00 10
11. Remove the spring.
CRIL03L094A00 11
26044 1 02/12/2004
F.10.F / 31
12. Remove the spring seat.
CRPH03I060A 12
13. Remove the balls using a magnet.
CRIL03L106A00 13
14. Discard the seals.
CRIL03L097A00 14
CRPH03I061A 15
26044 1 02/12/2004
F.10.F / 32
16. Remove the spring.
CRPH03I062A 16
17. To remove the bushings, refer to Command valve

Foot command valve - Special tools (F.10.F.12.10
- D.20.A.40).
CRIL03L098A00 17
18. Compress the spool return spring with the seat so

as to be able to tap it out.
NOTE: Be careful not to damage the spool surface. Do
not compress the spring by more than 4 mm.
CRPH03I064A 18
19. Remove the spool, spring seat, calibrated spring,

shim and washer.
CRPH03I065A 19
26044 1 02/12/2004
F.10.F / 33
20. Remove the bushing from the push-rod guide.
CRIL03L099A00 20
21. Remove the inner seal from the push-rod guide.
CRIL03L100A00 21
22. Remove the outer seal from the push-rod guide.

NOTE: Repeat steps 7 to 22 for the second control pedal
body.
CRIL03L101A00 22
26044 1 02/12/2004
F.10.F / 34
Command valve Foot command valve - Visual inspection

(F.10.F.12.10 - F.40.A.10)
CX225SR
1. Check for cracks, distortion or blocking of the

springs.
If defects are found, replace the springs.
2. Inspect the spools to ensure that their nish is not
damaged and that they are not bent or otherwise
defective.
Make sure that the spool slides freely in the foot
control body bore.
If defects are found, replace the foot control
assembly.
3. Check the bores for damage, internal damage
to housings or evidence of any othe foot control
internal wear.
If the foot control is damaged, replace the entire
assembly.
26044 1 02/12/2004
F.10.F / 35
Command valve Foot command valve - Assemble (F.10.F.12.10 -

F.10.A.20)
CX225SR
NOTE: Immerse all components in clean hydraulic uid to guarantee proper lubrication when assembling and
resuming operation.
NOTE: Assemble following the markings made during removal.
1. Install washer, shim, calibrated spring and spring
seat on the spool.
CRPH03I065A 1
2. Compress and engage the spring seat.

NOTE: Be careful not to damage the spool surface.
Do not compress the spring by more than 4 mm.
CRPH03I064A 2
3. Install the return spring.
CRPH03I062A 3
26044 1 02/12/2004
F.10.F / 36
4. Install the spool assembly in the bore of the foot

control body.
CRPH03I061A 4
5. Install the seals.
CRIL03L097A00 5
6. Install the balls.
CRIL03L106A00 6
7. Install the spring seat.
CRIL03L102A00 7
26044 1 02/12/2004
F.10.F / 37
8. Install the spring.
CRIL03L094A00 8
9. Install the piston.
CRIL03L093A00 9
10. Install the seal in the push-rod guide.
CRIL03L100A00 10
11. Installer the bushing in the push-rod guide.
CRIL03L099A00 11
26044 1 02/12/2004
F.10.F / 38
12. Oil and install the push-rod in the guide.
CRIL03L103A00 12
13. Assemble the push-rod guide assembly.

NOTE: Repeat steps 1 to 13 for the other control pedal
body.
CRIL03L104A00 13
14. To install the bushings, refer to Command valve

Foot command valve - Special tools (F.10.F.12.10
- D.20.A.40)
CRIL03L098A00 14
15. Install the upper body.
CRIL03L095A00 15
26044 1 02/12/2004
F.10.F / 39
16. Install the cover.
CRPH03I052A 16
17. Install the retaining screws and tighten them to

torque 8 - 10 Nm.
CRPH03I068A 17
18. Mount the cam and install the cam shaft.

NOTE: Repeat steps 13 to 18 for the other control pedal
body.
CRPH03I050A 18
19. Coat the threads of the linkage pin locking screw

with Loctite 241 and tighten it to torque 6 - 8 Nm
CRPH03I069A 19
26044 1 02/12/2004
F.10.F / 40
20. Tilt the cam and apply grease at the ends of the
push-rods and inject grease in the tappet guide
bushings.
CRIL03I073A01 20
21. Install the upper part of the gusset on the cam.

Apply a moisture repellent to the groove of the cover
to prevent any oxidation.
Install the lower part of the gusset on the cover.
CRPH03I070A 21
26044 1 02/12/2004
F.10.F / 41
Command valve Foot command valve - Install (F.10.F.12.10 -

F.10.A.15)
CX225SR
1. Install the foot control in position and x screws (1).

Install the oor mat.
CRIL03I083A02 1
2. Install levers (3), brackets (2) and pedals (1).
CRIL03I083A01 2
3. Remove the plugs.

Connect all hoses to the foot control following the
markings made during removal.
CRIL03L107A00 3

Install the side guard under the cab oor.
26044 1 02/12/2004
F.10.F / 42
Command valve Speed selection valve - Electrical test (F.10.F.12.15

- F.40.A.50)
CX225SR
SYSTEM - Special tools (A.30.A - D.20.A.40)
1. Disconnect connector (1) from the 2nd travel gear

CRIL04D002A02 1
2. Connect the appropriate test electrical connector

(3) to connector (1) on solenoid (Y4), then attach
multimeter (2).
CRIL03I078A03 2
3. The solenoid resistance reading of solenoid valve

(Y4) on multimeter (2) should be 45 ohms for a
temperature.
26044 1 02/12/2004
F.10.F / 43
Control valve - Disassemble (F.10.F.14 - F.10.A.25)

CX225SR
CRIL04A163G01a 1
RH and straight-line travel spools
CRIL04A169F01 2
26044 1 02/12/2004
F.10.F / 44
LH travel spool
1. Remove screws (74) and caps (8) and (12).

Discard seals (7).
2. Remove spools (5R), (5L) and (6).
IMPORTANT: Mark each spool to ensure that it is returned
to the correct housing during reassembly.
3. Remove the screws from spool (D).
Remove springs (B) and seats (C).
NOTE: To avoid damaging the spool surface when the
spool assembly is removed, use a soft-jawed vice and
clamp the spool as closely as possible to the head (spring
side) to prevent distortion. If the threaded part of the
screw is coated with thread lock uid, heat the screw
(the temperature should normally be 200 - 250 °C). If
the spring is distorted (impaired functioning) during this
4. Remove plugs (73) and discard the seals.
5. Remove screws (75) and anges (37).
Discard seals (36).
6. Remove plug (46).
Discard seal (47).
26044 1 02/12/2004
F.10.F / 45
Control valve - Assemble (F.10.F.14 - F.10.A.20)

CX225SR
Prior operation: To clean and check parts before assembly, refer to Stack valve - Visual inspection (A.10.A.18
- F.40.A.10)
CRIL04A163G01a 1
RH and straight-line travel spools
CRIL04A169F01 2
26044 1 02/12/2004
F.10.F / 46
LH travel spool
Torque settings
Plug (46) 107 - 117 Nm
Plug (73) 19 - 22 Nm
Screw (74) 39 - 44 Nm
Screw (75) 58 - 64 Nm
Spool screw (D) 20 - 22 Nm
1. Install check valve (49) and spring (48).
Install plug (46) tted with new seal (47).
2. Install plugs (73) tted with new seals and tighten to
the required torque.
3. Install valve (51) and spring (35).
Install new seals (36).
Install anges (37) with screws (75).
Tighten screws (75) to the required torque.
4. Coat the threaded parts of spools (5R), (5L) and
(6) with thread lock uid.
Place the spool ends (spring side) in a soft-jawed
vice.
Fit springs (B) and seats (C ) on screws (D).
Install and tighten the screws to the required torque.
Install spools (5R), (5L) and (6) in their respective
housings.
5. Install caps (8) and (12) tted with new seals (7).
Install and tighten screws (74) to the required
torque.
26044 1 02/12/2004
F.10.F / 47
Relief valve - Pressure test (F.10.F.16 - F.40.A.30)

CX225SR
NOTE: Travel secondary relief valves (K) and (L) are calibrated to a higher pressure than the main relief valve (A).
To check or calibrate the travel secondary relief valves, main relief valve (A) must be overcalibrated.
1. Overcalibrate main relief valve (A) by tightening the
adjusting screw by 180 °, refer to Relief valve -
Pressure setting (A.10.A.16 - F.45.A.70).
2. Connect a 0-600 bar (0-60 MPa) pressure gauge to
the pressure test point (M2) for right-hand travel and
to (M1) for left-hand travel.
3. Have a locking pin produced locally:
(A) = 35 mm
(B) = 68 mm
(C) = 250 mm
(D) = 70 mm
CRIL03I164A01 1
4. Start the engine at idling speed.

5. Carefully block the travel mechanically on the
side to be checked by positioning the locking pin
(A) between the sprocket and the chassis (see
drawing).
CRIL03I165A01 2
6. With the engine at full speed, operate the

corresponding travel control lever and hold it in
position (sprocket locked).
7. Read the forward and reverse travel pressures from
the pressure gauge, they should be 343 bar (34.3
MPa).
.
8. If the pressures are incorrect, calibrate travel relief
valves (K) and (L), refer to Relief valve - Pressure
setting (F.10.F.16 - F.45.A.70)
9. Recalibrate main relief valve (A), refer to Relief
valve - Pressure setting (A.10.A.16 - F.45.A.70).
10. Check that the relief valve is at the standard
pressure.
26044 1 02/12/2004
F.10.F / 48
12. Reconnect the power boost pilot hose to the main

relief valve.
26044 1 02/12/2004
F.10.F / 49
Relief valve - Pressure setting (F.10.F.16 - F.45.A.70)

CX225SR
Prior operation: Relief valve - Pressure test (F.10.F.16 - F.40.A.30)
1. Using a wrench, hold adjusting screw (2) on the

secondary relief valve concerned in position and
loosen lock nut (1).
CRIL04C133A01 1
2. Activate the travel control to be calibrated and hold

it in position.
3. Turn adjusting screw (2) on the secondary relief
valve concerned until the correct pressure is
obtained.
4. Using a wrench, hold adjusting screw (2) in position
5. Check the pressure again, refer to Relief valve -
Pressure test (F.10.F.16 - F.40.A.30).
If the desired value is not obtained, make the
adjustment again.
Next operation: Re-calibrate main relief valve (A), refer to Relief valve - Pressure setting (A.10.A.16 - F.45.A.70)
26044 1 02/12/2004
F.10.F / 50
Hydraulic motor - Leakage test (F.10.F.28 - F.40.A.40)

CX225SR
1. CHECKING FOR TRAVEL DRIFT

Make sure that the track tension is correct.
2. This test must be carried out with the hydraulic oil at
a temperature of 50 °C and on a hard, at stretch of
ground about 30 m long.
3. With the engine at full speed, press and hold the
travel pedals down as far as they will go.
4. Drive forwards for 25 m, making a note of the drift
over the last 20 m of travel.
5. If the drift is greater than 1 m:
Check the pilot pressure values on both travel valve
spools (must be more than 30 bar).
Check the leak values from the travel motors.
6. CHECKING FOR LEAKS FROM THE TRAVEL
MOTORS
TOOLS REQUIRED:
1 locking pin to be manufactured locally with the
following dimensions:
(A) = 35 mm
(B) = 68 mm
(C) = 250 mm
(D) = 70 mm
1 receptacle of 10 L,
1 hose,
1 plug.
CRIL03I164A01 1
7. Press the breather to relieve the pressure in the

8. Remove the travel motor shield.
9. Disconnect and plug the hydraulic motor drain hose.
10. Attach a hose between the drain port and the
receptacle.
11. Mechanically block the travel to be checked by
placing pin (A) carefully between the sprocket and
the chassis.
Forward travel (B) (see gure).
CRIL03I165A01 2
12. With the engine at full speed, operate the travel

control corresponding to the blocked sprocket.
26044 1 02/12/2004
F.10.F / 51
13. Measure the quantity of oil that escapes from the

drain in 1 minute.
CRIL03I168A00 3
14. Check for leaks on the other motor.

Compare the quantities of oil collected; if the
difference between the two motors is greater than 1
L/min, repair or replace the motor which produced
the most oil.
26044 1 02/12/2004
F.10.F / 52
Hydraulic motor - Remove (F.10.F.28 - F.10.A.10)

CX225SR
Prior operation: Remove upper shield panel from travel motor, refer to .Side shield - Remove (E.20.A.70
- F.10.A.10)
1. Mark and disconnect hoses (1), (2), (3) and (4).
CRIL04C145A01 1

Remove base (68), discard seal (60).
CRIL04A207A01 2
26044 1 02/12/2004
F.10.F / 53
Hydraulic motor - Disassemble (F.10.F.28 - F.10.A.25)

CX225SR
NOTE: Numbers in parentheses refer to Hydraulic motor - Exploded view (F.10.F.28 - C.10.A.20)
1. Remove screws (69) and cap (70), discard seal (71).
Remove guide washer (72), spring (73), thrust
washer (74).
Remove spool end (75), seal (76), spring (77) and
check valve (78).
Remove the matching assembly.
CRIL04A183A01 1
2. Remove cylinder spool (79).
CRIL04A184A01 2
3. Remove safety valves (80).

Disassemble valves
Remove plug (86), discard the seal.
Remove spring seat (88), seal (89), spring (90),
valve (91), piston (92), seal (94), back-up rings (93),
(95), valve body (96), valve (97), valve seat (98),
seal (100), back-up rings (99) and (101).
NOTE: Do not remove or alter the adjustment of screw
(85).
CRIL04A185A01 3
26044 1 02/12/2004
F.10.F / 54
4. Remove plug (102), discard seal (103).

Remove valve spool (104).
Remove snap ring (105), spool (106), back-up ring
(107), seals (108), (109) back-up ring (110).
Remove valve spool (111).
Remove plug (112), discard seal (113).
Remove spring guide (114), washer (115) and
spring (116).
CRIL04A186A01 4

Remove base (68).
CRIL04A187A01 5
6. Remove valve plate (117), centring pins (66), (67)

and bearing (55).
CRIL04A188A01a 6
7. Remove seals (59), (60) and springs (65).
CRIL04A189A01 7
26044 1 02/12/2004
F.10.F / 55
8. Remove brake piston (58) from the knuckle by

applying a jet of compressed air through the parking
brake orice.
Discard seals (56) and (57).
Remove friction plates (52) and intermediate plates
(53).
IMPORTANT: Adjust the compressed air to minimum
pressure.
CRIL04A190B01 8
9. Rotate cylinder barrel (42) to disengage the shoes.

Remove the cylinder barrel.
CRIL04A191A01 9
10. Remove piston assembly (43).
CRIL04A192A01 10
26044 1 02/12/2004
F.10.F / 56
11. Remove retaining plate (45).
CRIL04A193A01 11
12. Remove thrust ball (46).

Remove roller bearings (54).
CRIL04A194A01 12
13. Place barrel (42) under a press.

Insert a guide between the press and washer (48).
Activate the press.
Remove snap ring (51).
CRIL04A195A01 13
14. Remove washers (48) and spring (50).
CRIL04A196A01 14
26044 1 02/12/2004
F.10.F / 57
15. Remove swash plate (41).
CRIL04A197A01 15
16. Remove piston (62) and spring (61).

Remove balls (63).
CRIL04A198A01 16
17. Remove splined shaft (40), bearing (47) and seal

(49).
CRIL04A199A01 17
26044 1 02/12/2004
F.10.F / 58
Hydraulic motor - Check (F.10.F.28 - F.40.A.11)

CX225SR
IMPORTANT: Handle parts carefully to avoid damaging them.

IMPORTANT: Replace parts that show the following defects:
1. Shaft worn at the sealing surface with the lip seal.
Shaft splines damaged.
2. Cylinder barrel splines damaged.
Interior surface of the cylinder bore worn.
Bearing surface of the valve plate on the cylinder
barrel scratched or worn unevenly.
3. Piston shoe showing abnormal or uneven wear.
Axial clearance between piston and shoe greater
than 0.14 mm (value when new 0.04 mm).
4. Irregular wear of the internal circumference of the
retaining plate.
5. Traces of thermal seizing on the swash plate.
6. Irregular surface wear or traces of thermal seizing
on the brake friction plates..
7. Pressure points, aking and/or irregular wear on the
bearings.
8. Irregular wear and/or traces of thermal seizing on
the valve plate.
26044 1 02/12/2004
F.10.F / 59
Hydraulic motor - Assemble (F.10.F.28 - F.10.A.20)

CX225SR
NOTE: Numbers in parentheses refer to Hydraulic motor - Exploded view (F.10.F.28 - C.10.A.20)
1. Using a suitable tool, t seal (49).
CRIL04A201A01 1
2. Install balls (63), spring (61) and piston (62).
CRIL04A198A01 2
26044 1 02/12/2004
F.10.F / 60
3. Using a press and a suitable tool, install bearing

(47) on shaft (40).
Install the shaft.
CRIL04A202B01 3
4. Install swash plate (41).
CRIL04A197A01 4
5. Install thrust washers (48) and spring (50).
CRIL04A196A01 5
26044 1 02/12/2004
F.10.F / 61
6. Place barrel (42) under a press.

Insert a guide between the press and washer (48).
Activate the press.
Fit snap ring (51).
CRIL04A195A01 6
7. Fit thrust bearing (46).

Install roller bearings (54).
CRIL04A194A01 7
8. Install retaining plate (45) and pistons (43).
CRIL04A193A01 8
9. Fit piston assembly (43) in cylinder barrel (42).
CRIL04A192A01 9
26044 1 02/12/2004
F.10.F / 62
10. Install barrel (42) in knuckle (31).
CRIL04A191A01 10
11. Install friction plates (52) and intermediate plates

(53).
CRIL04B110A01a 11
12. Fit seals (56) and (57) on piston (58).

NOTE: Using a positioning tool, align the pin holes on
the knuckle and the piston.
CRIL04A204B01 12
26044 1 02/12/2004
F.10.F / 63
13. Fit springs (65) on knuckle (31).
CRIL04A205A01 13
14. Using a suitable tool, install bearing (55) in base

(68).
Install pins (66) and (67).
Install the valve plate (49).
CRIL04A206A01 14
15. Fit seals (59) and (60) on knuckle (31).

Install base (68) on knuckle.
Fit screws (64) and tighten them to a torque of 195
- 215 Nm.
CRIL04A207A01 15
16. Fit spring (116), washer (115) and spring guide

(114).
Fit seal (113) onto plug (112), tighten to the required
torque.
Install spool (111), spool (104), back-up ring (110),
seal (109), seal (108), back-up ring (107), install
spool (106), snap ring (105).
Install seal (103) on plug (102), tighten to the
required torque.
CRIL04A186A01 16
26044 1 02/12/2004
F.10.F / 64
17. Install valve (80) and tighten to the required torque.

Fit back-up ring (101), seal (100), back-up ring (99),
valve seat (98), valve (97), valve body (96), seal
(94), back-up rings (93), (95), valve (91), spring
(90), piston (88) and seal (89).
Fit seal (87) onto plug (86), tighten to the required
torque.
CRIL04A185A01 17
18. Install spool (79).
CRIL04A184A01 18
19. Install valve (78), spring (77), spool end (75), with
seal (76), spring seat (74), spring (73) and thrust
washer (72).
Fit spring seat (135), spring (134), seal (133).
Install seal (71) on cap (70).
Fit screws (69) on cap (70), tighten to the required
torque.
Install throttle valve (83), seal (82) on plug, tighten
to the required torque (81).
CRIL04A183A01 19
26044 1 02/12/2004
F.10.F / 65
Hydraulic motor - Install (F.10.F.28 - F.10.A.15)

CX225SR
1. Fit seal (60).

Install base (68).
Fit screws (64) and tighten them to the required
torque.
CRIL04A207A01 1
2. Connect hoses (1), (2),(3) and (4) following the

CRIL04C145A01 2
26044 1 02/12/2004
F.10.F / 66
Reducer, spur gear - Remove (F.10.F.44 - F.10.A.10)

CX225SR
Prior operation: Drive sprocket - Remove (D.50.B.45 - F.10.A.10)

Prior operation: Remove shield panel from travel motor, refer to.Side shield - Remove (E.20.A.70 - F.10.A.10)
1. Place a container under the reduction gear.

Drain the reduction gear.
Re-insert the drain plug on the reduction gear.
2. Place identication tags.
Place a container under the hydraulic motor.
Disconnect the supply hoses from the hydraulic
motor.
Plug the hoses and the ports.
CRIL04C145A01a 1
3. Using a suitable lifting device, attach and support

the moto-reduction gear.
Remove xing screws (1) and washers (2) from the
reduction gear.
Remove the reduction gear from the machine.
CRIL03F154A01a 2
26044 1 02/12/2004
F.10.F / 67
Reducer, spur gear - Disassemble (F.10.F.44 - F.10.A.25)

CX225SR
NOTE: Numbers in parentheses refer to Reducer, spur gear - Exploded view (F.10.F.44 - C.10.A.20)
1. Attach a lifting device to the rings.
Remove plugs (6) from the cover and discard the
seals.
CRIL04A152A01 1

Remove cover (2).
CRIL04A153A01a 2
3. Remove shim (9).
CRIL04A154A01a 3
26044 1 02/12/2004
F.10.F / 68
4. Remove pinion shaft (3).
CRIL04A155A01a 4
5. Remove rst stage planetary carrier (16).
CRIL04A156A01a 5
6. Disassemble rst stage planetary carrier.

Remove screws (4).
Remove retaining plate (10).
Remove stop (30).
Remove the second planetary pinion (15).
Remove roller bearing (29), bushing (28) and thrust
washer (32) from bracket (16).
CRIL04A157A01a 6
7. Remove snap ring (23), second stage sun gear (8).
CRIL04A158A01a 7
26044 1 02/12/2004
F.10.F / 69
8. Remove screw (11).

Remove stop (17).
Remove pinion (27).
Remove roller bearing (14), bushing (13) and
washer (26).
CRIL04A159A01 8
9. Remove screws (12) and washers (21) from pinion

bracket (25).
Remove pins (20) and shim (24).
NOTE: To remove the pinion bracket, turn the reduction
gear over, insert a pin and push symmetrically.
CRIL04A160B01 9
10. Attach a lifting device to the reduction gear, insert a

pin and push symmetrically.
Remove housing (1) from hydraulic motor (31).
CRIL04A161A01 10
26044 1 02/12/2004
F.10.F / 70
11. Remove seal (19) and bearings (18).
CRIL04A162A01 11
26044 1 02/12/2004
F.10.F / 71
Reducer, spur gear - Visual inspection (F.10.F.44 - F.40.A.10)

CX225SR
IMPORTANT: Handle the parts carefully to avoid damaging them.

IMPORTANT: Replace removed seals systematically.
IMPORTANT: Replace parts that show the following defects:
1. Signicant visible damage or abnormal wear
(chang or scratches).
2. Irregular wear on gear teeth.
3. Outside edge of the snap ring worn abnormally.
4. Pressure points, aked surface and irregular wear
of bearings.
IMPORTANT: When certain parts are replaced, the
preload or axial clearance must be readjusted. Refer to
Reducer, spur gear - Measure (F.10.F.44 - F.40.A.16)
and Reducer, spur gear Bearing - Preload (F.10.F.44.10
- F.45.A.30) .Reducer, spur gear Bearing - Preload
(F.10.F.44.10 - F.45.A.30)
IMPORTANT: Replacing certain parts necessitates
making adjustments to the bearing preload, refer to
Reducer, spur gear Bearing - Preload (F.10.F.44.10
- F.45.A.30).
26044 1 02/12/2004
F.10.F / 72
Reducer, spur gear Bearing - Preload (F.10.F.44.10 - F.45.A.30)

CX225SR
1. Fit shim (24) on inner bearing (18).

Using a press and a suitable centring piece, apply a
load (F) of 3000 kg.
Using a depth gauge, measure the height (H)
between the surface of bearing (3) and the edge
of housing (1).
CRIL04A178A01 1
2. Using a depth gauge, measure the distance (h) from

the second stage planetary pinion bracket (25).
CRIL04A179A01 2
3. (H) - (h) determine the thickness required for the

shimming operation.
NOTE: Use new shims only for shimming.
26044 1 02/12/2004
F.10.F / 73
Reducer, spur gear - Assemble (F.10.F.44 - F.10.A.20)

CX225SR
1. Place housing (1) under a press, using a suitable

centring piece, mount bearing (18).
Turn the housing over and mount the second
bearing.
CRIL04A172A01 1
2. Using the guide, t seal (19).
CRIL04A173A01 2
3. Install hydraulic motor (31) in housing (1).
CRIL04B142A01 3
4. Turn the housing over, t shim (24) set during the

bearing preload adjustment.
For the bearing preload adjustment, refer
to Reducer, spur gear Bearing - Preload
(F.10.F.44.10 - F.45.A.30) .
26044 1 02/12/2004
F.10.F / 74
5. Install studs (20), satellite carrier plate (25) (stage

2).
Install washers (21) on screws (12), coat with thread
locking uid and tighten to a torque of 512 - 566 Nm.
CRIL04B143A01 4
6. Install washer (26), bushing (13), roller bearing (14)

and washer (17).
Coat screw (11) thinly with thread locking uid and
tighten to a torque of 512 - 566 Nm.
CRIL04A159A01 5
7. Install solar pinion (8) and snap ring (23).
CRIL04A158A01 6
26044 1 02/12/2004
F.10.F / 75
8. Install rst stage planetary carrier (16).
CRIL04A174A01 7
9. Install washer (32), bushing (28), roller bearing (29)

and planetary pinion (15).
CRIL04A175A01 8
10. Install washer (30) and swash plate (10).

Coat screw (4) thinly with thead locking uid and
tighten to a torque of 53.9 - 63.7 Nm.
Install pinion shaft (3).
CRIL04A176A01 9
11. Apply pressure to rst stage satellite carrier plate

(10).
Using a thickness gauge, determine the height of
the gap between the edge of housing (1) and the
surface of swash plate (10).
CRIL04A177A01 10
26044 1 02/12/2004
F.10.F / 76
12. The shim to be used will be chosen based on this

dimension, refer to table below.
THICKNESS AND CLASSIFICATION SYMBOLS
OF SHIMS:
(A) 1.20-0.67
(B) 0.66-0.04
(C) 0.03-0.16
(D) 0.17-0.41
(E) 0.42-0.80
13. Install the chosen shim.
Coat the housing surface with sealing compound.
Install cover (2).
Install screws (5) and tighten them to a torque of
69.77 - 77.03 Nm.
CRIL04A153A01a 11
14. Install plugs (6) and tighten to a torque of 149 - 165

Nm.
26044 1 02/12/2004
F.10.F / 77
Reducer, spur gear - Install (F.10.F.44 - F.10.A.15)

CX225SR
1. Using a suitable lifting device, place the

moto-reduction gear in position.
CRIL03F159A01a 1
2. Fit washers (2) on screws (1), coat them with thread

locking uid and tighten them in the order indicated
to a torque of 267 - 312 Nm.
CRIL03F158A00a 2
3. Connect the hoses to the hydraulic motor, following

the markings made during removal.
CRIL04C145A01a 3
4. Fill the moto-reduction gear housings with oil.
Next operation: Drive sprocket - Install (D.50.B.45 - F.10.A.15).

Next operation: PRIMARY HYDRAULIC POWER SYSTEM - Bleed (A.10.A - F.35.A.25).
Next operation: Install the upper shield panel on the travel motor, refer to Side shield - Install (E.20.A.70 -
F.10.A.15).
26044 1 02/12/2004
F.10.F / 78
TRAVELLING Travel - Troubleshooting (F.10.F - G.40.A.10)

CX225SR

Travel drift Difference in speed between the two Check the travel motors for leaks. Refer
tracks. to Hydraulic motor - Leakage test
(F.10.F.28 - F.40.A.40)
Leaks in travel motor higher than Replace or repair the travel motor
authorised
Signicant travel pressure without load at Drain the travel reduction gear and check
(M1) or (M2). for contamination (metal particles).
Replace or repair the travel reduction gear
Pressure difference between P1 and P2 Check for negative pressures on pumps.
more than 30 bar (3 MPa). Refer to Hydraulic pump - Pressure test
(A.10.A.20 - F.40.A.30)
Negative pressure out of tolerance limits Check negative pressure valve (N1) or
(N2)
Pilot pressure below 30 bar (3 MPa) on To check control pedal operation, refer
travel pilot spool. to Command valve Foot command
valve - Troubleshooting (F.10.F.12.10 -
G.40.A.10).
Defective travel pilot spool. Check travel spool operation (spool spring,
scratched spool, etc.)
Defective regulator or pump. Check the defective regulator or pump
body
Leak between motor and travel reduction Replace the central seal.
gear
Unable to select 2nd travel Inadequate pilot pressure at the solenoid Test the electrical circuit of the solenoid
gear valve outlet valve, refer to Command valve Speed
selection valve - Electrical test
(F.10.F.12.15 - F.40.A.50)
Inadequate pilot pressure on the travel Internal leakage in the hydraulic swivel,
motors’ displacement change valve spool. repair or replace the hydraulic swivel
Travel motor’s displacement change valve Repair or replace the travel motor
spool defective
Command valve Foot command valve - Troubleshooting

(F.10.F.12.10 - G.40.A.10)
CX225SR
NOTE: The table below shows a list of common problems. This list is not exhaustive.
External oil leaks O-ring bearing surfaces scratched Repair or replace the parts
Defective seals Replace the seals
The secondary pressure Worn or broken spool return spring Replace the spring
does not increase
gradually or is out of
tolerance.
Dirt on the spool. Disassemble, clean and repair. Replace
the assembly if necessary
The lever does not move Dirt in the piston Disassemble, clean and repair. Replace
freely or does not return the assembly if necessary
to the neutral position
Dirt in the pushrod Disassemble, clean and repair. Replace
Dirt on the pivot pin and cam Disassemble, clean and repair. Replace
Worn or broken piston return spring Replace the spring
Damping force too weak Broken damper pin Replace the pin.
26044 1 02/12/2004
F.10.F / 79

Dirt in the piston Disassemble, clean and repair. Replace
Damping force too strong Piston restrictor port blocked Disassemble, clean and repair. Replace
26044 1 02/12/2004
F.10.F / 80
Index

Command valve Foot command valve - Assemble (F.10.F.12.10 - F.10.A.20) 36
CX225SR
Command valve Foot command valve - Disassemble (F.10.F.12.10 - F.10.A.25) 29
CX225SR
Command valve Foot command valve - General specication (F.10.F.12.10 - D.40.A.10) 5
CX225SR
Command valve Foot command valve - Install (F.10.F.12.10 - F.10.A.15) 42
CX225SR
Command valve Foot command valve - Remove (F.10.F.12.10 - F.10.A.10) 28
CX225SR
Command valve Foot command valve - Sectional view (F.10.F.12.10 - C.10.A.30) 14
CX225SR
Command valve Foot command valve - Special tools (F.10.F.12.10 - D.20.A.40) 5
CX225SR
Command valve Foot command valve - Troubleshooting (F.10.F.12.10 - G.40.A.10) 79
CX225SR
Command valve Foot command valve - Visual inspection (F.10.F.12.10 - F.40.A.10) 35
CX225SR
Command valve Speed selection valve - Electrical test (F.10.F.12.15 - F.40.A.50) 43
CX225SR
Control valve - Assemble (F.10.F.14 - F.10.A.20) 46
CX225SR
Control valve - Disassemble (F.10.F.14 - F.10.A.25) 44
CX225SR
Control valve - Sectional view (F.10.F.14 - C.10.A.30) 16
CX225SR
Hydraulic motor - Assemble (F.10.F.28 - F.10.A.20) 60
CX225SR
Hydraulic motor - Check (F.10.F.28 - F.40.A.11) 59
CX225SR
Hydraulic motor - Disassemble (F.10.F.28 - F.10.A.25) 54
CX225SR
Hydraulic motor - Exploded view (F.10.F.28 - C.10.A.20) 18
CX225SR
Hydraulic motor - Install (F.10.F.28 - F.10.A.15) 66
CX225SR
Hydraulic motor - Leakage test (F.10.F.28 - F.40.A.40) 51
CX225SR
Hydraulic motor - Remove (F.10.F.28 - F.10.A.10) 53
CX225SR
Hydraulic motor - Sectional view (F.10.F.28 - C.10.A.30) 20
CX225SR
Hydraulic motor - Torque (F.10.F.28 - D.20.A.10) 6
CX225SR
Reducer, spur gear - Assemble (F.10.F.44 - F.10.A.20) 74
CX225SR
Reducer, spur gear - Disassemble (F.10.F.44 - F.10.A.25) 68
CX225SR
Reducer, spur gear - Exploded view (F.10.F.44 - C.10.A.20) 23
CX225SR
26044 1 02/12/2004
F.10.F / 81
Reducer, spur gear - Install (F.10.F.44 - F.10.A.15) 78
CX225SR
Reducer, spur gear - Remove (F.10.F.44 - F.10.A.10) 67
CX225SR
Reducer, spur gear - Sectional view (F.10.F.44 - C.10.A.30) 25
CX225SR
Reducer, spur gear - Visual inspection (F.10.F.44 - F.40.A.10) 72
CX225SR
Reducer, spur gear Bearing - Preload (F.10.F.44.10 - F.45.A.30) 73
CX225SR
Relief valve - Pressure setting (F.10.F.16 - F.45.A.70) 50
CX225SR
Relief valve - Pressure test (F.10.F.16 - F.40.A.30) 48
CX225SR
Sensing system Alarm - Electronic schema (F.10.F.95.90 - C.20.A.50) 27
CX225SR
TRAVELLING Travel - Electronic schema (F.10.F - C.20.A.50) 7
CX225SR
CX225SR
CX225SR
CX225SR
TRAVELLING Travel - Troubleshooting (F.10.F - G.40.A.10) 79
CX225SR
26044 1 02/12/2004
F.10.F / 82
STABILISING Ballasting - 20.B
CX225SR
26045 1 02/12/2004
F.20.B / 1
Contents
SERVICE
Rear ballasting
Rear ballasting - Remove (F.20.B.61 - F.10.A.10) 3
CX225SR
Rear ballasting - Install (F.20.B.61 - F.10.A.15) 5

CX225SR
26045 1 02/12/2004
F.20.B / 2
FRAME POSITIONING - STABILISING Ballasting
Rear ballasting - Remove (F.20.B.61 - F.10.A.10)

CX225SR
Prior operation: Engine hood - Remove (E.20.A.72 - F.10.A.10)

Prior operation: Remove rear shield panels (1) and (2), refer to Upper shield - Remove (E.20.A.71 - F.10.A.10)
Prior operation: Remove the rear RH door, refer to Side shield - Remove (E.20.A.70 - F.10.A.10)
1. Remove the back rear-view mirror.

Remove screws (1) from rear counterweight (2).
With the upperstructure at a right-angle to the
undercarriage and attachments on the ground,
attach the sling of a suitable lifting device to the
lifting rings on the rear counterweight.
Gently lift and remove the counterweight towards
the rear of the machine, taking care not to damage
the neighbouring elements.
Place the rear counterweight on a safe platform.
CRIL04B191A01 1
2. Remove screws (1) from rear counterweight (3).

Gently lift and remove the counterweight towards
the rear of the machine, taking care not to damage
the neighbouring elements.
CRIL04B191A02 2

Screw lifting rings (1) into the holes provided on the
rear counterweight.
CRIL04B191A03 3
26045 1 02/12/2004
F.20.B / 3
4. Attach the slings on a suitable lifting device to the

Take up the slack in the slings.
Remove xing screws (1) located on rear
counterweight (4).
Gently lift and remove the upper counterweight

towards the rear of the machine, taking care not to
damage the neighbouring elements.
CRIL04B191A04 4
5. Remove xing screws (1) and (2) located under rear

counterweight (5).
Gently lift and remove the upper counterweight

towards the rear of the machine, taking care not to
damage the neighbouring elements.
CRIL04B192A01 5
26045 1 02/12/2004
F.20.B / 4
Rear ballasting - Install (F.20.B.61 - F.10.A.15)

CX225SR

Tighten the slings and lift.
2. Mount the counterweight on the rear of the machine,
taking care not to damage the neighbouring
elements.
Engage screws (1) and (2) and tighten them to a
Remove the slings and lifting rings
CRIL04B192A01 1

4. Mount the counterweight (4) on the rear of the
machine taking care not to damage the neighbouring
elements.
Engage and tighten screws (1).
CRIL04B191A04 2

elements.
CRIL04B191A02 3
26045 1 02/12/2004
F.20.B / 5

elements.
CRIL04B191A01 4
8. Install the doors and shield panels.

Install the back rear-view mirror.
26045 1 02/12/2004
F.20.B / 6
Index

Rear ballasting - Install (F.20.B.61 - F.10.A.15) 5
CX225SR
Rear ballasting - Remove (F.20.B.61 - F.10.A.10) 3
CX225SR
26045 1 02/12/2004
F.20.B / 7
26045 1 02/12/2004
F.20.B / 8
SWINGING Circular swing - 40.C
CX225SR
26046 1 02/12/2004
F.40.C / 1
Contents
TECHNICAL DATA
Command valve
Command valve Hand command valve - Torque (F.40.C.12.10 - D.20.A.10) 5
CX225SR
Hydraulic motor
Hydraulic motor - Service limits (F.40.C.28 - D.20.A.20) 5
CX225SR
Hydraulic motor - Special tools (F.40.C.28 - D.20.A.40) 5

CX225SR
Swivel
Swivel - General specication (F.40.C.69 - D.40.A.10) 7
CX225SR
FUNCTIONAL DATA
SWINGING Circular swing - Hydraulic schema (F.40.C - C.20.A.20) 8
CX225SR

CX225SR
Command valve
Command valve Hand command valve - Sectional view (F.40.C.12.10 - C.10.A.30) 12
CX225SR
Control valve
Control valve - Sectional view (F.40.C.14 - C.10.A.30) 13
CX225SR
Hydraulic motor
Hydraulic motor - Sectional view (F.40.C.28 - C.10.A.30) 14
CX225SR
Reducer, spur gear

Reducer, spur gear - Sectional view (F.40.C.44 - C.10.A.30) 16
CX225SR
Hydraulic brake
Hydraulic brake - Electronic schema (F.40.C.59 - C.20.A.50) 17
CX225SR
Swivel
Swivel - Exploded view (F.40.C.69 - C.10.A.20) 19
CX225SR
SERVICE
Command valve
Command valve Hand command valve - Remove (F.40.C.12.10 - F.10.A.10) 20
CX225SR
26046 1 02/12/2004
F.40.C / 2
Command valve Hand command valve - Disassemble (F.40.C.12.10 - F.10.A.25) 21
CX225SR
Command valve Hand command valve - Cleaning (F.40.C.12.10 - F.30.A.10) 26

CX225SR
Command valve Hand command valve - Visual inspection (F.40.C.12.10 - F.40.A.10) 27

CX225SR
Command valve Hand command valve - Assemble (F.40.C.12.10 - F.10.A.20) 28

CX225SR
Command valve Hand command valve - Install (F.40.C.12.10 - F.10.A.15) 33

CX225SR
Control valve
Control valve - Disassemble (F.40.C.14 - F.10.A.25) 34
CX225SR
Control valve - Assemble (F.40.C.14 - F.10.A.20) 35

CX225SR
Relief valve
Relief valve - Pressure test (F.40.C.16 - F.40.A.30) 36
CX225SR
Relief valve - Pressure setting (F.40.C.16 - F.45.A.70) 37

CX225SR
Hydraulic motor
Hydraulic motor - Leakage test (F.40.C.28 - F.40.A.40) 38
CX225SR
Hydraulic motor - Remove (F.40.C.28 - F.10.A.10) 39

CX225SR
Hydraulic motor - Disassemble (F.40.C.28 - F.10.A.25) 40

CX225SR
Hydraulic motor - Visual inspection (F.40.C.28 - F.40.A.10) 46

CX225SR
Hydraulic motor - Assemble (F.40.C.28 - F.10.A.20) 47

CX225SR
Hydraulic motor - Install (F.40.C.28 - F.10.A.15) 55

CX225SR
Hydraulic motor - Bleed (F.40.C.28 - F.35.A.25) 56

CX225SR
Reducer, spur gear

Reducer, spur gear - Remove (F.40.C.44 - F.10.A.10) 57
CX225SR
Reducer, spur gear - Disassemble (F.40.C.44 - F.10.A.25) 59

CX225SR
Reducer, spur gear - Visual inspection (F.40.C.44 - F.40.A.10) 64

CX225SR
Reducer, spur gear - Assemble (F.40.C.44 - F.10.A.20) 65

CX225SR
Reducer, spur gear - Install (F.40.C.44 - F.10.A.15) 70

CX225SR
Bearing and ring gear

Bearing and ring gear - Remove (F.40.C.45 - F.10.A.10) 71
CX225SR
Bearing and ring gear - Check (F.40.C.45 - F.40.A.11) 72

CX225SR
Bearing and ring gear - Install (F.40.C.45 - F.10.A.15) 73

CX225SR
26046 1 02/12/2004
F.40.C / 3
Hydraulic brake
Hydraulic brake - Pressure test (F.40.C.59 - F.40.A.30) 74
CX225SR
Hydraulic brake Electrovalve - Electrical test (F.40.C.59.10 - F.40.A.50) 75

CX225SR
Swivel
Swivel - Remove (F.40.C.69 - F.10.A.10) 76
CX225SR
Swivel - Disassemble (F.40.C.69 - F.10.A.25) 77

CX225SR
Swivel - Cleaning (F.40.C.69 - F.30.A.10) 79

CX225SR
Swivel - Assemble (F.40.C.69 - F.10.A.20) 80

CX225SR
Swivel - Install (F.40.C.69 - F.10.A.15) 82

CX225SR
DIAGNOSTIC
SWINGING Circular swing - Troubleshooting (F.40.C - G.40.A.10) 83
CX225SR
26046 1 02/12/2004
F.40.C / 4
FRAME POSITIONING - SWINGING Circular swing
Command valve Hand command valve - Torque (F.40.C.12.10 -

D.20.A.10)
CX225SR
Port plate xing screws 27.9 - 30.9 Nm

Universal joint on the control lever 44.2 - 50.0 Nm
Lock nut on the universal joint 63.7 - 73.5 Nm
Hydraulic motor - Service limits (F.40.C.28 - D.20.A.20)

CX225SR
Description of parts Wear limit Control Action

instrument
Clearance between the piston and 0.04 mm or less Micrometer Replace the cylinder assembly
the cylinder bore
Valve plate (sliding contact surface 0.8 Ra Gauge Polish the surface with a stone
roughness)
Cylidner barrel (sliding contact 0.4 Ra Gauge Polish the surface with a stone
surface roughness)
Swash plate (roughness) 0.8 Ra Gauge Polish the surface with a stone
Piston assembly (roughness on 0.8 Ra Gauge Polish the surface
contact surface of shoes)
Clearance between pistons and 0.4 mm or less Gauge Replace the parts
shoes
Scratches on the sliding surface of 0.4 mm or more Gauge Replace the parts
the shoes
Inspection of barrel, pistons and bearings

Cylinder bores Replace the cylinder barrel if the bores show signs of
scratches or seizing.
Pistons Replace any pistons showing signs of scratches or
seizing.
Taper roller bearings and needle bearings Replace any interior or exterior bearing rings showing
signs of scratching.
Hydraulic motor - Special tools (F.40.C.28 - D.20.A.40)

CX225SR
NOTE: The tools below should be manufactured locally.
NOTE: Numbers in parentheses refer to Hydraulic motor - Sectional view (F.40.C.28 - C.10.A.30)
CRIL04B169E01 1
Used to install bearing (4) and sleeve (1).
26046 1 02/12/2004
F.40.C / 5
(A) 60 mm
(B) 70 mm
(C) diameter 54.7 mm
(D) diameter 45.2 ±0.1 mm
CRIL04B170E01 2
Used for installing seal (3).

(A) 3 mm
(B) 17.4 mm
(C) 15 mm
(D) 2.3 - 2.4 mm
(E) diameter 100 mm
(F) diameter 100 mm
(G) diameter 50 ±0.1 mm
(H) 30 °
CRIL04B171E01 3
Used for installing brake piston (12).

(A) 30 mm
(B) diameter 150 mm
(C) diameter 190 mm
CRIL04B172E01 4
26046 1 02/12/2004
F.40.C / 6
Used for installing safety valve (39).

(A) 15 mm
(B) 36 mm
(C) 75 mm
(D) 75 mm
(E) 21.5 mm
(F) 32.1 - 32.3 mm
Swivel - General specication (F.40.C.69 - D.40.A.10)

CX225SR
Use of ports
Port A RH forward travel
Port B LH forward travel
Port C RH reverse travel
Port D LH reverse travel
Port E Leak return
Port F Travel motor pilot
26046 1 02/12/2004
F.40.C / 7
SWINGING Circular swing - Hydraulic schema (F.40.C - C.20.A.20)

CX225SR
CRIL04A038H01 1
Swing braking system - Dynamic description
Swing braking system

(15) Control valve (22) Swing motor
(B22) Swing pilot pressure switch (B26) Upper pilot pressure switch
26046 1 02/12/2004
F.40.C / 8
(C2) Swing brake pilot (Pa3/A3) Swing left

(Pb3/B3) Swing right (P1) Instrument panel
(Y3) Swing brake solenoid valve (pink band)
DYNAMIC DESCRIPTION
• Swing motor (22) is supplied by an output.
• On starting the engine, if the swing control is in the neutral position, swing brake solenoid valve (Y3) is
energised and the swing motor is braked.
• When the swing is operated, swing pilot pressure switch (B22) closes. The swing brake solenoid valve (pink
band) (Y3) is deactivated and the swing motor (22) brake is released. The upperstructure can then turn.
• When the attachment is operated within the 5 seconds following the return of the swing control to the
neutral position, lateral forces are generated on the equipment. To avoid these twisting forces, swing motor
(22) brake is released.
• Five seconds after the attachment or swing control has returned to neutral, the swing brake solenoid valve
(Y3) is energised and swing motor (22) is braked.
Starter switch Functions Swing pilot Upper pilot Swing brake Swing motor
pressure switch pressure switch solenoid valve
Open none Open Open De-activated Braked
Closed none Open Open Activated Braked
Attachment Open Closed Activated Braked
Swing Closed Closed De-activated Brake is released
Attachment Closed Closed De-activated Brake is released
+ Swing
Stop Open Open Energised after Braked
Attachment 5 secondes
26046 1 02/12/2004
F.40.C / 9
SWINGING Circular swing - Hydraulic schema (F.40.C - C.20.A.20)

CX225SR
CRIL04A039H01 1
Swing variable priority circuit - Dynamic description
Swing variable priority

(1) Swing priority valve (15) Main control valve
(22) Swing motor (81) Swing shuttle block
26046 1 02/12/2004
F.40.C / 10
(Pa3/A3) Swing left (Pb3/B3) Swing right

(Pa5/A5) Dipper out (Pb5/B5) Dipper in
(Pa9/Pb9) Dipper valve spool 2 (Pc3) Priority to swing
(Pb4) Boom valve spool 2 (Pbu) Swing priority valve piloting
DYNAMIC DESCRIPTION
• The swing pilot pressure is applied to main control valve (15) via orice (Pc3) after passing through swing
shuttle block (81) and controls swing priority valve (1). This provides the maximum possible torque to swing
motor (22) with high swing pressure, even the dipper is used at the same time.
• When digging, the pilot pressure for raising the boom actuates the swing priority valve (1) via orice (Pbu).
The swing ow is therefore in parallel with the dipper via swing priority valve (1). This has the effect of
improving the speed of the dipper.
• The trench is dug more uniformly even if the free passage is closed by the valve spool on boom 2.
• When the upperstructure is rotated and the dipper is retracted or the boom is raised at the same time, the
parallel arrangement is reduced and the swing pressure is maintained.
26046 1 02/12/2004
F.40.C / 11
Command valve Hand command valve - Sectional view (F.40.C.12.10

- C.10.A.30)
CX225SR
CRIL03I001G01 1
Description
(1) Lock nut (2) Boot
(3) Disc (4) Pusher
(5) Plate (6) Guide
(7) Seal (8) Spring seat
(9) Spring (10) Spring
(11) Spool (12) Body
(13) Port plate (14) Screw
(17) Spool (18) Spring
(19) Seal (20) Universal joint
(21) Retaining pin (22) Washer
26046 1 02/12/2004
F.40.C / 12
Control valve - Sectional view (F.40.C.14 - C.10.A.30)

CX225SR
CRIL04A166F01 1
Swing section

(12) Small cap (16) Swing valve spool
(D) Spool screw
26046 1 02/12/2004
F.40.C / 13
Hydraulic motor - Sectional view (F.40.C.28 - C.10.A.30)

CX225SR
CRIL04B139H01b 1
(1) Sleeve (2) Snap ring

(3) Seal (4) Bearing
(5) Retaining washer (6) Piston wear plate
(7) Thrust plate (8) Piston assembly
26046 1 02/12/2004
F.40.C / 14
(9) Friction disc (10) Steel disc

(11) Seal (12) Brake piston
(15) Cover (16) Seal
(17) Plug (18) Piston
(21) Bushing (22) Valve plate
(23) Bearing (24) Cylinder barrel
(25) Housing (26) Spring
(27) Bypass valve assembly (28) Valve
(31) Back-up ring (32) Check valve
(33) Spring seat (34) Valve
(37) Shim (38) Valve body
(39) Spring seat (40) Back-up ring
(41) Seal (42) Plug
(43) Sleeve (44) Liner
(45) Safety valve assembly (46) Screw
(47) Back-up ring (48) Seal
(49) Plug (50) Snap ring
(51) Shim
26046 1 02/12/2004
F.40.C / 15
Reducer, spur gear - Sectional view (F.40.C.44 - C.10.A.30)

CX225SR
CRIL04B148G01 1
(1) Pinion shaft (2) Stop

(3) Retaining ring (4) Thrust washer
(5) Roller bearing (6) Housing
(7) Seal (8) Roller bearing
(9) Centring stud (10) Ring gear
(11) Second stage sun gear (12) First stage sun gear
(13) Planetary pinion (14) First stage satellite carrier
(15) Planetary pinion (16) Roll pin
(17) Second stage satellite carrier (18) Retaining ring
(19) Spacer
26046 1 02/12/2004
F.40.C / 16
Hydraulic brake - Electronic schema (F.40.C.59 - C.20.A.50)

CX225SR
CRIL03G187F01 1
Circuit layout
(1) Swing brake (B22) Swing pilot pressure switch

(B26) Upper pilot pressure switch (yellow band) (K19) Swing brake relay
(Y3) Swing brake solenoid valve (pink band)
26046 1 02/12/2004
F.40.C / 17
CRIL03G188F02 2
Timing diagram
OPERATION OF THE SWING BRAKE CONTROL
1. Swing brake (1) will be activated 5 seconds after upper pilot pressure switch (B26) is in the open position.
2. Swing brake (1) will be activated 3 seconds after the supply cut-off delay.
26046 1 02/12/2004
F.40.C / 18
Swivel - Exploded view (F.40.C.69 - C.10.A.20)

CX225SR
CRIL04B067G01 1
(1) Screw (2) Washer

(3) Locking bar (4) Pivot
(7) Seal (8) Seal
(9) Thrust plate (10) Screw
(11) Seal (12) Cover
(15) Washer
26046 1 02/12/2004
F.40.C / 19
Command valve Hand command valve - Remove (F.40.C.12.10 -

F.10.A.10)
CX225SR
1. Remove the screws (1).

Raise the shield (2) and attach identication labels
to the electrical harnesses.
Disconnect the electrical harnesses.
Remove shields (2) and (3).
CRIL03I107B01 1
2. Attach identication labels to all the control lever

hoses.
Disconnect the hoses.
Plug the ports.
3. Remove the screws (1) and the control lever.
CRIL03I119A01 2
26046 1 02/12/2004
F.40.C / 20
Command valve Hand command valve - Disassemble (F.40.C.12.10

- F.10.A.25)
CX225SR
or dropped.
The components of the control lever may rust due to dirt and moisture if they are left unprotected after dismantling.
If work has to be interrupted, the components must be protected from contamination or corrosion.
1. Install the control lever in a soft-jawed vice.
Remove the boot.
CRPH03I001A 1
2. Remove the lock nut.
CRPH03I002A 2
3. Remove the disc.
CRPH03I003A 3
26046 1 02/12/2004
F.40.C / 21
4. Mount two nuts on the universal joint and tighten

them as far as the stop.
Holding the upper nut in place, turn the lower nut
anti-clockwise to loosen the universal joint.
Remove the universal joint.
NOTE: Remove the universal joint with care, making sure
that the plate and the push rods, which are spring-loaded,
do not spring out too quickly.
CRPH03I004A 4
5. Remove the plate.

NOTE: Make marks on the components removed in the
following steps to make their re-installation in their original
bores easier.
CRPH03I005A 5
6. Depending on the condition of the return springs,

the guides can be retained in place in the body by
the friction of the seals.
In this case, use a at screwdriver to remove the
guides.
Slide a screwdriver into the outer groove on the
guide, making sure not to damage the guide.
Proceed with caution as the guide can be ejected
very suddenly under the pressure of the return
springs.
CRPH03I006A 6
CRPH03I007A 7
26046 1 02/12/2004
F.40.C / 22
8. Turn the control valve the other way up in the vice.

Remove the screws and the washers.
CRPH03I008A 8
9. Remove the port plate.

Discard the seal.
CRPH03I009A 9
10. Remove the ring.
CRPH03I010A 10
26046 1 02/12/2004
F.40.C / 23
11. Push the spring in a few millimetres so as to

disengage the spool (11) from the spring seat (8).
Separate the spool (11) from the spring (10) and
the washer (22).
Keep these components together until required for
reassembly.
CRIL03I002B01 11
12. Remove the spool (17) and the spring (18) from the
guide.
CRIL03I003A01 12
13. Remove the push rod (4) from the guide (6).
CRIL03I004A01 13
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14. Discard the guide seal.
CRPH03I011A 14
15. Discard the guide seal.
CRPH03I012A 15
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Command valve Hand command valve - Cleaning (F.40.C.12.10 -

F.30.A.10)
CX225SR
1. Cleaning the components:

Soak them in a suitable cleaning solvent until dirt
and oil are removed.
The components can be damaged if they are
washed while still dirty.
2. Final washing:
Immerse the components in a clean receptacle
containing a suitable cleaning solvent.
Rotate the receptacle so as to wash the inner
surfaces of the components as well.
Dry the components with a clean cloth.
NOTE: Never use compressed air to dry the components.
The dust and water in the air could cause surface damage
or corrosion.
3. Corrosion prevention:
Apply an anti-rust product to all components.
NOTE: Components can rust if they are left exposed to
the open air after cleaning.
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Command valve Hand command valve - Visual inspection

(F.40.C.12.10 - F.40.A.10)
CX225SR

defective.
Make sure that the spool slides freely in the control
lever body bore.
If defects are found, replace the hand control
assembly.
2. Inspect the controls.
Replace the components if the wear on the shaft
pin and the seal causes play in the controls of more
than 2 mm.
A : 1 mm
B : 7 mm
CRIL03I005A01 1
3. If it is impossible to determine the cause of an

abnormal noise or a fall in primary pressure by
inspecting the parts, replace the the hand control.
26046 1 02/12/2004
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Command valve Hand command valve - Assemble (F.40.C.12.10 -

F.10.A.20)
CX225SR
1. Install the bushing in the body.
CRPH03I010A 1
2. Install the seal in the body groove.
CRPH03I013A 2
3. Install the port plate (13) with the plastic pin (21) in
port (A) of the body.
CRIL03I006A01 3
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F.40.C / 28
4. Mount the screws and washers on the port plate.

Tighten the screws alternately to the required
torque.
CRPH03I014A 4
5. Assemble the spool assembly by installing the

washer (22), the spring (10) and the spring seat (8)
on the spool (11).
CRIL03I007A01 5
6. Turn the control lever the other way up in the vice.

Install the return spring and the spool assembly
in the body following the markings made during
removal.
CRPH03I015A 6
7. Install the seal on the guide.
CRPH03I016A 7
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F.40.C / 29
8. Install the seals (19) with lips as shown opposite.
CRIL03I008B01 8
9. Coat the surfaces of push rod (4) with hydraulic uid

and install in the guide (6).
CRIL03I004A01 9
10. Install the spool (17) and the spring (18) in the guide
(6).
CRIL03I003A01 10
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11. Install the guide in the body.

Depending on the condition of the return springs,
the guides can be retained in place in the body by
the friction of the seals.
CRPH03I017A 11
12. Repeat steps 5 to 11 for the other three bores.

13. Install the plate and hold it in place with the universal
joint.
Tighten the universal joint to the required torque.
CRPH03I018A 12
14. Install the disc on the universal joint.

Tighten until the disc is in equal contact with the
four pushers.
CRPH03I003A 13
15. Install the lock nut and tighten it to the required

torque, retaining the disc ats with an open wrench.
CRPH03I019A 14
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16. Place a few spots of grease on the pushers.
CRPH03I020A 15
17. Install the gusset.
CRPH03I001A 16
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Command valve Hand command valve - Install (F.40.C.12.10 -

F.10.A.15)
CX225SR
1. Position the control lever and install the screws (1).
CRIL03I119A01 1

Connect all hoses to the control lever following the
3. Put the shields (2) and (3) in place.
Connect all electrical harnesses following the
Install the screws (1).
CRIL03I107B01 2
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F.40.C / 33
Control valve - Disassemble (F.40.C.14 - F.10.A.25)

CX225SR
CRIL04A166F01 1
Swing spool
1. Remove screws (74) and caps (8) and (12).

Discard seals (7).
2. Remove spool (16).
3. Remove screws from spool (D).
NOTE: To avoid damaging the spool surface when the
spool assembly is removed, use a soft-jawed vice and
clamp the spool as closely as possible to the head (spring
side) to prevent distortion. If the threaded part of the
screw is coated with thread lock uid, heat the screw
(the temperature should normally be 200 - 250 °C). If
4. Remove screws (75) and ange (37).
Discard seal (36).
26046 1 02/12/2004
F.40.C / 34
Control valve - Assemble (F.40.C.14 - F.10.A.20)

CX225SR
CRIL04A166F01 1
Swing spool
Torque settings
Screw (74) 39 - 44 Nm
Screw (75) 58 - 64 Nm
1. Install valve (34) and spring (35).
Install a new seal (36).
Fit ange (37) with screws (75).
Tighten screws (75) to the required torque.
2. Coat the threaded parts of spool (16) with thread
lock uid.
Place the end of the spool (spring side) in a
soft-jawed vice.
Fit spring (B) and seats (C) on screw (D).
Assemble and tighten the screws to the required
torque.
Install spool (16) in its housing.
Install and tighten screws (74) to the required
torque.
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Relief valve - Pressure test (F.40.C.16 - F.40.A.30)

CX225SR
1. Disconnect and plug swing brake pilot hose (1) from

orice (P) on swing motor.
CRIL03K062A03 1
2. Connect a pressure gauge 0-600 bar (0-60 MPa) to

the pressure test point (M2) on the main pump.
4. Slowly operate the swing lever to the right, then
gradually increase engine speed to full speed to
ensure that the swing is locked.
5. Repeat step 4 for the LH swing to be checked, the
pressures should be in (M2): LH and RH swing 304
± 4 bar (30.4 ± 0.4 MPa)
6. Note the pressures; if the pressures are incorrect,
adjust relief valves (I) and (J) by the number of
shims necessary (a 0.1 mm shim corresponds to 5
bar of pressure), refer to Relief valve - Pressure
setting (F.40.C.16 - F.45.A.70).
7. Connect swing brake pilot hose (1) to port (P) on
the swing motor.
8. Stop the engine and disconnect the pressure gauge.
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Relief valve - Pressure setting (F.40.C.16 - F.45.A.70)

CX225SR
Prior operation: Relief valve - Pressure test (F.40.C.16 - F.40.A.30)
1. Remove secondary relief valve concerned from the

hydraulic swing motor.
RH swing secondary relief valve (I)
LH swing secondary relief valve (J)
If both valves must be removed, mark them to
ensure they are replaced in their original position.
CRIL03K062A04 1
2. Secure the valve body in a vice and remove plug (1)

guide (2), lining (3), spacer (4), shims (5), spring (6),
valve (7) and valve tip (8).
CRIL04C107A01 2
3. Remove (to reduce pressure) or add (to increase

pressure) the number of shims (5) needed to obtain
the correct pressure.
4. Remove parts from (1) to (8) of the valve and tighten
plug (1) to a torque of 157 Nm.
5. Install the valve in the motor following the marks
made during removal, tighten to a torque of 78 Nm.
6. Check the valve pressures again, refer to Relief
valve - Pressure test (F.40.C.16 - F.40.A.30) make
sure there are no leaks, repeat the adjustment
operations if the required value is not obtained.
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Hydraulic motor - Leakage test (F.40.C.28 - F.40.A.40)

CX225SR
1. Disconnect the swing brake pilot hose from the port

on the swing motor and plug it.
3. Slowly operate the swing control lever and gradually
increase the engine speed to full speed to ensure
that swing is locked.
4. Stop the engine.
5. Press the breather to relieve the pressure in the
6. Disconnect hose (1) from the hydraulic motor orice
(drain) and plug it.
CRIL03I156A01 1
7. Use a hose to connect the drain orice to a

receptacle with a capacity of about 10 L.
8. Start the engine and run it at full speed. Operate
the swing control to the right or left and measure the
quantity of oil that escapes from the drain in 1 mn.
9. As the quantity of oil can vary depending on the
test point used, repeat the measurement with the
upperstructure at 90 °, then at 180 °.
26046 1 02/12/2004
F.40.C / 38
Hydraulic motor - Remove (F.40.C.28 - F.10.A.10)

CX225SR

Prior operation: To remove the protective panel, refer to Upper shield - Remove (E.20.A.71 - F.10.A.10)
1. Mark, disconnect and plug all hoses and unions

connected to the hydraulic swing motor.
Mark the hydraulic swing motor in relation to the
reduction gear.
Attach a suitable lifting device to the hydraulic swing
motor.
Remove screws (1).
CRIL04B168A02 1
2. Lift and carefully disengage the hydraulic swing

motor from the reduction gear.
Place the motor on a clean bench.

Discard the seal for the reduction gear housing.
NOTE: In order to avoid any contamination of the swing
reduction gear, cover the reduction gear with suitable
protection.
26046 1 02/12/2004
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Hydraulic motor - Disassemble (F.40.C.28 - F.10.A.25)

CX225SR
1. Remove the unions from the swing motor. Discard

the seals.
NOTE: Fit the plugs in the motor ports.
2. Remove safety valve assemblies (1).
Remove bypass valve assemblies (2).
Remove plugs (3), springs (4) and check valves (5).
Remove and discard all seals from each component.
CRIL04B076B01 1
3. Make identication marks (A) on cover (1) and

housing (2).
CRIL04B077A01 2
26046 1 02/12/2004
F.40.C / 40
4. Remove screws (1) from cover (2) then remove

cover from the motor housing.
CRIL04B078B01 3
5. Position the cover with the shaft pointing upwards.

Remove snap ring (1).
Using an extractor, remove inner bushing (2) of
needle bearing from the shaft.
Remove valve plate (3).
Remove pistons (4) from the valve plate.
CRIL04B079A01 4
6. Discard seal (1) on cover (2).
CRIL04B080A01 5
26046 1 02/12/2004
F.40.C / 41
7. Remove bushings (1), seals (2) and washers (3)

from cover (4).
CRIL04B081A01 6
8. Remove springs (1) from the brake piston.
CRIL04B082A01 7
9. Fit two screws M6 (A) in the tapped holes in piston

brake (1).
Lever these screws and free brake piston (1) from
housing (3).
Discard seal (2).

Remove the two screws M6 (A) from the piston
brake.
Discard seal (1) on housing (3).
NOTE: Protect the housing and the piston surfaces with

rags when you lever the piston out of the housing.
CRIL04B083B01 8
26046 1 02/12/2004
F.40.C / 42
10. Mark and remove friction plates (1) and steel plates
(2) from housing (3).
CRIL04B084B01 9
11. Remove barrel assembly (1) from motor housing (2).
CRIL04B085B01 10
12. Remove outer ring (1) from the tapered roller

bearing. Place housing in a press. With a sleeve or
a suitable centring piece, force seal (2) out of the
housing and discard it.
CRIL04B086A01 11
26046 1 02/12/2004
F.40.C / 43
13. Remove snap ring (1).

Using an extractor, remove tapered roller bearing
(2) and sleeve (3).
CRIL04B087B01 12
14. Remove shim (1) from the splined shaft. Remove

from barrel (2) the piston assembly (4), tted with
piston wear plate (3) and thrust plate (5).
NOTE: Mark the location of the pistons on the thrust plate
and in the cylinder barrel. It is essential that the pistons
be installed in the same bores on assembly.
CRIL04B088B01 13
15. Slide piston wear plate (1) out of the friction surfaces
of piston assembly (2), taking care not to damage it.
Remove the pistons from thrust plate (3).
CRIL04B089A01 14
26046 1 02/12/2004
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16. Remove retaining washer (1) from splined shaft (2).
CRIL04B090A01 15
26046 1 02/12/2004
F.40.C / 45
Hydraulic motor - Visual inspection (F.40.C.28 - F.40.A.10)

CX225SR
1. The valve plate includes crescent-shaped apertures

that ensure modulation between oil at high pressure
and oil at low pressure. Any damage to the contact
surface between the valve plate and the end
face of the cylinder barrel may cause leaks and
lead to reduced volumetric efciency, possibly
accompanied by increased "skating". Possible
seizing at these two contact surfaces may result
in a loss of mechanical efciency and cause more
signicant damage.
2. Repair all damage to the contact surface of the
piston shoes. If the shoe surfaces are seriously
damaged, replace the entire motor.
3. The external surface of the piston assembly should
show practically no wear. The motor should be
replaced if a piston assembly shows the slightest
evidence of seizing.
4. The cylinder barrel bores should show practically no
signs of wear. If the bores show signs of seizing or
abnormal wear, replace the entire motor.
5. Replace the bearings if damage is found on the
roller contact surfaces. We recommend replacing
the bearings as routine when reassembling the
motor, since they can easily be damaged when the
motor is disassembled.
6. Replace seals that show signs of damage. In
addition, replace seals even if there are no leaks
or signs of deterioration. Use new seals when
reassembling the motor.
26046 1 02/12/2004
F.40.C / 46
Hydraulic motor - Assemble (F.40.C.28 - F.10.A.20)

CX225SR
1. Apply clean hydraulic uid to the spherical part of

splined shaft (2).
Fit retaining washer (1).
CRIL04B090A01 1
2. Apply clean hydraulic uid to the friction surface

of pistons (1). Install pistons (1) in the orices on
thrust plate (2).
CRIL04B091A01 2
3. Apply clean hydraulic uid to cylinder barrel bores

(1). Install piston assembly (2) tted with thrust
plate (3) in cylinder barrel (1) following the marks
made during disassembly.
CRIL04B092B01 3
26046 1 02/12/2004
F.40.C / 47
4. Apply clean hydraulic uid to the friction surface of

piston assembly (1) and install piston wear plate (2).
Fit shim (3) on splined shaft (4).
CRIL04B093B01 4
5. Mount tapered roller bearing (1) on shaft (2), refer

to Hydraulic motor - Special tools (F.40.C.28 -
D.20.A.40).
CRIL04B094B01 5
6. Apply a thin coat of Loctite 515 or 518 to the site

where the sleeve (1) is to be mounted on the shaft.
Mount sleeve (1) on the shaft, refer to Hydraulic
motor - Special tools (F.40.C.28 - D.20.A.40) and
t snap ring (2).
CRIL04B095B01 6
26046 1 02/12/2004
F.40.C / 48
7. Place housing in a press. Grease seal lip (1). Using

a suitable sleeve (A) refer to Hydraulic motor -
Special tools (F.40.C.28 - D.20.A.40), t seal (1)
in housing bore (2).
CRIL04B096B01 7
8. Install the outer cage of tapered roller bearing (1)

in housing (2).
CRIL04B097A01 8
9. Mount housing (1) on shims (A) equal to or more

than 40 mm thick.
Carefully install cylinder barrel assembly (2) in
housing (1).
NOTE: The surface of barrel (2) should be below the
surface of housing (1) by approximately 15.5 mm. If this
value cannot be attained, it means that the piston wear
plate is positioned incorrectly in housing (1).
CRIL04B098B01 9
26046 1 02/12/2004
F.40.C / 49
10. Apply clean hydraulic uid to both surfaces of

friction plates (1) and steel plates (2).
Install steel plates (2) and friction plates (1)
alternately following the marks made during
disassembly.
CRIL04B084B01 10
11. Install seal (1) in housing (2).

Install seal (3) on piston brake (4).
CRIL04B101B01 11
26046 1 02/12/2004
F.40.C / 50
12. Apply clean hydraulic uid around the brake piston

(1), refer toHydraulic motor - Special tools
(F.40.C.28 - D.20.A.40) and install brake piston (1)
in housing (2) following the markings made during
disassembly.
CRIL04B102B01 12
13. Fit springs (1) in their original positions on the brake

piston.
CRIL04B082A01 13
14. Install washers (1) in cover (2). Fit Teon seals (4)
on bushings (3) and install them in cover (2).
Install pistons (5) on valve plate (6) following the
marks made during disassembly.
Install the valve plate on the cover (2).
NOTE: Apply a thin coat of grease to hold the parts
together.
CRIL04B103B01 14
26046 1 02/12/2004
F.40.C / 51
15. Using a press, mount inner bushing (1) of the needle

bearing on shaft (2).
Fit snap ring (3).
CRIL04B104A01 15
16. Install seal (1) on cover (2).
CRIL04B080A01 16
17. Apply a sealant to the mating surfaces (A) on the

engine housing and the cover.
CRIL04B105A01 17
26046 1 02/12/2004
F.40.C / 52
18. Install cover (1) on housing (2) following the marks

made during disassembly.
NOTE: The space between cover (1) and housing (2)
before tightening should be approximately 4.5 mm.
CRIL04B106B01 18
19. Install xing screws (1) on cover (2) and tighten to a

torque of 284 Nm.
CRIL04B107B01 19
26046 1 02/12/2004
F.40.C / 53
20. Install safety valve assemblies, refer to, tighten to

a torque of (1). Hydraulic motor - Special tools
(F.40.C.28 - D.20.A.40) 78 Nm
Install bypass valve assemblies (2), tighten to a
torque of 78 Nm.
Install valve (5), spring (4) and plug (3), tighten to a
torque of 137 Nm.
CRIL04B076B01 20
21. Apply a pilot pressure of 30 bar in the brake port.

Check that the drive shaft can turn freely at least
one turn by applying a torque in the range from 30 -
40 Nm.
If the shaft does not turn, the unit has not been
assembled correctly.
Disassemble and repeat assembly steps.
CRIL04B108B00 21
26046 1 02/12/2004
F.40.C / 54
Hydraulic motor - Install (F.40.C.28 - F.10.A.15)

CX225SR
1. Fit a seal on the reduction gear housing.

2. Attach a suitable lifting device to the swing motor.
Position the swing motor above the reduction gear.
Carefully lower the motor onto the swing reduction
gear, following the identication marks made during
removal.
Remove the lifting device.
3. Install xing screws (1) and tighten them to a torque
of 117.7 - 137.7 Nm.
Remove the plugs.
Install the unions and hoses on the motor.

Remove plug (2).
Fill the hydraulic swing motor.
Fit and tighten plug (2).
CRIL04B168A03 1

Next operation: Hydraulic motor - Bleed (F.40.C.28 - F.35.A.25)
Next operation: Install upper shield panel on hydraulic swing motor, refer to Upper shield - Remove (E.20.A.71 -
F.10.A.10).
26046 1 02/12/2004
F.40.C / 55
Hydraulic motor - Bleed (F.40.C.28 - F.35.A.25)

CX225SR
1. Start and run the engine at idling speed.

Loosen bleed plug (1) and check that hydraulic uid
escapes through this port.
If necessary, stop the engine and add uid through
this port.
Re-t the plug without tightening, then start and run
the engine at idling speed, allowing it to run until the
hydraulic uid escapes through the port.
Fully tighten the air bleed plug.
Rotate the upperstructure through at least two
complete revolutions to the left and the right.
Check the reservoir level and top up as necessary.
CRIL04B168A01 1
26046 1 02/12/2004
F.40.C / 56
Reducer, spur gear - Remove (F.40.C.44 - F.10.A.10)

CX225SR

Prior operation: Remove lower shield panel (1), refer to Protective shield - Remove (E.20.A.73 - F.10.A.10)
Prior operation: Remove the side shield panels from the hydraulic swivel, refer to Protective shield - Remove
(E.20.A.73 - F.10.A.10)
Prior operation: Remove upper shield panel(1) from hydraulic swing motor, refer to Upper shield - Remove
(E.20.A.71 - F.10.A.10)
1. Place a container under the drain plug (1).

Remove the drain plug and drain the oil.
Re-insert the drain plug.
CRIL03L046A01 1
2. Place a container under the drain plug (1).

Remove the drain plug and drain the oil.
Re-insert the drain plug.
CRIL04B166A01 2
3. Mark, disconnect and plug all the hoses and unions

connected to the swing moto-reduction gear.
CRIL04B165A00 3
4. Attach a suitable lifting device to the swing

moto-reduction gear.
5. Mark the swing moto-reduction gear with reference
to the chassis.
Remove the swing moto-reduction gear retaining
screws.
26046 1 02/12/2004
F.40.C / 57
6. Carefully lift and remove the swing rmoto-reduction

gear from the machine.
NOTE: Place the swing moto-reduction gear on suitable
stands, so that the pinion does not touch the oor.
7. Make an alignment mark (2) between the swing
motor and the reduction gear.
Remove xing screws (1) from the hydraulic swing
motor.
Carefully lift the swing motor and place it in a clean
area.
CRIL03I051B01 4
8. Discard the seal for the reduction gear housing.
26046 1 02/12/2004
F.40.C / 58
Reducer, spur gear - Disassemble (F.40.C.44 - F.10.A.25)

CX225SR
1. Remove rst stage sun gear (1) and thrust bushing

(2).
CRIL04B114A01 1
2. Remove rst stage satellite carrier assembly (1).
CRIL04B115A01 2
3. Remove second stage sun gear (1).
CRIL04B116A01 3
4. Remove second stage satellite carrier assembly (1).
CRIL04B117A01 4
26046 1 02/12/2004
F.40.C / 59
5. Place the satellite carrier assembly on a suitable

workbench.
6. Force the roll pins out the shafts and discard them.
CRIL04B118A00 5
7. Support the planetary gears and remove shafts (2)

from satellite carrier assembly (1).
CRIL04B119A01 6
8. Remove planetary pinions (1).
CRIL04B120A01 7
9. Remove thrust washers.
CRIL04B121A00 8
26046 1 02/12/2004
F.40.C / 60
10. Mark and remove ring gear (1) from housing (2).
CRIL04B122A01 9
11. Remove the four centring studs (1) from ring gear
(2).
CRIL04B123A01 10
12. Remove retaining ring (1) from its groove using

notch (B) in the housing for leverage.
Remove retaining ring (1).
CRIL04B124A01 11
13. Use a puller with jaws placed under the sealing

surface of the ring gear with the housing to remove
the pinion shaft assembly.
NOTE: If the pinion shaft assembly shows signs of wear,
it is advisable to change the entire assembly.
CRIL04B125A00 12
26046 1 02/12/2004
F.40.C / 61
14. Remove roller bearings (1) from the housing.
CRIL04B126A01 13
15. Remove and discard seal (1).
CRIL04B127A01 14
16. Remove retaining ring (1) and spacer (2).
CRIL04B128A01 15
17. Using a press and a special tool, extract bearing (1).
CRIL04B129A01 16
26046 1 02/12/2004
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18. Remove thrust washer (2) and spacer (1).
CRIL04B130A01 17
26046 1 02/12/2004
F.40.C / 63
Reducer, spur gear - Visual inspection (F.40.C.44 - F.40.A.10)

CX225SR
IMPORTANT: Handle parts with care to avoid damaging them.

IMPORTANT: Replace the removed seals.
IMPORTANT: Replace parts which have the following defects:
1. Heavy visible damage or abnormal wear (chang
and scratches).
2. Irregular wear on the gear teeth.
3. Pressure points, surface aking and irregular wear
on the bearings.
26046 1 02/12/2004
F.40.C / 64
Reducer, spur gear - Assemble (F.40.C.44 - F.10.A.20)

CX225SR
1. Install spacer (1) and thrust washer (2).
CRIL04B130A01 1
2. Fix the pinion shaft in a press. Heat bearing (1) to a

temperature of 80 °C in an oil bath and push it into
the pinion shaft using a press.
Install space (2) and retaining ring (3).
NOTE: Do not heat the bearing to a temperature higher
than 100 °C.
CRIL04B131A01 2
3. Fill the roller bearings with 600 cm³ of grease.

NOTE: The total capacity of grease to be used is 1000
cm³, the rest will be added during reassembly.
CRIL03L026A00 3
4. Clamp the reduction gear housing in a press.

Fit seal (1) to the reduction gear housing.
CRIL04B133A01 4
26046 1 02/12/2004
F.40.C / 65
5. Install a ring screw in pinion shaft (1), then lift it

vertically and t it into reduction gear housing (2)
using a press.
CRIL03L027A01 5
6. Install retaining ring (1).

NOTE: For ease of installation, maintain a gap of about
30 mm from the notch in the reduction gear housing.
CRIL04B124A02 6
7. Using a special tool and a press, install bearing (1).
CRIL03L030A01 7
8. Install centring studs (1).

Coat the mating housing surfaces with sealing
compound.
CRIL04B137A01 8
26046 1 02/12/2004
F.40.C / 66
9. Install ring gear (1) following the marks made during

disassembly.
Fit screws (2) opposite each other to hold ring gear
(1) in place.
CRIL04B138A01 9
10. Place the rst stage satellite carrier on a clean

bench.
11. Fit thrust washers (see arrow).
Install the planetary pinions.
CRIL04B121A01 10
12. Align the orices of pinions (1) with the orices on

satellite carrier (2), and install the shafts (3).
CRIL04B120A02 11
13. Install a roll pin (A).

B = 1 mm, recess dimension.
Brake using two awl strokes (arrows).
CRIL04B140A01 12
26046 1 02/12/2004
F.40.C / 67
14. Install second stage satellite carrier (1) so that it

engages correctly with the internal teeth of the ring
gear. Turn the satellite carrier slightly to engage the
uting of the pinion shaft.
CRIL04B117A01 13
15. Install second stage sun gear (1) so that it engages

with the planetary gear assembly.
CRIL04B116A01 14
16. Install the rst stage planetary gear assembly (1)

so that it engages correctly with the internal teeth
of the ring gear. Turn the planetary gear assembly
slightly to emgage the teeth of the planetary gears
with those of the second stage sun gear.
CRIL04B115A01 15
17. Install rst stage sun gear (1) and thrust bushing
(2). Engage the teeth of the sun gear with those of
the planetaries. Turn the rst stage satellite carrier
by hand to check that the take-off shaft rotates
smoothly.
CRIL04B114A01 16
26046 1 02/12/2004
F.40.C / 68
18. Measure dimension A

A = 4.2 - 2 mm or less.
Adjust or change shim (1) if necessary.
CRIL04B141A01 17
26046 1 02/12/2004
F.40.C / 69
Reducer, spur gear - Install (F.40.C.44 - F.10.A.15)

CX225SR
1. Fit the seal to the reduction gear housing.

2. Mount the hydraulic swing motor to the reduction
gear, following the markings (2) made during
removal.
Install screws (1) and tighten them to torque 117.7 -
137.7 Nm.
CRIL03I051B01 1
3. Using a suitable lifting device, attach and raise

the moto-reduction gear, place it on the machine,
following the markings made during removal.
4. Apply thread lock uid to the screws and tighten to
a torque of 521 - 608 Nm.
5. Fill the hydraulic motor with 4.8 L of hydraulic oil.
6. Remove the plugs and connect the hoses and
unions, following the markings made during
removal.
Next operation: Battery - Connect (A.30.A.83 - F.10.A.16).

Next operation: PRIMARY HYDRAULIC POWER SYSTEM - Bleed (A.10.A - F.35.A.25).
Next operation: Install the shield panel on the hydraulic swing motor, refer to Upper shield - Remove (E.20.A.71 -
F.10.A.10).
Next operation: Install the lower shield panel for the hydraulic swivel, refer to Protective shield - Remove
(E.20.A.73 - F.10.A.10). Install the lower shield panel (1), refer to Protective shield - Remove (E.20.A.73 -
F.10.A.10).
26046 1 02/12/2004
F.40.C / 70
Bearing and ring gear - Remove (F.40.C.45 - F.10.A.10)

CX225SR

Prior operation: Protective shield Guard - Remove (E.20.A.73.71 - F.10.A.10)
Prior operation: Swivel - Remove (F.40.C.69 - F.10.A.10)
Prior operation: Remove the attachment, refer to Arm - Remove (H.20.B.50 - F.10.A.10)
Prior operation: Remove the counterweight, refer to Rear ballasting - Remove (F.20.B.61 - F.10.A.10)
1. Drain the fuel tank.

2. Drain the hydraulic circuit.
3. Install lifting rings at the rear of the upperstructure.
Attach a suitable lifting device to these lifting rings
and to the lifting rings located at the front of the
upperstructure, above the boom brackets.
4. Mark the position of the ring gear in relation to the
upperstructure frame and undercarriage, to make
reassembly easier.
5. Remove thering gear mountings on the
upperstructure.
6. Carefully raise the upperstructure and place it on
suitable stands.
7. Install lifting rings on the turntable. Attach a suitable
lifting device to the lifting rings.
8. Remove the ring gear mountings from the carrier
chassis. Remove the lifting device from the lifting
rings and dismantle the lifting rings from the
turntable.
9. Carefully raise the turntable. Place the turntable on
suitable stands in order to protect its surfaces from
any damage.
10. Remove the lifting device and dismantle the lifting
rings.
26046 1 02/12/2004
F.40.C / 71
Bearing and ring gear - Check (F.40.C.45 - F.40.A.11)

CX225SR
If the upperstructure squeals, does not revolve properly or pauses before revolving, this indicates that the turntable
is worn or damaged. When an operator is working with the machine, he must pay attention to any unusual noises
that may indicate turntable wear. If the operator hears unusual noises and if the upperstructure pauses before
revolving, he must carry out the following inspection.
1. Park the machine on hard, level ground. Lower the

attachment to the ground.
2. Let the engine idle for 30 secondes then stop the
engine.
3. Remove the lower protective hood for the hydraulic
swivel and the lubrication access panel for the
turntable bearing.
4. Ask another person to operate the swing.
Use a torch to check for scratches, missing teeth,
aking, cracking or other damage to the ring gear.
If damage is found, replace the upperstructure ring
gear.
ATTENTION: You may be seriously injured if your hand is
in the access port to the ring gear when the upperstructure
is revolving. Before lubricating the ring gear by hand,
always check that the bucket or the tool is on the ground
and that the engine is stopped.
26046 1 02/12/2004
F.40.C / 72
Bearing and ring gear - Install (F.40.C.45 - F.10.A.15)

CX225SR
1. Clean the contact surfaces of the upperstructure,

the undercarriage and the turntable bearing.
2. Reassemble the ring gear and upperstructure in the
reverse order of removal, refer to Bearing and ring
gear - Remove (F.40.C.45 - F.10.A.10).
NOTE: The xing screws for the ring gear on the
undercarriage and upperstructure must be tightened to
a torque of 468 - 545 Nm.
26046 1 02/12/2004
F.40.C / 73
Hydraulic brake - Pressure test (F.40.C.59 - F.40.A.30)

CX225SR
1. Disconnect swing brake pilot hose (1) from the port

(P) on the swing motor.
CRIL03K062A03 1
2. To swing brake exible hose (1), attach a pressure

test point and a manometer 0 - 100 bar
4. Slowly operate the swing control lever to the right or
the left and gradually increase the engine speed to
full speed so that the swing is locked.
At that moment the reading on the pressure gauge
should be about 39 bar.
5. Place the swing control lever in neutral. At that
moment the reading on the pressure gauge should
be 0 - 3 bar.
6. Reconnect swing brake pilot hose (1) to port (P) on
the swing motor.
26046 1 02/12/2004
F.40.C / 74
Hydraulic brake Electrovalve - Electrical test (F.40.C.59.10 -

F.40.A.50)
CX225SR
SYSTEM - Special tools (A.30.A - D.20.A.40)
1. Disconnect connector (1) from swing brake solenoid

valve (Y3).
CRIL04D002A02a 1
2. Connect the appropriate test electrical connector

(3) to connector (1) on solenoid (Y3), then attach
multimeter (2).
CRIL03I078A02 2
3. The solenoid resistance reading of solenoid valve

(Y3) on multimeter (2) should be 45 ohms for a
temperature.
26046 1 02/12/2004
F.40.C / 75
Swivel - Remove (F.40.C.69 - F.10.A.10)

CX225SR
Prior operation: Remove the shield panel, refer to Upper shield - Remove (E.20.A.71 - F.10.A.10)
Prior operation: Remove hydraulic swivel lower shield panel, refer to Protective shield - Remove (E.20.A.73
- F.10.A.10)
1. Attach identication labels to all the hydraulic swivel

hoses.
2. Disconnect all the hoses on the hydraulic swivel
pivot.
Plug the ports.
CRIL04B071A00 1
3. Disconnect all the hoses on the hydraulic swivel

bushing.
Plug the ports.
CRIL04B070A00 2
4. Remove hardware (1), locking bar (2) and

hardware(3) from the hydraulic swivel bushing.
Raise the hydraulic swivel sufciently to disengage
it from its mounting.
Rotate it 90°.
Place the hydraulic swivel on the ground.
CRIL04B071A01 3
26046 1 02/12/2004
F.40.C / 76
Swivel - Disassemble (F.40.C.69 - F.10.A.25)

CX225SR
1. Remove screws (1) and cover (2) from bushing (3).
CRIL04B068A01 1
CRIL03K077A01 2
3. Remove screws (1) and base plate (2).
CRIL04B069A01 3
4. Using a press, remove pivot (1) from bushing (2).
CRIL03F004A03 4
26046 1 02/12/2004
F.40.C / 77
5. Discard seal (2) on pivot (1).
CRIL03F005A01 5
6. Discard seals (1) and (2) from bushing (3).
CRIL03K079A01 6
26046 1 02/12/2004
F.40.C / 78
Swivel - Cleaning (F.40.C.69 - F.30.A.10)

CX225SR
1. Clean all the components. Polish any scratched or

rough areas with an oil stone.
2. Clean the bushing with a cleaning solvent or
compressed air at low pressure.
26046 1 02/12/2004
F.40.C / 79
Swivel - Assemble (F.40.C.69 - F.10.A.20)

CX225SR
1. Fit seal (1) in the upper groove of bushing (3).

Install rings (2) starting from the second groove
counting from the top of bushing (3).
CRIL03K079A01 1
2. Check that the seal and rings are correctly tted,

using a mirror. Apply hydraulic uid and ensure that
the components are not protruding, twisted, etc.
CRIL03F008A01a 2
3. Fit seal (2) on pivot (1).
CRIL03F005A01 3
4. Insert pivot (1) in bushing (2).
CRIL03K080A01 4
26046 1 02/12/2004
F.40.C / 80
5. Install swash plate (2).

Fit screws (1) and tighten them to a torque of 31.4
- 37.3 Nm
CRIL04B069A01 5
6. Install seal (1).
CRIL03K077A01 6
7. Mount cover (2) on bushing (3).

Fit screws (1) and tighten them to a torque of 31.4
- 37.3 Nm
CRIL04B068A01 7
26046 1 02/12/2004
F.40.C / 81
Swivel - Install (F.40.C.69 - F.10.A.15)

CX225SR
1. Attach a suitable lifting device to the hydraulic

swivel.
2. Place the hydraulic swivel in position.
Tighten screws (3) to a torque of 109 - 127 Nm.
Install washers, locking bar (2), and screws (1) tted
with washers and tighten them to a torque of 109
- 127 Nm.
CRIL04B071A01 1

Connect all the hoses to the hydraulic swivel
bushing, following the markings made during
removal.
CRIL04B070A00 2

Connect all the hoses to the pivot of the hydraulic
swivel, following the markings made during removal.
CRIL04B071A00 3
Next operation: To install the shield panel, refer to Upper shield - Remove (E.20.A.71 - F.10.A.10)
Next operation: Install hydraulic swivel lower shield panel, refer to Protective shield - Remove (E.20.A.73
- F.10.A.10)
26046 1 02/12/2004
F.40.C / 82
SWINGING Circular swing - Troubleshooting (F.40.C - G.40.A.10)

CX225SR

No swing or slow swing Swing pressure too low. Adjust or replace the relief valves
(No problems with other
functions)
Brake release pressure lower than 30 bar Test the electrical circuit, refer to Hydraulic
brake Electrovalve - Electrical test
(F.40.C.59.10 - F.40.A.50)
Repair or replace the components in
question
Defective swing brake Repair the swing brake
Substantial leakage from the swing motor Repair or replace the motor
The swing brake does not Swing pressure too low. Adjust or replace the secondary relief
hold with the excavator valves
on a slope.
Pilot pressure at the brake solenoid valve Test the electrical circuit, refer to Hydraulic
outlet greater than 1 bar brake Electrovalve - Electrical test
(F.40.C.59.10 - F.40.A.50)
Repair or replace the components in
question
Defective swing brake Repair the swing brake
Signicant leakage from the swing motor Repair or replace the motor
26046 1 02/12/2004
F.40.C / 83
Index

Bearing and ring gear - Check (F.40.C.45 - F.40.A.11) 72
CX225SR
Bearing and ring gear - Install (F.40.C.45 - F.10.A.15) 73
CX225SR
Bearing and ring gear - Remove (F.40.C.45 - F.10.A.10) 71
CX225SR
Command valve Hand command valve - Assemble (F.40.C.12.10 - F.10.A.20) 28
CX225SR
Command valve Hand command valve - Cleaning (F.40.C.12.10 - F.30.A.10) 26
CX225SR
Command valve Hand command valve - Disassemble (F.40.C.12.10 - F.10.A.25) 21
CX225SR
Command valve Hand command valve - Install (F.40.C.12.10 - F.10.A.15) 33
CX225SR
Command valve Hand command valve - Remove (F.40.C.12.10 - F.10.A.10) 20
CX225SR
Command valve Hand command valve - Sectional view (F.40.C.12.10 - C.10.A.30) 12
CX225SR
Command valve Hand command valve - Torque (F.40.C.12.10 - D.20.A.10) 5
CX225SR
Command valve Hand command valve - Visual inspection (F.40.C.12.10 - F.40.A.10) 27
CX225SR
Control valve - Assemble (F.40.C.14 - F.10.A.20) 35
CX225SR
Control valve - Disassemble (F.40.C.14 - F.10.A.25) 34
CX225SR
Control valve - Sectional view (F.40.C.14 - C.10.A.30) 13
CX225SR
Hydraulic brake - Electronic schema (F.40.C.59 - C.20.A.50) 17
CX225SR
Hydraulic brake - Pressure test (F.40.C.59 - F.40.A.30) 74
CX225SR
Hydraulic brake Electrovalve - Electrical test (F.40.C.59.10 - F.40.A.50) 75
CX225SR
Hydraulic motor - Assemble (F.40.C.28 - F.10.A.20) 47
CX225SR
Hydraulic motor - Bleed (F.40.C.28 - F.35.A.25) 56
CX225SR
Hydraulic motor - Disassemble (F.40.C.28 - F.10.A.25) 40
CX225SR
Hydraulic motor - Install (F.40.C.28 - F.10.A.15) 55
CX225SR
Hydraulic motor - Leakage test (F.40.C.28 - F.40.A.40) 38
CX225SR
Hydraulic motor - Remove (F.40.C.28 - F.10.A.10) 39
CX225SR
Hydraulic motor - Sectional view (F.40.C.28 - C.10.A.30) 14
CX225SR
Hydraulic motor - Service limits (F.40.C.28 - D.20.A.20) 5
CX225SR
26046 1 02/12/2004
F.40.C / 84
Hydraulic motor - Special tools (F.40.C.28 - D.20.A.40) 5
CX225SR
Hydraulic motor - Visual inspection (F.40.C.28 - F.40.A.10) 46
CX225SR
Reducer, spur gear - Assemble (F.40.C.44 - F.10.A.20) 65
CX225SR
Reducer, spur gear - Disassemble (F.40.C.44 - F.10.A.25) 59
CX225SR
Reducer, spur gear - Install (F.40.C.44 - F.10.A.15) 70
CX225SR
Reducer, spur gear - Remove (F.40.C.44 - F.10.A.10) 57
CX225SR
Reducer, spur gear - Sectional view (F.40.C.44 - C.10.A.30) 16
CX225SR
Reducer, spur gear - Visual inspection (F.40.C.44 - F.40.A.10) 64
CX225SR
Relief valve - Pressure setting (F.40.C.16 - F.45.A.70) 37
CX225SR
Relief valve - Pressure test (F.40.C.16 - F.40.A.30) 36
CX225SR
CX225SR
CX225SR
SWINGING Circular swing - Troubleshooting (F.40.C - G.40.A.10) 83
CX225SR
Swivel - Assemble (F.40.C.69 - F.10.A.20) 80
CX225SR
Swivel - Cleaning (F.40.C.69 - F.30.A.10) 79
CX225SR
Swivel - Disassemble (F.40.C.69 - F.10.A.25) 77
CX225SR
Swivel - Exploded view (F.40.C.69 - C.10.A.20) 19
CX225SR
Swivel - General specication (F.40.C.69 - D.40.A.10) 7
CX225SR
Swivel - Install (F.40.C.69 - F.10.A.15) 82
CX225SR
Swivel - Remove (F.40.C.69 - F.10.A.10) 76
CX225SR
26046 1 02/12/2004
F.40.C / 85
SERVICE
PRINTED IN FRANCE
26043 1 02/12/2004
REPAIR MANUAL
WORKING ARM
CX225SR
26047 1 02/12/2004
H
Contents
WORKING ARM - H
BOOM Lift H.20.B

CX225SR
DIPPER Lift H.25.B

CX225SR
ARM TOOL ATTACHMENT Tilt H.30.C

CX225SR
26047 1 02/12/2004
H
WORKING ARM - H
BOOM Lift - 20.B
CX225SR
26048 1 02/12/2004
H.20.B / 1
Contents
WORKING ARM - H
BOOM Lift - 20.B
TECHNICAL DATA
BOOM Lift - Service limits (H.20.B - D.20.A.20) 4
CX225SR
Command valve
Command valve Hand control valve - Torque (H.20.B.12.10 - D.20.A.10) 5
CX225SR
Cylinder
Cylinder - Special tools (H.20.B.26 - D.20.A.40) 5
CX225SR
Cylinder - Torque (H.20.B.26 - D.20.A.10) 7

CX225SR
FUNCTIONAL DATA
BOOM Lift - Hydraulic schema (H.20.B - C.20.A.20) 8
CX225SR

CX225SR

CX225SR

CX225SR
Command valve
Command valve Hand control valve - Sectional view (H.20.B.12.10 - C.10.A.30) 16
CX225SR
Control valve
Control valve - Sectional view (H.20.B.14 - C.10.A.30) 17
CX225SR
Cylinder
Cylinder - Sectional view (H.20.B.26 - C.10.A.30) 18
CX225SR
Arm
Arm - Exploded view (H.20.B.50 - C.10.A.20) 19
CX225SR
Overload detection system

Overload detection system - Electronic schema (H.20.B.94 - C.20.A.50) 20
CX225SR
SERVICE
Command valve
Command valve Hand control valve - Overhaul (H.20.B.12.10 - F.10.A.40) 21
CX225SR
26048 1 02/12/2004
H.20.B / 2
Command valve Cushion valve - Remove (H.20.B.12.20 - F.10.A.10) 22
CX225SR
Command valve Cushion valve - Disassemble (H.20.B.12.20 - F.10.A.25) 23

CX225SR
Command valve Cushion valve - Assemble (H.20.B.12.20 - F.10.A.20) 24

CX225SR
Command valve Cushion valve - Install (H.20.B.12.20 - F.10.A.15) 25

CX225SR
Control valve
Control valve - Disassemble (H.20.B.14 - F.10.A.25) 26
CX225SR
Control valve - Assemble (H.20.B.14 - F.10.A.20) 28

CX225SR
Safety valve
Safety valve - Remove (H.20.B.15 - F.10.A.10) 30
CX225SR
Safety valve - Install (H.20.B.15 - F.10.A.15) 31

CX225SR
Safety valve - Pressure setting (H.20.B.15 - F.45.A.70) 32

CX225SR
Relief valve
Relief valve - Disassemble (H.20.B.16 - F.10.A.25) 33
CX225SR
Relief valve - Assemble (H.20.B.16 - F.10.A.20) 34

CX225SR
Relief valve - Pressure test (H.20.B.16 - F.40.A.30) 35

CX225SR
Relief valve - Pressure setting (H.20.B.16 - F.45.A.70) 36

CX225SR
Load holding valve

Load holding valve - Disassemble (H.20.B.19 - F.10.A.25) 37
CX225SR
Load holding valve - Assemble (H.20.B.19 - F.10.A.20) 38

CX225SR
Cylinder
Cylinder - Remove (H.20.B.26 - F.10.A.10) 39
CX225SR
Cylinder - Disassemble (H.20.B.26 - F.10.A.25) 42

CX225SR
Cylinder - Visual inspection (H.20.B.26 - F.40.A.10) 45

CX225SR
Cylinder - Assemble (H.20.B.26 - F.10.A.20) 46

CX225SR
Cylinder - Install (H.20.B.26 - F.10.A.15) 49

CX225SR
Arm
Arm - Remove (H.20.B.50 - F.10.A.10) 51
CX225SR
Arm - Install (H.20.B.50 - F.10.A.15) 52

CX225SR
26048 1 02/12/2004
H.20.B / 3
WORKING ARM - BOOM Lift
BOOM Lift - Service limits (H.20.B - D.20.A.20)

CX225SR
CRIL03G012E01 1
Linkage points
1. Foot of boom on chassis
CRIL03G015E01 2
(A) 682 mm 692 mm
(B) 681.5 mm 679.5 mm
(C) (a-b) 0.5 - 3 mm Shims
(D) pin diameter 90 mm 89 mm
2. Foot of boom cylinder on chassis
CRIL03L133E01 3
(A) 108 mm 106 mm
(B) 109 mm 115 mm
(C) clearance 1 - 2.5 mm Shims
26048 1 02/12/2004
H.20.B / 4
3. Boom cylinder head on boom
CRIL03L134E01 4
(A) 108 mm 106 mm
(B) 514 mm 501 mm
(C) clearance 1 - 2.5 mm Shims
Command valve Hand control valve - Torque (H.20.B.12.10 -

D.20.A.10)
CX225SR
NOTE: Refer to Command valve Hand command valve - Torque (F.40.C.12.10 - D.20.A.10)
Cylinder - Special tools (H.20.B.26 - D.20.A.40)

CX225SR
CRIL03J014E 1
Repair bench 380000812.
Used for repairing cylinders.
Piston screw ats (for information)

Nominal diameter Flats in mm Nominal diameter Flats in mm
M45 70 M48 75
M52 80 M55 85
M58 85 M62 90
M65 95 M68 100
M70 100 M75 110
M80 115
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H.20.B / 5
CRPH03J001E 2
Gland wrench.
Used for removing and retting glands.
OEM6210: opening capacity 50 - 120 mm
OEM6203: opening capacity 120 - 320 mm
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H.20.B / 6
Cylinder - Torque (H.20.B.26 - D.20.A.10)

CX225SR
CRIL04B034G02 1
Description
(1) Screw 267 Nm
(2) Plug 191.7 - 260.3 Nm
(3) Screw 25.62 - 37.88 Nm
(4) Screw 50.9 - 74.3 Nm
(5) Nut (M 65) 5500 Nm
(6) Screw 46.59 - 60.8 Nm
(7) Screw 46.2 - 67.6 Nm
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H.20.B / 7
BOOM Lift - Hydraulic schema (H.20.B - C.20.A.20)

CX225SR
CRIL04A040H01 1
Boom raising circuit - Dynamic Description
Boom raising
(1) Straight-line travel valve (2) RH travel spool
(3) Boom spool 2 (4) Boom spool 1
(15) Main distributor l (25) Boom cylinder
(26) Boom cylinder (32) Boom load holding valve
(57) Cushion valve (P1) Pump D2 outlet ow
(P2) Pump D1 outlet ow (Pa8/A8) Boom raising
(Pb8/B8) Boom lowering
DYNAMIC DESCRIPTION
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H.20.B / 8
• Boom raising (large cylinder chamber) (25) and (26) is supplied by outputs from pumps (D1) and (D2).
• The ow from pump (D2) arriving through port (P1) passes through straight-line travel valve (1) or RH travel
valve spool (2) then via the parallel passage to pass through boom valve spool 2 (3), and arrives at the
outlet of boom valve spool 1 (4).
• The output from pump (D1) arriving through port (P2) passes through the 2nd parallel passage and boom
valve spool 1 (4) to join the output from pump (D2).
• The outputs from pumps (P1) and (P2) supply the large boom cylinder chambers (25) and (26) by passing
through the boom load holding valve (32).
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H.20.B / 9

CX225SR
CRIL04A041H01 1
Boom raising and dipper return circuit (levelling) - Dynamic Description
Boom raising and dipper return (levelling)

(1) Straight-line travel valve (2) RH travel spool
(3) Boom spool 2 (4) Boom spool 1
(5) Swing priority valve (15) Main control valve
(25) Boom cylinder (26) Boom cylinder
(27) Dipper cylinder (32) Boom load holding valve
(57) Cushion valve (58) Cushion valve
(P1) Pump D2 outlet ow (P2) Pump D1 outlet ow
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H.20.B / 10
(Pa8/A8) Boom raising (Pb8/B8) Boom lowering

(Pbu) Swing priority valve piloting
DYNAMIC DESCRIPTION
• When boom raising and dipper return are operated simultaneously, the swing priority valve (5) piloted by port
(Pbu) is in the open position.
• The output from pump (D2) arriving through port (P1) passes through swing priority valve (5) to supply the
return of the dipper.
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H.20.B / 11

CX225SR
CRIL04A042H01 1
Boom lowering circuit, boom load holding valve - Dynamic Description
Boom lowering, boom load holding valve

(1) Boom spool 1 (15) Main control valve
(25) Boom cylinder (26) Boom cylinder
(32) Boom load holding valve (57) Cushion valve
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H.20.B / 12
(P2) Pump D1 outlet ow (Pa8/A8) Boom raising

(Pb8/B8) Boom lowering ( Pc2) Boom load holding
DYNAMIC DESCRIPTION
• Boom lowering (small cylinder chamber) (25) and (26) is supplied by pump output (D1) through port (P2).
When boom lowering is not activated, the oil from large chamber of boom cylinders (25) and (26) is retained by
boom load holding valve (32). This minimises leakage from boom spool 1 (1).
• When boom lowering is activated, only boom spool 1 (1) is piloted by port (Pb8).
At the same time, the pilot pressure arrives at (Pc2) and unlocks the load holding valve (32). This means that
the oil from the large chamber of boom cylinders (25) and (26) can be returned to the reservoir.
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H.20.B / 13

CX225SR
CRIL04A043H01 1
Boom lowering re-supply and anti-vibration circuit - Dynamic Description
Boom lowering re-supply and anti-vibration

(1) Boom spool 1 (2) Check valve
(3) Jet (4) Jet
(15) Main control valve (25) Boom cylinder
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H.20.B / 14
(26) Boom cylinder (32) Boom load holding valve

(57) Cushion valve (Pa8/A8) Boom raising
(Pb8/B8) Boom lowering ( Pc2) Boom load holding
RE-SUPPLY - DYNAMIC DESCRIPTION

• When the boom is lowered, boom spool 1 (1) is piloted. Boom load holding valve (32) is unlocked and some of
the oil from the large chambers of boom cylinders (25) and (26) is re-injected into the small chambers of boom
cylinders (25) and (26), passing through a non-return valve (2). As the pressure in the small cylinders of boom
cylinders (25) and (26) is lowered further, the ow if re-injected oil is increased.
• Even if boom spool 1 (1) is actuated fully, a connection still exists with the free passage via a jet (4) which
generates a ow reduction information pressure to the pump. This ow reduction is compensated by the
re-injection circuit. In addition, it allows the engine power to be used more efciently.
ANTI-VIBRATION - DYNAMIC DESCRIPTION

• When the boom lowering control is operated sharply, a jet (3), which is located between the supply and the
free passage on boom spool 1 (1), reduces pressure points and vibration.
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H.20.B / 15
Command valve Hand control valve - Sectional view (H.20.B.12.10 -

C.10.A.30)
CX225SR
NOTE: Refer to Command valve Hand command valve - Sectional view (F.40.C.12.10 - C.10.A.30)
26048 1 02/12/2004
H.20.B / 16
Control valve - Sectional view (H.20.B.14 - C.10.A.30)

CX225SR
CRIL04A165G01 1
Boom section 1 and 2
(3) Boom spool 1 (7) Seal

(15) Boom spool 2 (34) Valve
(37) Flange (38) Valve
(39) Spring (40) Spacer assembly
(67) Load holding valve (69) Secondary relief valve
(72) Plug (73) Plug
(D) Spool screw
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H.20.B / 17
Cylinder - Sectional view (H.20.B.26 - C.10.A.30)

CX225SR
CRIL04B034G01 1
(1) Screw (2) Washer (3) Clamp

(4) Pipe (5) Clamp (6) Screw
(7) Washer (8) Screw (9) Plug
(10) Seal (11) Barrel (12) Grease tting
(13) Bushing (14) Bushing (15) Seal
(16) Ball (17) Screw (18) Seal
(19) Seal (20) Shim (21) Seal
(22) Seal (23) Screw (24) Seal
(25) Bushing (26) Seal (27) Back-up ring
(28) Nut (29) Seal (30) Seal
(31) Snap ring (32) Gland (33) Rod
(34) Piston (35) Bushing
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H.20.B / 18
Arm - Exploded view (H.20.B.50 - C.10.A.20)

CX225SR
CRIL03L137F01 1
(1) Screw
(2) Nut
(3) Pin
(4) Shim
(5) Bushing
(6) Seal
(7) Grease tting
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H.20.B / 19
Overload detection system - Electronic schema (H.20.B.94 -

C.20.A.50)
CX225SR
OVERLOAD INDICATOR
CRIL03G223E01 1
Circuit layout
(A7) Overload indicator electronic control box (B45) Overload indicator pressure sensor
(H3) Overload indicator audible alarm device (S13) Overload indicator switch
CRIL03G224E02 2
Timing diagram
OVERLOAD INDICATOR PRESSURE SENSOR SPECIFICATION (B45)

Alarm ON 16.1 MPa (161 bar)
Alarm OFF 15.1 MPa (151 bar)
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H.20.B / 20
Command valve Hand control valve - Overhaul (H.20.B.12.10 -

F.10.A.40)
CX225SR
1. Refer to:
Command valve Hand command valve - Remove
(F.40.C.12.10 - F.10.A.10)
Command valve Hand command valve -
Disassemble (F.40.C.12.10 - F.10.A.25)
Cleaning (F.40.C.12.10 - F.30.A.10)
Command valve Hand command valve - Visual
inspection (F.40.C.12.10 - F.40.A.10)
Assemble (F.40.C.12.10 - F.10.A.20)
Command valve Hand command valve - Install
(F.40.C.12.10 - F.10.A.15)
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H.20.B / 21
Command valve Cushion valve - Remove (H.20.B.12.20 - F.10.A.10)

CX225SR
Prior operation: Remove the side guard from under the oor, refer to Side shield - Remove (E.20.A.70 -
F.10.A.10).
1. Attach identifying tags to all the damper hoses.

Disconnect the hoses (1).
Plug the ports.
Stop the vacuum pump.
Remove screws (2) and damper (3).
CRIL04D009A01 1
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H.20.B / 22
Command valve Cushion valve - Disassemble (H.20.B.12.20 -

F.10.A.25)
CX225SR
CRIL03L110F01 1
(1) Cushion valve (2) Spring

(3) Spool (4) Seal
(5) Connector (6) Plug
(7) Seal (8) Spring
(9) Spring guide (10) Seal
(11) Spool
1. Mark parts to ensure correct assembly in their
original positions.
2. Remove plugs (6) and springs (8).
Discard seal (7).
3. Remove spool (11).
Clamp the spool in a vice, protecting it with wooden
blocks.
Remove spring guide (9) and discard seal (10).
4. Remove unions (5).
Discard seals (4).
5. Install an M4 screw in the threaded orice of spool
(3) to extract it.
Remove spring (2).
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H.20.B / 23
Command valve Cushion valve - Assemble (H.20.B.12.20 - F.10.A.20)

CX225SR
1. Check condition and clean parts before assembling.

2. Assemble the parts in the reverse order of
disassembly, refer to Command valve Cushion
valve - Disassemble (H.20.B.12.20 - F.10.A.25)
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H.20.B / 24
Command valve Cushion valve - Install (H.20.B.12.20 - F.10.A.15)

CX225SR
1. Attach the damper (3) with screws (2).

Remove the plugs.
Connect the hoses (1).
CRIL04D009A01 1
2. Remove the vacuum pump.

Ensure there are no leaks.
Install the side guard under the oor.
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H.20.B / 25
Control valve - Disassemble (H.20.B.14 - F.10.A.25)

CX225SR
CRIL04A165G02 1
Boom spool section 1 and 2
1. Unscrew and remove the screws (74).

Remove caps (8) and (10) and discard seals (7).
Remove spools (3) and (15).
NOTE: Mark each spool to ensure that it is returned to the
correct housing during re-assembly.
NOTE: To avoid abrasion of the spool surface during
removal of the spool assembly, use a soft-jawed vice
(spring side) to avoid deformation. If the threaded part
of the screw is coated with locking uid, heat the screw
(usually the temperature should be 200 - 250 °C). If
26048 1 02/12/2004
H.20.B / 26
3. Remove plug (A) from spool (3).

Discard seal (C) and backing ring (B).
Remove spring (D) and check valve (E).
CRIL03L076A02 2

Remove the load holding valve assembly (67) then
remove the distributor seals.
Disassemble the parts of the load holding valve,
refer to Load holding valve - Disassemble
(H.20.B.19 - F.10.A.25).
5. Use a screw 6 x 1,0 mm as an extracting screw to
remove the spacer assembly (40).
Remove and discard seals (A) and (B) and the
back-up ring (C).
Remove spring (39) and check valve (38).
CRIL03L078A02 3
6. Unscrew and remove screws (75).

Remove anges (37) and (36) and discard seals.
7. Remove plugs (72) and (73) and discard seals
.Remove valves (69).
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H.20.B / 27
Control valve - Assemble (H.20.B.14 - F.10.A.20)

CX225SR
Prior operation: Clean and check parts before assembling, refer to Stack valve - Visual inspection (A.10.A.18
- F.40.A.10)
CRIL04A165G02 1
Boom spool section 1 and 2
Torque settings
Valve (69) 78 - 88 Nm
Plug (72) 73 - 79 Nm
Plug (73) 19 - 22 Nm
Screw (74) 39 - 44 Nm
Screw (75) 58 - 64 Nm
Screw (76) 39 - 44 Nm
1. Install valves and tighten to the required torque (69).
2. Install plugs (72) and (73) t with new seals and
tighten to the required torque.
Tighten the screws to torque (75).
26048 1 02/12/2004
H.20.B / 28
4. Install seals (A) and (B) backing ring (C) on the

spacer (40).
Install spring (39), valve (38) and spacer assembly
(40).
CRIL03L078A02 2
5. Install the load holding valve assembly (67) with

new seals.
Install and tighten screws (76) to torque.
6. Coat the threaded parts of spools (3) and (15) with
thread locking uid.
Place the ends of the spools (spring side) in a
soft-jawed vice.
Fit springs (B) and seats (C ) on screws (D).
Fit the screws and tighten to torque.
7. Install spring (D) and valve (E) on the spool (3).
Install seal (C) and backing ring (B) on the plug (A).
Install and tighten the plug (A).
Install spools (3) and (15) in their respective
housings.
CRIL03L076A02 3
Fit screws and tighten to torque (74).
26048 1 02/12/2004
H.20.B / 29
Safety valve - Remove (H.20.B.15 - F.10.A.10)

CX225SR
1. Mark, disconnect and plug all the hoses from the

safety valves (4) and (5).
Remove the connectors (1) from the hoses (2).
Disconnect the pressure overload indicator (3).
Unscrew the safety valve connectors (4) et (5), then
remove the safety valves.
CRIL04C002A02 1
26048 1 02/12/2004
H.20.B / 30
Safety valve - Install (H.20.B.15 - F.10.A.15)

CX225SR
1. Install safety valves (4) and (5) with new sealing

rings and tighten xing screws
Connect all hoses to the safety valves, taking care
to observe the markings made during their removal.
Set the overload pressure indicator (3).
Install connectors (1) for the hoses (2).
CRIL04C002A02 1
26048 1 02/12/2004
H.20.B / 31
Safety valve - Pressure setting (H.20.B.15 - F.45.A.70)

CX225SR
1. Disconnect the balance hose (1) from the safety

valve (B2) of the LH boom cylinder.
Install a male coupling connection on the hose,
complete with its union.
Plug the elbow union of the safety valve (B2) of the
LH boom cylinder.
Connect to the hose (1) a female coupling
connection, tted with a pressure test tting.
Connect the pressure controller or a 0 - 600 bar
pressure gauge to the pressure test tting.
Disconnect and plug the pilot hose on the safety
valve to be adjusted.
Place a receptacle under connection
to catch any leaks. Plug the union that has been left CRIL04C002A01 1
free by the disconnection of the pilot hose.
Start the engine.
Set the engine speed to 1000 tr/mn on the
instrument panel potentiometer.
Move the boom to mid-height.
Operate the boom lowering control and note the
pressure setting for valve (B1).
Repeat this operation several times, noting the
pressure each time.
The pressure read on the pressure gauge must be:
392 ± 5 bar (39.2 ± 0,5 MPa)
2. If the value is not correct, loosen lock nut (2) and
turn screw (3) to adjust the pressure whilst operating
the boom lowering control.
Tighten to increase the pressure, loosen to
decrease.
Re-tighten the lock nut (2).
CRIL04C003A01 2
3. To release pressure in the large chamber of the

boom cylinder, rst connect the pilot hose (1).
Start the engine to ll the accumulator.
Release the pressure in the hydraulic system.
4. Remove the plug from the safety valve connection
(B2) of the LH boom cylinder.
Disconnect the coupling connection of the pressure
test point.
Reconnect the balancing hose (1).
5. LH CHECK AND CALIBRATION (B2)
Carry out the same operations as for the RH side.
The difference between the two valves must be less
than 5 bar
26048 1 02/12/2004
H.20.B / 32
Relief valve - Disassemble (H.20.B.16 - F.10.A.25)

CX225SR
1. Discard seal (1) on body (2).
CRIL03L105B01 1
2. Remove plug (3) from body (2) and discard seal (4).
3. Remove the springs (5) and (6).
4. Remove the valve (7).
5. Remove nut (8) screw (9), washer (10), and discard
the seal (11).
6. Remove the tip of valve (12) from the body (2).
7. Extract the valve seat (13) and discard seals (14)
and (15).
8. Remove the spring (16) and valve seat (17).
9. Remove valve (18) and discard seals (19) and (20).
26048 1 02/12/2004
H.20.B / 33
Relief valve - Assemble (H.20.B.16 - F.10.A.20)

CX225SR
1. Install seals (19) and (20) on valve (18).
CRIL03L105B01 1
2. Install valve (18) in the tip of valve (12).

3. Install the valve seat (17) and spring (16) in position.
4. Install seals (14) and (15) on valve seat (13).
5. Install valve seat (13) in the tip of valve (12).
6. Install the tip of the valve (12) in the body (2).
7. Install spring (5), valve (7) and spring (6).
8. Fit the screw (9) with a seal (11).
9. Fit the plug (3) with a seal (4).
10. Install and tighten to a torque of 59 - 69 Nm the
plug (3).
11. Fit the screw (9) in a way that allows positioning of
a washer (10).
12. Install nut (8) without locking it, nal tightening will
be done when the relief valve is adjusted to a torque
of 27 - 31 Nm.
26048 1 02/12/2004
H.20.B / 34
Relief valve - Pressure test (H.20.B.16 - F.40.A.30)

CX225SR
NOTE: The secondary relief valves on the boom (B) and (C) are calibrated to a higher pressure than the main relief
valve (A). To check or calibrate the secondary relief valves, main relief valve (A) must be overcalibrated.
NOTE: If the excavator is equipped with safety valves on the boom, the secondary relief valves are not tted on
the valve block, or they are overcalibrated. In this case, the secondary relief valves mounted on the safety valves
must be calibrated.
the pressure test point .
3. Start the engine and run it at maximum speed.
4. Operate the control for the function to be checked
and hold it against the stop.
5. The raising and lowering pressures of the boom as
displayed on the pressure gauge should be 392 ±
5 bar (39.2 ± 0.5 MPa)
6. If the pressures are incorrect, calibrate boom relief
valves (B) and (C), refer to Relief valve - Pressure
setting (H.20.B.16 - F.45.A.70)
Next operation: To recalibrate main relief valve (A), refer to Relief valve - Pressure setting (A.10.A.16 - F.45.A.70)
26048 1 02/12/2004
H.20.B / 35
Relief valve - Pressure setting (H.20.B.16 - F.45.A.70)

CX225SR
Prior operation: Relief valve - Pressure test (H.20.B.16 - F.40.A.30)
1. Using a wrench, hold adjusting screw (2) of the

main relief valve in position and loosen lock nut (1).
CRIL03K054A01 1
2. Operate the control for the attachment to be

calibrated and hold it up against the stops.
3. Turn adjusting screw (2) until the correct pressure
is reached.
NOTE: Tighten the screw to increase pressure, loosen
the screw to reduce pressure.
5. Check the pressure again. If the desired value is
not obtained, make the adjustment again.
Next operation: Reset main relief valve (A), refer to Relief valve - Pressure setting (A.10.A.16 - F.45.A.70).
26048 1 02/12/2004
H.20.B / 36
Load holding valve - Disassemble (H.20.B.19 - F.10.A.25)

CX225SR
NOTE: Take care when disassembling the load holding valve, some parts are under pressure from the springs.
CRIL04A180F01 1
1. Secure the load holding valve assembly (67) in a

soft-jawed vice.
2. Remove the plug (P).
Remove piston (D), spool (E) and spring (G).
Unscrew and remove plug (C) then remove seal (N).
3. Remove sleeve (F) and valve (B).
4. Remove seals (J) and (K) and backup rings (L) and
(M) from the sleeve (F).
5. Remove spring seat (Q) and spring (H).
6. Remove plug (R), discard seal (S).
NOTE: The ball (T) is installed by force, do not try to
remove it.
26048 1 02/12/2004
H.20.B / 37
Load holding valve - Assemble (H.20.B.19 - F.10.A.20)

CX225SR
CRIL04A180F01 1
1. Fit seals (K) and (J) back-up rings (L) and (M) into
the grooves of the sleeve (F).
NOTE: Follow the positions of the seals and backup rings.
2. Install valve (B) and spool (E) in the oroce of
sleeve (F).
3. Fit spring seat (Q) on the end of valve (B), t spring
(H) on spring seat.
Insert the assembly in the load holding valve body.
Install a seal (N) on the plug (C).
Install the plug and tighten to a torque of 147 - 157
Nm (C).
Fit spring (G), spool (E) and piston (D) in the load
holding valve.
Install a seal (N) on the plug (P).
Nm (P).
4. Install the plug (R) tted with a new seal (S).
Tighten to a torque of 14 - 18 Nm.
26048 1 02/12/2004
H.20.B / 38
Cylinder - Remove (H.20.B.26 - F.10.A.10)

CX225SR
1. Attach a suitable lifting device to the cylinder. Use

all the equipment necessary to ensure sufcient
support during removal of the cylinder.
CRIL03K175A00 1
2. Remove nuts (3), screw (1) and bushing (2).

Recover the shim.
CRIL03K176A01 2
3. Tap out pin (3) to free up the cylinder head.

Recover the shim.
NOTE: Do not remove the pin: this would cause the
second cylinder to fall.
CRIL03K177A01 3
26048 1 02/12/2004
H.20.B / 39
4. Place the cylinder on a stand.
CRIL03K178A01 4
5. Attach a sling to retain the cylinder rod in the

cylinder barrel.
CRIL03K179A00 5
6. Start the vacuum pump.

Disconnect hoses (1).
Plug the ports.
CRIL04B015A01 6
7. If the machine is equipped with a safety valve.

Disconnect hoses from (1) to (5).
Plug ports.
Disconnect the pressure sensor harness.
CRIL04B016A01 7
8. Stop the vacuum pump.
26048 1 02/12/2004
H.20.B / 40
9. Remove nuts (1) and screw (2).

Remove pin (3).
Carefully lift the cylinder and place it on suitable
stands.
CRIL04B017A01 8
10. Remove the sling that holds the rod together with
the cylinder barrel.
26048 1 02/12/2004
H.20.B / 41
Cylinder - Disassemble (H.20.B.26 - F.10.A.25)

CX225SR
To use a cylinder bench for removal operations, refer to Cylinder - Special tools (H.20.B.26 - D.20.A.40)
1. Mark the retaining clips on the piping.

Remove the collars from piping if necessary.
Remove the lines and connectors from the cylinder
barrel.
Discard the seals.
2. Mount the cylinder on the repair bench.
Pull the rod out about 200 mm.
CRPH03J002A 1
3. Mark the gland and cylinder barrel.

Remove screws (1) from the gland.
CRIL03K193A01 2
4. Using slings and a suitable lifting device, remove

complete rod (1) from cylinder barrel (2).
Remove cylinder tube (2) from the repair bench.
CRIL03K194A01 3
26048 1 02/12/2004
H.20.B / 42
5. Mount the rod assembly on the repair bench.

Remove screw (1) and ball (2).
NOTE: During assembly, the locking screw is crimped
in two places with a punch.
Bore out the crimped section with a drill.
CRIL03K195A01 4
6. Remove the xing nut from the piston and the

washer.
NOTE: Unscrewing the nut requires a torque about 1,5
times greater than the tightening torque.
CRPH03J005A 5
7. Remove piston (2) and cushion bushing (1).

Discard seal (3).
CRIL03K196A01 6
8. Discard carrier seals (1), seals (2), (3), (4) and

back-up rings (5).
CRIL03K197A01 7
26048 1 02/12/2004
H.20.B / 43
9. Remove gland (1) from cylinder rod (2).

Discard seals (3), retaining ring (4), bushing (5),
seals (6), (7), back-up ring (8) and seal (9).
CRIL03K198A01 8
10. Discard seals (1) from the cylinder head.

Remove grease ttings (2).
CRIL03J023A01 9
11. Place the boom cylinder head in a press.

Using a suitable driver, remove the cylinder head
bushing.
NOTE: Repeat steps 10 and 11 for the cylinder foot.
CRPH03J006A 10
26048 1 02/12/2004
H.20.B / 44
Cylinder - Visual inspection (H.20.B.26 - F.40.A.10)

CX225SR
NOTE: Clean each part with a suitable detergent and inspect the parts listed below. Replace all seals with new
seals from the manufacturer.
1. INSPECTING THE ROD
If the rod is cracked, replace it.
If the thread is damaged, re-thread it or replace the
rod.
If the chrome surface is cracked, rusty or defective,
replace the rod.
If the bushing bore is poorly dened or worn, replace
the rod.
If the eye ring is worn, replace the ring.
If the rod has run-out deection greater than 1 mm
per 1 m, replace the rod.
2. ROD RUN OUT MEASUREMENT
Place the rod horizontally on V-shaped blocks, at
each end of the sliding surface.
Place a dial gauge in contact with the rod, positioned
halfway between the two supports.
Rotate the rod about its own axis and note the
differences displayed on the dial gauge between the
minimum and maximum.
This difference will correspond to the amount of rod
run out.
CRPH03J008A 1
3. BARREL INSPECTION
If cracks appear around the weld joints, replace the
tube.
If there are scratches in the tube bore, replace the
tube.
If the tube eye ring is worn, replace the ring.
4. INSPECTING THE GLAND
If the surface is worn and the clearance between
the rod and the gland exceeds 0.25 mm, replace
the ring.
If excessively deep scratches appear on the ring,
replace the ring.
5. INSPECTING SLIDING PARTS
Check sliding parts for wear or damage such as
scratches, dents, or bent components.
Small scratches can be removed with a hone or
crocus cloth.
26048 1 02/12/2004
H.20.B / 45
Cylinder - Assemble (H.20.B.26 - F.10.A.20)

CX225SR
Prior operation: Cylinder - Visual inspection (H.20.B.26 - F.40.A.10)
NOTE: Oil all parts before assembly.

1. Place the cylinder head in a press.
Using a suitable centring piece, install the bushing
in the cylinder head.
CRPH03J006A 1
2. Install seals (1) in the cylinder head.

Install grease ttings (2).
NOTE: Repeat instructions 1 and 2 for the cylinder foot.
CRIL03J023A01 2
3. Place gland (1) in a press.

Using a suitable driver, install bushing (5).
Install snap ring (4).
Install seals (6), (7), back-up ring (8) and seal (9).
Installer (3).
Fit seal Mount gland (1) on cylinder rod (2).
CRIL03K198A01 3
26048 1 02/12/2004
H.20.B / 46
4. Install seal (4), seal (3) and back-up rings (5) on

piston.
Install carrier seals (1) and (2) on the piston.
CRIL03K197A01 4
5. Install seal (3), cushion bushing (1) and piston (2)

on the cylinder rod.
CRIL03K196A01 5
6. Place the piston xing nut in position on the cylinder

rod.
Mount the cylinder rod on the repair bench.
Tighten the nut to the required torque.
CRPH03J005A 6
7. Install ball (2) and tighten locking screw (1) to the

required torque.
CRIL03L032A01 7
26048 1 02/12/2004
H.20.B / 47
8. Peen locking screw (1) in two places (2) and (3)

using a punch.
CRIL03J02601A 8
9. Using a sling and a suitable lifting device, install rod

(1) in cylinder barrel (2).
NOTE: Take care not to damage the various seals.
CRIL03K194A01 9
10. Tighten the gland screws to the required torque.

Follow the tightening order.
CRIL03L033A01 10
11. Attach the seals, connectors and lines to the

cylinder barrel.
Tighten to the required torque.
26048 1 02/12/2004
H.20.B / 48
Cylinder - Install (H.20.B.26 - F.10.A.15)

CX225SR

cylinder barrel.
CRIL03K179A00 1
2. Using a suitable lifting device, raise the cylinder.

Align the cylinder foot with the mounting brackets
on the chassis.
Support the cylinder on a stand.
CRIL03K178A01 2
3. Fit pin (3).

Fit the shims.
Fit the screw (2), the rst nut (1) then tighten until
the nut touches the shoulder.
Loosen the nut a quarter of a turn.
Fit the second nut (1) to keep the rst in position.
CRIL04B017A01 3

Remove the plugs.
CRIL04B015A01 4
26048 1 02/12/2004
H.20.B / 49

Attach hoses (1) to (5).
Plug in the pressure sensor harness.
CRIL04B016A01 5

Remove the sling that holds the rod together with
7. Align the cylinder rod with the boom mounting
brackets.
Install pin (3).
To check for play between the cylinder head and
the assembly support, refer to BOOM Lift - Service
limits (H.20.B - D.20.A.20).
If necessary remove the pin and add or remove
shims as required to obtain the correct clearance,
replace the pin.
Install ring (2), screw (1) and rst nut (3), and tighten
until the nut touches the shoulder.
CRIL03K176A01 6
8. Grease the linkages.

26048 1 02/12/2004
H.20.B / 50
Arm - Remove (H.20.B.50 - F.10.A.10)

CX225SR
Prior operation: To remove the side protective panel from the control valve , refer to Side shield - Remove
(E.20.A.70 - F.10.A.10)
NOTE: Numbers in brackets refer to Arm - Exploded view (H.20.B.50 - C.10.A.20)

1. To disconnect the boom cylinder rods, refer to
Cylinder - Remove (H.20.B.26 - F.10.A.10).
Mark and disconnect the hoses connecting the
boom foot and the chassis.
Plug the ports.
CRIL03L140A00 1
3. Unplug the working light electrical harness.

4. Attach a suitable lifting device to the boom.
Use all the play necessary to obtain sufcient
support during removal of the boom.
Remove pin (3) using a slide-hammer.
Move the machine backwards to separate the boom
from the chassis.
Recover shims (4).
7. Place the boom on suitable stands.
9. Remove grease tting (7).
10. To remove bushings (5) but only if they need
replacing, refer to BOOM Lift - Service limits
(H.20.B - D.20.A.20)
26048 1 02/12/2004
H.20.B / 51
Arm - Install (H.20.B.50 - F.10.A.15)

CX225SR
NOTE: Numbers in brackets refer to Arm - Exploded view (H.20.B.50 - C.10.A.20)

1. Install bushings (5).
2. Install seals (6).
3. Install grease tting (7).
4. Attach a suitable lifting device to the boom.
Bring the boom close to the machine.
Start the engine.
Align the boom ports with the ports on the chassis.
5. Install pin (3) and screw (1).
6. To check for play between the boom and the
chassis, refer to BOOM Lift - Service limits
(H.20.B - D.20.A.20).
If necessary, remove the pin and add shims as
required to obtain the correct play, re-install the pin
and the screw.
7. Install the rst nut on the screw (2) and tighten until
the nut touches the boss.
8. To connect the boom cylinder rods, refer to Cylinder
- Install (H.20.B.26 - F.10.A.15).
Remove the plugs.
Connect the boom foot/chassis hoses, following the
Stop and remove the vacuum pump.
CRIL03L140A00 1
10. Connect the boom working light electrical harness.

12. Install the control valve side protective panel.
26048 1 02/12/2004
H.20.B / 52
Index
WORKING ARM - H
BOOM Lift - 20.B

Arm - Exploded view (H.20.B.50 - C.10.A.20) 19
CX225SR
Arm - Install (H.20.B.50 - F.10.A.15) 52
CX225SR
Arm - Remove (H.20.B.50 - F.10.A.10) 51
CX225SR
CX225SR
CX225SR
CX225SR
CX225SR
BOOM Lift - Service limits (H.20.B - D.20.A.20) 4
CX225SR
Command valve Cushion valve - Assemble (H.20.B.12.20 - F.10.A.20) 24
CX225SR
Command valve Cushion valve - Disassemble (H.20.B.12.20 - F.10.A.25) 23
CX225SR
Command valve Cushion valve - Install (H.20.B.12.20 - F.10.A.15) 25
CX225SR
Command valve Cushion valve - Remove (H.20.B.12.20 - F.10.A.10) 22
CX225SR
CX225SR
CX225SR
CX225SR
CX225SR
CX225SR
CX225SR
CX225SR
CX225SR
CX225SR
CX225SR
CX225SR
Cylinder - Special tools (H.20.B.26 - D.20.A.40) 5
CX225SR
CX225SR
26048 1 02/12/2004
H.20.B / 53
Cylinder - Visual inspection (H.20.B.26 - F.40.A.10) 45
CX225SR
CX225SR
CX225SR
Overload detection system - Electronic schema (H.20.B.94 - C.20.A.50) 20
CX225SR
Relief valve - Assemble (H.20.B.16 - F.10.A.20) 34
CX225SR
Relief valve - Disassemble (H.20.B.16 - F.10.A.25) 33
CX225SR
CX225SR
CX225SR
CX225SR
CX225SR
CX225SR
26048 1 02/12/2004
H.20.B / 54
WORKING ARM - H
DIPPER Lift - 25.B
CX225SR
26049 1 02/12/2004
H.25.B / 1
Contents
WORKING ARM - H
DIPPER Lift - 25.B
TECHNICAL DATA
DIPPER Lift - Service limits (H.25.B - D.20.A.20) 4
CX225SR
Command valve
CX225SR
Cylinder
CX225SR
FUNCTIONAL DATA
DIPPER Lift - Hydraulic schema (H.25.B - C.20.A.20) 7
CX225SR

CX225SR
Command valve
CX225SR
Control valve
CX225SR
Cylinder
CX225SR
SERVICE
Command valve
CX225SR
Control valve
CX225SR

CX225SR
Safety valve
CX225SR

CX225SR

CX225SR
Relief valve
26049 1 02/12/2004
H.25.B / 2
Relief valve - Overhaul (H.25.B.16 - F.10.A.40) 22
CX225SR

CX225SR

CX225SR
Load holding valve

CX225SR

CX225SR
Cylinder
CX225SR

CX225SR

CX225SR

CX225SR
Arm
Arm - Remove (H.25.B.50 - F.10.A.10) 38
CX225SR
Arm - Install (H.25.B.50 - F.10.A.15) 40

CX225SR
26049 1 02/12/2004
H.25.B / 3
WORKING ARM - DIPPER Lift
DIPPER Lift - Service limits (H.25.B - D.20.A.20)

CX225SR
CRIL03G012E02 1
Linkage points
1. Dipper cylinder foot on boom
CRIL03G018E01 2
(A) frame 121 mm 127 mm
(B) cylinder 120 mm 118 mm
(C) (A-B) 0.5 - 2 mm shims
2. Cylinder foot on boom head
CRIL03G019E01 3
(A) boom 310 mm 313.5 mm
(B) dipper 309.5 mm 307.5 mm
(C) clearance 0.5 - 1.1 mm shims
26049 1 02/12/2004
H.25.B / 4
3. Dipper cylinder head on dipper
CRIL03G020E01 4
(C) clearance (A-B) 0.5 - 3.0 mm shims
Command valve Hand control valve - Torque (H.25.B.12.10 -

D.20.A.10)
CX225SR
26049 1 02/12/2004
H.25.B / 5
Cylinder - Torque (H.25.B.26 - D.20.A.10)

CX225SR
CRIL04B036G01 1
Description
(1) Screw 367 Nm
(2) Plug 191.7 - 260.3 Nm
(3) Screw 41.59 - 60.81 Nm
(4) Screw 74.9 - 109.9 Nm
(5) Nut (M70) 10300 Nm
(6) Screw 25.62 - 37.88 Nm
(7) Screw 46.2 - 67.6 Nm
(8) Screw 32.35 - 47.25 Nm
26049 1 02/12/2004
H.25.B / 6
DIPPER Lift - Hydraulic schema (H.25.B - C.20.A.20)

CX225SR
CRIL04A047H01 1
Dipper out circuit, load holding valve - Dynamic Description
Dipper out, load holding valve

(1) Dipper spool 1 (2) Dipper spool 2
(27) Dipper cylinder (31) Load holding valve
(57) Cushion valve (P1) Pump D2 outlet ow
26049 1 02/12/2004
H.25.B / 7
(P2) Pump D1 outlet ow (Pa5/A5) Dipper out

(Pb5/B5) Dipper return
DYNAMIC DESCRIPTION
The dipper cylinder (27) is supplied by pump outputs (D2) and (D1) through ports (P1) and (P2).
• When dipper out is not activated, the oil from the dipper cylinder small chamber (27) is retained by load holding
valve (31). This minimises leaks from boom spool 1 (1).
• When dipper out is activated, the spools of dipper 1 (1) and dipper 2 (3) are piloted by ports (Pa5) and (Pa9).
At the same time, the pilot pressure arrives at (Pc1) and unlocks the load holding valve (31). This means that
the oil in the large chamber of the dipper cylinder (27) can return to the reservoir.
26049 1 02/12/2004
H.25.B / 8
DIPPER Lift - Hydraulic schema (H.25.B - C.20.A.20)

CX225SR
CRIL04A048H01 1
Dipper return circuit - Dynamic Description.
Dipper return
(1) Dipper spool 1 (2) Straight-line travel valve
(3) Dipper spool 2 (4) Recycling valve
(5) Check valve (27) Dipper cylinder
26049 1 02/12/2004
H.25.B / 9
(31) Load holding valve (57) Cushion valve

(P1) Pump D2 outlet ow (P2) Pump D1 outlet ow
(Pa5/A5) Dipper out (Pb5/B5) Dipper return
(Pa9/pb9) Dipper spool pilot
DIPPER RETURN - DYNAMIC DESCRIPTION

• The dipper cylinder (27) is supplied by pump outputs (D2) and (D1) through ports (P1) and (P2).
• When the dipper return control is activated, dipper spools 1 (1) and 2 (3) are piloted by ports (Pa5)and (Pa9).
• The ow (D2) reaches dipper spool 1 (1) via the free passage or the parallel passage after passing through
the straight line travel valve (2).
• The ow (D1) reaches dipper spool 2 (3) via the free passage or the parallel passage after passing through
the straight line travel valve (2). It rejoins ow (D2) before dipper spool 1 (1). Flows (D1) and (D2) supply
the large chamber of the dipper cylinder (27). The return from the large chamber passes through dipper
spools (1) and (3), which reduces pressure drops.
DIPPER RETURN RE-SUPPLY - DYNAMIC DESCRIPTION

• When the dipper return control is activated, the pilot pressure arrives at (Pc1) and unlocks load holding
valve (31).
This means that oil from the small chamber of the dipper cylinder (27) is reinjected into the large chamber of
the dipper cylinder (27), passing through the narrow throat of recycling valve (4) and check valve (5).
• When the pressure in the large chamber of dipper cylinder (27) increases, recycling valve (4) is piloted
and set in restriction position.
This has the effect of stopping reinjection from the small chamber to the large chamber of dipper cylinder (27).
26049 1 02/12/2004
H.25.B / 10
Command valve Hand control valve - Sectional view (H.25.B.12.10 -

C.10.A.30)
CX225SR
26049 1 02/12/2004
H.25.B / 11
Control valve - Sectional view (H.25.B.14 - C.10.A.30)

CX225SR
CRIL04A164G01 1
Dipper section 1 and 2
(2) Dipper valve 2 (7) Seal

(12) Small drilled cap (14) Dipper spool 1
(40) Spacer assembly (67) Load holding valve
(69) Secondary relief valve (74) Screw M10x1.5 L=28
(E) Valve (F) Spring
(G) Plug
26049 1 02/12/2004
H.25.B / 12
Cylinder - Sectional view (H.25.B.26 - C.10.A.30)

CX225SR
CRIL04B036G02 1

(7) Washer (8) Screw (9) Plug
(13) Bushing (14) seal (15) Seal
(28) Nut (29) Seal (30) Seal
(34) Piston (35) Bushing (36) Seal
(37) Seal (38) Stop (39) Ring
26049 1 02/12/2004
H.25.B / 13
Command valve Hand control valve - Overhaul (H.25.B.12.10 -

F.10.A.40)
CX225SR
1. Refer to:
(F.40.C.12.10 - F.10.A.10)
Cleaning (F.40.C.12.10 - F.30.A.10)
inspection (F.40.C.12.10 - F.40.A.10)
Assemble (F.40.C.12.10 - F.10.A.20)
(F.40.C.12.10 - F.10.A.15)
26049 1 02/12/2004
H.25.B / 14
Control valve - Disassemble (H.25.B.14 - F.10.A.25)

CX225SR
CRIL04A164G02a 1
Dipper section 1 and 2

Remove caps (8), (10) and (12), and discard seals
(7).
Remove spools (2) and (14).
NOTE: Mark each spool to ensure that it is returned to the
correct housing during re-assembly.
26049 1 02/12/2004
H.25.B / 15
3. Remove plug (A) from the spool (14).

Discard the seal (C) and back-up ring (B).
Remove spring (D) and check valve (E).
CRIL03L077A02 2

Remove load holding valve assembly (67), then
remove distributor seals.
Disassemble the load holding valve parts, refer to
Load holding valve - Disassemble (H.20.B.19 -
F.10.A.25).
5. Use a screw 6 x 1.0 mm as an extracting screw to
remove the spacer assembly (40).
Remove and discard seals (A) and (B) and back-up
ring (C).
CRIL03L078A02 3

Remove anges (37) and (36) and discard seals.
7. Remove valves (69).
26049 1 02/12/2004
H.25.B / 16
Control valve - Assemble (H.25.B.14 - F.10.A.20)

CX225SR
- F.40.A.10)
CRIL04A164G02a 1
Dipper spool section 1 and 2
Torque settings
Valve (69) 78 - 88 Nm
Screw (74) 39 - 44 Nm
Screw (75) 58 - 64 Nm
Screw (76) 39 - 44 Nm
1. Install valves (69) and tighten to the required torque.
26049 1 02/12/2004
H.25.B / 17
3. Fit seals (A) and (B) and backing ring (C) on the
spacer (40).
Install spring (39), valve (38) and spacer assembly
(40).
CRIL03L078A02 2
4. Install the load holding valve assembly (67) with

new seals.
Install screws (76) and tighten to torque.
5. Install spring (D) and valve (E) on the spool (14).
Install seal (C) and backing ring (B) on the plug (A).
Install and tighten plug (A).
CRIL03L077A02 3
6. Coat the threaded parts of spools (2) and (14) with

thead locking uid.
Place the ends of the spools (spring side) in a
soft-jawed vice.
Fit springs (B) and seats (C) on screws (D).
Install and tighten the screws to the required torque.
Install spools (2) and (14) in their respective
housings.
7. Install caps (8), (10) and (12) tted with new seals
(7).
Install screws and tighten to torque (74).
26049 1 02/12/2004
H.25.B / 18
Safety valve - Remove (H.25.B.15 - F.10.A.10)

CX225SR
1. Remove the ange (1).

Remove screws (2).
Remove connectors (3).
Remove screws (4) and remove the safety valve (5).
Seal the cylinder port.
CRIL04D008A01 1
26049 1 02/12/2004
H.25.B / 19
Safety valve - Install (H.25.B.15 - F.10.A.15)

CX225SR
1. Install the safety valve (5) on the cylinder with a

new gasket.
Install and tighten screws (4).
Install and tighten connectors (3).
Install and tighten screws (2).
Install the ange (1).
CRIL04D008A01 1
26049 1 02/12/2004
H.25.B / 20
Safety valve - Pressure setting (H.25.B.15 - F.45.A.70)

CX225SR
1. Disconnect and plug the pilot hose (1) on the safety

valve.
Place a receptacle under union (2) to catch any
leaks.
Remove plug (3) and install a pressure test point
connection
Connect a pressure controller or a 0 - 600 bar

pressure gauge to pressure test point .
Start the engine.
Set the engine speed to 1000 tr/mn on the
instrument panel potentiometer.
Bring the boom to mid-height and extend the dipper.
Operate the dipper retracting control and CRIL04C004A01a 1
read the calibrated pressure for the valve. Repeat
this operation several times, noting the pressure
each time.
The pressure read on the pressure gauge must be:
392 ± 5 bar (39.2 ± 0.5 MPa).
2. If the value is not correct, loosen lock nut (5) and
turn calibrating screw (6) to adjust the pressure.
Tighten to increase the pressure, loosen to
decrease. While activating the dipper in control,
tighten lock nut (5).
CRIL04C004A02a 2
3. Connect pilot hose (1) before releasing the pressure

in the small chamber of the dipper cylinder.
Start the engine to ll the accumulator.
Release the pressure in the hydraulic system.
4. Disconnect the union tted with the pressure test
point.
Install plug (3) on the safety valve.
26049 1 02/12/2004
H.25.B / 21
Relief valve - Overhaul (H.25.B.16 - F.10.A.40)

CX225SR
1. To disassemble this valve, refer to Relief valve -

Disassemble (H.20.B.16 - F.10.A.25).
2. For assembly, refer to Relief valve - Assemble
(H.20.B.16 - F.10.A.20)
26049 1 02/12/2004
H.25.B / 22
Relief valve - Pressure test (H.25.B.16 - F.40.A.30)

CX225SR
NOTE: The dipper secondary relief valves (D) and (E) are calibrated to a higher pressure than the main relief valve
(A). To check or calibrate the secondary relief valves, main relief valve (A) must be overcalibrated.
NOTE: If the excavator is equipped with a safety valve on the dipper, secondary relief valve (D) is not tted on the
valve block, or it is overcalibrated. In this case, valve (D1) mounted on the safety valve must be calibrated.
5. The pressure readings on the pressure gauge
should be 392 ± 5 bar (39.2 MPa)
6. If the pressures are incorrect, calibrate dipper relief
valves (D) and (E), refer to Relief valve - Pressure
setting (H.25.B.16 - F.45.A.70)
26049 1 02/12/2004
H.25.B / 23
Relief valve - Pressure setting (H.25.B.16 - F.45.A.70)

CX225SR
Prior operation: Relief valve - Pressure test (H.25.B.16 - F.40.A.30)
1. Using a wrench, hold the adjusting screw (2) of the

relief valve and loosen the lock nut (1).
CRIL03K054A01 1

calibrated and hold against the stops.
3. Turn the adjusting screw (2) until the correct
pressure is obtained.
Next operation: To re-calibrate main relief valve (A), refer to Relief valve - Pressure setting (A.10.A.16
- F.45.A.70)
26049 1 02/12/2004
H.25.B / 24
Load holding valve - Disassemble (H.25.B.19 - F.10.A.25)

CX225SR
NOTE: Take care when disassembling the load holding valve, some parts are under pressure from the springs.
CRIL04A180F01 1
1. Secure the load holding valve assembly (67) in a

soft-jawed vice.
2. Remove the plug (P).
Remove piston (D), spool (E) and spring (G).
Unscrew and remove plug (C) then remove seal (N).
3. Remove sleeve (F) and valve (B).
4. Remove seals (J) and (K) and backup rings (L) and
(M) from the sleeve (F).
5. Remove spring seat (Q) and spring (H).
6. Remove plug (R), discard seal (S).
NOTE: The ball (T) is installed by force, do not try to
remove it.
26049 1 02/12/2004
H.25.B / 25
Load holding valve - Assemble (H.25.B.19 - F.10.A.20)

CX225SR
CRIL04A180F01 1
1. Fit seals (K) and (J) back-up rings (L) and (M) into
the grooves of the sleeve (F).
NOTE: Follow the positions of the seals and backup rings.
2. Install valve (B) and spool (E) in the oroce of
sleeve (F).
3. Fit spring seat (Q) on the end of valve (B), t spring
(H) on spring seat.
Insert the assembly in the load holding valve body.
Install a seal (N) on the plug (C).
Nm (C).
Fit spring (G), spool (E) and piston (D) in the load
holding valve.
Install a seal (N) on the plug (P).
Nm (P).
4. Install the plug (R) tted with a new seal (S).
Tighten to a torque of 14 - 18 Nm.
26049 1 02/12/2004
H.25.B / 26
Cylinder - Remove (H.25.B.26 - F.10.A.10)

CX225SR
1. Place a wooden chock under the cylinder.
CRIL03G066A00 1
2. Remove nuts (1) and (2).

Remove screw (3).
Remove pin (4).
CRIL04B044A01 2
3. Carefully raise the cylinder.

Attach a sling to retain the cylinder rod in the
cylinder barrel.
CRIL03G061A00 3
26049 1 02/12/2004
H.25.B / 27

Plug the ports.
CRIL03G068A01 4

Disconnect hoses (1), (2), (3) and (4).
Plug the ports.
CRIL04B045A01 5

7. Disconnect lubrication hose (1).
CRIL03G069A01 6
8. Attach a suitable lifting device to the cylinder.

Use all the equipment necessary to ensure sufcient
CRIL03G071A00 7
26049 1 02/12/2004
H.25.B / 28

Remove pin (3).
Carefully lift the cylinder and place it on suitable
stands.
Recover the shims.
CRIL03L048A01 8
10. Remove the sling that holds the rod together with
26049 1 02/12/2004
H.25.B / 29
Cylinder - Disassemble (H.25.B.26 - F.10.A.25)

CX225SR
1. Remove the collars from piping.

barrel.
Discard the seals.
CRPH03J002A 1
3. Remove screws (1) from the gland.
CRIL03K193A01 2

Remove cylinder barrel (2) from the repair bench.
CRIL03K194A01 3
26049 1 02/12/2004
H.25.B / 30

Remove locking screw (1) and ball (2) from piston.
NOTE: During assembly, the locking screw is crimped
in two places with a punch.
Bore out the crimped section with a drill.
CRIL03K195A01 4
6. Unscrew the nut from the piston.

NOTE: Unscrewing the piston nut requires a torque about
1,5 times greater than the tightening torque.
CRPH03J005A 5
7. Remove piston (2) and cushion bushing (1).

Discard seal (3).
CRIL03K196A01 6
8. Discard carrier seals (1), seals (2), (3) and (4), and
back-up rings (5).
CRIL03K197A01 7
26049 1 02/12/2004
H.25.B / 31

seals (6) and (7), back-up ring (8) and seal (9).
CRIL03K198A01 8

Remove grease tting (2).
CRIL03J023A01 9

Using a suitable driver, remove the cylinder head
bushing.
CRPH03J006A 10
26049 1 02/12/2004
H.25.B / 32
Cylinder - Assemble (H.25.B.26 - F.10.A.20)

CX225SR

CRPH03J006A 1

Install grease tting (2).
CRIL03J023A01 2

Install seals (6) and (7), back-up ring (8) and seal
(9).
Fit seal (3).
Mount gland (1) on cylinder rod (2).
CRIL03K198A01 3
26049 1 02/12/2004
H.25.B / 33

piston.
Install carrier seals (1) and (2) on the piston .
CRIL03K197A01 4
5. Install seal (3), cushion bushing (1) and piston (2)

on the cylinder rod.
CRIL03K196A01 5
6. Place the piston nut in position on the cylinder rod.

Tighten the piston nut to the required torque.
CRPH03J005A 6
7. Install the ball (2)

Install locking screw (1) and tighten it to the required
torque.
CRIL03L032A01 7
26049 1 02/12/2004
H.25.B / 34

using a punch.
CRIL03J02601A 8
9. Using slings and a suitable lifting device, install rod

CRIL03K194A01 9

CRIL03L033A01 10

cylinder barrel.
26049 1 02/12/2004
H.25.B / 35
Cylinder - Install (H.25.B.26 - F.10.A.15)

CX225SR

cylinder barrel.
CRIL03G061A00 1

Align the cylinder foot with the boom mounting
brackets.
Install shims (3) and pin.
Check clearance between the cylinder foot and the
support assembly, refer to DIPPER Lift - Service
limits (H.25.B - D.20.A.20).
replace the pin.
Fit the screw (2) and the rst nut (1) and tighten until
the nut touches the shoulder.
Fit the second nut (1) to keep the rst in position. CRIL03L048A01 2
3. Attach the lubrication hose (1) to the cylinder.
CRIL03G069A01 3

Remove the plugs.
CRIL03G068A01 4
26049 1 02/12/2004
H.25.B / 36

Connect hoses (1), (2) and (3) (4).
CRIL04B045A01 5

7. Align the cylinder rod with the dipper mounting
brackets.
Install pin (4).
To check for play between the cylinder head and the
assembly support, refer to DIPPER Lift - Service
limits (H.25.B - D.20.A.20).
replace the pin.
Install screw (3) and rst nut (2).
Tighten the nut until it touches the shoulder.
CRIL04B044A01 6

26049 1 02/12/2004
H.25.B / 37
Arm - Remove (H.25.B.50 - F.10.A.10)

CX225SR
Prior operation: To remove the bucket, refer to Arm - Remove (H.30.C.50 - F.10.A.10).
CRIL03L142G01 1
Description of components
(1) Screw (2) Nut
(3) Pin (4) Bushing
(7) Bushing (8) Grease tting
(9) Seal (10) Seal
1. To disconnect the dipper cylinder rod, refer to
Cylinder - Remove (H.25.B.26 - F.10.A.10).
Attach the dipper cylinder to the boom.
2. To install a vacuum pump, refer to PRIMARY
HYDRAULIC POWER SYSTEM - Drain uid
(A.10.A - F.35.A.20).
26049 1 02/12/2004
H.25.B / 38

Mark and disconnect the hoses between the boom
and the dipper.
Plug the ports.
CRIL03H006A00 2
4. Attach a suitable lifting device to the dipper.

Use all the play necessary to obtain sufcient
support during removal of the dipper.
Remove pin (3).
Move the machine backwards to separate the
dipper from the boom.
Lower the boom to the ground.
7. Place the dipper on suitable stands.
8. Discard seals (5), (9) and (10).
9. Remove grease ttings (8).
10. To remove bushings (4) only if they need replacing,
refer to DIPPER Lift - Service limits (H.25.B -
D.20.A.20).
11. To remove bushings (6) and (7) only if they need
replacing, refer to ARM TOOL ATTACHMENT Tilt -
Service limits (H.30.C - D.20.A.20).
26049 1 02/12/2004
H.25.B / 39
Arm - Install (H.25.B.50 - F.10.A.15)

CX225SR
CRIL03L142G01 1
(1) Screw (2) Nut
(3) Pin (4) Bushing
(7) Bushing (8) Grease tting
(9) Seal (10) Seal
1. Install bushings (4), (6) and (7).
3. Install grease ttings (8).
4. Attach a suitable lifting device to the dipper.
Bring the dipper close to the machine.
Start the engine.
Align the dipper orices with the orices on the
boom.
26049 1 02/12/2004
H.25.B / 40
5. Install pin (3) and screw (1).

6. To check for play between the dipper and the boom,
refer to DIPPER Lift - Service limits (H.25.B -
D.20.A.20).
If necessary, remove the pin and add shims as
required to obtain the correct play, re-install the pin
and the screw.
8. To connect the boom cylinder rod, refer to Cylinder
- Install (H.25.B.26 - F.10.A.15).
Remove the plugs.
Connect the hoses between the boom and the
dipper, following the markings made during removal.
Stop and remove the vacuum pump.
CRIL03H006A00 2
26049 1 02/12/2004
H.25.B / 41
Index
WORKING ARM - H
DIPPER Lift - 25.B

Arm - Install (H.25.B.50 - F.10.A.15) 40
CX225SR
Arm - Remove (H.25.B.50 - F.10.A.10) 38
CX225SR
CX225SR
CX225SR
CX225SR
CX225SR
CX225SR
CX225SR
CX225SR
CX225SR
CX225SR
CX225SR
CX225SR
CX225SR
CX225SR
CX225SR
DIPPER Lift - Service limits (H.25.B - D.20.A.20) 4
CX225SR
CX225SR
CX225SR
Relief valve - Overhaul (H.25.B.16 - F.10.A.40) 22
CX225SR
CX225SR
CX225SR
CX225SR
CX225SR
CX225SR
26049 1 02/12/2004
H.25.B / 42
WORKING ARM - H
ARM TOOL ATTACHMENT Tilt - 30.C
CX225SR
26050 1 02/12/2004
H.30.C / 1
Contents
WORKING ARM - H
TECHNICAL DATA
ARM TOOL ATTACHMENT Tilt - Service limits (H.30.C - D.20.A.20) 4
CX225SR
Command valve
Command valve Hand control valve - Torque (H.30.C.12.10 - D.20.A.10) 6
CX225SR
Cylinder
Cylinder - Torque (H.30.C.26 - D.20.A.10) 7
CX225SR
FUNCTIONAL DATA
ARM TOOL ATTACHMENT Tilt - Hydraulic schema (H.30.C - C.20.A.20) 8
CX225SR
Command valve
Command valve Hand control valve - Sectional view (H.30.C.12.10 - C.10.A.30) 10
CX225SR
Control valve
Control valve - Sectional view (H.30.C.13 - C.10.A.30) 11
CX225SR
Cylinder
Cylinder - Sectional view (H.30.C.26 - C.10.A.30) 12
CX225SR
SERVICE
Command valve
Command valve Hand control valve - Overhaul (H.30.C.12.10 - F.10.A.40) 13
CX225SR
Control valve
Control valve - Disassemble (H.30.C.13 - F.10.A.25) 14
CX225SR
Control valve - Assemble (H.30.C.13 - F.10.A.20) 15

CX225SR
Relief valve
Relief valve - Overhaul (H.30.C.16 - F.10.A.40) 16
CX225SR
Relief valve - Pressure test (H.30.C.16 - F.40.A.30) 17

CX225SR
Relief valve - Pressure setting (H.30.C.16 - F.45.A.70) 18

CX225SR
Cylinder
Cylinder - Remove (H.30.C.26 - F.10.A.10) 19
CX225SR
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H.30.C / 2
Cylinder - Disassemble (H.30.C.26 - F.10.A.25) 21
CX225SR
Cylinder - Assemble (H.30.C.26 - F.10.A.20) 24

CX225SR
Cylinder - Install (H.30.C.26 - F.10.A.15) 27

CX225SR
Arm
Arm - Remove (H.30.C.50 - F.10.A.10) 29
CX225SR
Arm - Install (H.30.C.50 - F.10.A.15) 31

CX225SR
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H.30.C / 3
WORKING ARM - ARM TOOL ATTACHMENT Tilt
ARM TOOL ATTACHMENT Tilt - Service limits (H.30.C - D.20.A.20)

CX225SR
CRIL03G012E03 1
Linkage points
1. Bucket cylinder foot on dipper
CRIL03G021E01 2
(C) (a-b) 0.5 - 3 mm shims
2. Yoke on dipper
CRIL03G022E01 3
(A) 32 mm 30 mm
(B) 296 mm 294 mm
(C) clearance 1 - 1.5 mm shims
26050 1 02/12/2004
H.30.C / 4
3. Connecting rod on bucket
CRIL03G023E01 4
(A) bucket 307 mm 313 mm
(B) connecting rod 306 mm 304 mm
(C) play 1 - 3.5 mm shims
4. Connecting rod, yoke and bucket cylinder head
CRIL03G024E01 5
(A) yoke 32 mm 30 mm
(C) clearance 1 - 1.5 mm shims
(D) 96 mm 98 mm
(E) 95 mm 93 mm
(F) clearance 0.5 - 2 mm shims
(G) pin diameter 80 mm 79 mm
(G) yoke bushing diameter 80 mm 81.5 mm
(G) bucket cylinder head bushing 80 mm 81.5 mm
diameter
26050 1 02/12/2004
H.30.C / 5
5. Bucket on bucket head
CRIL03G025E01 6
(A) bucket 307 mm 313 mm
(B) bucket head 306 mm 304 mm
(C) (a-b) 1 - 3.5 mm shims
(D) 16 mm 8 mm
(E) pin diameter 80 mm 79 mm
(E) dipper head bushing diameter 80 mm 81.5 mm
(E) bucket bushing diameter 80 mm 81.5 mm
Command valve Hand control valve - Torque (H.30.C.12.10 -

D.20.A.10)
CX225SR
26050 1 02/12/2004
H.30.C / 6
Cylinder - Torque (H.30.C.26 - D.20.A.10)

CX225SR
CRIL03L108G01 1
Description
(1) Screw 267 Nm
(2) Screw 41.59 - 60.81 Nm
(3) Screw 25.62 - 37.88 Nm
(4) Screw 32.35 - 41.25 Nm
(5) Nut (M 62) 6650 Nm
(6) Screw 46.2 - 67.6 Nm
(7) Screw 41.59 - 60.81 Nm
26050 1 02/12/2004
H.30.C / 7
ARM TOOL ATTACHMENT Tilt - Hydraulic schema (H.30.C -

C.20.A.20)
CX225SR
CRIL04A049G01 1
Bucket opening circuit - Dynamic Description
Bucket opening (small cylinder chamber) (28) is supplied by the output from pump (D1).
(15) Main control valve (28) Bucket cylinder
(P2) Pump D1 outlet ow (Pa7/A7) Bucket closing
(Pb7/B7) Bucket opening
26050 1 02/12/2004
H.30.C / 8
CRIL04A050G01 2
Bucket closing circuit - Dynamic Description
Bucket closing (large cylinder chamber) (28) is supplied by the output from pump (D1).
(15) Main control valve (28) Bucket cylinder
(P2) Pump D1 outlet ow 1 (Pa7/A7) Bucket closing
(Pb7/B7) Bucket opening
26050 1 02/12/2004
H.30.C / 9
Command valve Hand control valve - Sectional view (H.30.C.12.10 -

C.10.A.30)
CX225SR
26050 1 02/12/2004
H.30.C / 10
Control valve - Sectional view (H.30.C.13 - C.10.A.30)

CX225SR
CRIL04A167F01 1
Bucket section
(4) Bucket spool (7) Seal

(69) Secondary relief valve (74) Screw M10x1.5 L=28
26050 1 02/12/2004
H.30.C / 11
Cylinder - Sectional view (H.30.C.26 - C.10.A.30)

CX225SR
CRIL03L108G02 1

(7) Washer (8) Screw (9) Washer
(13) Bushing (14) Cushion bushing (15) Seal
(28) Nut (29) Seal (30) Piston
26050 1 02/12/2004
H.30.C / 12
Command valve Hand control valve - Overhaul (H.30.C.12.10 -

F.10.A.40)
CX225SR
1. Refer to:
(F.40.C.12.10 - F.10.A.10)
Cleaning (F.40.C.12.10 - F.30.A.10)
inspection (F.40.C.12.10 - F.40.A.10)
Assemble (F.40.C.12.10 - F.10.A.20)
(F.40.C.12.10 - F.10.A.15)
26050 1 02/12/2004
H.30.C / 13
Control valve - Disassemble (H.30.C.13 - F.10.A.25)

CX225SR
CRIL04A167F01 1
Bucket spool section

Remove spool (4).
Remove ange (37), and discard seal (36).
4. Remove valves (69).
26050 1 02/12/2004
H.30.C / 14
Control valve - Assemble (H.30.C.13 - F.10.A.20)

CX225SR
- F.40.A.10)
CRIL04A167F01 1
Bucket spool section
Torque settings
Valve (69) 78 - 88 Nm
Screw (74) 39 - 44 Nm
Screw (75) 58 - 64 Nm
1. Install valves (69) and tighten to torque.
Install ange (37) with screws (75).
3. Coat the threaded parts of the spool with thread
locking uid (4).
Place the end of the spool (spring side) in a
soft-jawed vice.
Install spring (B) and seats (C) on screw (D).
Assemble and tighten the screws to the required
torque.
4. Install the tted spool.
Install caps (8) and (12) t with new seals (7).
Install screws (74) and tighten to torque.
26050 1 02/12/2004
H.30.C / 15
Relief valve - Overhaul (H.30.C.16 - F.10.A.40)

CX225SR
1. To disassemble this valve, refer to Relief valve -

Disassemble (H.20.B.16 - F.10.A.25).
2. For assembly, refer to Relief valve - Assemble
(H.20.B.16 - F.10.A.20)
26050 1 02/12/2004
H.30.C / 16
Relief valve - Pressure test (H.30.C.16 - F.40.A.30)

CX225SR
NOTE: The secondary relief valves on the bucket, (F) and (G) are calibrated to a higher pressure than the main
relief valve (A). To check or calibrate the secondary relief valves, main relief valve (A) must be overcalibrated.
5. The pressure readings on the pressure gauge
should be 392 ± 5 bar (39.2 ± 0.5 MPa)
6. If the pressures are incorrect, calibrate bucket relief
valves (F) and (G), refer to Relief valve - Pressure
setting (H.30.C.16 - F.45.A.70)
26050 1 02/12/2004
H.30.C / 17
Relief valve - Pressure setting (H.30.C.16 - F.45.A.70)

CX225SR
Prior operation: Relief valve - Pressure test (H.30.C.16 - F.40.A.30)
1. Using a wrench, hold adjusting screw (2) of the

main relief valve in position and loosen lock nut (1).
CRIL03K054A01 1

calibrated and hold it up against the stops.
3. Turn adjusting screw (2) until the correct pressure
is reached.
Next operation: Reset main relief valve (A), refer to Relief valve - Pressure setting (A.10.A.16 - F.45.A.70)
26050 1 02/12/2004
H.30.C / 18
Cylinder - Remove (H.30.C.26 - F.10.A.10)

CX225SR
1. Attach a suitable lifting device to the cylinder.

Use all equipment necessary to ensure sufcient
Place a wooden chock under the cylinder.
CRIL03G073A00 1
CRIL03G074A01 2
3. Remove pin (1).
CRIL03G075A01 3
26050 1 02/12/2004
H.30.C / 19
4. Carefully lift the cylinder and attach a sling to retain

the cylinder rod in the cylinder barrel.
Recover shims (1).
CRIL03G076A01 4

Disconnect the supply hoses (1).
Plug ports.
CRIL03G077A01 5
6. Remove screws (1), plate (2) and pin (3).

Remove nuts (1) and (2).
Remove screw (3).
Remove pin (4).
CRIL04B035A01 6
7. Carefully lift the cylinder and place it on suitable

stands.
Recover shims (1).
CRIL03G079A01 7
26050 1 02/12/2004
H.30.C / 20
Cylinder - Disassemble (H.30.C.26 - F.10.A.25)

CX225SR
1. Mark the retaining clips on the piping.

Remove the collars from piping if necessary.
barrel.
Discard the seals.
CRPH03J002A 1
3. Mark the gland and cylinder barrel.

Remove screws (1) from the gland.
CRIL03K193A01 2

Remove cylinder barrel (2) from the repair bench.
CRIL03K194A01 3
26050 1 02/12/2004
H.30.C / 21

Remove screw (1) and ball (2).
NOTE: During assembly, the locking screw is peened in
two places with a punch.
Bore out the peened section with a drill.
CRIL03K195A01 4
6. Unscrew the piston xing nut.

NOTE: Unscrewing the nut requires a torque about 1,5
times greater than the tightening torque.
CRPH03J005A 5
7. Remove the xing nut from piston (4) and washer

(3).
Remove piston (2) and cushion bushing (1).
CRIL03L079A01 6
8. Discard carrier seals (1), seals (2), (3), (4) and

back-up rings (5).
CRIL03K197A01 7
26050 1 02/12/2004
H.30.C / 22

seals (6) and (7), back-up ring and seal (8), (9).
CRIL03K198A01 8

CRIL03J023A01 9
11. Place the boom cylinder head in a press.

Using a suitable centring piece, remove the cylinder
head bushing.
CRPH03J006A 10
26050 1 02/12/2004
H.30.C / 23
Cylinder - Assemble (H.30.C.26 - F.10.A.20)

CX225SR

CRPH03J006A 1

Install grease ttings (2).
CRIL03J023A01 2

Install seals (6) and (7), back-up ring (8) and seal
(9).
Fit seal (3).
Mount gland (1) on cylinder rod (2).
CRIL03K198A01 3
26050 1 02/12/2004
H.30.C / 24

piston.
Install carrier seals (1) and (2) on the piston.
CRIL03K197A01 4
5. Install cushion bushing (1), piston (2) and washer

(3) on the cylinder rod.
CRIL03L079A01 5
6. Place the piston xing nut in position on the cylinder

rod.
Tighten the nut to the required torque.
CRPH03J005A 6
7. Install ball (2) and tighten locking screw (1) to the

required torque.
CRIL03L032A01 7
26050 1 02/12/2004
H.30.C / 25

using a punch.
CRIL03J02601A 8
9. Using a sling and a suitable lifting device, install rod

CRIL03K194A01 9

CRIL03L033A01 10

cylinder barrel.
26050 1 02/12/2004
H.30.C / 26
Cylinder - Install (H.30.C.26 - F.10.A.15)

CX225SR

cylinder barrel.
CRIL03G061A00 1

Align the cylinder foot with the dipper mounting
brackets.
Fit shims (1).
CRIL03G079A01 2
3. Install pin (3).

Check clearance between the cylinder foot
and the mounting bracket, refer to ARM TOOL
ATTACHMENT Tilt - Service limits (H.30.C -
D.20.A.20).
replace the pin.
Install plate (2) and screws (1).
Install pin (4).
Fit screw (3) and rst nut (1) and tighten until the
nut touches the shoulder.
Fit the second nut to keep the rst in position. CRIL04B035A01 3

Remove the plugs.
Connect hoses (1).
CRIL03G077A01 4
26050 1 02/12/2004
H.30.C / 27
5. Align the cylinder rod with the yoke/connecting rod

assembly.
Fit the shims.
CRIL03G080A00 5
6. Install pin (3).

Check the clearance between the cylinder head and
the yoke/connecting rod assembly, refer to ARM
TOOL ATTACHMENT Tilt - Service limits (H.30.C
- D.20.A.20).
If necessary remove pin (3) and add or remove
replace the pin.
Fit screw (2) and rst nut (1) and tighten until the
nut touches the shoulder.
CRIL03G081A01 6

26050 1 02/12/2004
H.30.C / 28
Arm - Remove (H.30.C.50 - F.10.A.10)

CX225SR
CRIL03L143G01 1
(1) Pin (2) Retaining pin
(3) Pin (4) Snap ring
(5) Seal (6) Yoke
(7) Connecting rod (8) Grease tting
(9) Nut (10) Screw
(11) Pin (12) Shim
(13) Seal (14) Pin
(15) Bushing
1. Place the bucket at on at, level ground.
Operate the attachment controls so that pin (1) is
not under stress from the dipper load.
2. Remove snap rings (4) and retaining pins (2).
3. Remove pins (1) and (3).
26050 1 02/12/2004
H.30.C / 29

Disengage the bucket dipper.
6. Attach a suitable lifting device to yoke (6).
To disconnect the bucket cylinder rod from the
yoke and the connecting rods, refer to Cylinder -
Remove (H.30.C.26 - F.10.A.10).
9. Remove shaft (11) and connecting rods (7).
10. Recover shims (12).
11. To remove bushings (15), only if they need
replacing, refer to ARM TOOL ATTACHMENT Tilt -
Service limits (H.30.C - D.20.A.20).
26050 1 02/12/2004
H.30.C / 30
Arm - Install (H.30.C.50 - F.10.A.15)

CX225SR
CRIL03L143G01 1
(1) Pin (2) Retaining pin
(3) Pin (4) Snap ring
(5) Seal (6) Yoke
(7) Connecting rod (8) Grease tting
(9) Nut (10) Screw
(11) Pin (12) Shim
(13) Seal (14) Pin
(15) Bushing
1. Install bushings (15) in yoke (6).
2. Install pin (11), connecting rods (7), shims (12) and
screws (10).
26050 1 02/12/2004
H.30.C / 31
3. To check for play between the dipper and

the connecting rods, refer to ARM TOOL
ATTACHMENT Tilt - Service limits (H.30.C -
D.20.A.20).
If necessary, remove the pin and add or remove
shims as required to obtain the correct play, reinstall
the pin and the screw.
6. Install the bucket cylinder rod on the connecting
rod/yoke assembly, refer to Cylinder - Install
(H.30.C.26 - F.10.A.15).
Align the dipper’s orices with the ports on the
bucket.
Install pin (1), cotter pin (2) and snap ring (4).
9. Align the orices on the yoke with the ports on the
bucket.
Install pin (3), cotter pin (2) and snap ring (4).
10. To check for play between the yoke and the bucket,
refer to ARM TOOL ATTACHMENT Tilt - Service
limits (H.30.C - D.20.A.20).
If necessary, remove the pin and add or remove
shims as required to obtain the correct play, replace
the pin.
26050 1 02/12/2004
H.30.C / 32
Index
WORKING ARM - H

Arm - Install (H.30.C.50 - F.10.A.15) 31
CX225SR
Arm - Remove (H.30.C.50 - F.10.A.10) 29
CX225SR
ARM TOOL ATTACHMENT Tilt - Hydraulic schema (H.30.C - C.20.A.20) 8
CX225SR
ARM TOOL ATTACHMENT Tilt - Service limits (H.30.C - D.20.A.20) 4
CX225SR
Command valve Hand control valve - Overhaul (H.30.C.12.10 - F.10.A.40) 13
CX225SR
Command valve Hand control valve - Sectional view (H.30.C.12.10 - C.10.A.30) 10
CX225SR
Command valve Hand control valve - Torque (H.30.C.12.10 - D.20.A.10) 6
CX225SR
Control valve - Assemble (H.30.C.13 - F.10.A.20) 15
CX225SR
Control valve - Disassemble (H.30.C.13 - F.10.A.25) 14
CX225SR
Control valve - Sectional view (H.30.C.13 - C.10.A.30) 11
CX225SR
Cylinder - Assemble (H.30.C.26 - F.10.A.20) 24
CX225SR
Cylinder - Disassemble (H.30.C.26 - F.10.A.25) 21
CX225SR
Cylinder - Install (H.30.C.26 - F.10.A.15) 27
CX225SR
Cylinder - Remove (H.30.C.26 - F.10.A.10) 19
CX225SR
Cylinder - Sectional view (H.30.C.26 - C.10.A.30) 12
CX225SR
Cylinder - Torque (H.30.C.26 - D.20.A.10) 7
CX225SR
Relief valve - Overhaul (H.30.C.16 - F.10.A.40) 16
CX225SR
Relief valve - Pressure setting (H.30.C.16 - F.45.A.70) 18
CX225SR
Relief valve - Pressure test (H.30.C.16 - F.40.A.30) 17
CX225SR
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H.30.C / 33
SERVICE
PRINTED IN FRANCE
26047 1 02/12/2004
REPAIR MANUAL
TOOLS AND COUPLERS
CX225SR
26051 1 02/12/2004
J
Contents
TOOLS AND COUPLERS - J
DIGGING Hammer J.20.E

CX225SR
26051 1 02/12/2004
J
DIGGING Hammer - 20.E
CX225SR
26052 1 02/12/2004
J.20.E / 1
Contents
TECHNICAL DATA
Command valve
Command valve Foot command valve - Special tools (J.20.E.12.10 - D.20.A.40) 3
CX225SR
Command valve Foot command valve - General specication (J.20.E.12.10 - D.40.A.10) 3

CX225SR
FUNCTIONAL DATA
DIGGING Hammer - Hydraulic schema (J.20.E - C.20.A.20) 4
CX225SR
Control valve
Control valve - Sectional view (J.20.E.14 - C.10.A.30) 8
CX225SR
SERVICE
Command valve
Command valve Foot command valve - Remove (J.20.E.12.10 - F.10.A.10) 9
CX225SR
Command valve Foot command valve - Disassemble (J.20.E.12.10 - F.10.A.25) 10

CX225SR
Command valve Foot command valve - Visual inspection (J.20.E.12.10 - F.40.A.10) 12

CX225SR
Command valve Foot command valve - Assemble (J.20.E.12.10 - F.10.A.20) 13

CX225SR
Command valve Foot command valve - Install (J.20.E.12.10 - F.10.A.15) 14

CX225SR
Control valve
Control valve - Disassemble (J.20.E.14 - F.10.A.25) 15
CX225SR
Control valve - Assemble (J.20.E.14 - F.10.A.20) 16

CX225SR
DIAGNOSTIC
Command valve
Command valve Foot command valve - Troubleshooting (J.20.E.12.10 - G.40.A.10) 17
CX225SR
26052 1 02/12/2004
J.20.E / 2
TOOLS AND COUPLERS - DIGGING Hammer
Command valve Foot command valve - Special tools (J.20.E.12.10 -

D.20.A.40)
CX225SR
NOTE: Tool to be manufactured locally
CRIL03L111A01 1
Used for removing and installing the cover bushing.

(A) 10 mm
(B) 8 mm
(C) 20 mm
(D) 30 mm
(E) 2 mm
Command valve Foot command valve - General specication

(J.20.E.12.10 - D.40.A.10)
CX225SR
Working pressure 69 bar

Secondary pressure (Max. control pressure) 0 barto 29 bar
Authorised return pressure 2,9 bar
Rated ow 10 L/min
Operating angle ±10 °, ± 12,4 °, ± 15 °
26052 1 02/12/2004
J.20.E / 3
DIGGING Hammer - Hydraulic schema (J.20.E - C.20.A.20)

CX225SR
CRIL04A052H01 1
Hammer circuit - Dynamic description
Hammer circuit
(15) Main control valve (72) Foot control
(76) 3-way selector (P1) D2 outlet ow
26052 1 02/12/2004
J.20.E / 4
(Pa2/A2) Option circuit (Pb2/B2) Option circuit

(S14) Hammer/grab switch (Y9) Dual output hammer/grab option solenoid
valve.
HAMMER - DYNAMIC DESCRIPTION

• The 3-way selector (76) must be positioned for the hammer function.
The hammer is supplied by the output from pump (D2).
• When the hammer/grab switch (S14) is in the hammer position and the control pedal (72) is moved towards
the front of the machine, the option spool is piloted by port (Pa2) , which allows the hammer to be supplied
via port (A2).
• As soon as the hammer return pressure is higher than the regulating pressure for the safety valve for the
3-way selector (76), the oil returns to the reservoir via this same safety valve.
26052 1 02/12/2004
J.20.E / 5
CRIL04A051H01 2
Grab circuit - dynamic description
Grab circuit
(15) Main control valve (72) Foot control
(75) Flow re-injection valve (76) 3-way selector
(79) Control shuttle block (P1) Pump D2 outlet ow
(P2) Pump D1 outlet ow (Pa2/A2) Option circuit
(Pb2/B2) Option circuit (Pa9/Pb9) Dipper spool 2
(S14) Hammer/grab switch (Y9) Dual output hammer/grab option solenoid
valve.
26052 1 02/12/2004
J.20.E / 6
GRAB - DYNAMIC DESCRIPTION

• The 3-way selector (76) must be positioned for the grab function.
• The grab can be supplied by the outputs from pumps (D1) and (D2).
• The output from pump (D2) directly supplies the option spool. The output from pump (D1) is forced towards
the ow re-injection valve (75) and joins the output from pump (D2) at the option spool inlet.
• When the hammer/grab switch (S14) is in the grab position, the hammer/grab dual output solenoid valve
option (Y9) is activated.
• When the foot control (72) is moved forwards or backwards, the pilot pressure, after passing through the
shuttle valve ball block (79) and the dual output hammer/grab option solenoid valve (Y9), unlocks the ow
re-injection valve (75) and pilots dipper spool 2 via port (Pb9).This closes the free passage of dipper spool 2
and allows the output of the pump (P2) to be reinjected through the ow reinjection valve (75) through port
(P3) of the main distributor (15).
• The pilot pressure from the hammer/grab dual output solenoid valve option (Y9) reaches port (P) of the ow
re-injection valve (75) and actuates the unlocking spool for the load holding valve of the ow reinjection valve
(75). As a result, the oil arriving at port (B) is re-injected through port (A) of the ow re-injection valve (75)
towards port (P4) of the main control valve (15) so that it rejoins the output from pump (P1) at the option
spool inlet.
• When the dipper extending control is operated at the same time as the grab, the output from pump (P1)
supplies the grab and the output from pump (P2) supplies the dipper.
26052 1 02/12/2004
J.20.E / 7
Control valve - Sectional view (J.20.E.14 - C.10.A.30)

CX225SR
CRIL04A168F01 1
Option section (hammer or grab)

(12) Small cap (17) Optional spool
(64) Seal (74) Screw M10x1.5 L=28
(75) Screw M10x1.5 L=40 (87) Plug
(88) Cap (89) Seal
(91) Plug (92) Plug
(96) Screw (97) Plug
(D) Spool screw
26052 1 02/12/2004
J.20.E / 8
Command valve Foot command valve - Remove (J.20.E.12.10 -

F.10.A.10)
CX225SR
Prior operation: To remove the side guard from under the cab oor, refer to Side shield - Remove (E.20.A.70
- F.10.A.10)
1. Attach identication labels to all hoses on control

pedal (1).
Plug the ports.
CRIL03L135A01 1
2. Remove nut (1), screws (2) and remove pedal (3).

Remove the oor mat.
Remove screws and washers (4) then remove
control pedal (5).
CRIL03L136A01 2
26052 1 02/12/2004
J.20.E / 9
Command valve Foot command valve - Disassemble (J.20.E.12.10 -

F.10.A.25)
CX225SR
or dropped.
The control pedal components may rust due to contamination and humidity if they are left
without protection after disassembly.If work has to be interrupted, the components must be protected from
contamination or corrosion.
NOTE: Mark the position and bore of all parts.
CRIL03L116G01 1
Cross-sectional view
1. Tighten the control pedal in a vice with soft jaws.
Remove bellows (16).

2. Remove locking screw (18) from cam pin (21).
3. Remove cam pin (21) using a drift.
26052 1 02/12/2004
J.20.E / 10
4. Remove cam (20) complete with steel balls (17).

NOTE: Do not remove steel balls (17).
5. To remove bushings (19) from cam (20), refer to
Command valve Foot command valve - Special
tools (J.40.F.12.10 - D.20.A.40)
6. Remove xing screws (13) from cover (11).
7. Remove cover (11) from body (1).
8. Remove push rod guides (12) complete with seals
(10) and (14) push rod (15).
9. Remove push rod (15) from guide (12).
10. Remove seals (14) and (10) from guide (12).
11. Remove the spool assembly (2).
12. Remove return spring (8).
13. Compress the spool return spring with the seat so
as to be able to push it out.
NOTE: Be careful not to damage the spool surface.
Do not compress the spring by more than 4 mm.
14. Remove spool (2), spring seat (9), calibrated spring
(7), shim (6) and washer (5).
15. Remove plug (4).
16. Discard seal (3)
26052 1 02/12/2004
J.20.E / 11
Command valve Foot command valve - Visual inspection

(J.20.E.12.10 - F.40.A.10)
CX225SR
1. Check for cracks, distortion or blocking of the

springs.
If defects are found, replace the springs.
defective.
Make sure that the spool slides freely in the foot
control body bore.
If defects are found, replace the foot control
assembly.
3. Check the bores for damage, internal damage
to housings or evidence of any othe foot control
internal wear.
If the foot control is damaged, replace the entire
assembly.
26052 1 02/12/2004
J.20.E / 12
Command valve Foot command valve - Assemble (J.20.E.12.10 -

F.10.A.20)
CX225SR
CRIL03L116G02 1
Torque settings
Plug (4) 25.4 - 33.4 Nm
Fixing screws (13) on cover (11) 27.4 - 31.11 Nm
Locking screw (18) on the cam pin (21) 5.9 - 7.9 Nm (to be installed with thread lock uid)
1. The parts are assembled in the reverse order
of disassembly, refer to Command valve Foot
command valve - Disassemble (J.40.F.12.10 -
F.10.A.25)
26052 1 02/12/2004
J.20.E / 13
Command valve Foot command valve - Install (J.20.E.12.10 -

F.10.A.15)
CX225SR
1. Mount foot control (5) in place and install the screws

and washers (4).
Install the oor mat.

Install the foot pedal (3), nut (1) and screws (2).
CRIL03L136A01 1

Connect all hoses (2) to the foot control (1) following
the markings made during removal.
CRIL03L135A01 2
Next operation: To install the side guard under the cab oor, refer to Side shield - Remove (E.20.A.70 - F.10.A.10).
26052 1 02/12/2004
J.20.E / 14
Control valve - Disassemble (J.20.E.14 - F.10.A.25)

CX225SR
CRIL04A168F01 1
Option spool section (hammer or grab)

Remove spool (17).
Remove spring (B) and seats (C).
NOTE: To avoid abrasion of the slide valve surface during
dismantling of the slide valve assembly, use a soft-jawed
vice and clamp the slide valve as closely as possible to
the head in order to avoid any deformation. If the threaded
part of the screw is coated with locking uid, heat the
screw head with an industrial drier until it can be removed
easily (usually the temperature should be 200 - 250 °C).
If the spring is distorted (impaired functioning) during this
3. Remove plugs (91) and (97).
Discard seals (64).
Remove ange (43), discard seal (36).
Remove plug (92), discard seal.
Remove caps (88) and (89) and discard seals .
6. Remove plugs (87) and discard seals.
26052 1 02/12/2004
J.20.E / 15
Control valve - Assemble (J.20.E.14 - F.10.A.20)

CX225SR
- F.40.A.10)
CRIL04A168F01 1
Option spool section (hammer or grab)
Torque settings
Screw (74) 39 - 44 Nm
Screw (75) 58 - 64 Nm
Plug (87) 78 - 88 Nm
Plug (91) 19 - 22 Nm
Plug (92) 206 - 226 Nm
Screw (96) 58 - 64 Nm
Plug (97) 19 - 22 Nm
1. Install and tighten to torque plugs (87), (91), (92)
and (97) complete with new seals
Install ange (43) with screws (96).
Tighten screws to torque (96).
3. Install new seals (89) and caps (88).
4. Apply thread lock uid to the threaded parts of the
spool (17).
Clamp end of the spool (spring side) in a soft-jawed
vice.
Install spring (B) and seats (C) on screw (D).
Install and tighten screws to torque (D).
5. Install caps (8) and (12) complete with new seals (7).
26052 1 02/12/2004
J.20.E / 16
Command valve Foot command valve - Troubleshooting

(J.20.E.12.10 - G.40.A.10)
CX225SR
NOTE: The table below shows a list of common problems. This list is not exhaustive.
External oil leaks O-ring bearing surfaces scratched Repair or replace the parts
Defective seals Replace the seals
The secondary pressure Worn or broken spool return spring Replace the spring
does not increase
gradually or is out of
tolerance.
Dirt on the spool. Disassemble, clean and repair. Replace
The lever does not move Dirt in the piston Disassemble, clean and repair. Replace
freely or does not return the assembly if necessary
to the neutral position
Dirt in the pushrod Disassemble, clean and repair. Replace
Dirt on the pivot pin and cam Disassemble, clean and repair. Replace
Worn or broken piston return spring Replace the spring
Damping force too weak Broken damper pin Replace the pin.
Dirt in the piston Disassemble, clean and repair. Replace
Damping force too strong Piston restrictor port blocked Disassemble, clean and repair. Replace
26052 1 02/12/2004
J.20.E / 17
Index

Command valve Foot command valve - Assemble (J.20.E.12.10 - F.10.A.20) 13
CX225SR
Command valve Foot command valve - Disassemble (J.20.E.12.10 - F.10.A.25) 10
CX225SR
Command valve Foot command valve - General specication (J.20.E.12.10 - D.40.A.10) 3
CX225SR
Command valve Foot command valve - Install (J.20.E.12.10 - F.10.A.15) 14
CX225SR
Command valve Foot command valve - Remove (J.20.E.12.10 - F.10.A.10) 9
CX225SR
Command valve Foot command valve - Special tools (J.20.E.12.10 - D.20.A.40) 3
CX225SR
Command valve Foot command valve - Troubleshooting (J.20.E.12.10 - G.40.A.10) 17
CX225SR
Command valve Foot command valve - Visual inspection (J.20.E.12.10 - F.40.A.10) 12
CX225SR
Control valve - Assemble (J.20.E.14 - F.10.A.20) 16
CX225SR
Control valve - Disassemble (J.20.E.14 - F.10.A.25) 15
CX225SR
Control valve - Sectional view (J.20.E.14 - C.10.A.30) 8
CX225SR
DIGGING Hammer - Hydraulic schema (J.20.E - C.20.A.20) 4
CX225SR
26052 1 02/12/2004
J.20.E / 18
26052 1 02/12/2004
J.20.E / 19
SERVICE
PRINTED IN FRANCE
26051 1 02/12/2004
26051 1 02/12/2004
SERVICE
PRINTED IN FRANCE
9-40691 1 02/12/2004
22 27 26 25
P m1 Ps Ps P m2
30 *
P IT E M DE S C R IP T ION P R E S S UR E S E T T ING
C2
28 * 83 A= MAIN R E LIE F (S T ANDAR D) 34.3 MP a / 343 bar / 4977 ps i
E
T2 T1
*B 45 A=
B =
MAIN R E LIE F (B OOS T )
B OOM R AIS ING P OR T S E C ONDAR Y R E LIE F

37.3 MP a / 373 bar / 5410 ps i
39.2 MP a / 392 bar / 5685 ps i

Dr D1 C2 C2 B 1/B 2 = R E LIE F ON B OOM HB C V 39.2 MP a / 392 bar / 5685 ps i
E E
C = B OOM LOWE R ING P OR T S E C ONDAR Y R E LIE F 39.2 MP a / 392 bar / 5685 ps i
D= DIP P E R OUT P OR T S E C ONDAR Y R E LIE F 39.2 MP a / 392 bar / 5685 ps i
D1 = R E LIE F ON DIP P E R HB C V 39.2 MP a / 392 bar / 5685 ps i

P1 P2
K1 P2 P1
K2 E = DIP P E R IN P OR T S E C ONDAR Y R E LIE F 39.2 MP a / 392 bar / 5685 ps i
RED
RED
F = B UC K E T OP E N P OR T S E C ONDAR Y R E LIE F 39.2 MP a / 392 bar / 5685 ps i
P il L1 L2 G = B UC K E T C LOS E P OR T S E C ONDAR Y R E LIE F 39.2 MP a / 392 bar / 5685 ps i
H= P ILOT P R E S S UR E R E LIE F 3.9 MP a / 39 bar / 566 ps i

T A B C I= R IG HT -HAND S WING P OR T S E C ONDAR Y R E LIE F 30.4 MP a / 304 bar / 4409 ps i
V2 P il P il J = LE F T -HAND S WING P OR T S E C ONDAR Y R E LIE F 30.4 MP a / 304 bar / 4409 ps i
K 1/K 2 = T R AV E L R E V E R S E P OR T S E C ONDAR Y R E LIE F 34.3 MP a / 343 bar / 4975 ps i

T T
J I GB V2 V2
L1/L2 = T R AV E L F OR WAR D P OR T S E C ONDAR Y R E LIE F 34.3 MP a / 343 bar / 4975 ps i
GA N1/N2 = NE G AT IV E C ONT R OL R E LIE F 2.55 MP a / 25.5 bar / 370 ps i
O/P = S E C ONDAR Y R E LIE F (2eme OP T ION) 1.5 MP a / 15 bar / 217 ps i
P m2 P m1 R = MAIN R E LIE F (2eme OP T ION) 23.5 MP a / 235 bar / 3408 ps i

77 15
MU B P b5 23 51 = AC C UMULAT OR P R E C HAR G E 1.5 MP a / 15 bar / 218 ps i
23 21 16 21 29 29
A
C B
A B E F D 77 15
A P b8
R IG HT
LE F T R H F R ONT LH F R ONT
R H R E AR LH R E AR
* 73 R IT E M DE S C R IP T ION
1.2 44 84 * B1 A1
1. HY DR AULIC R E S E R V OIR
71 P a1 2. B R E AT HE R
2
0.2 MP a
42 A2 A1 Y9 15
4. B Y -P AS S V ALV E
A 5. S C R E E N F ILT E R
29 ps i A2
2 bar B 6. R E T UR N F ILT E R
10. MAIN HY DR AULIC P UMP

10 P
Ps1 Dr T2 T1 T3 T5 T4 Ps2 D4 15. MAIN C ONT R OL V ALV E
A A
76 T 16. HY DR AULIC S WIV E L
41 0.1MP a
14.5 ps i
T 21. T R AV E L MOT OR
1 bar A 22. S WING MOT OR

D B
78 N1 N2 23. T R AV E L MOT OR B R AK E
10µ
2
T
45
83
* 71
55 P b1
25.
26.
R IG HT B OOM C Y LINDE R
LE F T B OOM C Y LINDE R
P c1 31 R E T R AC T E D
1 O 27. DIP P E R C Y LINDE R
DIP P E R (2) 15 28. B UC K E T C Y LINDE R
P b9 1.2 E C D B2
29. B OOM S AF E T Y V ALV E
A5
30. DIP P E R S AF E T Y V ALV E
0.03 MP a
B5
DIP P E R (1) E XT E NDE D P a9 B P 31. DIP P E R LOAD HOLDING V ALV E
4.35 ps i 0.004 MP a R E T R AC T E D 73 42
32. B OOM LOAD HOLDING V ALV E
0.3 bar 0.58 ps i 30 P b5'
75
56 T A
41. F ILT E R (ULT R A-C LE AN)
0,04 bar P il
P b5 D 42. OIL C OOLE R
43 P a5
B P c2 43. R E T UR N MANIF OLD
* 76 T T
HY DR AULIC / E LE C T R IC
P a5 E XT E NDE D 44. OIL C OOLE R B Y -P AS S V ALV E
A8
C 32
C X225S R E XC AV AT OR
A B 10µ 45. NON-R E T UR N C HE C K V ALV E
D1
94 B8 51. AC C UMULAT OR
0.103 MP a
14.9 ps i
T D2
T1
P c3'
D E
B OOM (1)
LOWE R
P b8'
* 78
53.
54.
B OOM & B UC K E T C ONT R OL LE V E R
S WING & DIP P E R C ONT R OL LE V E R

10µ
1.03 bar
D3 81 P c3 P b8 29 55. T R AV E L C ONT R OL P E DAL
150 ME S H S3 P il
R AIS E P a8' 56. DIP P E R C ONT R OL S HOC K AB S OR B E R
T1 P bu
P a8 15 57. B OOM & DIP P E R C ONT R OL S HOC K AB S OR B E R
S C HE MAT IC
B OOM (2) 57
P b4 B7 P b4' T 60. P ILOT S Y S T E M MANIF OLD
105 51 72. C ONT R OL P E DAL (OP T IONAL)

15 P b4'
OP E N A7 73. S E C OND OP T ION C ONT R OL V ALV E
P a8 B3 B UC K E T
P b7 S E C OND B T 75. F LOW R E -INJ E C T ION B LOC K (OP T IONAL)
5 1 4 6 A B
77
* 2.5
A3 R IG HT S WING
C LOS E D P a7
OP T ION
* 71 C1
1.5 MP a
212 ps i 60 82
76.
77.
3-WAY S E LE C T OR (OP T IONAL)
S AF E T Y V ALV E R E T UR N S Y S T E M MANIF OLD (OP T IONAL)
29 30
P b3 F 15 bar 78. R E T UR N F ILT E R (OP T IONAL)
P a3
T T
LE F T
B6
Y4 Y2 P3
79. C ONT R OL S HUT T LE B LOC K (OP T IONAL)
76 2.5 T R AV E L 81. S WING S HUT T LE B LOC K
D B2 A6 10 µ
P P0 P 82. P ILOT C IR C UIT F ILT E R
P b6 55
56
T 76 A2 HAMME R (H) G 1
83. S HUT -OF F V ALV E (OP T IONAL)
A R E AR C3 C2
0.049 MP a 84 T -S HUT T LE B LOC K (OP T IONAL)
P b2 7.10 ps i
B D F R ONT P a6 55 1 T 2 85. HAND/F OOT C ONT R OL P ILOT F ILT E R
79 P a2 0.49 bar 0.098 MP a
79 ON 2 14.2 ps i 86. P ILOT F ILT E R B Y -P AS S V ALV E
E
B2
B1 Y5 Y3 0.98 bar
93. P ILOT C IR C UIT S UP P LY MANIF OLD
P4 P
C 94. P ILOT C IR C UIT R E T UR N MANIF OLD
P1 P2 95. B OOM/DIP P E R P ILOT C IR C UIT MANIF OLD
P B1
T R AV E L 73 73 96. S WING P ILOT C IR C UIT C US HION V ALV E
A A1 R E AR P b1
85 P a1 86 105. 4 E LE C T R OV ALV E B LOC K
55 B 22. S WING P ILOT P R E S S UR E S WIT C H
15
P c3 *75 3
P b1 B 26. UP P E R P ILOT P R E S S UR E S WIT C H (Y E LLOW B AND)
55 P a1 F R ONT B 27. T R AV E L P ILOT P R E S S UR E S WIT C H
96 B 4 B 45. OV E R LOAD INDIC AT OR P R E S S UR E S WIT C H

A Y 2. P ILOT P R E S S UR E S OLE NOID V ALV E (B LUE B AND)
81 Y 3. S WING B R AK E S OLE NOID V ALV E (P INK B AND)
B A Y 4. 2 S T AG E T R AV E L S OLE NOID V ALV E (R E D B AND)
P1 P T ON 2.0 MP a PP P A ON 1.2 MP a P2 P3 PH Y 5. P OWE R -UP S OLE NOID V ALV E (Y E LLOW B AND)
290 ps i 174 ps i Y 9. C R US HE R /B R E AK E R OP T ION T WO F LOW S OLE NOID V ALV E

20 bar 12 bar
S2 S3 S1 B 27 OF F 1.5 MP a B 26 OF F 0.9 MP a 15
217 ps i 130 ps i
15 bar 9 bar
2S 3S 1S
P d2
LE G E ND
B 22 2 1
105 D2
A P UMP 1
D3
P UMP 2
93 P4 P5 T4 T5
43 72 * 55 P ILOT S Y S T E M P UMP
94 D1 OP T IONAL R E T UR N T O R E S E R V OIR
P3 P2 P1 T3 T2 T1 A LE AK -OF F R E T UR N
T R AV E L (LE F T ) T R AV E L (R IG HT )
P ILOT S Y S T E M C IR C UIT
85
P P R E AR F R ONT F R ONT R E AR 10 C OMP ONE NT B OUNDAR Y
54 53
85 R AIS E HOS E
C P i2
T T
1 T 2 P d1 P IP ING C ONNE C T ION
D LOWE R P IP ING C R OS S -OV E R

D1
P
D4 41 C OMP ONE NT IT E M NO.
B 85
* C OMP ONE NT NUMB E R
DIP P E R
R E T R AC T E XT E ND LE F T
S WING
R IG HT LOWE R
B OOM
R AIS E
B UC K E T
OP E N C LOS E D
T
F
R
79
* M
15
3 1 A1 S1 A2 73
IS UZU P b1
6B G 1T R B P
1 2 4 T 3
103 K w C ONNE C T ION IT E M NO.
2 4 3 1 2 4 B1 S2 B2 1950 tr/mn
85 85 85 H E XT E NDE D 15
P5a4
a2
15
P b2 85
P
* OP T ION IT E M NO.
Din3
A 2 G R E T R AC T E D P T
C 4
15 15 15 15
P b6 P a6 P a1 P b1 Pa
D 3
E Y9 *
B 1
57 79
A A1 S1 P i1 S2 P d3
Dr
95
C X225S R E XC AV AT OR
H
HY DR AULIC S C HE MAT IC
Number 9-43710
F 21
5 R 207 5 R 207 1 5 R 207 5 R 207 2 K E NN-Nr. B E ZE IC HNUNG
2 LR 261 2 LR 061 2 2 LR 061 2 LR 061 5 R 204 1 F 23
R W 206 206, 484, 540, 544, 546, 013 A2. E LE K T R ONIS C HE S S T E UE R G E R ÄT F ÜR DIE S E LMOT OR
CN C1
5 R 100
5 R 204
0.85 G R 312 A3. E LE K T R ONIS C HE B E S C HLE UNIG UNG
C N 22
2
013, 418, 419, 430, 431, 436, 439, 451, 455, 514, 540, 544, 546
A7. S T E UE R E LE ME NT ÜB E R LAS T ANZE IG E
1
2
F 22
1
484, 506, 830, 890, 899, 900, 902, 903, 930, 980 1 A8. MOT OR B E T R IE B S AR T -AUS WAHLS C HALT E R
2
0.85 B rR 544
WR 546
F8 F 17 F7 F3 F9 F4 F6 F2 F 20 F1 F 16 F 19 F 18 F 14 F5 F 15 F 10 F 13 F 11 F 12 B 1. WAS S E R -T E MP E R AT UR F ÜHLE R DE S DIE S E LMOT OR S
2
1
15A 10A 20A 10A 30A 10A 10A 10A 15A 15A 15A 10A 15A 10A 10A 15A 10A 20A 10A 10A B 10. T HE R MOR E G LE R HY DR AULIK ÖLT E MP E R AT UR
CN C2
K7 B 21. ÖLDR UC K DIE S E LMOT OR
R W 203
R 206
C ONNE C T ION
0.85 LR 380
R G 243
LR 250
V W 280
1.25 G rR 330
LgR 305
2 WR 052
0.85 W 323
0.85 Y R 278
0.85 G R 310
0.85 OR 379
L 290
0.85 B rR 360
OW 355
B rW 232
0.85 WR 370
R 295
1.25 LW 340
R 222
R Y 220
4
OF F AC C
20
HE AT B G1 G2 Acc M ST B 22. DR UC K S C HALT E R S C HWE NK S T E UE R UNG
ON
5R
ST HE AT
R 206 R W 203 B 26. DR UC K S C HALT E R DE S S E R V OS T E UE R UNG S DR UC K S (G E LB E R R ING )
OF F
60 R 200 60 R 201 60 R 001 B 27. DR UC K S C HALT E R S T E UE R UNG DE S F AHR B E T R IE B S
AC C
0.85 G R 312
M8 24V 40A
60 B 799
5 B 797 M5 E B 41. DIE S E LMOT OR -DR E HZAHLG E B E R
R3 ON
S 16 S 29 M8
G2
0.85 LR 381
W 328
0.85 G R 228
R L 294
0.85 B rR 304
R 279
LgR 540
S T AR T M10 M10 M10 M10 B 45. DR UC K G E B E R F ÜR ÜB E R DR UC K -ANZE IG E
R 225
M4
3
2
1
- + - + WR 546
B 81. S IG NALHOR N
M8
0.85 LgR 020

M4
B 9. WAS S E R -T E MP E R AT UR F ÜHLE R DE S DIE S E LMOT OR S
S1 1 2 3
0.85 B
0.85 Y
0.85 L
4 5 6 12V 12V E 2. AR B E IT S -S C HE INWE R F E R (AUS R ÜS T UNG )
6
2
1
4
5
0.85 W 323
3 2 1 E 3. AR B E IT S S C HE INWE R F E R (K AB INE )
CN A
WR 391
LgR 542
G rR 010
R Y 220
1
2
3
G1 M5
1
2
3
4
E 4. K AB INE NB E LE UC HT UNG
1 5 R 100 B
1
1 2 3 4 E 51. ZIG AR E T T E NANZÜNDE R
G 450
B G 603
Y R 452
B G 607
0.85 L 480
0.85 B L 490
0.85 LY 470
CN A E 52. K LIMAANLAG E
CN C9
1
B 750
F 1. S IC HE R UNG 20 A, E LE K T R . DIE S E LMOT OR -S T E UE R G E R ÄT
2
SG
60 B 799
F 10. S IC HE R UNG 10A; S T E UE R E LE ME NT ÜB E R LAS T ANZE IG E
0.85 B rR 544
F 11. S IC HE R UNG 10A; S P E IC HE R
WR 546
602, 606
M8 F 12. S IC HE R UNG 10A; ANLAS S -S C HALT E R
R Y 220 2 B 600 0.85 B rR 544 2 L
010, 450, 452, 542 2 B rR 547 2 B 700 1 F 13. S IC HE R UNG 20A; K LIMAANLAG E , HE IZUNG
0.85 LgR 020 R
9 10 11 12 13 14 15 16 17 18
0.85 B rW 549
8
1
0.85 B rR 543
0.85 B rR 544
R W 206 R W 206
2
603, 607 1 WR 548 M8 F 14. S IC HE R UNG 10A; F AHR B E T R IE B S ME LDUNG (LB X - NA)
B rR 030
P1 G ND
CN 9
7
LgR 540 2 LgR 540
1
WR 391 F 15. S IC HE R UNG 15A; AR B E IT S S C HE INWE R F E R
R
L
3
6
WR 546 WR 546
4 F 16. S IC HE R UNG 15A; ZWE IF AC HK R E IS LAUF B R E C HE R /HAMME R
5
470, 480, 490 Y R 830 Y R 830
G rR 504
WR 390 0.85 B rR 544 5 0.85 B rR 544 F 17. S IC HE R UNG 10A; G LE IC HS T OMWANDLE R (24 V - 12 V )
LgR 502
1 1 G rR 013 6 G rR 013
G rR 013 F 18. S IC HE R UNG 10A; S C HE IB E NWIS C HE R UND S C HE IB E NS P ÜLE R
1
2
1
2
0.85 G R 312 7 0.85 G R 312
4
2 2 S IC HE R UNG 10A; S IG NALHOR N
ANLAS S E R 24V 1 G rR 010 OR 506 F 19.
OR 506 8
3
2 LgR 542 F 2. S IC HE R UNG 10A; B E LE UC HT UNG INS T R UME NT E NB R E T T UND K LIMAANLAG E N-K ONS OLE
9
2
60 R 001 M10 B
S T E UE R UNG 24V 3 LgR 540 CN P6 CN P5 OG 514 10 OG 514 M F 20. S IC HE R UNG 15A; ZIG AR E T T E NANZÜNDE R UND K AB INE NS IT Z-K OMP R E S S OR E INS T E LLUNG
1
LE IS T UNG 24V 4 0.85 W 324
S 51 S 15 0.85 P L 484 11 0.85 P L 484
11 12 13 14 15 16 17 18 19 20
9 10
F 21. S IC HE R UNG S K AS T E N
5 S 30 S 14 Y W 899 12 Y W 899
E R DUNG (LE IS T UNG ) 6 0.85 B G 605 0.85 B W 520 2 M1 F 22. S C HUT ZS IC HE R UNG E N 20A; DE R K R E IS E F 11 UND F 12
E4 13
M
M4
8
E R DUNG (B E T R IE B S S T UNDE NZÄHLE R ) 7 0.85 B G 602 14 F 23. S C HUT ZS IC HE R UNG E N 65A; DE R K R E IS E F 1 - F 10, F 13 - F 20
0.85 WL 930 0.85 WL 930 0.85 WL 930 1
7
8
C N M1A
1 B Y 971 0.85 G R 890 15 0.85 G R 890 F 3. S IC HE R UNG 10A; R E LAIS F AHR B E T R IE B S MODUS
6
B E T R IE B S S T UNDE NZÄHLE R 9 0.85 B rW 549 24V

2 Y W 970 V W 902 16 V W 902 F 4. S IC HE R UNG 10A; ANNULIE R UNG DE R HY DR AULIK S T E UE R UNG
LIC HT MAS C HINE 10 0.85 B rR 543 G rR 013 S
5
3 B L 973 LW 829 17 WG 820
CN A
K R AF T S T OF F -F ÜLLS T ANDG E B E R 11 0.85 Y 419 F 5. S IC HE R UNG 10A; R E LAIS F ÜR S C HWE NK UNG S B R E MS E
4
R 770
B 771
1 1
1
1
2
2
B 752 18
1
2
3
4
4 LW 972
1
B rR 030 R
2
3
2
3
WAS S E R T E MP E R AT UR G E B E R 12 0.85 Y B 418 1 2 1 2 3 4
3
2 3 2 3 19
F 6. S IC HE R UNG 10A; R UNDUMLE IUC HT E
5 0.85 B 724 LgW 903 LgW 903
B E LE UC HT UNG 13 0.85 W 323
2
Y R 830
R G 243
V R 900
L 290
F 7. S IC HE R UNG 20A; K R AS T S T OF F -F ÜLLP UMP E
OR 537
B 713
0.85 LW 914
OR 379
6 WR 390 WR 390 20
1
2
14 WL 587
1
7 0.85 LR 836 CN A CN A 1 2 F 8. S IC HE R UNG 15A; NOT -AUS -MOT OR F ÜR DIE S E LMOT OR

B E LE UC HT UNG (E R DUNG ) 15 WL 808
8 0.85 L 835 F 9. S IC HE R UNG 30A; V OR G LÜHK E R ZE
16 M 9 0.85 B 711
20 19 18 17 16 15 14 13 12 11 10
1
B AT T E R IE -R E LAIS 17 WR 546
10 0.85 B rR 304 B rR 304 H2 G 1. B AT T E R IE
2
18 2 LR 061 M4 DR E HS T R OMG E NE R AT OR
11 0.85 G R 892 835, 836, 892 G 2.
3
19 243, 900
12 0.85 B 742 0.85 B 742 H2. F AHR E NB E T R IE B S ME LDUNG (LB X - NA)
4
20 830, 290
13
R1 H3. AK US T IS C HE R ALAR M ÜB E R LAS T UNG
CN 4
WG 820 2
14 OR 537
M3 B 752 1 K 1. NOT -AUS -R E LAIS DIE S E LMOT OR
312, 506, 514

B 713
W1
5
K 18. R E LAIS F AHR B E T R IE B S MODUS
R 766
B 767
6
B 752 K 19. R E LAIS S C HWE NK UNG S B R E MS E
C N D7
1
7
K 2. V OR G LÜHK E R ZE N-R E LAIS
2
8
1
2
K 20. R E LAIS S C HE IB E NWIS C HE R MOT OR
9
B G 640 1
K2 K 18 K 19 K4 K 28 LgY 436 2 B 21 K 21. R E LAIS WAS C HANLAG E NP UMP E NMOT OR
970, 971, 972, 973

LG 463 0.85 G R 890 1 0.85 G R 890 1
Y G 827
G Y 462
24V 24V K 22. R E LAIS K LIMAANLAG E N-MAG NE T K UP P LUNG

WG 513 0.85 B 740 2 0.85 B 740 2
55W 70W
ÜB E R HIT ZUNG S S C HALT E R (WAS S E R , ÖL) WR 1 WL 439 K 23. R E LAIS S C HWAC HE S G E B LÄS E
C N A5
ÖLDR UC K S C HALT E R VW 2 LgY 436 K 24. R E LAIS MIT T LE R E S G E B LÄS E
1
S C HWE NK DR UC K S C HALT E R VR 3 B rY 451
E3 E2 K 25. R E LAIS MAX. G E B LÄS E
2
CN A
CN A
4 Y G 431 1 1 2
1
2
2
0.85 B P 494 t C K 27. R E LAIS F AHR E NB E T R IE B S ME LDUNG (LB X - NA)
F AHR B E T R IE B S S C HALT E R BW 5 G Y 453 G Y 453 2 1
1 4 2 1 4 2 1 4 2 1 4 2 1 4 2
B1
B G 607
B G 606
B G 603
B G 602
OB E R E R S C HALT E R 0.85 B rR 6 LG 430 5 5 5 5 5 0.85 B W 520 0.85 P L 484 2 K 28. R E LAIS LE IS T UNG S S T E IG E R NDE S MAG NE T V E NT IL
9 10 11 12 13 14 15 16
5
2
2
4
4
3
1
3
1
3
1
3
1
3
1
3 3 3 3 3
8
K R AF T S T OF F T ANK LE E R (HE IS S LE IT E R ) LW 7 L 455 0.85 B 740 K 4. AR B E IT S S C HE INWE R F E R -R E LAIS

2 B 600
7
BL 8 K 5. R UNDUMLE UC HT E N-R E LAIS

C N M1B
2 WR 052
1.25 WR 051
OR 506
2 LR 061
LgR 306
LgR 305
Lg 805
Y W 899
B rW 232
B rW 233
V W 809
V W 902
0.85 WR 370
0.85 WR 371
WL 808
0.85 G R 890
LgR 308
LgR 307
Y 822
LgW 903
312, 506, 514
222, 391
6
G rR 9 1 2 K 7. B AT T E R IE -R E LAIS
10
5
C N A7
E /G F E HLE R YR 11 LW 512 M1. ANLAS S E R
4
1
WR 391
Y W 970
M14. K R AF T S T OF F -B E T ANK UNG S P UMP E NMOT OR

LW 972
2 B 600
G LÜHLAMP E 12
3
B Y 971
WY OG 514
B L 973
2
R 222
X6 LgR 307 0.85 G R 892
1
LE E R LAUF S C HALT E R WV 13 G 450
2
M2. NOT -AUS -MOT OR DIE S E LMOT OR

1 2 3 4 Y L 488 1
2
E R DUNG B rW 14 B G 606
X8
1
1 2 5 6 7 8 9 805, 808, 809, 822, 892 B Y 498 M3. S C HE IB E NWIS C HE R -MOT OR

15 2
Y9
1
2
3
4
5
6
7
8
9
16
052, 232, 305, 370 0.85 LW 914 0.85 LW 914 1
R2 M4. S C HE IB E NS P ÜLE R -MOT OR
2
1
061, 506, 890, 899, 902, 903 B 700 B 700 2 M5. MOT OR LUF T E INLAS S (INNE N/AUS S E N
0.85 G R 228
B 716
C N A8
M6. MOT OR AUS R IC HT UNG DE R B E LÜF T UNG S DÜS E N
1
1 2
E 51
2
M7. T E MP E R AT UR E INS T E LL-MOT OR
1 M8. LÜF T E R MOT OR
B 717 2
0.85 LW 379
2 P 1. INS T R UME NT E NB R E T T
LR 229 1
0.85 Y R 278
WC 826
0.85 B 715
D 487 1
B 41 P 6. B E T ÄT IG UNG K LIMAANLAG E
B 700
CN A W 497
24V .5A
1
2
K 20 K 21 K 27 K1 K5 P 8. T AB LE AU DE C OMMANDE C HAUF F AG E
2
R 1. V OR G LÜHK E R ZE
F AHR B E T R IE B S MODUS 1 Lg 805 0.85 B 715
WR V W 902 1 Y3
1
2
S C HE IB E NWIS C HE R VW 2 Y L 804 0.85 Y R 278 R 2. WIDE R S T AND E INS T E LLUNG K R AF T S T OF F -F ÖR DE R ME NG E
1
5
B 762 2
3 R 3. S T E UE R UNG B E S C HLE UNIG UNG
C N A2
WAS C HANLAG E VR Y G 803
2B 700
0.85 OR 379
2
6
A3
9 10 11 12
6
AR B E IT S S C HE INWE R F E R WV 4 WL 806 R 4. T HE R MIS T OR
7
3
5
C N M2C
S C HWE NK UNG S B R E MS E BW 5 V W 809
8
4
R 5. K R AF T S T OF F S T ANDS F ÜHLE R
0.85 B 742
3 2 1
4
F AHR E NB E T R IE B S ME LDUNG 0.85 B rR 6 WG 828 1 4 2 1 4 2 1 4 2 1 4 2 1 4 2

Y W 899 1
Y4 R 7. R E S IS T ANC E V IT E S S E MOT E UR V E NT ILAT ION C LIMAT IS E UR
B 752
3
7 5 5 5 5 5 1.25 R G 950 1
X13 X14 C N 27 B 761 2
VB
5
2
2
4
4
3
1
3
1
3
1
3
1
3
1
3 3 3 3 3 S 1. ANLAS S -S C HALT E R
2
8
8 1.25 B rB 951 2 LE IS T UNG (MAS S E )

R
1
7
9 0.85 G R 954 3 E INS T E LLUNG S 13. ÜB E R DR UC K -ANZE IG E S C HALT E R
0.85 LR 836
0.85 B rR 361
Y L 804
0.85 B 722
0.85 L 835
0.85 B rR 362
0.85 B rR 360
Y G 803
0.85 WL 930
OW 355
OW 356
WG 828
LW 829
0.85 L 910
0.85 LR 381
0.85 B rR 530
0.85 LY 912
0.85 LW 911
LR 250
LR 251
G R 533
G rR 893
1
2
3
LE E R LAUF S C HALT UNG LW

10
11 G R 511
X4 228, 278, 379
0.85 WL 482 4 ZAHNS T ANG E 1S T
E S 14. S C HALT E R F ÜR HAMME R /ZANG E
B P 633
P 588
B P 632
1 0.85 WY 472 5 VC C
0.85 B rY 575
Y R 830
Y2 S 15. S IG NALHOR N-S C HALT E R
B G 620
V Y 577
12
B 760 2 L 496 6 T AC HOG E NE R AT OR (S IG NAL) D S 16. LE E R LAUF S T E UE R UNG DIE S E LMOT OR
Y 486 7 T AC HOG E NE R AT OR (MAS S E )
B G 620
S 28. F AHR E NB E T R IE B S ME LDUNG -ANZE IG E S C HALT E R (LB X - NA)
V G 576
0.85 Y G 508 8 LE E R AUF

S 29. DR UC K S C HALT E R E NE R G IE V E R S T ÄR K E R
575, 576, 577, 588
LgW 903 1
4 S 30. MODE N/E -ANZE IG E S C HALT E R
Y5
9 10
0.85 B 722
4
B 745 2 S 51. S C HALT E R ANNULLIE R UNG S HE B E L DE R B E T ÄT IG UNG
1
4
C N A3
803, 804, 828, 835, 836
3
X15 S 52. K UP P LUNG S S C HALT E R
2
5
CN 5
250, 330, 355, 360, 380, 381
3
6
829, 930 S 6. S C HALT E R DE R R UNDUMLE UC HT E
7
S 9. NOT -AUS -S C HALT E R DE S DIE S E LMOT OR S
6
0.85 Y R 281
2
12V 1.25 LG 952 1 VB
U1. G S -G S -WANDLE R (24 V - 12 V )
5
1
0.85 R W 282 1.25 G rB 953 4 LE IS T UNG (MAS S E )
1
5
0.85 B Y 729 U1 B 760 2 W1. ANT E NNE

2
6
PA
B 761 0.85 B G 955 3 E INS T E LLUNG

X1. V E R S OR G UNG K R AF T S T OF F -F ÜLLP UMP E
7
3
0.85 B W 492 MAS S E (S IG NAL)

S 13 S 28 S9 S6 B 762 5
X11. ANS C HLUS S ÜB E R LAS T DR UC K K ONT R OLLE
8
4
0.85 B Y 714 0.85 Y B 418 1 0.85 Y B 418 0.85 WG 473 6 VC C

B rY 451 2 B rY 451 B 745 X13. ANS C HLUS S F E HLE R DIAG NOS E E INHE IT
WL 439 3 WL 439 X14. ANS C HLUS S S P E IC HE R E NT LE E R UNG
V W 280 6
LgY 436 4 LgY 436
R 279 2 X15. ZUB E HÖR S T E C K E R
Y G 431 5 Y G 431
B 702 5 X2. V E R S OR G UNG R UNDUMLE UC HT E
E 52 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 0.85 Y R 281 1
LG 430 6 LG 430 1
X4. DIAG NOS E -ANS C HLUS S DE S DIE S E LMOT OR S
L 455 7 L 455
1
2
3
2
3
2
3
2
3
2
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 9 10 11 12 13 14 15 16 17 18 0.85 R W 282 3 1 1 1 1 0.85 Y 419 8 0.85 Y 419 0.85 LG 507 3 NOT -MODUS X6. K OMP R E S S OR MOT OR ANS C HLUS S K AB INE NS IT Z
0.85 B Y 729 4
W 833
L 834
WG 826
Y G 827
0.85 B rR 501
0.85 B 720
G R 533
B 723
2 3 2 3 2 3 2 3 V R 900 9 V R 900 V R 900
7
X8. ANS C HLUS S T E IL R ADIO
C N AC 1 C N AC 2 0.85 WR 980 10 0.85 WR 980 B 753 B 81 Y 2. S T E UE R DR UC K -MAG NE T V E NT IL (B LAUE R R ING )
80 B 798
1
C N A4
CN A CN A CN A CN A
2
Y 3. DR E HE NDE S B R E MS MAG NE T V E NT IL (R OS A R ING )
24V . 95 105dB
3
C N H1
B 753 Y 4. 2-S T UF E N-ANT R IE B S MAG NE T V E NT IL (R OT E R R ING )
1
1
2
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
1
2
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
M10 Y 5. LE IS T UNG S S T E IG E R NDE S MAG NE T V E NT IL (G E LB E R R ING )
2
0.85 WR 530 Y 8. MAG NE T K UP P LUNG K LIMAK OMP R E S S OR
Y R 1409
R 225
G Y 1400
Y B 1413
R 346
Y 1433
R Y 1407
WL 1405
WR 1408
WB 1434
LR 528
OL 529
WG 527
O 1410
B 701
L 1414
L B G 1411
G 1404
L gB 1406
LR 1432
Y W 1403
G R 526
LR 1427
R Y 1422
WR 1430
R W 1423
G W 1421
LgR 1425
OR 1424
B W 1429
WG 1431
B rR 1426
LW 1420
G R 1428
0.85 B rR 501 Y 9. HAMME R /ZANG E WAHLWE IS E MIT ZWE IF LUS S -MAG NE T V E NT IL

WL 449 1
0.85 B 720
B G 643 2 B 10
1.25 B 743
826, 827
B G 643 E R K LÄR UNG

G rR 893 1 G rR 893
1.25 G rR 330 2 1.25 G rR 330
WL 449
OHNE ANS C HLUS S
H3 0.85 LR 380 3 0.85 LR 380 MIT ANS C HLUS S
0.85 L 910 4 0.85 L 910 0.85 Y B 418
B 701 W 833 0.85 LW 911 5 0.85 LW 911 M4 B9 M14
1
1 1.25 LW 340 1.25LW 340 24V . 71 83dB R 818 0.85 LY 912 6 0.85 LY 912
2
M8 M 2 1.25 LB 1415 R 225 7
MAS S E AM F AHR G E S T E LL MAS S E K AB E L
0.85 LR 407 8 0.85 LR 407
1.25 LW 345
0.85 WR 417 9 0.85 WR 417

1.25 G rR 330 1 1.25 G rR 330
0.85 B L 427 10 0.85 B L 427 M
1.25 B 743 2 1.25 B 743 E INF AC HE DR AHT V E R B INDUNG K AB E LS T R ANG
11
CN A
R 295
2
1
B 710 12 M5
L 455 1 24V
13
X11 1.25 B 743 14 1.25 B 743 B G 660 2
R5
0.85 WR 417
0.85 R L 407
0.85 B L 427
0.85 Y 419 3
X1 S T E C K E R S T IF T S T E C K E R B UC HS E
1
5
G 572
R 295
B 710
Y 573
L 834
1
S WP
0.85 LY 905
2
6
2 1
7
3
W 328 W 328
CN B3
1
1 2 3 4
R7
8
4
6
7
3 1.25 LB 904 2 WL 567 WL 567
2
1
2
3
4
5
6
7
8
5 6 7 8 MAG NE T IS OLAT ION

OR 537
5
8
0.85 LW 906
3
4 3 B rR 1426
G rR 893
14 13 12 11 10 9
L
RL
BL
4
B
Y
G
R
WR
S WP
4
X2
C N 13
B W 1429 B 712 1 B B 755 P E R MANE NT E V E R S OR G UNG
5 WR 1430 R L 294 2 RL
9 10 11 12 13 14 15 16 17 18
8
OR 510 3 OR B rY 451 2
6 1
CN A
R Y 1422
B 22
3
2
4
4 V E R S OR G UNG NAC H ZÜNDUNG

7
LG 463 LG
K 22 K 23 K 24 K 25 B G 652 1
6
G W 1421
2
1
3
Y G 464 5 YG
5
1
LW 1420
WB 1434
Y W 1403
WL 1405
4 5 6 6
G Y 1400
1 2 3
LY 1432
CN12 (R)
O 1401
G 1404
Y 1433
B 1402
9 7
M6 1 2 3
10 8
1 2
M2
4 5 6
4
11 K E NNZAHL DE S S T E C K E R S S T E C K E R F AR B E
G Y 462
Y G 464
3
1 2 (IN DE R K AB INE ) (WE NN NIC HT ANDE R S ANG E G E B E N, WE IS S )

5
4
6
2
3
1
2
1
3
6
5
4
5 O 1410 CN A 12
2
Y G 431 2 0.85 L 910 1 L

K E NNB UC HS T AB E DE S S T E C K E R S
4 13
B 27
1
Y R 1409 LgR 1425

B G 651 1 0.85 LW 911 2 LW (AN DE R K AB INE AUS S E N)
1
2
6 B G 1411 14 WG 1431
A8 A7 0.85 LR 380 4 LR
M
2 R Y 1407 15 R W 1423 1 4 2 1 4 2 1 4 2 1 4 2
0.85 LY 912 5 LY 60 B 001
5 5 5 5
3 WR 1408 1 2 0.85 B 748 6 B
5
5
2
OR 1424
4
4
16
3
1
3
1
3
1
3
1
M 3 3 3 3 DR AHT QUE R S C HNIT T DR AHT -Nr.

1 3
LgB 1406 17 G R 1428 F AR B E
1.25 LW 341
1.25 LW 342
G R 526
0.85 WR 980
0.85 LW 906
1.25 LW 343
WG 527
1.25 B 691
0.85 LW 905
1.25 LW 344
LR 528
1.25 B 692
1.25 LB 904
1.25 LW 345
OL 529
1.25 B 693
18 LR 1427 T AB E LLE DE R F AR B S Y MB OLE

LG 430 2
M5 M7 B G 650 1 B 26 S Y MB OL F AR B E
C N D6
4
1
B S C HWAR Z
5
2
0.85 B 749
0.85 L 913
6
0.85 WR 980
6
3
W WE IS S
5
1.25 B 693 1 2
M
P6 P8
4
1.25 LW 345 Br B R AUN

3
526, 527, 528, 529, 904, 905, 906
1
2
P R OS A
2
1
1 2 V IOLE T T
1 2 V
0.85 WR 980 2
C N 21
1.25 W 981 1
S 52 G G R ÜN
1
2
O OR ANG E
1 OB 1412 CN B9
R4 2 Y B 1413 R R OT
2B 700 2 2B 700 1
C N A0 C N A1 CN 7 CN 8 0.85 B L 427 3 0.85 B L 427 Y G E LB
2B 600 1 2B 600 1 1
0.85 R L 407 1 0.85 R L 407 2
B 45 Lg HE LLG R ÜN
CN A
0.85 WR 417 2 0.85 WR 417 3

S WP S WP
1
2
1 2 3 4 5 6 7 8 9 10 11 33 34 35 36 37 38 39 40 58 59 60 61 62 63 64 65 66 67 89 90 91 92 93 B W 505
Sb HE LLB LAU
12 13 14 15 16 17 18 19 20 21 22 23 24 41 42 43 44 45 46 47 48 49 50 68 69 70 71 72 73 74 75 76 77 78 79 94 95 96 97 98 99 100 484, 501, 510
1.25 B 730
1
25 26 27 28 29 30 31 32 51 52 53 54 55 56 57 80 81 82 83 84 85 86 87 88 101 102 103 104 1.25 W 981 1 1.25 W 981 1 L B LAU
0.85 G R 310
2
Gr G R AU
1
3
3
2
470, 480, 490, 502, 504, 511, 512, 513, 575, 576, 577, 588
HINWE IS :
Y8 1. "B R " B E DE UT E T S C HWAR ZE S K AB E L MIT R OT E N S T R E IF E N
2. DIC HT E V E R B INDUNG E N, DIE AN DE R K AB INE N-AUS S E NS E IT E B E NUT ZT WE R DE N
1.25 G rB 953
0.85 WG 473
1.25 B rB 951
0.85 WY 472
1.25 R G 950
0.85 G R 313
0.85 G R 312
0.85 G R 954
0.85 B rR 501
0.85 Y G 508
0.85 B G 955
0.85 B rY 575
1.25 LG 952
0.85B W 492
0.85 LG 507
0.85 B P 494
0.85 G R 311
0.85 G R 310
0.85 WL482
0.85 B G 631
1.25 B G 630
0.85 LY 470
0.85 P L 484
0.85 B L 490
2B 700
B G 660
B G 652
B G 651
B G 650
1.25 B 731
1.25 B 730
2B 600
0.85 L 481
0.85 L 480
680
681
C N A0
C N A1
G rR 504
LgR 503
LgR 502
OG 514
WG 513
OR 506
B W 505
B Y 498
G R 511
OR 510
LW 512
V G 576
B L 782
Y L 488
V Y 577
W 497
O 487
Y 486
L 496
P 588
1.25 B 743
CN 7
CN 8
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
39
42
33
51
54
52
34
35
36
37
38
40
41
43
44
45
46
7
8
9
10
11
12
13
14
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
47
48
49
50
53
55
56
57
1
2
4
15
16
5
17
MASSE (WASSER- UND KRAFTSTOFF-TEMPERATURFÜHLER)

KR AFTS TOFF-TE MPE R ATUR FÜHLE R (S IGNAL)
DIE S E LMOTOR -DR E HZAHLGE BE R (S IGNAL)
DIE S E LMOTOR -DR E HZAHLGE BE R (MAS S E )
BE S C HLE UNIGUNGS VOLUME N (S IGNAL)

BE S C HLE UNIGUNGS VOLUME N (S IGNAL)
WAS S E R -TE MPE R ATUR FÜHLE R (S IGNAL)
BE S C HLE UNIGUNGS VOLUME N (MAS S E )

S IG NAL MOTOR S TILLS TAND (R E D 4)
B E S C HLE UNIG UNG S VOLUME N (5 V)
MAP WAHL -3
MAP WAHL -1
E INGANGS S IGNAL S TILLS TAND DE S DIE S E LMOT.

MAP WAHL -2
MAP WAHL -0
T AC HOG E NE R AT OR (S IG NAL)
T AC HOG E NE R AT OR (MAS S E )
NOT MODUS (R E D 4)
MAS S E (MV )
V B B (R E D 4)
MAS S E (R E D 4)
S HLD (R E D 4)
MAS S E (R E D 4)
V B B (R E D 4)
E INS T E LLUNG (R E D 4)
5V (R E D 4)
V 1S T (R E D 4)
E INS T E LLUNG (R E D 4)
5V (R E D 4)
S IG NAL MAS S E (R E D 4)
ÜB E R HIT ZUNG (WAS S E R )

AUS WAHLC HALT E R C AN
C AN-H
C AN-L
E INS TE LLUNG KR AFTS TOFF-FÖR DE R ME NGE
E INS TE LLUNG KR AFTS TOFF-FÖR DE R ME NGE

NV V B
P S (G E ) P WR V B
MOT OR UMDR E HUNG

DIAG NOS E -B E T R IE B S S C HALT E R
HE IZUNG S R E LAIS
LE UC HT E G LÜHLAMP E
P S (G E ) P WR MAS S E
C AN MAS S E
NOT MODUS
LÖS C HE N DE S S P E IC HE R S
ANLAS S -S C HALT E R
T E C H 2 (T XD)
V E R S OR G UNG (V B )
V E R S OR G UNG (V B )
T E C H 2 (R XD)
DIAG NOS E -WAHL

DIAG NOS E LE UC HT E AUS
MAS S E
MAS S E
DIE S E LMOT OR AUS
LÖF F E LB AG G E R C X 225S R
A2
5 B 796
S T R OMLAUF P LAN
M6 M6 Nummer 9-43720

Case CX225SR EN

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CX225SR Crawler excavator

SERVICE MANUAL ..................................................................................................................................9-40691GB

* Consult the Engine Service Manual

Configurations contained in this Service Manual:

Copyright © 2004 CNH France S.A.

Safety rules ( - A.50.A.10) 4

Basic instructions ( - A.90.A.05) 6

Hydraulic contamination ( - A.92.A.60) 16

Product identication ( - A.80.A.10) 18

Product identication ( - A.80.A.10) 19

INTRODUCTION TO THE REPAIR MANUAL

This manual is organised according to types of function and information.

Safety rules ( - A.50.A.10)

Basic instructions ( - A.90.A.05)

Gaskets, O-rings and at seals

STANDARD TIGHTENING TORQUE

Order of tightening nuts and cap screws.

Standard torque setting table.

SPECIAL TORQUE SETTINGS

Machine tted with monobloc boom 5.70 m

Dippers 1.90 m 2.40 m 3.00 m

FLUIDS AND LUBRICANTS

Transmission component oil

Components made from plastic or resin

Hydraulic contamination ( - A.92.A.60)

CLEANING THE HYDRAULIC SYSTEM

The following is an incomplete list of these problems:

The following are a few examples of problems caused by microscopic contamination:

The following are a few examples of problems caused by visible contamination:

• The uid contains metal or other fragments.

Product identication ( - A.80.A.10)

(1) TYPE (2) YEAR OF MANUFACTURE (3) SERIAL NUMBER

Serial numbers of hydraulic components

Product identication ( - A.80.A.10)

(1)TYPE (2)YEAR OF MANUFACTURE (3)SERIAL NUMBER

Serial numbers of hydraulic components

PRIMARY HYDRAULIC POWER SYSTEM A.10.A

HYDRAULIC COMMAND SYSTEM A.14.A

ELECTRICAL POWER SYSTEM A.30.A

LIGHTING SYSTEM A.40.A

PRIMARY HYDRAULIC POWER SYSTEM - 10.A

PRIMARY HYDRAULIC POWER SYSTEM - 10.A

PRIMARY HYDRAULIC POWER SYSTEM - General specication (A.10.A - D.40.A.10) 7

PRIMARY HYDRAULIC POWER SYSTEM - Special tools (A.10.A - D.20.A.40) 9

PRIMARY HYDRAULIC POWER SYSTEM - Special tools (A.10.A - D.20.A.40) 11

PRIMARY HYDRAULIC POWER SYSTEM - Seed rates (A.10.A - D.50.A.60) 13

Hydraulic pump - Service limits (A.10.A.20 - D.20.A.20) 18

PRIMARY HYDRAULIC POWER SYSTEM - Dynamic description (A.10.A - C.30.A.10) 20

Stack valve - Sectional view (A.10.A.18 - C.10.A.30) 26

Stack valve Inlet section - Sectional view (A.10.A.18.10 - C.10.A.30) 31

Stack valve Outlet section - Sectional view (A.10.A.18.20 - C.10.A.30) 32

PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A - F.35.A.51) 41

PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20) 42

PRIMARY HYDRAULIC POWER SYSTEM - Bleed (A.10.A - F.35.A.25) 43

PRIMARY HYDRAULIC POWER SYSTEM - Pressure test (A.10.A - F.40.A.30) 44

PRIMARY HYDRAULIC POWER SYSTEM - Decontaminating (A.10.A - F.30.A.60) 46

Stack valve - Overhaul (A.10.A.18 - F.10.A.40) 49

Stack valve Outlet section - Disassemble (A.10.A.18.20 - F.10.A.25) 50

Stack valve Inlet section - Disassemble (A.10.A.18.10 - F.10.A.25) 51

Stack valve - Visual inspection (A.10.A.18 - F.40.A.10) 52

Stack valve Inlet section - Assemble (A.10.A.18.10 - F.10.A.20) 53

Stack valve Outlet section - Assemble (A.10.A.18.20 - F.10.A.20) 54

Stack valve - Install (A.10.A.18 - F.10.A.15) 55