CX210 230 240 WSM

CX210 - CX230 - CX240 Crawler Excavators
Table of Contents
DIVISION/SECTION SECTION N° REFERENCE N°
1 GENERAL INFORMATION
Safety, general information and standard torque data .....................................1001 7-27690GB
General specifications and special torque setting............................................1002 7-29361GB
2 ENGINE
Removal and installation of the engine ............................................................2000 7-28230GB
Radiator and oil-cooler.....................................................................................2001 7-28050GB
Engine specifications ............................................................................................. *
Disassembly and assembly of the engine.............................................................. *
3 FUEL SYSTEM
Fuel tank ..........................................................................................................3001 7-27970GB
Fuel engine system................................................................................................ *
4 ELECTRICAL SYSTEM
Electrical system, electrical and electronic troubleshooting .............................4001 7-27724GB
Inspection and maintenance of batteries and connecting a booster battery ....4002 7-27921GB
Main and engine electronic control boxes........................................................4003 7-27933GB
5 UNDERCARRIAGE
Removal and installation of tracks ...................................................................5001 7-27750GB
Rollers..............................................................................................................5003 7-27772GB
Sprocket...........................................................................................................5004 7-27781GB
Idler wheel and tension shock absorber ..........................................................5005 7-27803GB
6 DRIVE TRAIN
Drive motor and final drive transmission removal and installation ...................6001 7-27841GB
Drive motor and final drive transmission disassembly and assembly ..............6002 7-28090GB
Swing reduction gear, removal and installation................................................6003 7-27820GB
Swing reduction gear, disassembly and assembly (CX210 - CX230) ..............6004 7-28371GB
Swing reduction gear, disassembly and assembly (CX240) ............................6004 7-28391GB
7 UNDERCARRIAGE HYDRAULICS
8 UPPERSTRUCTURE HYDRAULICS
Depressurising and decontaminating the hydraulic system, use of the
vacuum pump and bleeding the components ..............................................8000 7-27952GB
Specifications, troubleshooting, checks and hydraulic pressure settings ........8001 7-27704GB
Hydraulic reservoir removal and installation ....................................................8002 7-27990GB
Main and pilot pumps, removal and installation ...............................................8003 7-27860GB
Main hydraulic control valve, removal and installation.....................................8004 7-27890GB
Attachment cylinders, removal and installation................................................8005 7-27791GB
Hydraulic swivel, removal and installation .......................................................8006 7-27811GB
Pilot blocs, removal and installation.................................................................8007 7-28130GB
Swing motor, removal and installation (CX210 - CX230) .................................8008 7-28071GB
Swing motor, removal and installation (CX240) ...............................................8008 7-28071GB
Main hydraulic pump, disassembly and assembly...........................................8010 7-35490GB
Main hydraulic control valve, disassembly and assembly................................8011 9-36270GB
Attachment cylinders, disassembly and assembly...........................................8012 7-27902GB
Hand control levers, disassembly and assembly .............................................8013 7-28110GB
Foot control levers, disassembly and assembly ..............................................8014 7-28210GB
Six-solenoid valves, disassembly and assembly .............................................8015 7-27911GB
Caution valve, disassembly and assembly ......................................................8016 7-27942GB
Safety valve .....................................................................................................8017 7-29631GB
Hydraulic swivel, disassembly and assembly ..................................................8018 7-28080GB
Swing motor, disassembly and assembly (CX210 - CX230)............................8019 7-28011GB
Swing motor, disassembly and assembly (CX240) ..........................................8019 7-29760GB
Hydraulic functions...........................................................................................8020 7-28490GB
Copyright  2005 CNH France S.A.
Printed in France
CNH Cre 9-93540GB May 2005
DIVISION/SECTION SECTION N° REFERENCE N°
9 UPPERSTRUCTURE
Quick coupler ...................................................................................................9000 9-93630GB
Upperstructure, turntable and counterweight...................................................9002 7-27982GB
Boom, dipper and bucket .................................................................................9003 7-27963GB
Seat and seat belt ............................................................................................9004 7-28120GB
Cab and cab equipment...................................................................................9005 7-28022GB
Air conditioning troubleshooting.......................................................................9006 9-88730GB
Air conditioning unit disassembly and assembly..............................................9007 7-29910GB
Air conditioning servicing .................................................................................9008
Air conditioning components............................................................................9009
Large format hydraulic and electrical schematics .........................................Pocket 7-27623
* Consult the Engine Service Manual

Sections to be distributed at a later date
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.
Cre 9-93540GB Issued 05-05

1001
Section
1001
SAFETY, GENERAL INFORMATION

AND TORQUE SPECIFICATIONS
Copyright  2000 Case France

Printed in France
Case Cre 7-27690GB September 2000
1001-2
TABLE OF CONTENTS
GENERAL INFORMATION .......................................................................................................................................3
SAFETY..................................................................................................................................................................... 4
STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS............................................................................... 6
WARNING : This symbol is used in this manual to indicate important safety messages. Whenever you see
! this symbol, carefully read the message that follows, as there is a risk of serious injury.

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

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

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

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

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

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

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

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

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

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

1001-6
STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS

Tightening of cap screws, nuts
Tighten alternately so that tightening torque can be applied evenly. The numbers in the figure below indicate the
order of tightening.
JS00481A
Cap screws which have had Loctite used (white residue remains after removal) should be cleaned with loght oil or
suitable cleaning solvent and dried. Apply 2-3 drops of Loctite to the thread portion of the cap screw and then
tighten.

1001-7
Torque table
Tighten cap screws and nuts according to the table below if there are no other special instructions.
Cap Screw Name Size (Size) M6 M8 M10 M12 M14 M16 M18 M20
[mm] 10 13 17 19 22 24 27 30
Spanner
[in.] 0.39 0.51 0.67 0.75 0.87 0.95 1.06 1.18
Cap Screw
[Nm] 6.9 15.7 32.3 58.8 98.0 137.2 196.0 274.0
Tightening
torque [lb-ft] 5.1 11.6 23.9 43.4 72.3 101.2 144.6 202.4
[mm] 5 6 8 10 12 14 14 17
Spanner
Socket [in.] 0.20 0.24 0.32 0.39 0.47 0.55 0.55 0.67
Head Cap
Screw Tightening [Nm] 8.8 21.6 42.1 78.4 117.6 176.4 245.0 343.0
torque
[lb-ft] 6.5 15.9 31.1 57.8 86.8 130.1 180.8 253.1

1001-8

1002
Section
1002
GENERAL SPECIFICATIONS
AND SPECIAL TORQUE SETTINGS

Printed in France
1002-2
TABLE OF CONTENTS
TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE ....................................................3
Machine.................................................................................................................................................................3
Engine ................................................................................................................................................................... 3
Component serial numbers ................................................................................................................................... 3
FLUIDS AND LUBRICANTS ..................................................................................................................................... 4
Hydraulic fluid....................................................................................................................................................... 4
Transmission component oil ................................................................................................................................ 4
Grease ................................................................................................................................................................. 4
Engine oil .............................................................................................................................................................. 5
Oil viscosity/Oil range............................................................................................................................................ 5
Fuel ...................................................................................................................................................................... 6
Anti-freeze/Anti-corrosion..................................................................................................................................... 6
Environment ......................................................................................................................................................... 6
Components made from plastic or resin .............................................................................................................. 6
SPECIFICATIONS..................................................................................................................................................... 7
Engine ................................................................................................................................................................... 7
Capacities ............................................................................................................................................................. 7
Electrical system ................................................................................................................................................... 7
Hydraulic system ................................................................................................................................................... 8
Cylinder .................................................................................................................................................................8
Control valve ......................................................................................................................................................... 9
Swing .................................................................................................................................................................... 9
Travel .................................................................................................................................................................... 9
Undercarriage ....................................................................................................................................................... 9
Attachment ............................................................................................................................................................ 9
Weight of components ........................................................................................................................................10
DIMENSIONS AND LIMIT OF WEAR AND TEAR OF THE TRACKS SET ............................................................11
Toothed wheel.....................................................................................................................................................11
Idler wheel...........................................................................................................................................................12
Upper roller .........................................................................................................................................................13
Lower roller .........................................................................................................................................................14
Track ...................................................................................................................................................................15
DIMENSIONS AND LIMIT OF WEAR AND TEAR OF THE MOBILE JOINTS OF THE ATTACHMENT................16
Boom foot/Undercarriage ....................................................................................................................................16
Boom cylinder foot/Undercarriage.......................................................................................................................17
Boom cylinder head/Boom ..................................................................................................................................17
Dipper cylinder foot/Boom...................................................................................................................................18
Boom/Dipper .......................................................................................................................................................18
Dipper cylinder head/Dipper................................................................................................................................18
Bucket cylinder foot/Dipper .................................................................................................................................19
Connecting rod/Dipper ........................................................................................................................................19
Compensator/Bucket...........................................................................................................................................19
Connecting rod/Compensator/Bucket cylinder head...........................................................................................20
Dipper/Bucket......................................................................................................................................................20
SPECIAL TORQUE SETTINGS ..............................................................................................................................21
MACHINE OVERALL DIMENSIONS.......................................................................................................................24
WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see
! this symbol, carefully read the message that follows, as there is a risk of serious injury.

1002-3
TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE

When placing a parts order or making a request for information or assistance, always give you CASE Dealer the
type and serial number of the machine concerned.
Enter the required information on the lines below: Type, serial number, year of manufacture of the machine and the
serial numbers of hydraulic and mechanical components
Machine
1 3
2
CT04D014 CT04A171
(1) Type.............................................................................
(2) Serial number..............................................................
(3) Year of manufacture....................................................
Engine
Make and type .............................................................................................................................................................
Serial number ..............................................................................................................................................................
Component serial numbers

Hydraulic pump............................................................................................................................................................
Swing reduction gear...................................................................................................................................................
Travel reduction gears .................................................................................................................................................
Travel control valve......................................................................................................................................................
Attachment control valve .............................................................................................................................................
Swing control valve......................................................................................................................................................

1002-4
FLUIDS AND LUBRICANTS

Lubricants must have the correct properties for each application.
WARNING: The conditions of use for individual fluids and lubricants must be respected.
!
Hydraulic fluid Grease
CASE hydraulic fluid is specially designed for high The type of grease to use depends on ambient tem-
pressure applications and for the CASE hydraulic perature.
system. The type of fluid to be used depends on the
ambient temperature.
Temperate and hot climates
-20°C to +60°C
Temperate climates
Extreme pressure grease EP NLGI grade 2 with molyb-
-20°C to +40°C denum disulphide.
Fluid type ISO VG 46
CASE reference: POHYDR
Cold climates
-40°C to +20°C
Hot climates
Extreme pressure grease EP NLGI grade 0.
0°C to +60°C
CASE reference: POHYPC
Cold climates
-40°C to +20°C
CASE reference: POHYPF
These various grades of fluid must be in conformity
with the CASE specification.
Transmission component oil

Extreme pressure oil used for transmission compo-
nents inside sealed housings.
Extreme pressure oil TYPE API GL5 GRADE 80W90 or
ISO VG 150.

1002-5
Engine oil
CASE engine oil No. 1 is recommended for your
engine. This oil ensures correct lubrication of your
engine in all working conditions.
If CASE No. 1 Multiperformance or Performance
engine oil is not available, use oil corresponding to
category API/CG/CF.
NOTE: Do not put any Performance Additive or other
additive in the sump. Oil change intervals shown in
this manual are based on tests carried out on CASE
lubricants.
RD97F136
RD97F100
Oil viscosity/Oil range
CS98M561
(A) FAHRENHEIT TEMPERATURE (2) WINTER
(B) CELSIUS TEMPERATURE (3) TROPICAL
(1) ALL SEASONS (4) ARCTIC
(*) SHOWS THAT AN ENGINE OIL HEATER OR ENGINE COOLANT SOLUTION HEATER MUST BE USED

1002-6
Fuel Environment
Use fuel that is to ASTM (American Society for Test- Before carrying out any servicing operation on this
ing and Materials) D975 standard. machine and before disposing of used fluids or lubri-
cants, always think of the environment. Never throw
Use Grade No. 2 fuel. The use of other types of fuel
fluid or oil on the ground and never keep them in
can result in a loss of power and may cause high fuel
leaking receptacles.
consumption.
Consult your local ecological recycling centre to
In cold weather, the use of a mixture of fuels No. 1
obtain information on the appropriate means of dis-
and No. 2 is temporarily permitted. Consult your fuel
posing of these substances.
supplier.
If the temperature falls below the fuel cloud point Components made from plastic or
(point at which wax begins to form) the wax crystals resin
will cause power loss or will prevent the engine from
starting. When cleaning plastic parts, the console, the instru-
ment panel, the gauges, etc., do not use petrol (gaso-
IMPORTANT: In cold weather, fill the fuel tank at the line), paraffin (kerosene), paint solvents, etc. Use
end of the day’s work, in order to prevent the forma- only water, soap and a soft cloth.
tion of condensation.
The use of petrol (gasoline), paraffin (kerosene),
Fuel storage paint solvents, etc, will cause discoloration, cracking
Long storage can lead to the accumulation of impuri- or deformation of these components.
ties and condensation in the fuel. Engine trouble can
often be traced to the presence of water in the fuel.
The storage tank must be placed outside and the
temperature of the fuel should be kept as low as pos-
sible. 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.
In environments with a temperature higher than
-36°C, use a mixture of 50% ethylene-glycol based
anti-freeze.
For areas where the temperature is below -36°C, it is
advisable to use a blend of 40% water and 60% anti-
freeze.

1002-7
SPECIFICATIONS
Engine
CX210/CX230 CX240
Make.............................................................................................. Isuzu ........................................................... Isuzu
Model........................................................................................................................... BB-6BG1T
Type: Four stroke, water-cooled, overhead valve, direct injection (electronically controlled), in-line engine with
turbo-charger.
Number of cylinders............................................................................................................. 6
Bore and stroke ..........................................................................................................105x125 mm
Displacement................................................................................................................ 6494 cm3
Operating conditions
Idling ............................................................................................................................. 1000 rpm
Max speed ..................................................................................1950 rpm ..................................................2150 rpm
ECC 1289 power rating ........................................................ 105 kW (143 hp) ............................. 140,5 kW (190 hp)
Max torque......................................................................... 532 Nm at 1600 rpm ....................... 676 Nm at 1800 rpm
Capacities
Engine oil capacity..........................................................................................................24 litres
Engine cooling system....................................................................................................27 litres
Capacity of the radiator only........................................................ 12 litres .................................................. 12.2 litres
Fuel tank..................................................................................... 265 litres .................................................. 340 litres
Hydraulic fluid reservoir capacity...................................................................................120 litres
Total hydraulic system capacity .................................................. 206 litres .................................................. 225 litres
Capacity of the cooler only ..........................................................5.3 litres.................................................... 5.7 litres
Travel reduction gear housing capacity ......................................................................... 4.7 litres
Swing drive housing capacity ......................................................4.5 litres....................................................... 6 litres
Idler wheel capacity ....................................................................................................... 180 cm3
Upper roller capacity...................................................................................................50 to 55 cm3
CX210 CX230/CX240
Lower roller capacity....................................................................210 cm3 .................................................... 250 cm3

NOTE: These capacities are only provided in an indicative manner. To check fluid levels, always use the oil dipstick,
sight glasses or the filler cap.
Electrical system
Type of system ...................................................................................................24 volts negative earth
Alternator amperage......................................................................................................... 40 A
Battery
Number of batteries required .......................................................................................... 2
Voltage of each battery ..............................................................................................12 volts
Capacity ..................................................................................................................... 140 Ah
Reserve ......................................................................................................................160 min
Cold starting capacity at -17°C.................................................................................... 800 A
Load for load checking ................................................................................................ 400 A
Starter motor
Voltage .......................................................................................................................24 volts
Power ......................................................................................................................... 4.5 kW
Voltage regulator ..............................................................................................integrated, not adjustable

1002-8
Hydraulic system
Main hydraulic pump
CX210/CX230 CX240
Double, axial piston, variable flow pump.
Max flow ................................................................................... 2x201 l/min ............................................ 2x212 l/min
Displacement........................................................................... 2x101.5 cm3 ............................................2x97.2 cm3
Hydraulic pilot pump
CX210 CX230 CX240
Fixed flow pump.
Max flow ...................................................................................... 22 l/min ..................... 20L/mn.....................22 l/min
CX210/CX230 CX240
Displacement.................................................................................................................. 10 cm3
Pressure settings
Pilot circuit secondary relief valve .................................................................................39±1 bar
Main relief valve (standard) ..........................................................................................343±3 bar
Main relief valve (higher pressure - 2-stage relief) .......................................................373±5 bar
Relief valves (boom, dipper and bucket) ......................................................................392±5 bar
Relief valves (swing).................................................................. 279±4 bar ................................................290±4 bar
Relief valves (travel) .....................................................................................................353±5 bar
Safety valve (boom and dipper)....................................................................................392±5 bar
Cylinder
Boom cylinder
Barrel diameter ............................................................................ 120 mm .....................................................125 mm
Rod diameter ................................................................................ 85 mm ........................................................90 mm
Stroke ......................................................................................... 1255 mm .................................................. 1284 mm
Dipper cylinder
Rod diameter ................................................................................ 95 mm ......................................................105 mm
Stroke ......................................................................................... 1474 mm .................................................. 1627 mm
Bucket cylinder
Rod diameter ................................................................................ 80 mm ........................................................90 mm
Stroke ......................................................................................... 1012 mm .................................................. 1073 mm
Leaks on the cylinder - attachment lowering (without load)
Boom cylinders (rod retracting) .......................................................................................... ≤ 5 mm/5 min
Dipper cylinder (rod extending) .......................................................................................... ≤ 5 mm/5 min
Bucket cylinder (rod extending) .......................................................................................... ≤ 7 mm/5 min
Full (at the end of the attachment) .................................................................................. ≤ 200 mm/10 min
Cylinder speeds (in mode S)
Boom raising (open bucket on the floor)...................................3.5±0.6 sec. ........................................... 3.7±0.6 sec.
Boom lowering (open bucket)...................................................2.9±0.6 sec. .............................................. 3±0.6 sec.
Dipper extension.......................................................................2.7±0.6 sec. .............................................. 3±0.6 sec.
Dipper retraction .......................................................................3.7±0.6 sec. ........................................... 4.2±0.6 sec.
Bucket opening.........................................................................2.3±0.6 sec. ........................................... 2.8±0.6 sec.
Bucket closing ........................................................................... 4±0.6 sec. ............................................... 5±0.6 sec.

1002-9
Control valve
Five section control valve for dipper, boom acceleration, swing, option and RH travel.
Four section control valve for dipper acceleration, bucket, boom and LH travel.
Load holding valve for boom and dipper.
Swing
CX210/CX230 CX240
Fixed flow, axial piston motor.
Automatic disc brake.
Upperstructure swing speed.........................................................12 rpm .....................................................10,4 rpm
Displacement...............................................................................151 cm3 .................................................... 146 cm3
Work output ................................................................................ 155 l/min .................................................. 182 l/min
Reduction ratio ............................................................................. 16.757 ........................................................22.097
Braking torque.....................................................................................≥ 739 Nm .......................................................≥ 806 Nm
Minimum brake pressure .................................................................................................29 bar
Acceptable hydraulic motor leakage............................................ xx l/min.......................................................xx l/min
Travel
CX210 CX230 CX240
Two-speed, axial piston motor.
Automatic disc brake.
Slow speed ................................................................................. 3.3 km/h ....................3,2 Km/h ..................3.4 km/h
Fast speed.................................................................................. 5.7 km/h................... 5,3 Km/h .................5.5 km/h
CX210/CX230 CX240
Incline that can be overcome........................................................................................ 70% (35°)

CX210 CX230 CX240
Tractive force ............................................................................ 18 340 daN ...................... daN ...............19 100 daN
CX210 CX230/CX240
Displacement...........................................................................162.2/95 cm3 ................................... 168.9/100.3 cm3

Work output ................................................................................ 201 l/min .................................................. 212 l/min
Reduction ratio ............................................................................................................... 43.246
Braking torque (including reducer) .............................................................................. 20 900 Nm
Number of turns at the sprockets (10 turns)
Mode "S", fast speed...........................................................14.2±0.6 sec. ........................................... 13±0.6 sec.
Mode "S", slow speed .........................................................23.4±0.7 sec. ........................................ 21.4±0.7 sec.
Permitted deviation in travel over a distance of 20 m
Mode "H", full speed...................................................................................................... 1 m
Acceptable hydraulic motor leakage.............................................xx l/mn ..................... xx l/mn .......................xx l/mn
Undercarriage
CX210 CX230 CX240
One-piece undercarriage with welded components.
Lubricated rollers and idler wheels.
Grease type track tension.
Ground pressure
with 550 mm track pads ................... .......................................................................... 0,54 Bar
with 600 mm track pads ..........................................................0.41 bar .....................................................0.47 bar
Track tension ............................................................................................................ 280 to 300 mm
1002-10
Attachment
CX210/CX230 CX240
Break-out force ......................................................................... 14 110 daN ............................................ 17 300 daN
Penetration force
1.90 m dipper............................................................................ 14 500 daN
2.40 m dipper............................................................................ 12 560 daN
3.00 m dipper............................................................................ 10 050 daN
2.50 m dipper............................................................................................................................................ 15 000 daN
3.10 m dipper............................................................................................................................................ 12 500 daN
3.50 m dipper.............................................................................................................................................11 400 daN
Weight of components
CX210/CX230 CX240
Engine .............................................................................................................................512 kg
Hydraulic pump................................................................................................................157 kg
Attachment control valve .................................................................................................199 kg
Swing motor/reduction gear assembly ......................................... 223 kg ........................................................ 345 kg
Travel motor/reduction gear assembly ............................................................................308 kg
Boom cylinder............................................................................... 169 kg ........................................................ 192 kg
Dipper cylinder.............................................................................. 257 kg ........................................................ 327 kg
Bucket cylinder ............................................................................. 151 kg ........................................................ 194 kg
Counterweight ............................................................................. 4000 kg ..................................................... 5100 kg
Cab ..................................................................................................................................254 kg
Upperstructure attachment .......................................................... 8670 kg .................................................. 10 290 kg
Machine without attachment.......................................................15 430 kg................................................. 18 110 kg
Attachment .................................................................................. 3680 kg ..................................................... 4620 kg
Boom attachment ........................................................................ 2110 kg ..................................................... 2620 kg
Dipper attachment ........................................................................ 928 kg ...................................................... 1190 kg
Radiator and cooler set ................................................................. 76 kg ........................................................... 84 kg
Fuel tank...........................................................................................................................87 kg
Hydraulic tank..................................................................................................................127 kg
CX210 CX230/CX240
Turnable bearing .......................................................................... 263 kg ........................................................ 389 kg

Undercarriage attachment ........................................................... 6570 kg ..................................................... 7610 kg
Hydraulic swivel................................................................................................................31 kg
Idler wheel ..................................................................................... 82 kg ........................................................... 91 kg
Upper roller.......................................................................................................................17 kg
Lower roller.................................................................................... 36 kg ........................................................... 40 kg
Shock absorber ............................................................................ 126 kg ........................................................ 142 kg
Track 550 mm..............................................................................................................................................................
Track 600 mm.............................................................................. 1263 kg ..................................................... 1365 kg
Track 700 mm.............................................................................. 1470 kg ..................................................... 1502 kg
Track 800 mm.............................................................................. 1599 kg ..................................................... 1633 kg

1002-11
DIMENSIONS AND LIMIT OF WEAR AND TEAR OF THE TRACKS SET

Toothed wheel
Dimensions
a P
Ød
Øb Øc
CS01B512
Marking Dimension (mm)

Standard 66
a
Limit 60
Standard 582.5
Øb
Limit 576.5
Standard 659
Øc
Limit 653
Standard 644.6
Ød
Limit ---
Standard 190
P
Limit ---
Gauge
CS01B513

1002-12
Idler wheel
Dimensions
Dimension (mm)
Marking CX230
CX210
CX240
Standard 494 494
Øa
b Limit 490 490
Standard 19 19
c b
Limit --- ---
Standard 84 84
c
Limit 80 80
Standard 65 70
Ø d (pin)
Øa Limit 64.5 69.5
Standard 65 70
Ø d (ring)
Limit 65.8 70.8
Standard 69 74
e
Limit 68.6 73.6
Standard 12.4 15.9
f
e f Limit 11.9 15.5
Ød
CS01B514
Gauge
CS01B515

1002-13
Upper roller
Dimensions
Marking Dimension (mm)
g e Standard 120
Øa
Limit 112
Standard 10
b
Limit ---
Standard 85
c
Limit 79
Standard 46
Ø d (pin)
Øa Ød Limit 45.5
Standard 46
Ø d (ring)
Limit 46.8
Standard 83
e
Limit 82.6
b
Standard 5.5
f
Limit 5
f c Standard 22.5
g
Limit 22
CS01B516
Gauge
CS01B517

1002-14
Lower roller
Dimensions
d
f g
Øe
Øa
b
CS01B518
Dimension (mm) Dimension (mm)

Marking CX230 Marking CX230
CX210 CX210
CX240 CX240
Standard 150 160 Standard 65 70
Øa Ø e (ring)
Limit 142 152 Limit 65.8 70.8
Standard 15 15 Standard 69 74
b f
Limit --- --- Limit 68.6 73.6
Standard 173 173 Standard 23.3 20.8
d g
Limit 179 179 Limit 22.8 20.5
Standard 65 70
Ø e (pin)
Limit 64.5 69.5
Gauge
CS01B519

1002-15
Track
d
Øe Øe
Øf Øf
Øg Øg
h h
CS01B520
Dimension (mm) Dimension (mm)

Marking CX230 Marking CX230
CX210 CX210
CX240 CX240
Standard 34.5 36 Standard 58.72 58.72
a Ø e (ring)
Limit 21.5 23 Limit 57.5 57.5
Standard 106 106 Standard 37.3 37.3
b Ø f (ring)
Limit 101 101 Limit 38.3 38.3
Standard 37.985 37.985 Standard 36.3 36.3
c Ø g (pin)
Limit 36 36 Limit 35.5 35.5
Standard 19.95 17.95 Standard 190 190
d h
Limit 16 16 Limit 195 195

1002-16
DIMENSIONS AND LIMIT OF WEAR AND TEAR OF

THE MOBILE JOINTS OF THE ATTACHMENT
3 4
1
5
6
2 11
10 8 7
CS01B521
1. Boom foot/Undercarriage
a c
b
Ød
CS01B522
Dimension (mm)
Marking CX210
CX240
CX230
Standard 682 696
a
Limit 692 706
Standard 681.5 695.5
b
Limit 679.5 693.5
Standard 0.5 to 3 0.5 to 3
c (a - b)
Limit Shims Shims
Standard 90 100
Ø d (pin)
Limit 89 99
Standard 90 100
Ø d (ring)
Limit 91.5 101.5

1002-17
2. Boom cylinder foot/Undercarriage

a c
b
Ød
CS01B523
Dimension (mm)
Marking CX210
CX240
CX230
Standard 106 109
a
Limit 112 115
Standard 105 108
b
Limit 103 106
Standard 1 to 2.5 1 to 2.5
c (play)
Limit Shims Shims
Standard 80 90
Ø d (pin)
Limit 79 89
Standard 80 90
Ø d (ring)
Limit 81.5 91.5
3. Boom cylinder head/Boom

a b a c
Ød
CS01B524
Dimension (mm)
Marking CX210
CX240
CX230
Standard 100 108
a
Limit 98 106
Standard 525 528
b
Limit 512 522
c (play)
Limit Shims Shims
Standard 85 90
Ø d (pin)
Limit 84 89
Standard 85 90
Ø d (ring)
Limit 86.5 91.5
1002-18
4. Dipper cylinder foot/Boom

a c Dimension (mm)
Marking CX210
b CX240
CX230
Standard 121 121
a
Limit 127 127
Standard 120 120
b
Ød Limit 118 118
c (a - b)
Limit Shims Shims
Standard 80 90
Ø d (pin)
Limit 79 89
Standard 80 90
CS01B525 Ø d (ring)
Limit 81.5 91.5
5. Boom/Dipper
a b c Dimension (mm)
Marking CX210
CX240
CX230
Standard 310 330
a
Limit 313.5 333.5
Standard 309.5 329.5
b
Ød Limit 307.5 327.5
Standard 0.5 to 1.1 0.5 to 1.1
c (play)
Limit Shims Shims
CS01B526 Standard 90 100
Ø d (pin)
Limit 89 99
Standard 90 100
Ø d (dipper)
Limit 91.5 101.5
Standard 90 100
Ø d (boom)
Limit 91.5 101.5
6. Dipper cylinder head/Dipper

Dimension (mm)
Marking CX210
CX240
CX230
Standard 121 121
a
Ød Limit 127 127
Standard 120 120
b
Limit 118 118
b
a c c (a - b)
Limit Shims Shims
Standard 80 90
CS01B527 Ø d (pin)
Limit 79 89
Standard 80 90
Ø d (ring)
Limit 81.5 91.5

1002-19
7. Bucket cylinder foot/Dipper

a c Dimension (mm)
b Marking CX210
CX240
CX230
Standard 101 116
Ød a
Limit 107 122
Standard 100 105
b
Limit 98 103
c (a - b)
Limit Shims Shims
Standard 75 80
CS01B528 Ø d (pin)
Limit 74 79
Standard 75 80
Ø d (ring)
Limit 76.5 81.5
8. Connecting rod/Dipper
Dimension (mm)
Marking CX210
c CX240
CX230
Standard 32 40
a
Limit 30 38
b
Standard 296 316
b
Limit 294 314
c (play)
a Limit Shims Shims
Standard 75 80
Ød Ø d (pin)
Limit 74 79
Standard 75 80
Limit 76.5 81.5
9. Compensator/Bucket
Ød Dimension (mm)
Marking CX210
CX240
c CX230
Standard 307 317
a
Limit 313 323
Standard 306 316
b a b
Limit 304 314
c (play)
Limit Shims Shims
Standard 80 90
Ø d (pin)
Limit 79 89
Standard 80 90
Limit 81.5 91.5

1002-20
10. Connecting rod/Compensator/Bucket cylinder head

Dimension (mm)
Marking CX210
a CX240
CX230
f Standard 32 40
a
Limit 30 38
b e d
Standard 296 316
b
Limit 294 314
c c (play)
Limit Shims Shims
Standard 96 106
Øg d
Limit 98 108
Standard 95 105
CS01B531 e
Limit 93 103
f (d - e)
Limit Shims Shims
Standard 80 90
Ø g (pin)
Limit 79 89
Øg Standard 80 90
(compensator) Limit 81.5 91.5
Standard 80 90
Ø g (cylinder)
Limit 81.5 91.5
11. Dipper/Bucket
Øe Dimension (mm)
Marking CX210
CX240
CX230
d Standard 307 326
a
Limit 313 332
Standard 306 325
b
a b Limit 304 323
c (a - b)
Limit Shims Shims
Standard 16 16
c d
Limit 8 8
Standard 80 90
Ø e (pin)
Limit 79 89
CS01B532
Standard 80 90
Ø e (dipper)
Limit 81.5 91.5
Standard 80 90
Ø e (bucket)
Limit 81.5 91.5

1002-21
SPECIAL TORQUE SETTINGS

Screw Key Torque setting
No. Component
(Ø) (mm) (Nm)
1* Travel motor/reduction gear assembly M16 24 267-312
2* Sprocket M16 24 267-312
3* Idler wheel M16 24 267-312
4* Upper roller M20 30 521-608
5* Lower roller M18 27 371-432
6 Chain guide M18 27 380-443
7 Track pad M20 30 300 + 120°
M27 41 1058-1235
8 Counterweight
M30 46 1333-1549
M20 30 468-545
9 Turntable (undercarriage)
M24 36 783-913
M20 30 468-545
10 Turntable (upperstructure)
M24 36 783-913
M20 30 521-608
11 * Swing motor/reduction gear assembly
M24 36 783-913
12 * Engine M16 24 265-313
13 * Engine support M10 17 64-74
14 Radiator M16 24 147-176
M10 17 64-74
15 * Hydraulic pump
M20 30 367-496
16 * Hydraulic reservoir M16 24 232-276
17 * Fuel tank M16 24 232-276
18 * Control valve M16 24 267-312
19 * Hydraulic swivel M12 19 109-127
20 Cab M16 24 78-80
21 Battery M10 17 20-29
NOTE: Use Loctite 262 or an equivalent on retaining screws of components marked with an asterisk (*).

1002-22
15
11 16 18 12 13
17 14
8
21
7
19 1 2
9 10 5
6
20
3 4
CS00E507
6
1
CS00E508 CS00E509
6
5
3 8
CS00E510 CS00E511

1002-23
11
13
12
9 9 10
CS00E512 CS00E514
15
15
CS00E517
14 CS00E515
16 CS00E518 17 CS00E519
18 CS00E521
19 21
20
CS00E522 CS00E523 CS00E525

1002-24
MACHINE OVERALL DIMENSIONS

E G
B A
F
M
K I
J H
L D
C
CS01B533
CX210 CX230 CX240

Dippers Dippers Dippers
1.90 m 2.40 m 3.00 m 2.50 m 3.10 m 3.50 m 2.50 m 3.10 m 3.50 m
A 3.07 m 2.91 m 3.04 m 3.10 m 2,92 m 3.31 m 3.08 m 3.30 m
B 2.88 m 2.88 m 2.88 m 2.95 m 2.95 m 2.95 m 2.96 m 2.96 m 2.96 m
C 9.47 m 9.39 m 9.59 m 9.58 m 9.48 m 9.95 m 9.88 m 9.91 m
D 4.95 m 4.95 m 4.95 m 4,95 m 4,95 m 4,95 m 5.22 m 5.22 m 5.22 m
E 2.75 m 2.75 m 2.75 m 2.50 m 2.50 m 2.50 m 2.75 m 2.75 m 2.75 m
F 1.04 m 1.04 m 1.04 m 1.09 m 1.09 m 1.09 m 1.10 m 1.10 m 1.10 m
G 2.72 m 2.72 m 2.72 m 2.83 m 2.83 m 2.83 m 2.91 m 2.91 m 2.91 m
H 4.46 m 4.46 m 4.46 m 4.24 m 4.24 m 4.24 m 4.64 m 4.64 m 4.64 m
I 3.66 m 3.66 m 3.66 m 3.46 m 3.46 m 3.46 m 3.83 m 3.84 m 3.84 m
J 2.39 m 2.39 m 2.39 m 1,99 m 1,99 m 1,99 m 2.59 m 2.59 m 2.59 m
K (standard track pads) 0.60 m 0.60 m 0.60 m 0.55 m 0.55 m 0.55 m 0.60 m 0.60 m 0.60 m
L (standard track pads) 2,54 m 2,54 m 2,54 m
L (with 600 mm track pads) 2.99 m 2.99 m 2.99 m 3.19 m 3.19 m 3.19 m
M 0.49 m 0.49 m 0.49 m 0.48 m 0.48 m 0.48 m 0.46 m 0.46 m 0.46 m

Section
2000
REMOVAL AND INSTALLATION OF THE ENGINE
2000

Printed in France
2000-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 2
SPECIAL TORQUE SETTINGS ............................................................................................................................... 2
ENGINE.................................................................................................................................................................... 3
Removal and installation ...................................................................................................................................... 3
SPECIFICATIONS
Weight of engine............................................................................................................................. See Section 1002

Engine retaining screws ................................................................................................................. See Section 1002

2000-3
ENGINE
Removal and installation STEP 6
STEP 1
CD00J037
Remove the engine throttle control.
JS00163A
Park the machine on hard, flat ground. Lower the STEP 7
attachment to the ground.
STEP 2
Release pressure in the hydraulic system and in the
hydraulic reservoir (see Section 8000).
1
STEP 3
1 2
CD00J038
Disconnect the fuel supply pipe (1) and the fuel return
pipe (2) and plug them.
STEP 8
CD00F091
Disconnect the earth cable from the battery (1) (-). 1
STEP 4 2
Refer to Section 8003 and remove the hydraulic
pump.
STEP 5
Refer to Section 2001 and remove the radiator and
oil-cooler assembly.
CD00J039
Remove the hoses (1) and (2) from the heater system
and plug them.

2000-4
STEP 9 STEP 12
1
CD00J044 CD00J047
Label and disconnect the electrical connections from Label and disconnect the electrical supply (1) to the
the water temperature sensor (1). pre-heating plugs.
STEP 10 STEP 13
CD00J045 CD00J048
Label and disconnect the electrical connections from Label and disconnect the electrical connections to
the fuel temperature sensor (1). the starter motor. Remove the earth cable (1) at the
engine end.
STEP 11
CD00J046
Label and disconnect the electrical connections from
the oil pressure detector (1) and the engine speed
detector (2).

2000-5
STEP 14 STEP 16
CD00J040 CD00J042
Label and disconnect the connectors to the electronic Label and disconnect the electrical connections to
regulator and disconnect the fuel flow regulation the alternator.
resistance.
NOTE: If the machine is equipped with air
STEP 15 conditioning, remove the compressor mounting
hardware and move the compressor away from the
engine.
STEP 17
Remove all the clips, etc, which fasten the electrical
harnesses to the engine and move the harnesses out
of the way.
STEP 18
CD00J041
Remove the hose connecting the turbo-charger to the
air filter.
CD00J043
Install a suitable lifting device on the engine lifting
rings (for the weight of the engine, see Section 1002).

2000-6
STEP 19 STEP 20
Remove the engine retaining hardware. When there is nothing interfering with the removal of
the engine, raise the engine carefully and install it on
NOTE: When installing, make a visual inspection of the
a suitable repair bench.
condition of the rubber flexible mountings and change
them if necessary. Tighten the engine retaining screws NOTE: When installing the engine in the machine,
to the torque specified in Section 1002. proceed in the reverse order from removal.
Before operating the machine, carry out the following operations:
- Bleed and prime the fuel system (see Operator’s Manual).
- Fill and bleed the engine cooling system (see Operator’s Manual).
- Check the hydraulic, fuel and cooling systems for leaks.
- Check the oil level in the hydraulic reservoir. Top up if necessary.

2001
Section
2001
RADIATOR AND OIL-COOLER

Printed in France
2001-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 2
RADIATOR AND OIL-COOLER ............................................................................................................................... 3
Removing the oil-cooler ....................................................................................................................................... 3
Installing the oil-cooler ......................................................................................................................................... 3
Removing the radiator .......................................................................................................................................... 4
Installing the radiator ............................................................................................................................................ 6
CHANGING THE RADIATOR OR THE OIL-COOLER............................................................................................. 7
Disassembly and assembly.................................................................................................................................. 7
! this symbol, carefully read the message which follows. Your safety depends on it.
SPECIFICATIONS
Coolant solution.............................................................................................................................. See Section 1002
Total cooling system capacity ...................................................................................................................... 26.4 litres
Thermostat opening range
Starts to open..................................................................................................................................................82°C
Completely open .............................................................................................................................................95°C
Hydraulic fluid ................................................................................................................................. See Section 1002

2001-3
RADIATOR AND OIL-COOLER

Before carrying out any operation on the machine, perform the following operations in the order shown:
- Park the machine on hard, flat ground.
- Lower the attachment to the ground.
- Shut down the engine.
- Remove the starter switch key.
- Make sure that pressure in the hydraulic system has been completely released (see Operator’s Manual).
WARNING: When the machine is working, the engine components and the hydraulic pump reach a high
temperature. To avoid being burnt by hot metal or scalded by high temperature water or oil, allow the
! machine to cool down before starting any servicing operation.
Removing the oil-cooler STEP 4
STEP 1 2
1
1
1
CD00G013
Disassemble the four retaining screws (1) from the
CD00G009
oil-cooler (2) and remove the oil-cooler.
Remove the upper grille (1), then remove the air
conditioning heat exchanger (2) without disconnecting it. Installing the oil-cooler
STEP 2 When installing, proceed in the reverse order from
that of removal.
Release pressure in the hydraulic reservoir to allow
the vacuum pump to be mounted (see Section 8000). Before using the machine, check the level of oil in the
hydraulic reservoir. Top up if necessary. Check the
STEP 3 hydraulic fluid cooling circuit for leaks.
2
4
CD00G010
Disconnect and plug the hoses (1) and (2). Drain the
oil from the oil-cooler (3) into a clean receptacle.
Disassemble the four screws (4) from the oil-cooler
bracket (3).

2001-4
Removing the radiator STEP 4
STEP 1
3
1 4
1
1 2
CD00G014
Disassemble the retaining screws (1) from the hinges
CD00G009
(2) of the oil-cooler bracket (3) at the radiator bracket
Remove the upper grille (1). end (4). The oil-cooler bracket (3) is then separated
from the radiator bracket (4).
STEP 2
STEP 5
Remove the cap from the expansion reservoir.
IMPORTANT: Do not remove the cap when the
2 engine is hot, since the system would still be under
pressure and you could be scalded.
STEP 6
Drain the cooling system (see Operator’s Manual).
1 STEP 7
CD00G012
Disassemble the four retaining screws (1) from the 1
oil-cooler bracket (2).
STEP 3 2
CD00G015
Disconnect the expansion reservoir hose (2) and the
return hose (3) from the radiator (1).
CD00G152
Pivot the oil-cooler bracket assembly (1) to the
maximum opened position. Wedge the assembly (1)
into position.

2001-5
STEP 8 STEP 11
1
2 1
4
CD00G016 CD00G019
Disconnect the water pump intake hose (4) from the Disassemble the two retaining screws (1) and
radiator (1). remove the rear tie-rod (2).
STEP 9 STEP 12
1
1
2 2
3
CD00G017 CD00G020
Loosen the retaining band (1) as far as possible, then Disassemble the two retaining screws (1) and
slide the retaining band (1) and the rubber skirt (2) remove the front mounting angle bracket (2).
onto the shroud (3).
STEP 13
STEP 10
1
1
CD00G018
Remove the lower retaining screws (1) from the
radiator bracket.
CS00G513
Pass a suitable sling right around the radiator and
support assembly and, using a suitable lifting device,
remove the radiator and support assembly.

2001-6
Installing the radiator

When installing, proceed in the reverse order from
that of removal.
Before operating the machine, fill and bleed the
engine cooling system (see Operator’s Manual) and
check the engine cooling system for leaks.

2001-7
CHANGING THE RADIATOR OR THE OIL-COOLER

Disassembly and assembly
NOTE: The parts are numbered in order of disassembly. Assembly is carried out in the reverse order from that of
disassembly.
3 3 7
2 10
1
11
12
4
5 13
CI00G506
1 INTAKE SHROUD RETAINING SCREWS 10 FILTER
2 INTAKE SHROUD 11 GUARD RETAINING HARDWARE
3 RADIATOR UPPER RETAINING SCREWS 12 GUARD
4 RADIATOR LOWER RETAINING SCREWS 13 RADIATOR SUPPORT
5 RADIATOR
6 OIL-COOLER BRACKET RETAINING SCREWS
7 OIL-COOLER
8 OIL-COOLER BRACKET
9 FILTER RETAINING SCREWS

2001-8

3001
Section
3001
REMOVAL AND INSTALLATION

OF THE FUEL RESERVOIR

Printed in France
Case Cre 7-27970GB April 2001
3001-2
TABLE OF CONTENTS
SPECIFICATIONS .................................................................................................................................................. 2
FUEL RESERVOIR ................................................................................................................................................ 3
Removal .............................................................................................................................................................. 3
Installation ........................................................................................................................................................... 4
Description .......................................................................................................................................................... 5
SPECIFICATIONS
See Section 1002

3001-3
FUEL RESERVOIR
Removal
STEP 1 STEP 9
Remove the screws (8) and the protective plate (9)
from on top of the fuel reservoir (1).
STEP 10
Loosen the two screws (10) located underneath the
machine. Open the side portion of the machine and
remove the two screws (11) located on the RH side of
the fuel reservoir (1). Remove the protective plate of
the reservoir (12).
STEP 11
Remove the two screws (13) that hold the fuel oil filter
JS00163A (14). Attach tags to the two hoses (15) and (16).
Park the machine on hard, flat ground. Lower the Remove the fuel oil filter (14) by removing the two
attachment to the ground. hoses (15) and (16) and the circlips (17) and (18).
STEP 2 STEP 12
Reduce the engine speed to idle for 30 seconds, then Shift the plastic protection (19) from the fuel probe
shut down the engine. (20). Remove the retaining screws (21) then the fuel
probe (20) as well as the seal (22).
STEP 3
Turn the ignition key to "ON" without starting the
STEP 13
engine. Remove the four screws (23) from the fuel reservoir
(1), as well as the shims (24).
STEP 4
Attach a "DO NOT OPERATE" tag to the ignition key
STEP 14
in the cab. Remove the fuel reservoir (1) using a hoist.
STEP 5 STEP 15
NOTE: The numbers in brackets refer to the figures See the operator’s manual for removing the fuel filter.
on pages 5 and 6.
Remove the access panel under the fuel reservoir
(1).
STEP 6
Open the filling plug of the reservoir (2). Empty the
reservoir using the valve (3) then remove the latter.
STEP 7
Lift the hood of the front boot. Remove the retaining
screw (4) of the access ramp (5). Remove the access
ramp (5).
STEP 8
Remove the screws (6) on top and then inside the
front boot, then remove the protective housing (7).

3001-4
Installation
NOTE: The numbers in brackets refer to the figures STEP 7
on pages 5 and 6.
Install the protective housing (7) on top of the front
STEP 1 boot using the screws (6) then put back the screw
mask.
Using a hoist, position the fuel reservoir (1) on the
machine. STEP 8
STEP 2 Install the access ramp (5) using screws (4). Close
the front boot.
Install the shims (24) as well as the four screws (23),
tighten the screws to a torque, see specifications. STEP 9
Install the valve (3) and tighten the valve (3) to a
torque of 14.7 Nm. Fill the fuel reservoir (see the operator’s manual) and
make sure that there are no leaks.
STEP 3
STEP 10
Install a new seal (22), then the fuel probe (20) using
the five screws (21), reposition the plastic protection Reinstall the protective plate on top of the machine.
correctly (19).
STEP 4
Install the fuel oil filter (14) on the reservoir using
screws (13). Install the two hoses (15) and (16)
taking help of the tags installed during removal.
Tighten using circlips (18) and (17).
STEP 5
Install the reservoir protection (12) using screws (10)
and (11). Tighten the screws (10) and (11).
STEP 6
Install the protective plate (9) on top of the fuel
reservoir (1). Tighten the screws (8).

3001-5
Description
Location
4 5
11
6
12 10 4
CS00F539
9
6
8 4
CS00F540
4 SCREW 10 SCREW
5 ACCESS RAMP 11 SCREW
6 SCREW 12 RESERVOIR PROTECTIVE PLATE
7 PROTECTIVE HOUSING
8 SCREW
9 FUEL RESERVOIR PROTECTIVE PLATE

3001-6
Fuel reservoir
2 13 1
17
18
20
15
22
21
14
19
17 18
16
3 24
23
CI00F506
1 FUEL RESERVOIR 17 CIRCLIP
2 PLUG 18 CIRCLIP
3 VALVE 20 FUEL PROBE
13 SCREW 21 SCREW
14 FUEL OIL FILTER 22 SEAL
15 HOSE 23 SCREW
16 HOSE 24 SCREW

4001
Section
4001
ELECTRICAL AND ELECTRONIC

CIRCUIT AND TROUBLESHOOTING
Copyright  2005 CNH France SA

Printed in France
4001-2
TABLE OF CONTENTS
SPECIFICATIONS ....................................................................................................................................................4
SPECIAL TOOLS ..................................................................................................................................................... 4
LOCATION OF COMPONENTS .............................................................................................................................. 6

General location of the components (outside the cab) ......................................................................................... 6
General location of the components (outside the cab) ......................................................................................... 8
Relay and main fuses (battery compartment) ....................................................................................................10
General location of the components (inside the cab) .........................................................................................12
Fuse box ............................................................................................................................................................14
Instrument panel ................................................................................................................................................15
OPERATING PRINCIPLES ....................................................................................................................................16

Engine checks ....................................................................................................................................................16
Work mode selection ..........................................................................................................................................18
H/S/L mode checking .........................................................................................................................................20
Auto mode checking ...........................................................................................................................................21
Acceleration checking ........................................................................................................................................22
Engine idle checking (automatic/manual) ..........................................................................................................23
Breaker mode checking .....................................................................................................................................24
Automatic engine preheat ..................................................................................................................................25
Auto engine warm-up .........................................................................................................................................28
Idle checking using the battery voltage and the coolant temperature ................................................................30
Engine emergency stop .....................................................................................................................................32
Back-up mode ....................................................................................................................................................34
Function locking .................................................................................................................................................36
Power boost .......................................................................................................................................................37
Swing brake .......................................................................................................................................................38
Travel mode .......................................................................................................................................................40
Supply cut-off delayed ........................................................................................................................................43
Protection by power transistor ............................................................................................................................44
Coolant temperature indicator ............................................................................................................................44
Hydraulic oil temperature indicator .....................................................................................................................46
Fuel level ............................................................................................................................................................47
Engine fuel injection pump electronic regulator .................................................................................................48

4001-3
ACCESS AND CONTENTS OF MONITOR DISPLAYS (Diagnostic mode) ...........................................................50
Access to monitor displays .................................................................................................................................50
Machine condition ..............................................................................................................................................51
Diagnostic code ..................................................................................................................................................54
Machine history ..................................................................................................................................................57
Re-initialisation ...................................................................................................................................................60
WARNING MESSAGES .........................................................................................................................................63

Message display ................................................................................................................................................63
EXCAVATOR MODEL SELECTION PROCEDURE ..............................................................................................64

Changing the language code .............................................................................................................................65
CHANGING THE ACCESS CODE FOR THE ANTI-THEFT SYSTEM ..................................................................66
TROUBLESHOOTING ...........................................................................................................................................67
Prior inspections .................................................................................................................................................67
Reading the organisation charts ........................................................................................................................68
Procedures .........................................................................................................................................................69
Low fuel ..............................................................................................................................................................70
Add coolant solution ...........................................................................................................................................71
Low engine oil pressure .....................................................................................................................................72
Overheating ........................................................................................................................................................73
Defective battery charge circuit ..........................................................................................................................76
Electrical system troubleshooting .......................................................................................................................78
Travel .................................................................................................................................................................82
ELECTRICAL INSPECTION OF COMPONENTS ..................................................................................................83

Inspection equipment .........................................................................................................................................83
Proportional solenoid .........................................................................................................................................85
Engine emergency stop motor ...........................................................................................................................86
6 solenoid valve block ........................................................................................................................................86
Engine rpm sensor .............................................................................................................................................87
Engine coolant and hydraulic oil temperature sensor ........................................................................................88
Pressure sensor .................................................................................................................................................89

4001-4
SPECIFICATIONS
See section 1002.
SPECIAL TOOLS
BS98G045
1 Service connector kit CAS-30039

2 Multimeter CAS-1559

4001-5
This page is intentionally left blank

4001-6
LOCATION OF COMPONENTS
General location of the components (outside the cab)
CX130/CX160/CX180 Model
X2 E2 B45 B81 B26

E1
E3
M4
X1
R5
B27
B41
F25
B21
B22 Y7
S52 M2
52
S55
G1
B43
F25
F24 B44
F23
F22
K7
B1 G2 Y8 R1 R2 A3 M1 B2 B42
CM02H001

4001-7
52 6 solenoid valve bank
A3 Electronic acceleration
B1 Coolant temperature sensor
B2 Hydraulic oil temperature sensor
B21 Engine oil pressure switch
B22 Swing pilot pressure switch
B26 Upper pilot pressure switch
B27 Travel pilot pressure switch
B41 Engine rpm sensor
B42 Pump pressure sensor P1
B43 Pressure sensor (nega-cont)
B44 Pump pressure sensor P2 (yellow band)
B45 Overload indicator pressure switch
B81 Horn
E1 Working light (upperstructure)
E2 Working light (attachment)
E3 Working light (cab)
F22 Fuse 20 A; main fuse for circuits F11 and F12
F23 Fuse 65 A; main fuse for circuits F3 to F10 and F13 to F20
F24 Fuse 20 A; main fuse for circuit F2
G1 Batteries
G2 Alternator
K7 Relay battery
M1 Starter motor
M2 Engine emergency stop motor
M4 Washer motor
R1 Glow plugs
R2 Fuel flow adjustment resistor
R5 Fuel sensor
S52 Air conditioning compressor clutch switch
S55 Minimum coolant solution level switch
X1 Fuel filler pump connector
X2 Rotary light connector
Y7 Main pump proportional solenoid
Y8 Air conditioner magnet clutch

4001-8
General location of the components (outside the cab)

X2 E2 B45 B81
E1
E3
M4
X1
R5
B26
B22 B27
B41
G1
B21
F25
F24 M2
F23 52
F22 B42
K7
B44
S55
S52 Y7
B1 G2 Y8 R1 R2 A3 M1 B43 B2
CM02H002

4001-9
52 6 solenoid valve bank
B2 Hydraulic oil temperature sensor
B21 Engine oil pressure switch
B22 Swing pilot pressure switch
B26 Upper pilot pressure switch
B27 Travel pilot pressure switch
B43 Pressure sensor (nega-cont)
B45 Overload indicator pressure switch
B81 Horn
E1 Working light (upperstructure)
E2 Working light (attachment)
E3 Working light (cab)
G1 Batteries
G2 Alternator
K7 Relay battery
M1 Starter motor
M2 Engine emergency stop motor
M4 Washer motor
R1 Glow plugs
R2 Fuel flow adjustment resistor
R5 Fuel sensor
S52 Air conditioning compressor clutch switch
S55 Minimum coolant solution level switch
X1 Fuel filler pump connector
X2 Rotary light connector
Y7 Main pump proportional solenoid
Y8 Air conditioner magnet clutch

4001-10
Relay and main fuses (battery compartment)
K7
F24
F23 F25
F22
CI00E501
1 Battery cables
K7 Relay battery

4001-11
F23 F22 F24 F25
K7
CI00E502
1. Relay battery
2. Fuse 65 A: for F3 to F10 and F13 to F20A circuits
3. Fuse 20 A: for F11 and F12 circuits (before contact)
4. Fuse 20 A: for F1 circuits
5. Fuse 20 A: for F2 circuits
6. Battery cables

4001-12
General location of the components (inside the cab)
M3 A4
S54
S16
S15
P1
S51
R3
S14 S1
S53
P6
S13 E4
E52
E51
F21
X8
A1
B61
A2
K5 K1 K4 K3 K2 U1
CM00E002

4001-13
A1 Computer
A2 Engine controller
A4 Wiper controller
B61 Sunload sensor
E4 Cab light
E51 Cigarette lighter
E52 Air conditioner
F21 Fuse box
K1 Relay-engine emergency stop
K2 Relay-glow plug
K3 Relay-horn
K4 Relay-working lights
K5 Relay-rotary light
M3 Wiper motor
P1 Instrument panel
P6 Air conditioner control panel
R3 Throttle volume
S1 Key switch
S13 Overload switch
S14 Breaker/crusher switch
S15 Horn switch
S16 One touch idle
S51 Hydraulic function cancellation lever switch
S53 Door limit switch
S54 Front window limit switch
U1 DC-DC converter 24 V-12 V
X8 Radio connector

4001-14
Fuse box
CM00E005
F1 Fuse 20 A: Engine controller

F2 Fuse 20 A: Computer, instrument panel and diagnostic test socket
F3 Fuse 20 A: Computer power
F4 Fuse 10 A: Hydraulic control cancellation
F5 Fuse 15 A: Lubrication device (not used)
F6 Fuse 10 A: Rotary light
F7 Fuse 20 A: Fuel filler pump
F8 Fuse 15 A: Engine emergency stop motor
F9 Fuse 30 A: Glow plugs
F10 Fuse 10 A: Option line and lubricator connector
F11 Fuse 10 A: Back-up
F12 Fuse 10 A: Key switch
F13 Fuse 20 A: Heater / air conditioner
F14 Fuse 5 A: Air conditioner compressor
F15 Fuse 15 A: Working lights
F16 Fuse 15 A: Working light (not used)
F17 Fuse 10 A: DC-DC converter (24 V - 12 V)
F18 Fuse 15 A: Wiper and washer
F19 Fuse 10 A: Horn
F20 Fuse 15 A: Cigarette lighter, cab seat adjustment compressor

4001-15
Instrument panel
P4 S2 S3 S4 S7 S8 S9 P5
S5 S6 S10 S11 S12
CM00E001
P4 Monitor display
P5 Hourmeter 1 2 3 P4
S2 Travel mode switch
S3 Work mode switch
S4 Auto mode switch
S5 Cushion control switch
S6 Rotary light switch
S7 Audible alarm cut out switch
S8 Swing brake switch
S9 Engine emergency stop switch
S10 Working light switch
S11 Wiper switch
S12 Washer switch 4 5 6
CS00F521
1 Travel speed indicator
2 Work mode indicator
3 Idle mode indicator
4 Coolant temperature indicator
5 Hydraulic oil temperature indicator
6 Fuel level indicator

4001-16
OPERATING PRINCIPLES
Engine checks
1) Circuit configuration
S1 A2 1
A3
R3
S9
P1
B41
R2
B1
A1
A2 A3
Current position Current

signal value 2
Target
value
Target position signal
3 4 5
Back-up mode
Stop signal
CS01M536
1 Engine R2 Fuel flow adjustment resistor
2 Rack sensor R3 Throttle volume
3 Test circuit S1 Key switch
4 Linear motor control circuit S9 Engine emergency stop switch
5 Electronic acceleration circuit
A1 Computer
P1 Instrument panel

4001-17
2) Fuel consumption checking 4) Engine checking when stopped
1. The engine controller (A2) calculates the target When the engine controller receives the engine stop
speed on the basis: signal (when the ignition is turned off or the
- of data on the work mode sent through CAN emergency stop (S9) is activated), it (A2) transmits
communications from the computer (A1), the rack "no injection" position signal to the electronic
- on the voltage signals of the throttle volume acceleration (A3) and activates the engine stop
(R3), signal.
- on the voltage signals of the water temperature
sensor (B1) 5) Electronic acceleration power-assist
- of the voltage signals (key switch S1) that error and back-up mode
power the engine controller. 1. The rack sensor signal comes to the engine
2. The engine controller (A2) calculates the fuel flow by controller (A2).
analysing the difference between the target speed 2. The engine controller (A2) compares the target
(electronic acceleration tachometric sensor) and the position and the actual position of the rack.
actual speed (engine rpm sensor (B41).
3. If the engine controller (A2) determines that the rack
3. The engine controller (A2) converts the fuel flow in is not in its correct target position, it considers it as a
the target position of the electronic acceleration rack power-assist error and stops the engine.
(A3) and corrects this target position according to
the adjustment regulator (R2). 4. If the back-up mode is activated during an electronic
acceleration power-assist error (A3), the engine
3) Engine checking while starting runs in back-up mode (see chapter on back-up
1. By putting the switch (S1) in the start position, the mode).
start signal is sent simultaneously to the starter
motor and the engine controller (A2).
2. The engine controller (A2) determines the fuel flow
injection. This flow is determined by the data on the
water temperature and the actual engine rpm.
3. Once the start signal is switched off, the engine
controller (A2) goes from start fuel control to normal
flow injection control.

4001-18
Work mode selection

Y7 1
S3
A3
S4 2
P4
P1 A1 A2
CS01N579
2) Timing diagram
e
Battery 24V
master key 0V d b
5V
1 0V
c c
5V
2 0V
Work
AUTO S H S H L S AUTO AUTO S H AUTO S S H
mode
a
1 Engine P1 Instrument panel

2 SERIAL communication P4 Monitor display
A1 Computer S3 Work mode switch
A2 Engine controller S4 Auto mode switch
A3 Electronic acceleration Y7 Main pump proportional solenoid

4001-19
3) Mode selection switch 4) Operation
a) When the ignition switch is turned on, the "S" 1. The work mode (S3) and auto mode (S4) switches
mode is selected by default (except if auto signal is managed by the computer (A1) that
mode was selected at the time of turning off the changes the mode according to the input signal.
ignition switch). 2. The computer (A1) transmits the selected mode to
b) Each time the work mode switch (S3) is the monitor display (P4) via series communication
pressed, the mode changes: (2). The monitor display (P4) displays the selected
S→H→L→S→H mode.
c) If the auto mode switch (S4) is activated, the 3. The computer (A1) transmits the selected mode to
mode changes to auto mode. If the auto mode the engine controller (A2) via CAN communications
switch (S4) is pressed once again, the mode that control the electronic acceleration (A3).
changes to "S" mode. The engine controller (A2) transmits the mode and
the data concerning the rpm to the computer (A1)
d) When auto mode is activated, if the work mode via CAN communications.
switch (S3) is pressed, the work mode does not
change. 4. The computer (A1) calculates the proportional
solenoid (Y7) current based on the selected mode
e) After turning off the ignition switch in auto mode, and the data on the actual rpm and the target rpm of
when the ignition switch is turned on again, the the engine.
mode remains automatic.
5. The computer (A1) transmits the new data to the
monitor display (P4) via series communications.

4001-20
H/S/L mode checking

Y7
A1 A2 1
Y5 A3
CS00F509
1 Engine A3 Electronic acceleration
A1 Computer Y5 Power-up solenoid valve (yellow band)
A2 Engine controller Y7 Main pump proportional solenoid
2) Fixed values for each model
CX160 CX210 Hydraulic

CX130 CX240
CX180 CX230 power boost
Engine rpm (Max) rpm 2150 2250 2000 2200
Automatic
H mode Current (variable (Max) mA 600 600 407 427
checking
current) (Min) mA 450 490 292 307
Engine rpm (Max -200) rpm 1950 2050 1800 2000
Automatic
S mode Fixed current intensity
mA 450 490 292 307 checking
(90% torque)
Engine rpm (Max -300) rpm 1850 1950 1700 1900
L mode Fixed current intensity Constant
mA < 100 < 280 < 50 < 50
(70% torque)
Eng. idling Engine rpm rpm 1000 1000 900 900 -----
Engine rpm at maximum torque rpm 1600 1600 1600 1800 -----
NOTE: The values listed above are those in normal conditions, the following are exceptions:
1. If the target engine rpm is less than the maximum 3. In "L" mode, if the hydraulic breaker or the grab is
torque rpm, the pump is controlled by the "L" mode used, the pump is controlled by the "S" mode
current value (same in H/S modes). current value.
2. In "L" mode, if only travel is selected, the pump is 4. If the engine coolant temperature is too low, or if the
controlled by the "S" mode current value. voltage coming in to the engine controller (A2) is too
low, the idle rpm increases to avoid over-cooling of
the engine or discharging of the battery.

4001-21
Auto mode checking

B2
B42
B1
Y7
B44
A3
B43
Y5
B27
A1 A2 1
CS01N537
1 Engine B27 Travel pilot pressure switch
A1 Computer B42 Pump pressure sensor P1
A2 Engine controller B43 Pressure sensor (nega-cont)
A3 Electronic acceleration B44 Pump pressure sensor P2 (yellow band)
B1 Coolant temperature sensor Y5 Power-up solenoid valve (yellow band)
B2 Hydraulic oil temperature sensor Y7 Main pump proportional solenoid
2) Description
1. If the auto mode is selected, 2 modes, SA and LA,
are available. CX160
CX130
CX180
2. When the auto mode is selected, the LA mode is
Engine rpm (MAX) rpm 1950 2050
engaged and then it automatically changes to SA or SA Current (equal to S mode
LA mode depending on the work conditions. mA 490 530
mode + 40 mA)
3. If the coolant temperature is less than 50°C or the oil Hydraulic power boost --- Automatic Automatic
temperature is less than 25°C, auto mode checking LA
Current (equal to mode S) mA 450 490
does not work and the LA mode is selected. When mode
Hydraulic power boost --- Automatic Automatic
the coolant temperature is greater than 50°C and
the oil temperature is greater than 25°C, auto mode
checking starts and continues to function even if the CX210
CX240
coolant and oil temperatures reduce. CX230
4. During auto mode checking, if the travel pilot SA Current (equal to S mode
pressure switch (B27) is activated, the change of mA 332 347
mode + 40 mA)
mode does not take place. (If the travel pilot Hydraulic power boost --- Automatic Automatic
pressure switch (B27) is activated in SA mode, the Engine rpm (MAX) rpm 1700 1900
LA
SA mode remains, and if the travel pilot pressure mode
Current (equal to mode S) mA 292 307
switch (B27) is activated in LA mode, the LA mode Hydraulic power boost --- Automatic Automatic
remains).

4001-22
Acceleration checking
Y7 R3
A1 A2 A3 1
CS00F511
A1 Computer R3 Throttle volume
A2 Engine controller Y7 Main pump proportional solenoid
2) Operation
1. The computer (A1) transmits the selected work 4. The electronic acceleration (A3) calculates the
mode to the engine controller (A2) through CAN target position of the rack and its actual position
communications. (value measured by the rack sensor) and moves the
rack by rotating the electric motor to adjust the fuel
2. The engine controller (A2) calculates the rpm based
injection quantity.
on the efficiency of the engine (based on the
selected mode) and the analog signal (volume) of 5. By repeating this process, the engine controller (A2)
the throttle volume (R3). checks the electronic acceleration (A3) to obtain:
actual number of revolutions = target number of
3. The engine controller (A2) calculates the target
revolutions.
position of the rack using the target rpm and data
from each sensor (actual engine rpm, actual 6. If the engine rpm becomes less than the rpm at the
position of the rack, fuel flow adjustment resistor), torque fixed by the throttle volume (R3), the value of
and it transmits the signal to the electronic the current provided by the proportional solenoid
acceleration. (Y7) becomes the same as in L mode.
3) Relationship between the throttle volume and the engine rpm
5.0
NH H mode
NS S mode
Input voltage (Volt)
Engine rpm (rpm)
NL L mode
NI
0 100 0 100
Throttle volume (%) Throttle volume (%)

4001-23
Engine idle checking (automatic/manual)

P1 A1 A2 1
S16
B26
H1 A3
B27
P4
CS00F512
A1 Computer H1 Audible warning device
A2 Engine controller P1 Instrument panel
A3 Electronic acceleration P4 Monitor display
B26 Upper pilot pressure switch (yellow band) S16 One touch idle
2) Transition between auto and manual idle
1. The idle mode can be changed by keeping the 5. If auto idle is activated, it is possible to put the
one touch idle (S16) pressed for 3 seconds. The engine into idle mode by pressing on the one touch
audible warning device (H1) sounds for idle (S16). On the other hand, if auto idle is not
3 seconds. The "ON" or "OFF" mode is displayed activated, idling can be enabled only by pressing on
on the monitor display (P4). the one touch idle (S16).
- "ON" = auto idle
6. When the auto or manual idle mode is operating, the
- "OFF" = manual idle by pressing on the one
message "ENG. IDLING" is displayed on the
touch idle (S16).
monitor display (P4).
2. When the machine is started, it is the previous idle
mode that is retained.
3. If no function is activated and the idle mode is on
"ON", the engine rpm automatically returns to idle
after 5 seconds. (This interval can be set to between
1 and 30 seconds).
4. If auto idle is activated and the engine is idling, when
one of the functions of the machine is called upon,
the engine automatically returns to the original
mode.

4001-24
Breaker mode checking

S14 Y7 R3
B25 A3
A1 A2 1
CS00F513
1 Engine B25 Breaker pilot pressure switch
A1 Computer R3 Throttle volume
A2 Engine controller S14 Breaker/crusher switch
A3 Electronic acceleration Y7 Main pump proportional solenoid
2) Operation
When the breaker/crusher switch (S14) is in breaker position (in the case when the breaker/crusher option is
installed) and the option pedal is pressed, the breaker pilot pressure switch (B25) is activated and the engine rpm
drops to the preset breaker rpm (see engine rpm adjustment for the breaker option).
When the option pedal returns to neutral, the breaker pilot pressure switch (B25) is deactivated and the engine rpm
returns to the throttle volume adjustment.
For the preset breaker rpm adjustment to function, the throttle volume (R3) must be set to an rpm that is higher than
the preset rpm.
When the breaker pilot pressure switch (B25) is activated, the value of the current supplied by the proportional
solenoid (Y7) becomes that of "S" mode.
3) Timing diagram
Breaker/grab (5V)
switch (5V)
Breaker pilot (5V)
pressure switch
(0V)
Engine rpm
Preset breaker rpm
Throttle volume less than the

preset rpm

4001-25
Automatic engine preheat

A2 K2 1
P1 A1 R1
S1 B1
P4
A3
CS01N574
1 Engine K2 Relay-glow plug
A1 Computer P1 Instrument panel
A2 Engine controller P4 Monitor display
A3 Electronic acceleration R1 Glow plug
B1 Coolant temperature sensor S1 Key switch
2) Operation
1. Once the ignition is turned on (IN1 = ON), the 6. After the ignition key (S1) returns from "START" to
computer (A1) calculates the preheat time (Tp) "RUN" (IN1 = ON; IN2 = OFF), the engine controller
based on the coolant temperature (see graph). (A2) activates the preheat relay (K2) for the after-
preheat time (Ta).
2. The engine controller (A2) activates the preheat
relay (K2) during the preheat time (Tp) previously 7. During the after-preheat time (Ta), the message
calculated, and transmits a signal to the computer "ENG. PRE HEAT" appears on the monitor display
(A1). (P4).
3. After the preheat period (Tp), the preheat relay (K2) 8. The checking system mentioned above starts
remains activated for 2 seconds. immediately, once the ignition is turned on, the
message "ENG. PRE HEAT" appears on the
4. When the ignition key (S1) is turned to "START" (ST,
monitor display (P4) only if the preheat time is
IN2 = ON), the engine controller (A2) reactivates the
greater than 3 seconds (coolant temperature less
preheat relay (K2) but does not transmit a signal to
than -5°C).
the computer (A1).
NOTE: When the ignition is turned on, the "CASE"
5. The engine controller (A2) after preheat time (Ta)
logo is displayed on the monitor display (P4) for
based on the coolant temperature (see graph).
3 seconds.

4001-26
3) Graph of preheat time (Tp) and after preheat time (Ta)
16 80
After preheat time (Ta) in seconds

14 70
Preheat time (Tp) in seconds
12 60
10 50
8 40
6 30
4 20
2 10
0 0
-20 -15 -10 -5 0 5 10 -20 -15 -10 -5 0 5 10
Engine water temperature (°C) Engine water temperature (°C)
4) Flowchart
Engine start
Begin
Ignition plug
Contact point activated
Preheat Water After preheat

Water
time calculation temp. time calculation
temp.
Calculated time
Calculated time
Ignition plug
Ignition plug Active signal activated
activated
Elapsed time
Elapsed time
Plug
Ignition plug Signal deactivated
activated
deactivated
2 seconds
End
Plug
deactivated

4001-27
5) Timing diagram
a) If the engine starts within 2 seconds following the display "ENG. PRE HEAT"
ST
Key
ON
switch
OFF
Glow ON
plug OFF A B C D
3 sec.
Monitor display
Preheat
CASE logo OFF
b) If the engine starts within 2 seconds following the display "ENG. PRE HEAT"
ST
Key ON
switch
OFF
Glow ON
plug OFF A B C D
3 sec.
Monitor display
Preheat
CASE logo OFF
c) If the engine starts during the "ENG. PRE HEAT"
ST
Key
ON
switch
OFF
Glow ON
plug OFF A B D
3 sec.
Monitor display
Preheat
CASE logo OFF
A. Preheat time Tp
B. 2 seconds additional preheat
C. Preheat time for engine start
D. Time after preheat Ta

4001-28
Auto engine warm-up

S16 B26 R3
B1
P4
B27 A3
P1 A1 A2 1
CS01N575
A2 Engine controller P4 Monitor display
A3 Electronic acceleration R3 Throttle volume
B1 Coolant temperature sensor S16 One touch idle
B26 Upper pilot pressure switch (yellow band)
2) Operation
1. When starting the engine, if the coolant 4. If one of the above conditions is not fulfilled, the auto
temperature is less than or equal to 50°C, the engine warm-up is interrupted. To reactivate auto
computer (A1) transmits an auto engine warm-up engine warm-up, the engine has to be stopped and
signal to the engine controller (A2). restarted.
2. The engine controller (A2) handles the auto engine 5. During auto engine warm-up, "AUTO WARM UP" is
warm-up. displayed on the monitor display (P4).
3. Conditions for auto engine warm-up:
- Coolant temperature (B1) less than or equal to
50°C.
- Upper pilot pressure switch (yellow band) (B26)
and travel pressure switch (B27) not activated.
- One touch idle (S16), not activated.
- Position of the throttle volume (R3), not
changed.
- Engine rpm not higher than 1800 rpm for
3 minutes.

4001-29
3) Timing diagram
Engine rpm Engine rpm

(rpm) (rpm)
1800 1800
Throttle
1500 volume 1500
position
1200 1200
Throttle
volume
position
5 3 3 3 5 3 3
Warm-up time in minutes Warm-up time in minutes

4001-30
Idle checking using the battery voltage and the 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.
A2 1
B1
A3
CS00F516
A2 Engine controller B1 Coolant temperature sensor
2) Operation
When the idle time is too long and the voltage supplied to the engine controller (A2) reduces or the coolant
temperature (B1) is low, the idle rpm automatically increases (see figure below).
Adjusting the rpm according to the battery voltage
NOTE: The numbers in brackets ( ) show the values
1200 for the CX130/CX160/CX180.
(1300)
1100
(1200)
Idle rpm (rpm)
1000
(1100)
900
(1000)
800
(900)
700
(800) 18 22 26 28
Engine controller supply voltage
(volts)

4001-31
Adjusting the idle rpm according to the coolant temperature
NOTE: The numbers in brackets ( ) show the values
1200 for the CX130/CX160/CX180.
(1300)
1100
(1200)
Idle rpm (rpm)
1000
(1100)
900
(1000)
800
(900)
700
(800) -30 -15 10 20
Coolant temperature (°C)

4001-32
Engine emergency stop

M2
K1
S9
P1
A3
P4
A2 1
CS01N576
1 Engine M2 Engine emergency stop motor
A2 Engine controller P1 Instrument panel
A3 Electronic acceleration P4 Monitor display
K1 Relay-engine emergency stop S9 Engine emergency stop switch
2) Operation
1. If the engine emergency stop switch (S9) is 4. The electronic acceleration (A3) starts checking the
activated, the transistor output OUT 1 = 0 volts stopping of the engine by receiving the signal
and the switch LED blinks. (position of the rack = 0 mm).
2. OUT 1 being at 0 volts, the relay-engine emergency 5. The emergency stop status is maintained even after
stop (K1) is activated as well as the emergency stop the ignition is switched off. To deactivate the
motor (M2). emergency stop, the engine emergency stop switch
(S9) has to be pressed once again, LED goes off.
3. The input of the stop signal (IN1) on the engine
controller (A2) drops to 0 volts, the engine controller
(A2) regards it as an emergency stop status and
transmits the "engine stop" signal OUT 2 = 0 volts.

4001-33
3) Timing diagram
24 V
Power supply
0V
Engine
ON
emergency OFF
stop switch
ON
OUT1/IN1 OFF
ON
LED OFF
Relay-engine
emergency NO
NC
stop
Engine
ON
emergency OFF
stop motor
ON
OUT2 OFF

4001-34
Back-up mode
A2 1
S1 B41
P4
A3
P1 A1 R3
CS01N577
1 Engine P1 Instrument panel
A1 Computer P4 Monitor display
A2 Engine controller R3 Throttle volume
A3 Electronic acceleration S1 Key switch
2) Electronic acceleration governor assistance checking
The electronic acceleration governor (A3) checks the engine rpm (1) by checking the position of the electronic
acceleration (A3) rack.
- The engine controller (A2) sends the target position of the rack by a PWM signal to the electronic acceleration
(A3) governor. The governor compares the value of the actual position with the target position according to the
rack position sensor built into the governor. Based on the calculated result, the electric motor built into the
electronic acceleration (A3) is activated to check the position of the rack. Then, the actual value of the rack
position is sent to the engine controller (A2).
- The engine controller (A2) checks if the electronic acceleration governor (A3) is functioning correctly by
comparing the target position sent with the actual value of the rack.
- If there is a difference of more than 2 mm between the actual position and the target value of the rack, this gives
rise to variations in the engine rpm (see table below). The engine controller (A2) regards this as an electronic
acceleration governor assistance error (A3).
- If the governor assistance error is confirmed, the engine controller (A2) stops the engine to avoid it from running
out of control.
The engine controller (A2) transmits the problem codes to the computer (A1) when a governor assistance error
occurs and the "ELEC. PROBLEM" error code is displayed on the monitor display (P4).
When starting the engine Machine operation

Variation in the engine rpm ≥ 500 rpm for 1 second Variation in the engine rpm ≥ 1000 rpm for 1 second
Variation in the engine rpm < 500 rpm for 10 seconds Variation in the engine rpm < 1000 rpm for 10 seconds

4001-35
3) Back-up mode checking
1. The engine controller (A2) stops the engine by 3. When running in back-up mode, the engine
cutting off fuel injection, if an electronic controller (A2) checks only the position of the rack
acceleration (A3) governor assistance error is using the engine rpm obtained by the engine rpm
detected during the operation or starting of the sensor (B41). Thus the normal operation of the
engine (1). engine (1) cannot be obtained, but the back-mode
has been activated.
2. After the engine (1) stops because of a governor
assistance error, the engine can be restarted in
back-up mode (IN3 = ON = GND).
4) Timing diagram
ST
Key
ON
switch
OFF 10 sec
24 V
Power supply 0V
5V
Back-up mode (IN3) 0V
State of the motor ON

OFF
Governor ON
assistance error OFF
OUT (IN4) 5V
back-up mode 0V
Engine checking
1a 1b 1c 1d 1e
mode
1a. Normal 1d. Stop

1b. Stop 1e. Back-up mode
1c. Back-up mode
5) Checking the engine when the back-up
mode is in operation 1600
The engine controller (A2) determines the target
engine rpm according to the position of the throttle
volume (R3). Engine rpm
The engine controller (A2) checks the position of the (rpm)
electronic acceleration (A3) rack by analysing the
difference between the actual engine rpm (1)
obtained by a signal from the rpm sensor built into the
electronic acceleration (A3) (or by the engine rpm 900
sensor (B41) installed on the bowl of the motor) and
the target rpm.
0 100
In back-up mode, the engine rpm (1) is checked only Throttle volume (%)
by the throttle volume (R3). Throttle volume (R3)
checking is different from checking in normal
conditions.

4001-36
Function locking
K7 F21
F23 F4
Y2
G1 S51
CS00F501
F4 Fuse 10 A; cancellation of hydraulic controls K7 Relay battery
F21 Fuse box S51 Hydraulic function cancellation lever switch
F23 Fuse 65 A; main fuse for circuits F3 to F10 and Y2 Pilot pressure solenoid valve (blue band)
F13 to F20
G1 Battery
2) Timing diagram
24 V
Key switch 0V
3 sec 3 sec
Power supply ON
OFF
Function cancellation ON
lever switch position OFF
Pilot pressure solenoid ON

valve OFF
3) Operation
When the engine is running and the function When the pilot pressure solenoid valve (blue band)
cancellation lever switch is in work position, the pilot (Y2) is activated, the pilot pressure is supplied to the
pressure solenoid valve (blue band) (Y2) is activated. power assistance and the machine is ready to
operate.

4001-37
Power boost
A1 A2
B42
B44 A
B27
B25 Y5
CS00F502
A Main relief (standard) B27 Travel pilot pressure switch
A1 Computer B42 Pump pressure sensor P1
A2 Engine controller B44 Pump pressure sensor P2 (yellow band)
B25 Breaker pilot pressure switch Y5 Power-up solenoid valve (yellow band)
2) Increasing the pressure in each work mode
CX130/CX160/CX180 CX210/CX230/CX240
H mode Automatic power boost (*) Automatic power boost (*)
(Pressure) (34.3 ↔ 36.3 MPa) (34.3 ↔ 37.3 MPa)
S mode Automatic power boost (*) Automatic power boost (*)
(Pressure) (34.3 ↔ 36.3 MPa) (34.3 ↔ 37.3 MPa)
L mode Constant power boost (*) Constant power boost (*)
(Pressure) (36.3 MPa) (37.3 MPa)
* When the travel pilot pressure switch (B27) or the optional pilot pressure switch (B25) is activated, power boost is
deactivated.
3) Operation
When operating in H or S mode, the computer (A1) If the pump pressure (P1) or (P2) is greater than
records the ratio between: 300 bar (30 MPa) and the load ratio is within a range
- The engine load transmitted by the engine of ± 5% for 2 seconds, the computer (A1) activates
controller (A2). the power-up solenoid valve (yellow band) (Y5) for
- The hydraulic circuit load transmitted by the 8 seconds, which increases the main pressure.
pump pressure sensors (P1) (B42) and (P2)
When the travel pilot pressure switch (B27) or the
(B44).
optional pilot pressure switch (B25) is activated, the
computer (A1) deactivates the power-up solenoid
valve (yellow band) (Y5).

4001-38
Swing brake
B22
S8
S1
B26
B27
B42
1
B44
Y3
P1 A1
CS00F503
1 Swing brake B44 Pump pressure sensor P2 (yellow band)
B22 Swing pilot pressure switch S1 Key switch
B26 Upper pilot pressure switch (yellow band) S8 Swing brake switch
B27 Travel pilot pressure switch Y3 Swing brake solenoid valve (pink band)
2) Operation of the swing brake control
When the swing brake switch (S8) is activated, the When swing is jammed, the transistor output OUT 2
red LED lights up and the swing brake (1) jams. is activated and the swing brake (1) is jammed.
When the swing brake switch (S8) is activated again, The state of the swing brake is maintained in its
the red LED goes off, the swing brake (1) releases and previous state even after the ignition is turned off.
switches to automatic checking (see paragraph 4).

4001-39
3) Timing diagram
Key ON
switch OFF
Power supply 24 V
0V
Swing brake ON
switch OFF
OUT 5V (OFF)
(N1) OV (ON)
Swing pilot 5V
pressure switch 0V
Brake OFF ON ON OFF ON ON
ON
LED OFF
4) Automatic orientation brake checking

Automatic brake checking takes place when the The swing brake is automatically deactivated when:
orientation brake red LED is off. - The swing pilot pressure switch (B22) is
activated.
When swing and an attachment function are
- When the pressure detected by the pressure
simultaneously activated, the mechanical swing
sensors P1 (B42) or P2 (B44) is greater than
braking is automatically released. After the operation
150 bar (15 MPa).
is stopped, the mechanical swing brake is
automatically activated by the computer (A1). The swing brake is automatically activated when:
- The upper pilot pressure switch (B26) is
deactivated for more than 5 seconds.
- The key switch (S1) is in STOP position.
When the pressure supplied by the pump (P1 or P2)
exceeds 150 bar (15 MPa) during only travel, the
mechanical swing brake is deactivated for 5 seconds
then reactivated.

4001-40
Travel mode
P1 A1
B42
B44
S2 B43
B27
Y4
P4
CS01N578
B27 Travel pilot pressure switch P4 Monitor display
B42 Pump pressure sensor P1 S2 Travel mode switch
B43 Pressure sensor (nega-cont) Y4 2 stage travel solenoid valve (red band)
2) Timing diagram
24 V
Power supply
0V
Travel mode ON
switch OFF
5V
IN1 0V
Speed I II I II I II I I II

4001-41
3) Operation
When the starter motor switch is positioned in the Travel speed II selected
"ON" position, the 1st speed is selected by default.
1. When the pressure of the pumps P1 or P2 is less
Every time the travel mode switch is pressed (S2), than 40 bar (4 MPa), the output from the
the computer (A1) registers a signal (IN1: 0 volts). computer (OUT) (A1) of the 2 stage travel
solenoid valve (Y4) is deactivated (1st speed).
The computer (A1) changes the travel speed in the
following way I → II, II → I and transmits the 2. When the pressure of the pumps P1 or P2 is greater
modifications to the monitor display (P4). than 40 bar (4 MPa), the output from the computer
(OUT) (A1) of the 2 stage travel solenoid valve
Travel speed I selected
(Y4) is activated (2nd speed).
The output from the computer (OUT) (A1) of the When the attachment controls are operated, the
2 stage travel solenoid valve (Y4) is deactivated output from the computer (OUT) (A1) of the
(1st speed). 2 stage travel solenoid valve (Y4) cannot be
activated or deactivated.
3. When the travel pressure is greater than 260 bar
(26 MPa), the travel motor displacement change
spool is pushed back and the swash plate angle is
in high displacement (1st speed).
4. Travel speed II can be forced (for cleaning tracks) by
holding the travel mode switch pressed (S2) for over
2 seconds (IN1 = 0 volts).

4001-42
4) Flowchart
Contact point
YES
Speed change ≥ 2 seconds

control
< 2 seconds
NO
Engine
YES
NO Travel pressure
switch
YES
Power-assist YES
pressure sensor
NO
NO 2nd speed
selected
YES
YES
P1 < 4 MPa
NO
YES P2 < 4 MPa
NO
1ST SPEED 2ND SPEED SOLENOID VALVE
SOLENOID VALVE SOLENOID VALVE CANNOT BE ACTIVATED
DEACTIVATED ACTIVATED OR DEACTIVATED

4001-43
Supply cut-off delayed

F22
F24
F23 F21
G1
S1
K7
G2
A1 1
CS00F506
1 Engine F24 Fuse 20 A; main protection for circuit F2
A1 Computer G1 Battery
F21 Fuse box G2 Alternator
F22 Fuse 20 A; protection for circuits F11 and F12 K7 Relay battery
F23 Fuse 65 A; protection for circuits F3 to F10 and F13 S1 Key switch
to F20
2) Timing diagram
ON
Key switch
OFF
Computer 24 V
power supply 0V
(IN1)
Start engine 24 V
(IN2) 0V
0.5 sec 3 sec 0.5 sec 3 sec
Battery relay coil excited ON (24 V)

(OUT) OFF (0 V)
Battery relay ON
power supply OFF

4001-44
Protection by power transistor

To protect the circuits of the computer in the event of
Con- a short-circuit of a solenoid valve or a relay, the
Path Functions
nector power transistors cut off the electrical supply and the
CN5 8 Power-up solenoid valve (Y5) message "ELEC. PROBLEM" appears on the
instrument panel monitor display. Use the diagnostic
CN6 18 Relay-rotary light (K5) mode to locate the short-circuit.
CN6 20 Relay battery (K7)
Check the wiring and the components of the affected
CN6 27 Swing brake solenoid valve (Y3) circuit.
CN6 28 Travel speed solenoid valve (Y4)
CN6 29 Cushion control solenoid valve (Y6)
CN6 31 Swing shut-off solenoid valve (Y1)
Coolant temperature indicator

2 3 B1
P4 1
P1 A1 A2 4
CM00F007
1 Coolant temperature indicator
2 Series connection
3 CAN connection
4 Engine
A1 Computer
P1 Instrument panel
P4 Monitor display

4001-45
ON
8 OFF 105
Water temperature indicator bar
ON
7 OFF 103
ON
6 OFF 100
ON
5 OFF 97
ON
4 OFF 82
ON
3 OFF 77
ON
2 OFF 50
40 50 60 70 80 90 100 110
Water temperature (°C)
2) Operation
A. The coolant temperature sensor (B1) sends a signal
to the engine controller (A2).
B. The engine controller (A2) sends the converted
signal to the computer (A1) via the CAN connection
(3).
C. The computer (A1) calculates the number of bars to
display and transmits the information to the coolant
temperature indicator (1) of the monitor display (P4)
via the series connection (2).
D. When the 8th bar on the coolant temperature
indicator (1) is displayed, the message "OVER
HEAT" appears on the monitor display (P4) of the
instrument panel (P1) and the audible warning
device sounds.

4001-46
Hydraulic oil temperature indicator

2 B2
P4 1
P1 A1
CM00F008
ON
Hydraulic oil temperature indicator bar
8 OFF 98
ON
7 OFF 95
ON
6 OFF 88
ON
5 OFF 80
ON
4 OFF 60
ON
3 OFF 45
ON
2 OFF 25
20 30 40 50 60 70 80 90 100
Hydraulic oil temperature (°C)
1 Hydraulic oil temperature indicator B2 Hydraulic oil temperature sensor

2 Series connection P1 Instrument panel
A1 Computer P4 Monitor display
2) Operation
A. The hydraulic oil temperature sensor (B2) attached C. When the 8th bar is displayed on the hydraulic oil
to the inlet pipe of the hydraulic reservoir sends a temperature indicator (1), the message "OVER
signal to the computer (A1). HEAT" appears on the monitor display (P4) of the
B. The computer (A1) calculates the number of bars to instrument panel (P1) and the audible warning
be displayed and sends the information to the device sounds.
hydraulic oil temperature indicator (1) via the series
connection (2).

4001-47
Fuel level
2 R5
P4 1
P1 A1
CM00F009
1 Fuel level indicator P1 Instrument panel
2 Series connection P4 Monitor display
A1 Computer R5 Fuel sensor
2) Operation
A. The fuel sensor (R5) sends a signal to the computer
(A1).
B. The computer (A1) calculates the number of bars to
display and sends the information to the fuel level
indicator (1) via the series connection (2).
C. When only one bar is displayed on the fuel level
indicator (1), the message "LOW FUEL" appears on
the monitor display (P4) of the instrument panel (P1)
and the audible warning device sounds.
Remaining fuel (L)

Fuel sensor Input voltage
CX210/CX230/ Bars displayed
CX130/CX160/CX180 resistance (Ω) (V)
CX240
191.1 - 261.6 - 10.0 - 18.1 0.455 - 0.766 8
159.8 - 191.1 232.8 - 261.6 18.1 - 23.9 0.766 - 0.964 7
128.5 - 159.8 190.0 - 232.8 23.9 - 29.6 0.964 - 1.142 6
97.1 - 128.5 147.1 - 190.0 29.6 - 36.5 1.142 - 1.337 5
65.7 - 97.1 104.2 - 147.1 36.5 - 46.3 1.337 - 1.582 4
34.4 - 65.7 51.2 - 104.2 46.3 - 60.8 1.582 - 1.891 3
15.6 - 34.4 25.6 - 51.2 60.8 - 74.7 1.891 - 2.138 2
- 15.6 - 25.6 74.7 - 80.0 2.138 - 2.222 1

4001-48
Engine fuel injection pump electronic regulator

1 2
4 B41
3
R2
7 9
6
8 10
R3
A2
5
S1
A1
CM00F010
1 Engine 11 Linear motor
2 Hydraulic system 12 Rack
3 Injection pump 13 Linear motor control section
4 Electronic regulator 14 Rack position detector
5 CAN connection A1 Computer
6 Detector and sensor information input A2 Engine controller
7 Engine speed signal B41 Engine rpm sensor
8 Rack position detector signal R2 Fuel flow adjustment resistor
9 Rack control signal R3 Throttle volume
10 Engine rpm sensor signal S1 Key switch

4001-49
2) Electronic regulator
13
12
14
11
CS00F532
3) Operation
A. To ensure low fuel consumption and optimum D. The calculation section (engine controller A2)
productivity, the engine controller (A2) memorises compares the information received with the
the different work modes (H, S and L) and selects memorised data and then transmits a control signal
the optimum work mode in accordance with the to the control section (13) of the linear motor (11) via
signal that it receives from the computer (A1) via the the connections (7), (8), (9) and (10).
CAN connection (5). E. The control section (13) sends a signal to the
B. The electronic regulator (4) has an input section, a regulator (4) linear motor (11) to actuate the fuel
calculating section and a linear motor control section injection pump (3) rack control (12).
(13).
C. The input section (computer A1) receives the
signals coming from the detectors and sensors (6)
and transmits them after processing to the
calculation section (engine controller A2).

4001-50
ACCESS AND CONTENTS OF MONITOR DISPLAYS (Diagnostic mode)

Access to monitor displays
Key switch turned "ON"
Normal display (Coolant temperature, hydraulic oil temperature, fuel level, travel mode, work mode,
idle mode)
A
D C
Machine Diagnostic Machine Re-

B B B E
condition code history initialisation
CHK1 DIAG1 HR12 C HR1 RST1
C C C
C
CHK2 DIAG2 HR11 HR2
C C C
C
CHK3 DIAG3 HR10 HR3
F C C C
C
CHK4 DIAG4 HR9 HR4
C C C
C
CHK5 DIAG5 HR8 HR5
G C C
C
CHK6 DIAG6 HR7 HR6
C C
A. Press the travel mode and work mode switches E. To re-initialise the system, press the audible alarm
simultaneously for a minimum of 3 seconds. cut out switch.
B. Press the auto work mode switch. To programme the system, press the travel mode
switch.
C. Press the audible alarm cut out switch.
To erase the data, press the work mode switch for a
D. To erase the data, press the work mode switch for a minimum of 10 seconds and the audible warning
minimum of 10 seconds and the audible warning device sounds.
device sounds. F. To initialise the automatic overload detection on the
electrical circuit, press the travel mode switch.
G. To initialise the automatic detection of short-circuits,
press the travel mode switch for a minimum of
10 seconds and the audible warning device sounds.

4001-51
Machine condition
1. Machine condition CHK1
MODE: Travel - work
CHK MODE II H ENG 2000 rpm
P1: Main pump pressure
1
P2: Main pump pressure
P1 030.0 MPa I 0300 mA
N: Negative pressure (N)
ENG: Engine rpm
P2 030.0 MPa WT 0080 °C
I: Proportional solenoid current
WT: Coolant temperature
N 03.00 MPa OT 0055 °C
OT: Hydraulic oil temperature

R: Engine load rate
CHK MODE II H TR1 0000
FT: Not used
2
TV: Rate of acceleration
R 0080 % TR2 0000
TR1 to TR2: Computer transistor outputs
TR3 to TR4: Not used
FT 0000 °C TR3 0000
TV 0100 % TR4 0000
Transistor output: 0 = OFF, 1 = ON
TR1 0 0 0 0 TR2 0 0 0 0
Swing brake Relay battery
2 stage travel speed Shock absorption
X Swing pilot shut-off
Power boost X
X: Not used
SW1 to SW3: Pressure switch information,
CHK MODE II H SW4 0000
coolant level and battery charge
3 inputs into the computer
SW1 0000 SW5 0000 SW4 to SW7: Switch position inputs into the
computer
SW2 0000 SW6 0000
SW3 0100 SW7 0000
Pressure switch and computer switch inputs: 0 = OFF, 1 = ON
SW1 0 0 0 0 SW2 0 0 0 0 SW3 0 0 0 0

Higher pilot pressure Engine oil pressure Battery charge
Travel pilot pressure Coolant level X
Swing pilot pressure Safety valve pressure X
Breaker pilot pressure X X

4001-52
SW4 0 0 0 0 SW5 0 0 0 0 SW6 0 0 0 0

Shock absorption Swing brake Windshield washer
X Emergency stop X
X Working lights Breaker mode
Engine idle Windshield wiper X
SW7 0 0 0 0
Anti-theft
Key switch
Overload indicator
X
X = Not used
FS: Fuel gauge
CHK MODE I H TG 0000
AC: A/C control temperature
4
TR5: Computer transistor outputs
FS 0080 BP 0000 (not used)
TG: Engine rpm
AC 0005 SP1 0000 BP: Boom cylinder pressure
SP1 and SP2: Not used
TR5 0010 SP2 0000
AC 0 0 0 4
1: below 30°C
2: between 30°C and 45°C

When the travel mode switch is pressed the CHK5
screen appears on the CHK2 screen and the TR1
and TR2 windows show any overloads in the
5
corresponding electrical circuits.
R 0080 % TR2 0001
No overload = 0, Overload = 1
FT 0000 °C TR3 0000 Example: In the screen opposite, TR1 and TR2
windows show an overload on the swing brake and
TV 0100 % TR4 0000
battery relay circuit.
NOTE: In diagnostic mode, if an error code is reset to
zero, the data is also erased.

4001-53
1) When the return to idle and the key switch are both
actuated simultaneously without starting the engine,
automatic checking for short-circuits in output
6
transistors is initialised.
R 0080 % TR2 0000
2) If the message "ELEC. PROBLEM" is displayed on
the monitor display, return to screen CHK5 and press
FT 0000 °C TR3 0000 the travel mode switch for 10 seconds, the CHK6
screen will be displayed and the windows TR1 and
TV 0100 % TR4 0000 TR2 will show any short-circuits on the corresponding
lines.
NOTE: If there is no message and the audible
warning device sounds 6 times, that means that there
is no defect.
Example: In the screen opposite, TR1 window shows
a short-circuit at the travel mode solenoid valve
control transistor output.
3) When the key switch is in OFF position, the results
are erased.
No short-circuit = 0, short-circuit = 1

4001-54
Diagnostic code
1. Detection of engine failures DIAG1
E: Failure code
DIAG MODE II H E 0000
1
E 0015 E 0000
E 0000 E 0000
E 0000 E 0000
Failure code
E0000: No defect
E0015: Coolant temperature sensor
E0025: Fuel flow adjustment resistor
E0031: Linear motor control circuit in electronic regulator
E0032: Electronic regulator rack position detector
E0041: Electronic regulator engine rpm receiver
E0042: Engine rpm sensor
Example: In the screen above, there is a defect in the coolant temperature sensor.
2. Previous failures in the engine DIAG2
E: Failure code
2
E 0032 E 0000
E 0025 E 0000
E 0000 E 0000
Example: The screen above shows that there is a defect in the electronic regulator rack position detector (0032)
and in the fuel flow adjustment resistor (0025).

4001-55
3. Previous failures in the engine DIAG3
This screen is connected to the previous screen (DIAG2) as concerns failures involving the hourmeter.
E: Failure code
3
E 1200 E 0000
E 1000 E 0000
E 0000 E 0000
Example:
The screen above shows that the failure code 0032 (electronic regulator rack position detector) occurred at 1200 H and
that failure code 0025 (fuel flow adjustment resistor) occurred at 1000 H.
A. The numbers of hours shown indicate the time at which the failure occurred for the first time since the data was
reinitialised.
B. If you wish to erase the failure codes and the number of hours, press the work mode switch for 10 seconds.
C. When data is erased from screens DIAG2 and DIAG3, it is recorded in the electronic control box memory (this data is
only visible using an external computer).
4. Excavator failure detection DIAG4
M: Failure code
DIAG MODE II H M 0000
4
M 0020 M 0000
M 0000 M 0000
M 0000 M 0000
Failure code
M0000: No defect
M0010: Transistor output short-circuit
M0020: Hydraulic oil temperature sensor
M0030: Fuel sensor
M0040: Pump pressure sensor P1
M0050: Pump pressure sensor P2
M0060: Pressure sensor (nega-cont)
M0070: Key switch
M0080: Upper or travel pilot pressure switch
M0090: CAN communication circuit
M00A0: Computer reinitialisation
M00B0: Engine controller
M00C0: Boom cylinder pressure
Example:
The screen above shows a failure in the hydraulic oil temperature sensor (0020).

4001-56
5. Previous failures on the excavator DIAG5
M: Failure code
5
M 0020 M 0000
M 0030 M 0000
M 0000 M 0000
Example:
The screen above shows that there is a failure in the hydraulic oil temperature sensor and in the fuel level sensor.
6. Previous failures on the excavator DIAG6
This screen is connected to the previous screen (DIAG5) as regards failures involving the hourmeter.
M: Failure code
6
M 1200 M 0000
M 1000 M 0000
M 0000 M 0000
Example:
The screen above shows that failure code 0020 (hydraulic oil temperature sensor) occurred at 1200 H and that
failure code 0030 (fuel sensor) occurred at 1000 H.
A. The numbers of hours shown indicate the time at which the failure occurred for the first time since the data was
reinitialised.
B. To erase the failure codes and the number of hours, press the work mode switch for 10 seconds.
C. When data is erased from screens DIAG5 and DIAG6, it is recorded in the electronic control box memory (this data is
only visible using an external computer).

4001-57
Machine history
1. Screen HR1
ENG: Hourmeter
HR MODE II H T 0000 HR
WRK: Length of time that excavator has been
1
used (with attachment or travel operating)
ENG 0000 HR S 0000 HR U: Length of time that attachment has been
used
WRK 0000 HR PU 0000 HR T: Length of time that travel has been used
S: Length of time that swing has been used
U 0000 HR BRK 0000 HR PU: Length of time that power boost has been
used
BRK: Length of time that breaker has been used
2. Screen HR2
H: Length of time excavator was used in mode H

HR MODE II H A 0000 HR
S: Length of time excavator was used in mode S
2
L: Length of time excavator was used in mode L
H 0000 HR WT 0000 °C A: Length of time excavator was used in AUTO
mode
S 0000 HR OT 0000 °C WT: Maximum coolant temperature
OT: Maximum hydraulic oil temperature
L 0000 HR FT 0000 °C FT: Not used
3. Screen HR3
1: Length of time the computer was used

HR MODE II H 4 0000
2: Length of time slow travel was used
3
3: Length of time fast travel was used
1 0000 5 0000 4: Length of time travel alone was used
5: Maintenance intervals
2 0000 6 0000 6: Not used
7: Not used
3 0000 7 0000
4. Screen HR4, operating time of the various P1 pressures
1: 100 bar (10 MPa) or lower

HR MODE II H 4 0000
2: Between 100 bar (10 MPa) and 150 bar
4
(15 MPa)
1 0000 5 0000 3: Between 150 bar (15 MPa) and 200 bar
(20 MPa)
(25 MPa)
(30 MPa)
(35 MPa)
7: 350 bar (35 MPa) or above

4001-58
5. Screen HR5, operating time of the various P2 pressures
1: 100 bar (10 MPa) or lower

HR MODE II H 4 0000
5
(15 MPa)
(20 MPa)
(25 MPa)
(30 MPa)
(35 MPa)
7: 350 bar (35 MPa) or above
6. Screen HR6, operating time of the various engine speeds
1: 1200 rpm or lower

HR MODE II H 4 0000
2: Between 1200 rpm and 1400 rpm
6
1 0000 5 0000 4: Between 1600 rpm and 1800 rpm
2 0000 6 0000 6: Between 2000 rpm and 2200 rpm
7: 2200 rpm or above
3 0000 7 0000
7. Screen HR7, operating time of the various coolant temperatures
1: 77°C or lower (1st and 2nd bar)

HR MODE II H 4 0000
2: 77°C to 82°C (3rd bar)
7
3: 82°C to 97°C (4th bar)
1 0000 5 0000 4: 97°C to 100°C (5th bar)
5: 100°C to 103°C (6th bar)
2 0000 6 0000 6: 103°C to 105°C (7th bar)
7: 105°C or higher (8th bar)
3 0000 7 0000
8. Screen HR8, operating times of the various hydraulic oil temperatures
1: 45°C or lower (1st and 2nd bar)

HR MODE II H 4 0000
2: 45°C to 60°C (3rd bar)
8
3: 60°C to 80°C (4th bar)
1 0000 5 0000 4: 80°C to 88°C (5th bar)
5: 88°C to 95°C (6th bar)
2 0000 6 0000 6: 95°C to 98°C (7th bar)
7: 98°C or higher (8th bar)
3 0000 7 0000

4001-59
9. Screen HR9, not used
10. Screen HR10, operating time of the various engine load rates
1: 30% or lower
HR MODE II H 4 0000
2: 30% to 40%
10
3: 40% to 50%
1 0000 5 0000 4: 50% to 60%
5: 60% to 70%
2 0000 6 0000 6: 70% to 80%
7: 80% or higher
3 0000 7 0000
11. Screen HR11, operating time of the various engine load rates in mode "H"
(maximum rpm)
1: 30% or lower
HR MODE II H 4 0000
2: 30% to 40%
11
3: 40% to 50%
1 0000 5 0000 4: 50% to 60%
5: 60% to 70%
2 0000 6 0000 6: 70% to 80%
7: 80% or higher
3 0000 7 0000

4001-60
12. Screen HR12, operating time of the various engine load rates in mode "S"
(maximum rpm)
1: 30% or lower
HR MODE II H 4 0000
2: 30% to 40%
12
3: 40% to 50%
1 0000 5 0000 4: 50% to 60%
5: 60% to 70%
2 0000 6 0000 6: 70% to 80%
7: 80% or higher
3 0000 7 0000
To erase all data from the machine history mode (screens HR1 to HR12), press the work mode switch for
10 seconds.
Re-initialisation
1. Re-initialisation RST1
MODE: Travel mode - work mode

RST MODE II H PA 0000
BRK: Setting engine rpm for breaker option
1
L/M: Not used
BRK 0000 rpm AU 0000 AI: Adjusting timing of automatic return to
idle (from 1 to 30 seconds)
L/M 0000 rpm HLD 0000 PA: Adjusting fuel injection pump
AU: Automatic power boost
AI 0000 sec OUT 0000 HLD: Data management
OUT: Not used
PA = Adjusting fuel injection pump 0 = OFF, 1 = ON

AU = Automatic power boost 0 = ON, 1 = OFF
HLD 0 0 0 0
Auto mode (0 = Maintain previous data / 1 = Update data)
Work mode (0 = Maintain previous data / 1 = Update data)
Travel mode (0 = Maintain previous data / 1 = Update data)
Hourmeter maintenance (0 = ON, 1 = OFF)
NOTE: To select the various adjustment windows, press as many times as necessary on the audible warning
device stop switch (the window is selected when the item concerned changes from negative to positive).

4001-61
2. Setting engine rpm for the breaker option
A. Select window BRK (see NOTE on page 60).
RST MODE 2 H PA 0000 B. Start the engine, then using the throttle volume, set
1 the required engine rpm which is displayed in the
BRK window on screen RST1.
BRK 1800 rpm AU 0000 C. To save the engine rpm, press the work mode switch
for 10 seconds. The audible warning device sounds
L/M 0000 rpm HLD 0000 when saving is completed.
D. Turn the key switch to the OFF position.
AI 0000 sec OUT 0000 E. Check the engine rpm on screen CHK1.
Example:
In the above screen, the engine rpm for the breaker option is set at 1800 rpm
3. Setting the automatic return to idle timing
A. Select window AI (see NOTE on page 60).
RST MODE 2 H PA 0000 B. Press the travel mode switch as many times as
1 necessary to obtain the required time delay. The
setting must be between 1 and 30 seconds.
BRK 0000 rpm AU 0000 C. To save the time delay, press the work mode switch
L/M 0000 rpm HLD 0000 when saving is completed.
AI 0010 sec OUT 0000
Example:
In the above screen, the automatic return to idle time delay is set at 10 seconds.
4. Selecting the type of supply to the fuel injection pump
0= Normal mode
RST MODE 2 H PA 0001
1= Low power mode
1
A. Select window PA (see NOTE on page 60).
BRK 0000 rpm AU 0000
B. To select the type of supply to the fuel injection
pump, press the travel mode switch (the right-hand
L/M 0000 rpm HLD 0000 figure changes alternately from 0 to 1 each time the
travel mode switch is pressed).
AI 0000 sec OUT 0000 C. To save the selection, press the work mode switch for
10 seconds. The audible warning device sounds
when saving is completed.
Example:
In the above screen, the type of supply to the selected injection pump is in low power mode.

4001-62
5. Selecting automatic power boost
0= With power boost

1= Without power boost
1
A. Select window AU (see NOTE on page 60).
B. To activate or de-activate automatic power boost,
press the travel mode switch (the right-hand figure
L/M 0000 rpm HLD 0000 changes alternately from 0 to 1 each time the travel
mode switch is pressed).
AI 0000 sec OUT 0000 C. To save the selection, press the work mode switch
when saving is completed.
6. Data management
0= Maintain previous data

1= Re-initialising the data
1
L/M 0000 rpm HLD 0000
AI 0000 sec OUT 0000
HLD 0 0 0 0
Auto mode
Work mode
Travel mode
Hourmeter maintenance (0 = ON, 1 = OFF)
A. Select window HLD (see NOTE on page 60).

B. To set data management, press the travel mode switch until the required figure appears (each time the travel mode
switch is pressed the figures scroll down in the following order: 0000, 0001, 0010, 0011, 0100, 0101 ... up to 1100,
1101, 1110, 1111, 0000).
C. To save the settings, press the work mode switch for 10 seconds. The audible warning device sounds when saving is
completed.

4001-63
WARNING MESSAGES
Message display
Key switch ON Engine running

ELEC. PROBLEM ALTERNATOR
LOW FUEL LOW OIL PRESS.
LOW COOLANT ENG. IDLING
OVER HEAT AUTO WARM UP
ENG. PRE HEAT POWER UP
SERVICE DUE
AUDIBLE
MESSAGES WARNING
DEVICE
This message shows that the engine must be pre-heated before starting. The
ENG. PRE HEAT Yes audible warning device will sound once the correct temperature is reached, the
engine can then be started.
This message shows that the engine is automatically warming up. The message
AUTO WARM UP will disappear when the engine reaches its operating temperature or when the
acceleration rotating knob or a control lever is operated.
This message shows that the engine has been set at idle speed by means of the
ENG. IDLING
return to idle control.
This message shows that maximum power is automatically provided for the
POWER UP
attachment.
This message shows that the 500 hours service interval is due. The message is
displayed five times for one minute when the engine is started up. To reset the
SERVICE DUE
maintenance period hourmeter, press the audible alarm cut out switch for
20 seconds.
This message shows that the level of fuel in the fuel tank is low and that more fuel
LOW FUEL Yes
should be added.
This message shows that the coolant solution level is low. Shut down the engine,
LOW COOLANT Yes remove the starter switch key, allow the system to cool down then check the level of
coolant solution in the expansion reservoir and the radiator.
This message shows that the engine oil pressure is too low. Stop the engine,
LOW OIL PRESS. Yes
remove the starter switch key, then check the level.
This message shows that the coolant solution or hydraulic fluid temperature is too
OVER HEAT Yes high. Reduce engine rpm. If the temperature does not decrease, shut down the
engine, remove the starter switch key and find the reason for the problem.
This message shows that there is a problem in the alternator. Shut down the
ALTERNATOR Yes
engine, remove the starter switch key, then check the alternator.
This message shows that there is a problem in the electrical system. Shut down the
ELEC. PROBLEM Yes
engine, remove the starter switch key, then find the reason for the problem.

4001-64
EXCAVATOR MODEL SELECTION PROCEDURE

The excavator model is selected after reinitialising 4. Press the travel mode switch until the required
the machine code or replacing an electronic control destination code is displayed.
box.
Destination Pressure
1. Key switch ON, the screen below appears and "?" Destination T° unit
code unit
for machine is selected:
3 EUROPE MPa °C
4 Rest of world KgF °C
MACHINE : SH ? -3
5. Press the work mode switch. The screen below
TERRITORY : ? LANGUAGE : ? appears and "?" for language is selected.
CONT. P / N KHR2668
MACHINE : SH0120- 3
2. Press the travel mode switch until the required TERRITORY : 3 LANGUAGE : ?
machine code is displayed.
CONT. P / N KHR2668
MACHINE CODE MACHINE MODEL
SH0120 CX130
6. Press the travel mode switch to display the required
SH0150 CX160 language code:
SH0180 CX180 0 = Japanese
1 = English
SH0200 CX210/CX230
2 = Thai
SH0220 CX240 3 = Chinese
SH0250 CX290 4 = German
5 = French
SH0300 CX330
6 = Italian
SH0400 CX460 7 = Spanish
SH0800 CX800 8 = Portuguese
9 = Dutch
10 = Danish
11 = Norwegian
MACHINE : SH0120- 3
12 = Swedish
13 = Finnish
TERRITORY : ? LANGUAGE : ? 14 = Icons
CONT. P / N KHR2668
MACHINE : SH0120- 3
3. Press the work mode switch. The screen below
appears and "?" for territory is selected. TERRITORY : 3 LANGUAGE : 5
CONT. P / N KHR2668
MACHINE : SH0120- 3
Example:
TERRITORY : ? LANGUAGE : ?
The screen above corresponds to a CX130 model
CONT. P / N KHR2668 excavator for Europe in French.

4001-65
7. After selecting the machine code, the destination 10. To confirm the excavator model selection, press the
code and the language code, press the auto mode auto work mode switch for 10 seconds:
switch and the screen below will appear: The screen below will appear
MACHINE : SH0120- 3
TERRITORY : 3 LANGUAGE : 5
CONT. P / N KHR2668
11. Press the auto work mode switch again and the
CS00F533 work screen will appear:
Then the work screen is displayed:
CS00F521
CS00F521 12. Re-initialising the data
8. If the machine code does not correspond to the In the excavator model selection screen, if the auto
engine controller installed, the error code: "E. mode switch is pressed for 10 seconds, all the data
CONT. ERROR" appears on the screen and the will be erased and the audible warning device will
audible warning device sounds. sound.
If the key switch is turned OFF and then ON, the
screen below will appear and the procedure starts
MACHINE : SH0120- 3 again from the beginning.
MACHINE : SH ? -3
CONT. P / N KHR2668
TERRITORY : ? LANGUAGE : ?
E. CONT. ERROR
CONT. P / N KHR2668
9. Check that the machine code corresponds to the

engine controller installed on the excavator. Changing the language code
- If the machine code is wrong, start the procedure Display the excavator model confirmation screen
again from the beginning. (press the auto mode switch for 10 seconds).
- If the engine controller installed is not correct, To change the language code, press the travel mode
change it. switch to display the required code.
To confirm the language code, press the work mode
switch and the audible warning device sounds.
Turn the key switch to OFF.

4001-66
Example:
MACHINE : SH0120- 3 In the screen opposite, the language code has

changed from 5 (French) to 1 (English).
CONT. P / N KHR2668
CHANGING THE ACCESS CODE FOR THE ANTI-THEFT SYSTEM

1. Remove the hood (1) located behind the 3. Turn the key switch to ON and then OFF.
operator’s seat.
4. Reconnect the two wires (2) (3) which authorize the
anti-theft system (see paragraph 2).
5. To save the new access code, consult the anti-theft
protection section in the operator’s manual.
CD00F011
1 Hood
2. Disconnect the two wires (2) (3) which authorize the
anti-theft system.
2 3
X8
CD00F012
2 Violet wire marked 469 female plug
3 Black wire marked 621 male plug
X8 Radio connector

4001-67
TROUBLESHOOTING
Prior inspections
Item Target Action

POINTS TO BE CHECKED WHEN STARTING
Lubricants - Coolants
1. Check the quantity of fuel --- Add fuel
2. Check that fuel is not contaminated --- Clean, drain
3. Check the quantity of hydraulic fluid --- Fill with fluid
4. Inspect the hydraulic fluid filter --- Drain, clean
5. Check the quantity of oil in each reduction gear --- Fill with oil
6. Check the quantity of engine oil --- Fill with oil
7. Check the quantity of coolant --- Fill with coolant
8. Check the filter restriction indicator (dust) --- Clean or replace
Electrical equipment
9. Check the battery terminals and wiring for tightness and corrosion --- Tighten or replace
10. Check the alternator terminals and wiring for tightness and corrosion --- Tighten or replace
11. Check the starter motor terminals and wiring for tightness and --- Tighten or replace
corrosion
OTHER POINTS TO CHECK
Hydraulic system - Mechanical equipment
12. Abnormal noise or smell --- Repair
13. Check for oil leaks --- Repair
14. Air in the system --- Bleed the air
Electrical system - Electrical equipment
15. Check the battery voltage (with the engine shut down) 23-26 V Replace
16. Check the quantity of fluid in the battery --- Add or replace
17. Make sure that the cables are not discoloured, burnt or stripped --- Replace
18. Check for missing or loose cable retaining clips --- Repair
19. Check for damp on cables (especially on connectors and terminals) --- Disconnect and dry
if damp
20. Check fuses for condition and corrosion --- Replace
21. Check the alternator voltage (with the engine speed above the 27.5-29.5 V Replace
throttle mid-point) (when battery charge is insufficient, there can be
25 V only at start up)
22. Noise from relay battery (with starter motor ON or OFF) --- Replace

4001-68
Reading the organisation charts

Error code and description of problem
The error code and the description of the problem are shown in the organisation charts.
Error code Description of the problem

1 The message is still displayed even after refuelling
2 The message is still displayed even after adding coolant solution
Prior checks Wire colour

Before identifying the cause of the problem, always When troubleshooting, refer to the table below for the
make prior checks. wire colours. (For connector numbers, refer to the
following pages).
How to proceed
Table showing wire colours
After checking or measuring the items described in
one step, depending on the results, choose YES or
Symbol Colour Symbol Colour
NO and pass on to the next step.
B Black R Red
The description in the YES or NO branches refers
directly to the cause of the problem as the result of W White Y Yellow
checks or measurements made. Refer to the Br Brown Lg Light green
description of the cause and carry out the repair P Pink Sb Sky blue
procedures described on the right-hand side.
V Violet L Blue
The inspection methods/measurements are
G Green Gr Grey
described in one step. YES should be chosen if the
criteria or questions meet the situation; NO if they do O Orange
not meet it.
BR indicates a wire of colour B striped with R.
The necessary preparation work, operating method Example: BR indicates a black wire with red stripes
and the criteria are described under one step. This
IMPORTANT: Before removing or installing a
should be carefully read before starting the
connector, always turn the key switch OFF.
inspection and the measurements and the
procedures should be followed, starting with step (1)
since negligent preparation work or incorrect
operating methods can cause damage to the
machine.

4001-69
Procedures
1. This is how one has to proceed to detect defects when the message is still displayed after all necessary
measures have been taken to correct the error.
Message displayed Description of the problem Problem No.

LOW FUEL The message is still displayed even after refilling the fuel tank 1
LOW COOLANT The message is still displayed even after refilling with coolant 2
solution
LOW OIL PRESS. The message is still displayed even after adjusting the engine 3
oil pressure
OVER HEAT The message is still displayed even when the hydraulic oil 4
temperature is 84°C or less and the engine coolant temperature
is 92°C or less
ALTERNATOR The message is still displayed 5
ELEC. PROBLEM The message is still displayed 6
2. This is how one has to proceed if the problem is not indicated by a message but machine operation is not correct.
A. Engine
Description of the problem Problem No.
The engine does YES

"ELEC. PROBLEM" is shown on the monitor. 6
not start.
NO
7
3. Problem without message.
Description of the problem Problem No.
Impossible to change travel speed 8

4001-70
Low fuel
Description of problem No. 1
- The message is still displayed even after refilling the fuel tank.
R5
A1
CM00F001
A1 Computer R5 Fuel sensor
Troubleshooting Cause Action

Key switch ON
Measure the fuel
sensor resistance (R5) YES Replace the
using maintenance Defective
computer
support CHK4. (Refer computer (A1)
(A1)
to the table below for
the resistance).
Key switch OFF
Disconnect the fuel
sensor connector (R5)
to measure the NO Replace or
NO resistance on the Fuel sensor
check the fuel
connector at the fuel (R5) defective
sensor (R5)
sensor end. (Refer to
the table below for the
resistance).
Disconnect the CN24
connector to measure Bad
the resistance between NO Clean the
YES connection on
GL female and the GND connection
fuel sensor
earth. (Refer to the terminal
table below for the (R5)
resistance).
Disconnect connector
CN1 to measure the
resistance between GL NO Bad Clean CN24
YES
female and GND earth. connection on connection
(Refer to the table CN24 terminal
below for the
resistance).
Replace the
Defective
computer
computer (A1)
YES (A1) or clean
or incorrect
the CN1
CN1
connection
connection
terminal
Note: All the bar-graph indicators are off when the circuit is open
Resistance between GL and BG

Monitor 1. Refill the tank 2 3 4 5 6 7 8
Resistance (OHM) 80-75 75-61 61-47 47-37 37-30 30-24 24-19 19-10

4001-71
Add coolant solution

- The message is still displayed even after adding coolant solution.
S55
A1
CM00F002
A1 Computer S55 Minimum coolant solution level switch

Key switch ON
Replace the
Disconnect the minimum YES Defective
minimum
coolant solution level switch minimum coolant
coolant
connector (S55) to see if the solution level
solution level
message disappears switch (S55)
switch (S55)
Short-circuit on
wire GrG
YES between the
NO Disconnect connector CN24 to Repair wire
minimum coolant
see if the message disappears GrG
solution level
switch (S55) and
CN24
Short-circuit on
NO Disconnect connector CN4 to YES wire GrG Repair wire
see if the message disappears between CN24 GrG
and CN4
NO Defective Replace the

computer (A1) computer (A1)

4001-72
Low engine oil pressure

- The message is still displayed even when the engine oil level is satisfactory.
B21
A1
CM00F003
A1 Computer B21 Engine oil pressure switch

Check the following points during the 12 seconds following starting the engine
Disconnect the engine oil YES Replace the

Oil pressure
pressure switch connector engine oil
switch (B21)
(B21) to see if the message pressure
defective
disappears switch (B21)
Short-circuit on
YES wire LgY
NO Disconnect connector CN24 to between the Repair wire
see if the message disappears engine oil LgY
pressure switch
(B21) and CN24
YES Short-circuit on
NO Disconnect connector CN4 to wire LgY Repair wire
see if the message disappears between CN24 LgY
and CN4
NO Defective Replace the

computer (A1) computer (A1)

4001-73
Overheating
- The message is still displayed even when the actual temperature is lower than the following:
Temperature of hydraulic oil 84°C, temperature of coolant 92°C
Prior check:
1. Make sure that 8 bars are displayed on the hydraulic oil and engine coolant temperature gauge bar-graphs.
A2
B1
A1
B2
CM00F004
A1 Computer B1 Coolant temperature sensor
A2 Engine controller B2 Hydraulic oil temperature sensor

4001-74

1. The 8 bars on the coolant temperature bar-graph are displayed.
Key switch ON
The temperature of the

coolant temperature
sensor (B1) is abnormal
compared to
maintenance YES
assistance CHK1
(comparison between
the actual temperature
and the indicated
temperature).
See coolant
temperature in CHK1
WT. Measure the actual
temperature
Check problem code
E0015 for the coolant
temperature sensor
(B1) with the
maintenance diagnostic
(DIAG1)
YES
Disconnect the coolant NO Defective Replace the

temperature sensor coolant coolant
connector (B1) to temperature temperature
measure the resistance sensor (B1) sensor (B1)
Disconnect the Bad
connectors CN24 and connection Clean the
CNAO to measure the NO on the coolant
resistance between the coolant temperature
YES
female terminals PL temperature sensor
and BP. (Refer to the sensor connecting
table below for the connector terminal (B1)
resistances). (B1)
Disconnect the
connectors CN7 and
CNAO to measure the Clean the
NO Bad
resistance between the connecting
YES connections
female terminals PL terminal on
on CN24
and BP. (Refer to the CN24
table below for the
resistances).
Replace the
Defective engine
engine controller
controller (A2) or clean
YES (A2) or bad the
CN7 and connecting
CNAO terminals on
connections CN7 and
CNAO
Note: In the event of a short-circuit, the bar-graph goes off completely.

4001-75
Overheating (continued)

2. The hydraulic temperature bar-graph displays 8 bars.
Key switch ON
The hydraulic oil

temperature sensor
(B2) temperature is
abnormal compared to
maintenance YES
assistance CHK1
(comparison between
the actual temperature
and that indicated).
See hydraulic oil
temperature in CHK1
OT. Measure the actual
temperature
See problem code
M0020 for the oil
temperature sensor
(B2) using maintenance
diagnostic (DIAG4)
YES
Disconnect the
hydraulic oil
temperature sensor NO Defective Replace the
connector (B2) to hydraulic oil hydraulic oil
measure the resistance. temperature temperature
(Refer to the table sensor (B2) sensor (B2)
below for the
resistances).
Bad
Disconnect the CN24
connection Clean the
connector to measure
NO on the hydraulic oil
the resistance between
hydraulic oil temperature
YES the male terminals OL
temperature sensor
and BO. (Refer to the
sensor connecting
table below for the
connector terminal (B2)
resistances).
(B2)
CN1 to measure the
Clean the
resistance between the NO Bad
connecting
YES female terminals OL connections
terminal on
and BO. (Refer to the on CN24
CN24
table below for the
resistances).
Replace the
Defective computer
computer (A1) or clean
YES (A1) or bad the
connection connecting
on CN1 terminals on
CN1
Note: In the event of a short-circuit, the bar-graph goes off completely.

4001-76
Coolant and hydraulic oil temperature sensor resistances
NOTE: The resistance varies with temperature.
Coolant or hydraulic oil Hydraulic oil temperature sensor

Coolant temperature sensor (B1)
temperature (B2)
20°C 6.08 kΩ 2.45 kΩ
30°C 4.24 kΩ 1.66 kΩ
40°C 3.02 kΩ 1.15 kΩ
50°C 2.18 kΩ 0.81 kΩ
60°C 1.61 kΩ 0.58 kΩ
70°C 1.20 kΩ 0.43 kΩ
80°C 0.91 kΩ 0.32 kΩ
Defective battery charge circuit

- The message is still displayed.
S1 K7
P5
G2
A1
M1
CM02A001
A1 Computer M1 Starter motor
G2 Alternator P5 Hourmeter
K7 Relay battery S1 Key switch

4001-77

Disconnect CN13 to Clean the
NO Bad connection
measure the voltage YES connecting
The hourmeter (P5) does not on CN13 or
between the female terminal CN13 or
work defective
terminal on wire BrW545 replace the
hourmeter (P5)
and earth. Over 10 V hourmeter (P5)
NO
Bad connection
Disconnect CN26 to
on CN26 or
measure the voltage YES Clean terminal on
short-circuit on
between the female CN26 or repair
wire BrW545
terminal on wire BrR544 wire BrW545
between CN26
and earth. Over 10 V
and CN13
NO
Bad connection
Disconnect CN22 to
on CN22 or Clean the terminal
measure the voltage YES short-circuit on on CN22 or repair
between the female
wire BrR543 or wire BrR543 or
terminal on wire BrR543
BrR544 between BrR544
and earth. Over 10 V
YES CN26 and CN22
Short-circuit on
wire BrR543
NO between CN22 Repair wire
and the BrR543 or change
alternator (G2) or the alternator (G2)
defective
alternator (G2)
Disconnect CN1 to Clean the
Bad connection
measure the voltage YES connecting
on CN1 or
between wire BrR543 at terminal on CN1
defective
the computer end (A1) and or replace the
computer (A1)
earth. Over 10 V computer (A1)
Short-circuit on
wire BrR543 Repair wire
NO
between CN1 BrR543
and CN26
Disconnect the connector from terminal R on the alternator (G2)

Defective Replace the
to measure the voltage between wire LgR at the alternator end NO
alternator (G2) alternator (G2)
(G2) and earth. Over 10 V
YES
Bad connection
at terminal R of
Clean the terminal
Disconnect CN22 to measure the alternator
on CN22 or repair
the voltage between the male (G2) or short-
NO wire LgR between
terminal on wire LgR and circuit on wire
CN22 and the
earth. Over 10 V LgR between
alternator (G2)
CN22 and the
alternator (G2)
Short-circuit on
wire LgR540
Repair wire
YES between the key
LgR540 or replace
switch (S1) and
the key switch
CN22 or
(S1)
defective key
switch (S1)

4001-78
Electrical system troubleshooting

- The message is still displayed
Y2
Y3
Y4
F4 Y5
K7
Y6
Y1
Y7
B41
A1
A2 A3
CS00F528
1 Engine Y1 Swing pilot shut-off solenoid valve (green band)
A1 Computer Y2 Pilot pressure solenoid valve (blue band)
A2 Engine controller Y3 Swing brake solenoid valve (pink band)
A3 Electronic acceleration Y4 2 stage travel solenoid valve (red band)
B41 Engine rpm sensor Y5 Power-up solenoid valve (yellow band)
F4 Fuse 10 A; cancellation of hydraulic controls Y6 Cushion control solenoid valve (light green band)
K7 Relay battery Y7 Main pump proportional solenoid

4001-79

Troubleshooting using the diagnostic system
Key switch ON
NO
Failure code displayed in DIAG1 To DIAG4
YES
YES Defective electronic acceleration Check the electronic
Display E0031
circuit (A3) acceleration (A3)
NO
YES Problem with rack detector signal
Display E0032 Same as above
in regulator
NO
YES
Display E0041 Problem with TDC detector signal Same as above
Failure code displayed in DIAG4

YES
YES Replace the engine
M00B0 Faulty engine controller (A2)
controller (A2)
NO
M0010 Check that the transistor is not short circuited
YES
To CHK6
Self-detection finds the short-circuit

YES
The failure code disappears after disconnecting the solenoid YES Replace the solenoid
Defective (Yn) solenoid valve
valve connector valve (Yn)
NO
The failure code disappears after disconnecting connector YES Short-circuit on wire between
Repair the wiring
CN22 CN22 and the solenoid valve
NO
Repair the wiring
CN23 CN23 and the solenoid valve
NO
Repair the wiring
CN6 CN23 and CN6
NO
Repair the wiring
CN5 CN22 and CN5
NO
Replace the
Defective computer (A1)
computer (A1)

4001-80
The engine will not start even when the message "ELEC. PROBLEM" is not displayed.
Prior checks:
1- Make sure that there are no problems with the engine and in the fuel system.
2- Make sure that the fuses are intact.
3- Make sure that the starter motor is working and turning the engine.
1
K1
M2
S9
2
3 4
F8
CM00F006
1 Stop position F8 Fuse 15 A; engine emergency stop motor
2 Start position K1 Relay-engine emergency stop
3 Cab end M2 Engine emergency stop motor
4 Service connector end S9 Engine emergency stop switch

4001-81

Key switch ON
The fuel inlet cut-off NO Problem with Check the
lever is in the stop engine engine
position (1) system system
CND6 from the engine Open circuit
stop motor (M2). Connect on wire LR
the appropriate service between the
connector (6P) to NO engine stop
YES connector CND6 at the motor Repair the
engine harness end, connector wire LR
measure the voltage (M2) and CN
between the earth (-) and or on wire LR
the (+) wire LR. The between the
voltage should be fuse and CN
between 20 V and 30 V
Using the same
configuration, check for
continuity between YES Engine stop Replace the
YES wires L and LW:
motor (M2) engine stop
Key switch ON:
defective motor (M2)
continuity
Key switch OFF: no
continuity
Measure the voltage at
the engine emergency
stop relay terminals,
Replace the
between wire L (+) and NO Engine
engine
earth (-) emergency
NO emergency
Engine emergency stop stop relay
stop relay
switch (S9) ON = 0 V (K1) defective
(K1)
Engine emergency stop
switch (S9) OFF = 20 V
to 30 V
Open circuit
You can also check the Replace the
between the
engine emergency stop engine
engine
relay (K1) by replacing emergency
emergency
it temporarily by one of YES stop relay
stop relay
the relays from the (K1) or repair
(K1) and
other functions wire L
wire L

4001-82
Travel
- Not possible to change travel speed
No. Test Result Repair

Check the signal at connector
0 Volt continuous, replace the
CN4 terminal 64 on the computer
computer (A1)
(A1)
Changing to second speed is not
0 Volt continuous, check the
shown on the monitor display (P4)
1 connecting cable between
when pressing the travel mode Check the signal at connector terminals 3 and 64
switch (S2) CN13 terminal 3 on the instrument
panel (P1) 5 Volts continuous when pressing
the switch, replace the travel
mode switch (S2)
The electrical harness between
the computer (A1) and the 2 stage
travel solenoid valve (red band)
The travel mode changes when (Y4) is defective
the travel mode switch (S2) is held The voltage is equal to 24 V at the Check the solenoid valve and the
2
pressed down for over two output from the computer (CN6 hydraulic system (see hydraulic
seconds terminal 28) system troubleshooting)
The voltage is below 24 V at the
output of the computer (A1) (CN6 Replace the harness
terminal 28)
In diagnostic mode CHK3, the the computer and the travel pilot Repair the harness
travel pilot pressure switch (B27) pressure switch (B27) is cut
3
does not change to ON when the
travel mode switch (S2) is pressed The travel pilot pressure switch Replace the travel pilot pressure
(B27) is defective switch (B27)
the computer (A1) and the
In diagnostic mode CHK3, the Repair the harness
pressure switch (B27) is short
4 upper pilot pressure switch circuited
(yellow) (B26) stays ON
The upper pilot pressure switch Replace the upper pilot pressure
(yellow) (B26) is defective switch (yellow) (B26)
Check the pressure sensors P1 One of the harnesses is defective Repair the harness
(B42), P2 (B44) and the pressure Voltage under 5 V, at the input to
5
sensor (nega-cont) (B43) using one of the sensors (B42), (B44) or Replace the computer (A1)
mode CHK1 (B43)
the hydraulic oil temperature
sensor (B2) and the computer Repair the electrical harness
(CN1 terminal 6 and 13) (A1) is
The hydraulic oil temperature is defective
6 not displayed or is below 25°C on Voltage under 5 V, at the input to
the CHK1 monitor display the hydraulic oil temperature Replace the computer (A1)
sensor (B2)
Voltage equal to 5 V, at the input to
Replace the hydraulic oil
the hydraulic oil temperature
temperature sensor (B2)
sensor (B2)

4001-83
ELECTRICAL INSPECTION OF COMPONENTS

Inspection equipment
Tool: See "Special tools"
Details of service connector kit
BS98F225
4. For harness end of engine emergency stop motor
(6P)
BS98F222
1. Not used
BS98F226
5. For solenoid valve and fuel gauge
BS98F223
2. Not used
BS98F227
6. 7.For main pump proportional solenoid
BS98F224
3. For engine emergency stop motor (6P)
BS98F228
8. For pressure switch (2P)

4001-84
CD00N019
BS98F229 14. Not used
9. For harness end of pressure switch
CS00E531
BS98F230 15. For hydraulic oil and coolant solution temperature
10. For air conditioning compressor clutch switch (2P) sensor
BS98F231
11. Not used
CS00E530
BS98F232
16. For engine rpm sensor
12. Not used
CS00E532
17. For pressure sensor
CD00N018
13. Not used

4001-85
Proportional solenoid
CX130/CX160/CX180
Y7
CS00J512
1
18. For electronic acceleration (RED4)
CD00F021
CX210/CX230/CX240
1 Y7
CS00J513
CD00F022
1. Disconnect connector (1) from the main pump
proportional valve (Y7).
CS00J514
2 3
4
CS00E534
2. Connect the appropriate service connector (2P) (4)
between the connector at the pump end (2) and the
connector at the main harness end (3) and install
the meter (5).
NOTE: The + terminal of the meter should be
connected to wire BrB (brown/black) on the service
connector coming from the main harness and the
- terminal to wire BrB (brown/black) on the service
connector coming from the hydraulic pump.
4001-86
3. When the connections have been made, start the 4. Turn the starter switch key to "ON", the meter
engine and check the current on the meter (5) in reading should be 24 V.
each work mode, at maximum speed.
6 solenoid valve block
Current in mA
1. Disconnect connector (1) from one of the
Mode H Auto solenoids on the 6 solenoid valve bank (52).
Machine S L
Max Min S L
type
CX130 600 450 450

100 or
490 450
Y1 Y5 Y4
less
CX160 280 or
600 490 490 530 490
CX180 less
CX210 50 or
407 292 292 332 292
CX230 less
50 or
CX240 424 307 307 347 307
less
Engine emergency stop motor Y2

Y6
Y3
M2 52
1
1
CS00E535 CD00F023
1. Disconnect the connector (1) from the engine
Band
emergency stop motor (M2). Mark Function
colour
Y1 Swing pilot shut-off solenoid valve Green
2 4 3 Y5 Power-up solenoid valve Yellow
Y4 2 stage travel solenoid valve Red
Y6 Cushion control solenoid valve Light green
Y3 Swing brake solenoid valve Pink
Y2 Pilot pressure solenoid valve Blue
CS99A846
to the connector at the main harness end (2) only.
3. Make sure that wire LR (blue/red) on the service
connector (4) is connected to wire LR on the main
harness (2) and install the meter (3).
NOTE: The + terminal on the meter must be
connected to wire LR (blue/red) on the service
connector and the - terminal to the machine earth.

4001-87
CX210/CX230/CX240
2 Yn
3
B41
1 1
CS99A843
CD00F025
to the connector on the disconnected solenoid (1)
1. Disconnect the connector (1) from the engine rpm
only (Yn) and install the meter (2).
sensor (B41).
3. When the connection has been made, the solenoid
resistance reading on the meter (2) should be
45 Ω at 20°C. 3
NOTE: The value of the resistance varies with
temperature.
Engine rpm sensor

1
CX130/CX160/CX180
B41
2
BS98F255
B41
to the connector (1) on the engine speed sensor
(B41) only and install the meter (3).
3. When the connection has been made, the rpm
sensor (B41) resistance read on the meter (3)
should be 0.7 kΩ at 25°C.
1
NOTE: The value of the resistance varies with
CD00F024 temperature.

4001-88
Engine coolant and hydraulic oil

temperature sensor 3
4
CX130/CX160/CX180
9
5
6
1 B1
7
CS99A851
3 Service connector (2P)
4 Thermometer
5 Beaker
CD00F026
6 Temperature sensor (B1) or (B2)
CX210/CX230/CX240 7 Tripod
8 Spirit lamp
9 Meter
1 to the temperature sensor (B1) or (B2) connector (1)
B1 or (2) and install the meter (3).
3. When the connection has been made, place the
temperature sensor (B1) or (B2) in the beaker (5)
containing water. Place the beaker (5) on the tripod
(7). Using the spirit lamp (8) gradually increase the
water temperature in the beaker (5). Using the
meter (9), check the resistance value in function of
the temperature read on the thermometer (4) (see
table below).
CD00F027
Coolant
Oil temperature
Temperature temperature
sensor
sensor
20°C 6.08 kΩ 2.45 kΩ
30°C 4.24 kΩ 1.66 kΩ
40°C 3.02 kΩ 1.15 kΩ
2 50°C 2.18 kΩ 0.81 kΩ

60°C 1.61 kΩ 0.58 kΩ
B2 70°C 1.20 kΩ 0.43 kΩ
80°C 0.91 kΩ 0.32 kΩ
CD00F028
1. Disconnect the connector (1) for the coolant
temperature sensor (B1) or the connector (2) for
the oil temperature sensor (B2). Then remove the
coolant temperature sensor (B1) or the oil
temperature sensor (B2) from the machine.

4001-89
Pressure sensor
CX130/CX160/CX180
5
1
B42
1 2 3
4
B43
B44
6
2
B43
CD00E145
CX210/CX230/CX240
CS00E541
B42
1 between sensor (B42), (B43) or (B44) and the
B44 corresponding connector (1), (2) or (3) of the main
harness (5) and install the meter (6).
NOTE: The + terminal on the meter should be
connected to wire YL (yellow/blue) on the service
3 connector and the - terminal to the machine earth.
2
3. When the connection has been made, start the
engine and check the voltages read on the meter (6)
B43 in accordance with the pressures indicated in the
table below.
CD00E146 Pump pressure sensor P1 and P2
1. Disconnect the connector (1) for the pump 1
(B42) pressure sensor or the connector (2) for the Pressure (MPa) Voltage (V)
pump 2 (B44) pressure sensor or the connector 50 4.5
(3) for the negative pressure sensor (B43). 43.7 4
37.5 3
25 2
17.5 1
0 0.5
Pressure sensor (nega-cont)
Pressure (MPa) Voltage (V)

5 4.5
4.37 4
3.75 3
2.50 2
1.25 1
0 0.5

4001-90

4002
Section
4002
INSPECTION AND MAINTENANCE OF BATTERIES

AND CONNECTING A BOOSTER BATTERY

Printed in France
4002-2
TABLE OF CONTENTS
SAFETY INSTRUCTIONS........................................................................................................................................ 3
SPECIFICATIONS.................................................................................................................................................... 3
MAINTENANCE ....................................................................................................................................................... 4
Electrolyte level .................................................................................................................................................... 4
Inspecting and cleaning the battery ..................................................................................................................... 4
INSPECTING THE BATTERY.................................................................................................................................. 5

Visual checks ....................................................................................................................................................... 5
Checking the specific gravity................................................................................................................................ 5
Charge test........................................................................................................................................................... 6
CHARGING THE BATTERY .................................................................................................................................... 7
BATTERY CHARGING GUIDE ................................................................................................................................ 8
PREPARING A DRY CHARGED BATTERY FOR USE........................................................................................... 8
CONNECTING A BOOSTER BATTERY.................................................................................................................. 9

4002-3
SAFETY INSTRUCTIONS
WARNING: Never try to charge a battery WARNING: Battery acid causes very severe
! which has frozen electrolyte. burns. Batteries contain sulphuric acid. Avoid
all contact with the skin, eyes and clothes.
Antidote:
EXTERNAL - Rinse copiously with plenty of
WARNING: Never cause sparks and never
water.
smoke near batteries which are being
INTERNAL - Drink large quantities of water or
! charged or which have recently been
milk. Follow this with milk of magnesia, a
charged.
beaten egg or vegetable oil.
Consult a doctor immediately.
EYES - Rinse copiously with plenty of water
WARNING: When disconnecting cables from
! for 15 minutes and obtain medical assistance
batteries, always disconnect the earth cable immediately.
! first. When reconnecting cables to a battery, Batteries produce explosive gases. Keep
always reconnect the earth cable last. sparks, flames and cigarettes well away. If
you use or charge a battery in a confined
space, make sure that it is well ventilated.
Always protect your eyes when you are
WARNING: Some batteries have a breather
working near batteries.
tube. If the breather tube contains battery acid,
Keep batteries and the acid they contain out
it could spill out when the battery is turned
of the reach of children.
round. When you turn the battery round,
! always keep the end of the ventilation tube
away from yourself and persons in the vicinity.
Battery acid can cause very severe burns.
SPECIFICATIONS
See Section 1002

4002-4
MAINTENANCE
Electrolyte level If the battery has to be cleaned, remove the battery
from its retaining bracket and clean the battery, the
If the battery is a maintenance-free battery, check the cable terminals and the battery retaining bracket. If
electrolyte level every 1000 hours of use or every six possible, use CASE Battery Saver and Cleaner,
months, whichever comes first. For all other batteries, following the instructions on the cartridge. CASE
check the electrolyte level every 250 working hours. Battery Saver and Cleaner also fights corrosion. If
CASE Battery Saver and Cleaner is not available, use
Inspecting and cleaning the battery bicarbonate of soda and water. MAKE SURE that you
If the battery is damaged and leaks, it must be do not allow the cleaning product to enter the battery
replaced. Regularly check for contamination, corrosion cells.
and deterioration of the battery. If the top of the battery
is contaminated by impurities or electrolyte, the battery WARNING: When disconnecting cables from
may become discharged, since the current can pass the battery, always disconnect the earth cable
across the terminals. ! first. When reconnecting cables to the battery,
always reconnect the earth cable last.
WARNING: When disconnecting cables from
the battery, always disconnect the earth cable Reinstall the battery on the machine and check that
! first. When reconnecting cables to the battery, the retainers are fully tightened. Apply CASE Battery
always reconnect the earth cable last. Saver and Cleaner or a urethane product to the battery
terminals to prevent corrosion. Refer to the Parts
Catalogue. Do not use grease.

4002-5
INSPECTING THE BATTERY

NOTE: To carry out a correct inspection of the 2. Read the float.
battery, carry out each step of the inspection; this will
3. Read the thermometer if the reading is higher than
enable you to find out the real condition of the battery.
26.7°C, add specific gravity points to the reading to
Visual checks obtain the specific gravity. If the reading is lower
than 26.7°C, subtract specific gravity points from
- Check cable connections are clean and correctly the reading to obtain the specific gravity. See the
tightened. Remove all foreign bodies from the top of illustration below and add or subtract specific gravity
the battery. points as required.
- Check there is no damage to the battery housing,
terminals and cables.
- Check the electrolyte level, see page 4.
- If you have added water to the battery, charge the
battery for 15 minutes at between 15 and 25 amps
to allow the water to mix correctly with the
electrolyte.
Checking the specific gravity

Use an acid hydrometer to check the specific gravity
of the electrolyte. The specific gravity shows the
charge level in each cell.
JS00532A
Acid hydrometers are designed to show the correct
4. Record the corrected specific gravity for each cell.
specific gravity when the electrolyte is at a
temperature of 26.7°C. 5. If the difference between the high and low readings
is minimum 0.050, charge the battery and check the
Before checking the specific gravity, check the
specific gravity again. If, after charging, the
temperature of the electrolyte. If the hydrometer
difference is still minimum 0.050, install a new
does not have a thermometer, use a thermometer to
battery.
measure the temperature of the electrolyte. The
thermometer must be graduated to at least 52°C. NOTE: When the battery is changed, do not install a
used battery with a new battery. That would reduce
1. Remove enough electrolyte from each cell to
the life-time of the new battery.
allow the float to move freely in the tube.
NOTE: If it is not possible to check the specific gravity
without first adding water to each cell, charge the
battery for 15 minutes at between 15 and 25 amps to
allow the water to mix correctly with the electrolyte.
Then check the specific gravity.

4002-6
6. The corrected specific gravity shows the charge Charge test
level for each cell. The charge level for each cell
should be 75% minimum. For maintenance-free For this check, use a variable charge tester such as
batteries, the charge level is 75% minimum when the Sun Electric VAT-33 or an equivalent machine.
the corrected specific gravity is 1.240 minimum. For Connect the tester as per the manufacturer’s
all other batteries the charge level is 75% minimum instructions.
when the corrected specific gravity is 1.230 1. The charge level should be at least 75%. Carry
minimum. out the specific gravity check in this section.
7. If the difference between the high and low readings 2. Prepare the tester for the tests (the diagram shows
is lower than 0.050 and the charge level is 75% a Sun Electric VAT-33).
minimum in each cell, carry out the charge test.
A. Select the voltmeter range between 1 and
8. If the difference between the high and low readings 18 volts.
is lower than 0.050 but the charge level is lower than
75% in one of the cells, charge the battery and B. Check that the charge control knob is in the
check the specific gravity again. If after charging: OFF position.
A. The charge level is lower than 75% in one of the C. Select the ammeter range between 0 and
cells, replace the battery by a new battery. 1000 amps.
B. The charge level is 75% minimum in each of the D. Move the voltmeter switch to the INT position.
cells, carry out the charge test. E.
1
2
JS00533A
1 CHARGE CONTROL KNOB
2 AMMETER CLAMP (WITH THE POINT OF THE ARROW
DIRECTED AWAY FROM THE BATTERY)
NOTE: Never apply the charge for more than

15 seconds. Every 15 seconds, turn the charge
control knob to OFF for at least 1 minute.

4002-7
3. Apply a charge of 15 amps to the battery for 8. Compare the reading and the electrolyte
15 seconds. Wait at least 3 minutes before temperature with the values shown below.
continuing the test.
Electrolyte temperature Minimum voltage
4. Measure and note the temperature of the
21°C minimum 9.6
electrolyte.
16°C 9.5
5. Refer to specifications for the correct charge for this 10°C 9.4
test. 4°C 9.3
6. The correct charge corresponds to half the value of -1°C 9.1
the cold start current (-17°C). -7°C 8.9
-12°C 8.7
7. Turn the charge control knob until the ammeter
shows the current required. Maintain the charge for -18°C 8.5
15 seconds and read the voltmeter. Turn the charge A. If the result of the test is higher than or equal to
control knob to OFF. the voltage shown, the battery is in good
condition.
B. If the result of the test is less than the voltage
shown, replace the battery with a new battery.
CHARGING THE BATTERY
WARNING: Never try to charge a battery Refer to Specifications on page 3 for the reserve
! which has frozen electrolyte. battery charge of this machine.
Reduce the rate of charge if:
Before charging the battery, check the electrolyte 1. The electrolyte spills out of the cells since they
level. are producing too much gas.
It is difficult to state an exact charging rate since the 2. The temperature of the electrolyte exceeds 52°C.
following conditions are variable: (1) temperature of
the electrolyte, (2) charge level, and (3) condition of NOTE: For optimum charging, select slow charging
the battery. Refer to the Charging Guide for correct rates. The battery is fully charged when, after slow
charging time. charging for 3 hours, no cell is producing too much
gas and the specific gravity remains unchanged.

4002-8
BATTERY CHARGING GUIDE

Recommended rates* and duration for a completely discharged battery.
Capacity of the battery

See "Reserve" in the Slow charging Quick charging
specifications on page 3
80 minutes maximum 10 hours at 5 amps 2.5 hours at 20 amps
5 hours at 10 amps 1.5 hour at 30 amps
Between 80 and 125 minutes 15 hours at 5 amps 3.75 hours at 20 amps
7.5 hours at 10 amps 1.5 hour at 50 amps
Between 125 and 170 minutes 20 hours at 5 amps 5 hours at 20 amps
10 hours at 10 amps 2 hours at 50 amps
Between 170 and 250 minutes 30 hours at 5 amps 7.5 hours at 20 amps
15 hours at 10 amps 3 hours at 50 amps
In excess of 250 minutes 24 hours at 10 amps 6 hours at 40 amps
4 hours at 60 amps
* Initial rate for a standard charger.
PREPARING A DRY CHARGED BATTERY FOR USE

1. Remove the plugs from the battery. 5. Charge the battery at 30 amps until the specific
gravity reaches 1.250 minimum and the
2. Fill each cell with electrolyte, up to the top of the
temperature of the electrolyte reaches at least
separators. This is because the electrolyte volume
15.5°C.
can increase when it is heated by being on charge.
6. If necessary, add electrolyte to each cell until the
3. Install the plugs on the battery.
maximum level indicator is reached (uppers) which
4. Connect the battery charger to the battery. corresponds to a value of 10 to 15 mm above the
battery polarity plates.

4002-9
CONNECTING A BOOSTER BATTERY

1. Open the left-hand side access doors. Remove
WARNING: When a battery is frozen it may the lid and the screws (1) from the batteries.
explode if (1) you try to charge it or (2) you try
to start the engine using jump leads. To
prevent the electrolyte freezing, always keep
! the battery fully charged. Non-observance of
these instructions can endanger your safety
and that of those around you. 1
WARNING: Batteries contain acid and

explosive gases. A spark, flame or incorrect
cable connection can cause the battery to
explode. The correct procedure for
! connecting jump leads to the machine’s
battery is explained on this page. Non- CD00F052
observance of these instructions may lead to 2. While seated in the operator’s seat, ask your
serious or fatal injury. assistant to carry out the connections. Check that
the voltage of the booster batteries is indeed
24 volts.
WARNING: Batteries produce explosive 3. If the connection is being made from another
gases. Keep all cigarettes, sparks and flames machine, make sure that the two machines do not
away from the area. If you charge or use a touch each other.
! battery in a confined space, make sure that it
4. Connect the positive jump lead (+) (1) to the positive
is well ventilated. Always protect your eyes
terminal (+) on the battery.
when working near batteries.
1
WARNING: When connecting the jump leads,
do not allow the positive (+) and negative (-)
! cables to touch each other.
2
WARNING: Incorrect connecting of jump
leads may cause an accident. Always
! proceed with the greatest caution.
JD00531A
5. Connect the negative jump lead (-) (2) to a clean

earth, away from the battery.

4002-10
6. If the connection is being made from another
machine, start the machine and run it at half of
maximum engine speed.
7. Start the engine of the machine requiring the
booster connection and ask your assistant to
disconnect the negative jump lead (-) first and the
positive jump lead (+) last.
8. Install the lid on the battery and close the left-hand
access doors.
9. Do not stop the engine for at least 20 minutes. This
is to allow the batteries to recharge correctly.

Section
4003
4003
MAIN ELECTRONIC CONTROL BOX
ENGINE ELECTRONIC CONTROL BOX

Printed in France
4003-2
TABLE OF CONTENTS
MAIN ELECTRONIC CONTROL BOX AND ENGINE ELECTRONIC CONTROL BOX .......................................... 3
Removal ............................................................................................................................................................... 3
Main electronic control box .................................................................................................................................. 4
Engine electronic control box ............................................................................................................................... 4
Installation ............................................................................................................................................................ 4

4003-3
MAIN ELECTRONIC CONTROL BOX AND ENGINE ELECTRONIC

CONTROL BOX
Removal CX210/CX230/CX240
STEP 1
CD00F046
Disconnect the main earth cable (-) (A) from the
JS00001A battery.
Park the machine on hard, flat ground. Lower the
attachment to the ground. STEP 4
STEP 2
Shut down the engine and position the starter switch
on OFF.
STEP 3 B
CX130/CX160/CX180 A C
CD00F011
Remove the panel (A) located behind the operator’s
seat, taking care to disconnect the connector from
the cigarette lighter (B) and the solar radiation
A detector (C).
CD00F045

4003-4
Main electronic control box Engine electronic control box

STEP 5 STEP 5
D
B
A B
C
A
CD00F047 CD00F048
Disconnect the connectors CN1 to CN6 from the Identify and remove the engine stop relay (A) and the
main electronic control box (B). rotary light relay (B).
STEP 6 STEP 6
Remove the 4 retaining screws (A) from the main Disconnect the connectors CNA0, CNA1, CN7 and
electronic control box (B). CN8 from the engine electronic control box (C).
STEP 7 STEP 7
Remove the main electronic control box (B). Remove the 4 retaining screws (D) from the engine
electronic control box (C).
STEP 8
Remove the engine electronic control box (C).
Installation
To install, proceed in the reverse order from that of
removal.
NOTE: To rebooting the main and engine electronic
control boxes, see Section 4001.

5001
Section
5001

OF THE TRACKS SET

Printed in France
5001-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 2
SPECIAL TOOLS ..................................................................................................................................................... 3
TRACKS SET ........................................................................................................................................................... 4

Description ........................................................................................................................................................... 4
Removal ............................................................................................................................................................... 5
Installation ............................................................................................................................................................ 8
Track tension adjustment ...................................................................................................................................10
Checking pin and bushing wear .........................................................................................................................12
WARNING: This symbol is used in this manual to indicate important safety messages. Every time you see
! this symbol, read carefully the message that follows, as it indicates that there is a risk of serious injury.
SPECIFICATIONS
See Section 1002

See Section 1002

5001-3
SPECIAL TOOLS
926407
1. Track removal hydraulic press CAS 10044

2. Loctite 262
3. Hammer
4. Lifting jib
5. Impact wrench
6. Torque spanner
7. Supports 10 T
8. Roller pump
9. Protractor attachment CAS 2162

5001-4
TRACKS SET
Description
Lower mechanism
12 6
5
7
8
7
4
14
9
11
13
14
3
10
CI00E511
1 TRACK PAD 8 END OF CHAIN PIN SPACER
2 SCREW 9 RETAINER PIN
3 NUT 10 RH STANDARD TRACK PIN HALF-LINK
4 END OF CHAIN PIN HALF-LINK 11 LH STANDARD TRACK PIN HALF-LINK
5 END OF CHAIN HALF-LINK 12 STANDARD TRACK PIN
6 END OF CHAIN PIN 13 STANDARD TRACK PIN SPACER
7 SHIM 14 UNION

5001-5
Removal
STEP 1
Park the machine on hard, flat ground. Rotate the
upperstructure of the machine so that the cab is over
the track to be removed.
2
STEP 2
JD00272A
Operate the machine until the main axle is close to
the centre of the sprocket. Operate machine to lower
track to be removed to ground. Rotate the upper
structure of the machine so that the cab is facing the
front. Shut down the engine.
STEP 4
JD00270A
Lower the bucket or the tool to lift the track a few
centimetres off the ground.
NOTE: If the machine does not have a bucket or tool
installed, install wood blocks under the dipper and
lower the dipper onto the wood blocks. Then, lower
the dipper to raise the machine.
STEP 3
JD00273A
Do not remove the non-return check valve. The
1 grease in the track adjustment cylinder is under high
pressure. Slacken the track by gradually loosening
the non-return check valve by about two turns. The
grease will escape from a port on the check valve
thread.
WARNING: Grease is under heavy spring

JD00271A
pressure. Disassembly without releasing
The main axle (1) can be identified by flat surfaces on
pressure may result in serious injury or
one end and the pin (2) that fastens it at the other
death. Do not disassemble the track
end.
! compensating system before completely
releasing the grease pressure. Release
grease pressure by loosening check valve.
Do not remove the non-return check valve
or retaining bracket.

5001-6
STEP 5 STEP 7
JD00274A JD00277A
Remove the four screws (1) and the track pad nuts Remove the four screws and the nuts from the track
on top of the end of chain axle. Remove the track pad under the end of chain axle. Remove the track
pad. pad.
STEP 6 STEP 8
JD00275A B504423M
Install a portable hydraulic press CAS 10044 on the
end of chain axle. Using the portable hydraulic press,
force the end of chain axle out.
STEP 9
Remove the portable hydraulic press.
JD00276A
Straighten up one end of the pin (1) and remove the
pin from the end of chain axle.

5001-7
STEP 10 STEP 12
JD00278A JS00280A
Using a crowbar, separate the chain links. Remove Sling the lower end of the track. Start the engine.
the two spacers (1) from the end of chain axle. Operate the machine backwards and move the
dipper out at the same time. When the track is free
STEP 11 from the sprocket, stop reversing the machine.
Continue operating the dipper out until the track is
pulled from beneath the machine. Stop the engine,
move the track to be replaced away from the
machine.
JD00279A
Start the engine. Using the attachment, lift the
upperstructure on the side of the track to be
removed. Install supports under the machine to hold
the machine in place and lower the machine onto the
supports. Shut down the engine.

5001-8
Installation STEP 4
STEP 1
CD00F057
Connect lifting equipment to the track. Lift the track
JD00279A on the idler wheel.
Lift the undercarriage. Install supports under the
machine to hold the machine in place. STEP 5
STEP 2
JS00283A
Sling the track to the attachment. Start the engine,
JD00281A operate the machine forward and move the dipper
Place and align the new track under the lower roller. out at the same time to pull the track on the sprocket.
STEP 3 Keep the track engaged on the sprocket teeth.
Lower the machine onto the track chain.

5001-9
STEP 6 STEP 9
B5573689M JD00284A
Connect suitable pulling equipment to both ends of Remove the portable hydraulic press. Install a new
the track chain. Operate the pulling equipment to pull pin (1) in the end of chain axle. Bend the ends of the
both ends of the track chain together. pins to brake the end of chain axle.
STEP 7 STEP 10
Install the two track pads, the screws and the nuts.
1 STEP 11
JD00278A
Install two spacers (1) in the two half links where the
end of chain axle is assembled.
STEP 8 B5171389M
Tighten the track pad screws to a torque (see the
specifications).
STEP 12
See "Track tension adjustment" in this section and
adjust the track tension.
B5491989M
Install the end of chain axle with the portable
hydraulic press CAS 10044.

5001-10
Track tension adjustment STEP 4

Check the tension of the tracks as required. Adjust Do the following procedure to increase the track
the tension for the type of surface the machine will be tension:
operating on. Tighten the track for operation on hard
1. Clean the grease fitting of the track adjustment
surfaces and loosen the track for operation on soft
cylinder.
surfaces.
STEP 1
upper structure of the machine so that the cab is over
the track to be checked.
STEP 2
JD00273A
2. Check that the check valve is tight.
JD00270A
Lower the attachment to lift the machine until the
track to be checked is lifted off the ground by a few
centimetres.
STEP 3
JD00287A
3. Inject grease into the track tension cylinder until

the required tension is obtained.
JD01074A
Measure the distance between the bottom surface of
the track frame and the top surface of the track shoe.
Compare the values with the specifications.

5001-11
STEP 5
Do the following procedure to decrease the track
tension:
JD00273A
1. Do not remove the non-return check valve.

Grease in the track tension cylinder is under high
pressure. Release the track by gradually
loosening the non-return check valve by about
two turns, the grease escapes from a port in the
check valve thread.
WARNING: Grease is under havy spring

or retaining bracket.
2. When the track tension is correct, tighten the

check valve.
3. Clean the grease from the check valve.

5001-12
Checking pin and bushing wear

The wear on the pins and bushings can be measured STEP 2
with a micrometer or an outside calliper.
Measure the inside diameter of the bushing.
STEP 1 Compare the values with the specifications. Replace
them if necessary.
1 2
STEP 3
Measure the outer diameter of the track pin.
Compare the values with the specifications. Replace
them if necessary.
JS00288A
1 OUTSIDE CALLIPER
2 BUSHING
Measure the outer diameter of the bushing. Compare

the values with the specifications. Replace them if
necessary.

Section
5003
5003
UPPER AND LOWER ROLLERS

Printed in France
5003-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 3
SPECIAL TOOLS ..................................................................................................................................................... 3
LOWER ROLLER ..................................................................................................................................................... 4

Description ........................................................................................................................................................... 4
Removal ............................................................................................................................................................... 5
Reconditioning ..................................................................................................................................................... 6
Disassembly ......................................................................................................................................................... 6
Inspection ............................................................................................................................................................. 7
Assembly .............................................................................................................................................................. 7
Installation ............................................................................................................................................................ 9
UPPER ROLLER.................................................................................................................................................... 10
Description .........................................................................................................................................................10
Removal .............................................................................................................................................................11
Reconditioning ...................................................................................................................................................12
Disassembly .......................................................................................................................................................12
Inspection ...........................................................................................................................................................14
Assembly ............................................................................................................................................................15
Installation ..........................................................................................................................................................17
CHECKING FOR LEAKS ....................................................................................................................................... 18

5003-3
SPECIFICATIONS
See Section 1002

See Section 1002
SPECIAL TOOLS
B407320M
Use CAS 1450 and CAS 1682 for the leak checks
shown below
1. 10 T capacity supports
2. Micrometer gauges
3. Torque spanner 700 Nm
4. Jack 5 T
5. Roller pump
6. Loctite 262

5003-4
LOWER ROLLER
Description
A
B
3
2
1 6 8 5 4
CS01B539
1 LOWER ROLLER 5 FACE SEAL
2 DRAIN PLUG 6 SHAFT
3 SNAP RING 7 O-RING
4 END CAP 8 BUSHING
CX130 CX160 CX180/CX210 CX230/CX240

A ................................. 259.8 to 261 mm 317.8 to 319 mm 317.8 to 319 mm 317.8 to 319 mm
B ................................. 224 mm 246 mm 246 mm 246 mm

5003-5
Removal STEP 4
STEP 1
upperstructure of the machine so that the cab is over
the lower rollers to be removed.
STEP 2
JD01075A
Install the supports (1) of suitable capacity under the
machine.
STEP 5
JD00273A
Do not remove the non-return check valve. The
grease in the track adjustment cylinder is under high
pressure. Slacken the tracks by slowly loosening the
non-return check valve by about two turns, the
grease will escape from a port in the thread of the
check valve.
WARNING: Grease is under heavy spring

pressure. Disassembly without releasing 1
pressure may result in serious injury or JD01076A
death. Do not disassemble the track At each end of the track, install wood blocks (1) under
! compensating system before completely the track.
grease pressure by loosening check valve. STEP 6
or the retaining bracket.
STEP 3
Lower the attachment to lift the machine until a
sufficient gap between the track frame and the track
is obtained so that the lower roller can be removed.
JD00299A
Install a wood block under the lower roller to support
it. Remove the four screws and the retaining washers
and remove the lower roller.

5003-6
Reconditioning STEP 3
When the roller is worn out or is leaking, it must be
reconditioned or replaced by a new one. See 4
Section 1002 for limits of wear.
5
Disassembly
STEP 1
JS00303A
Remove the face seals (5) from the end caps (4) with
2 a screwdriver or similar tool. Be careful not to
damage the seal bore in the end cap. Discard the
face seals.
STEP 4
JS00301A
Clean the lower roller (1) using a suitable solvent.
Remove the two drain plugs (2) and drain the oil.
STEP 2
4 7
7
6
3
6 1
3
JS00304A
Remove and discard the O-rings (7) from the shaft
(6). Take the shaft (6) out of the lower roller.
4 STEP 5
JS00302A
Remove the retainer rings (3) and the end caps (4) 1
from the shaft (6). Discard the retainer rings.
5
JS00305A
Remove and discard the face seals (5) from the lower
roller (1) or the shaft (6).

5003-7
STEP 6 Assembly
STEP 1
8
1
8
8
1
JS00306A 8
NOTE: Carry out this step only if inspection reveals
JS00309A
that the bushings (8) need to be replaced.
If removed, install new bushings (8) in the lower roller
Using a hammer and a brass punch, drive the (1) using a hydraulic press and a proper size rod.
bushings (8) from the lower roller (1). Be careful not
to damage the seal bore in the lower roller. Discard STEP 2
bushings. 5
Inspection
STEP 1
Clean all components with solvent. 5
STEP 2
Inspect the bushing surfaces on the shaft (6) for
scoring, pitting, and other damage. Measure the
1
diameter of the shaft at four opposing points.
Compare the values with the specifications, replace
them if necessary.
JS00310A
STEP 3 Install an O-ring and a face seal metal bushing (5) in

the seal bore on each side of the lower roller.
Inspect bushings (8) for wear and damage. Measure
the inner diameter and width of the bushing.
Compare the values with the specifications, replace
them if necessary.
STEP 4
Inspect the bore in each end cap and in the lower
roller for damage that will result in leakage. Use new
parts as required.

5003-8
STEP 3 STEP 5
3 4
1
7
6 3
1 4
7 2
JS00311A JS00314A
Apply clean grease on the shaft surface (6) and Install the end caps (4) on the shaft (6) and install
install the shaft in the lower roller (1), lubricate and new retainer rings (3). Install one drain plug (2).
assemble the O-rings (7) on the shaft (6).
NOTE: Check the adjustment settings of the face
STEP 4 seal covers as well as those of the retaining pitch
holes, see page 4.
4 STEP 6
See the chapter on leak checks, carry out an
5 inspection to ensure that the lower roller has been
correctly installed.
STEP 7
4
JS00312A
2
A
JS00315A
Fill the lower roller (1) with clean oil, see
5
specifications. Install the drain plug (2) in the end cap
(4).
4
JS00313A
Install the O-ring and remaining face seal metal
bushings (5) in the seal bore of the end cap (4). Apply
clean oil copiously to the face seals (A).

5003-9
Installation STEP 3
STEP 1 Tighten the four retaining screws of the lower roller
end caps to the torque (see specifications). Remove
the wood blocks.
STEP 4
At each end of the track, remove the wood blocks
from beneath the track. Remove the two supports
from beneath the machine.
STEP 5
Refer to "Adjusting track tension", see section 5001.
JD00316A
Align the lower roller in position under the lower
undercarriage.
STEP 2
JD00299A
Apply Loctite 262 to the threads of the four screws.
Assemble the four hardened washers and the
screws.

5003-10
UPPER ROLLER
Description
5 A B C
13 7 10 8 11 9 1 12
CS01B540
1 UPPER ROLLER 7 THRUST PLATE
2 DRAIN PLUG 8 SHAFT
3 SNAP RING 9 FACE SEAL
4 COVER 10 BUSHING
5 O-RING 11 BUSHING
6 SCREW 12 BRACKET
13 ROLL PIN
CX130 CX160 CX180/CX210 CX230/CX240

A ................................. 95.8 to 96.2 mm 114.3 to 114.7 mm 114.3 to 114.7 mm 114.3 to 114.7 mm
B ................................. 60 mm 65 mm 65 mm 65 mm
C ................................. --- 11.5 mm 11.5 mm 11.5 mm

5003-11
Removal STEP 3
STEP 1
JD00317A
Install a hydraulic jack on the side frame. Using the
JS00163A jack, lift the track just enough to remove the upper
Park the machine on hard, flat ground. Lower the tool roller.
to the ground.
STEP 4
STEP 2
JD00318A
JD00273A Place wooden shims between the track and the
Do not remove the non-return check valve. The undercarriage.
grease in the track adjustment cylinder is under high
pressure. Slacken the track by slowly loosening the
non-return check valve by about two turns, the
grease will escape from a port in the check valve
thread.
WARNING: Grease is under havy spring

or the retaining bracket.

5003-12
STEP 5 Reconditioning
When the upper roller is worn or is leaking, it must be
reconditioned or a new upper roller installed. See
Section 1002 for wear limits.
Disassembly
STEP 1
JD00319A 2
Loosen the two screws (1) holding the upper roller to
the undercarriage. Using a soft peening hammer, tap
gently on the upper roller to separate it from the
undercarriage.
1
STEP 6
JS00322A
Clean the upper roller (1) using a suitable solvent.
Remove the drain plug (2) and drain the oil.
STEP 2
5
4
3
JD00320A
Support the upper roller. Remove the two screws
1
holding the upper roller to the undercarriage.
Remove the upper roller.
13
CS01B538
Remove the snap ring (3), the cover (4) and the roll
pin (13) from the upper roller (1). Remove and
discard the O-ring (5) from the cover.

5003-13
STEP 3 STEP 6
1 1
6
9
7
JS00324A JS00326A
Secure the upper roller in a vice. Remove the two Remove and discard the face seal (9) from the upper
screws (6) holding the thrust plate (7). Remove the roller (1) using a screwdriver or other suitable tool. Be
thrust plate (7). careful not to damage the seal bore in the upper
roller. Scrap the face seal.
STEP 4
STEP 7
9
8 8
12 12
8 9
JS00325A
12
Pull the upper roller (1) from the shaft (8). JS00327A
Remove and scrap the face seal (9) from the bracket
NOTE: Carry out step 5 only if inspection reveals that
(12) using a screwdriver or other suitable tool. Be
the shaft (8) needs to be replaced.
careful not to damage the seal bore in the bracket.
STEP 5
Using a press, remove the shaft (8) from the bracket
(12). Be careful not to damage the seal bore in the
bracket.

5003-14
NOTE: Carry out step 8 only if inspection reveals that Inspection
the bushings (10 and 11) need to be replaced.
STEP 1
STEP 8
Clean all the components with cleaning solvent.
10
1 STEP 2
Inspect the bushing surfaces on the shaft (8) for
scoring, pitting, and other damage. Measure the
diameter of the shaft at four opposing points.
11 Compare the values with the specifications, replace if
necessary.
STEP 3
Check for wear and damage to the bushings.
Measure the inner diameter and width of the bushing.
Compare the values with the specifications, replace if
JS00328A necessary.
Using a hammer and a brass punch, drive the
bushings (10) and (11) from the upper roller (1). Be STEP 4
careful not to damage the seal bore in the upper Inspect the thrust plate for wear and damage.
roller. Measure the thicknes of the thrust plate. Compare
the values with the specifications, replace if
necessary.
STEP 5
Inspect the bore in the bracket (12) and the upper
roller (1) for damage that could result in leakage. Use
new parts as required.

5003-15
Assembly STEP 3
STEP 1
1
12
8 9
JS00333A
Install an O-ring and a face seal (9) metal bushing in
JS00331A the seal bore of the upper roller (1). Liberally apply
If the shaft (8) has been removed from the bracket clean oil on the edge of the face seal.
(12), install the shaft in the bracket using a press. Be
careful not to damage the seal bore in the bracket. STEP 4
NOTE: The retaining ports of the thrust plate (7) 8
should be perpendicular to the retaining plane of the 12
bracket (12).
NOTE: Respect the recess dimension of the shaft in
the bracket, see page 10.
9
STEP 2
11 8 9
11 12
JS00334A
1 Install the O-ring and the remaining face seal (9)

1 metal bushing in the seal bore of the bracket (12).
Apply clean oil copiously to the face seal.
10
STEP 5
10
JS00332A
8
Install the bushings (11) and (10) in the upper roller
(1).
NOTE: The grooves of the bushings should be
rotated by 90°
1
JS00335A
Apply clean grease on the surface of the shaft (8) and
install the shaft in the upper roller (1).

5003-16
STEP 6 STEP 9
1
7 2
1
JS00336A JS00337A
Apply grease on the inside of the thrust plate (7). Fill the upper roller (1) with synthetic oil (see the
Position the thrust plate on the shaft (8) and install specifications for quantity). Install the drain plug (2) in
the two screws (6). Apply brake thread fluid to the the cover (4).
screws and tighten to a torque of 63 to 72.5 Nm.
STEP 7
5
4
13
CS01B538
Apply grease on the O-ring (5) and install in the
groove of the cover (4). Install the cover (4) and the
roll pin (13) in the upper roller (1). Install the snap ring
(3) to secure the cover (4).
STEP 8
Check for leaks to ensure that the upper roller has
been correctly reassembled and check for any
damage which could give rise to leaks at seals and
other components.

5003-17
Installation STEP 3
STEP 1
JD00317A
Remove the wood blocks between the track pad and
JD00338A the undercarriage.
Place the shims on the undercarriage, then install
and support the upper roller. STEP 4
STEP 2 Operate the hydraulic jack to lower the track onto the
upper roller. Remove the jack.
STEP 5
Refer to "Track tension setting" in section 5001.
JD00319A
Apply Loctite 262 to the screw threads. Install two
tempered washers and screws to fasten the upper
roller bracket to the undercarriage. Tighten the
screws to torque (see specifications).

5003-18
CHECKING FOR LEAKS

Use CAS 1450 and CAS 1682 for the leak checks STEP 4
shown below.
Connect the pressure gauge pipe to the quick
coupler.
STEP 5
1
Make sure that the shut-off valve (1) is open.
STEP 6
Adjust the pressure regulator (2) until the pressure
gauge shows 1.9 bar.
STEP 7
2 Turn the shaft of the unit under test four revolutions.
STEP 8
B407320M
Adjust the regulator until the pressure gauge shows
STEP 1
1 bar.
Connect the shut-off valve (1) to the pressure
regulator (2). Connect a union for the air supply hose STEP 9
to the shut-off valve. Close the shut-off valve. Maintain the air pressure of
step 8 for 10 seconds. A reduction in air pressure
STEP 2
during this period shows a defective component or
Install the adaptor and a quick coupler to the oil filler incorrect assembling.
orifice. Use a seal washer with the adapter.
STEP 3
Turn the knob anti-clockwise to close the pressure
regulator (2).

Section
5004
5004
SPROCKET

Printed in France
5004-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 2
SPROCKET.............................................................................................................................................................. 3
Removal ............................................................................................................................................................... 3
Installation ............................................................................................................................................................ 4
SPECIFICATIONS
See Section 1002

See Section 1002

5004-3
SPROCKET
Removal STEP 4
STEP 1
See "Removing and installing a set of tracks"
(Section 5001) and disengage the sprocket from the
chain. 1
STEP 2
JD00292A
To facilitate reassembly, make alignment marks (1)
on the sprocket and the reduction gear.
STEP 5
JD00290A
Move the machine so that the track is in the position
shown.
STEP 3 1
JD00293A
Remove the screws (1) and the hardened washers
which attach the sprocket to the reduction gear.
STEP 6
JD00291A
Swing the upperstructure so that the cab is over the
side of the machine from which the sprocket has to
be removed. Use the attachment to raise the side of
the machine until the sprocket teeth are disengaged
from the chain.
JD00294A
Using a soft-faced hammer, drive the sprocket off the
reduction gear housing. Remove the sprocket from
the machine.

5004-4
Installation STEP 4
STEP 1 1
1 3 4
JS00296A
Tighten the four screws in the order shown to the
JD00292A specified torque, see "specifications". Then
Install the sprocket on the drive reduction gear, progressively tighten the remaining screws to the
ensuring that the alignment marks (1) are lined up same torque setting.
correctly.
STEP 5
STEP 2
See "Removing and installing a set of tracks" for
installing the tracks.
JD00295A
If necessary, use a soft-faced hammer to seat the
sprocket correctly on the reduction gear flange.
STEP 3
JD00293A
Apply Loctite 262 to the screw threads (2). Assemble
the hardened washers and the screws.

Section
5005
IDLER WHEEL AND TENSION SHOCK ABSORBER
5005

Printed in France
5005-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 3
SPECIAL TOOLS ..................................................................................................................................................... 3
REMOVAL AND INSTALLATION OF THE IDLER WHEEL AND THE TENSION SHOCK ABSORBER................. 4
Removal ............................................................................................................................................................... 4
Installation ............................................................................................................................................................ 6
DISASSEMBLY AND ASSEMBLY OF THE IDLER WHEEL.................................................................................... 8

Description .......................................................................................................................................................... 8
Reconditioning .................................................................................................................................................... 8
Disassembly ........................................................................................................................................................ 9
Inspection ...........................................................................................................................................................10
Assembly ............................................................................................................................................................11
Leakage test .......................................................................................................................................................13
DISASSEMBLY AND ASSEMBLY OF THE TENSION SHOCK ABSORBER ........................................................14

Description .........................................................................................................................................................14
Disassembly .......................................................................................................................................................15
Assembly ............................................................................................................................................................15
TRACK TENSION CYLINDER (CX130, CX160, CX180, CX230 AND CX240) ......................................................16
Description .........................................................................................................................................................16
Removal .............................................................................................................................................................17
Disassembly .......................................................................................................................................................17
Inspection ...........................................................................................................................................................18
Assembly ............................................................................................................................................................18
Installation ..........................................................................................................................................................19
TRACK TENSION CYLINDER (CX180, CX210).....................................................................................................20

Description .........................................................................................................................................................20
Removal .............................................................................................................................................................20
Disassembly .......................................................................................................................................................21
Inspection ...........................................................................................................................................................22
Assembly ............................................................................................................................................................22
Installation ..........................................................................................................................................................23

5005-3
SPECIFICATIONS
Idler wheel ...................................................................................................................................... See section 1002
Shock absorber spring
Pre-stressed during assembly.... xx mm (CX130); 455 mm (CX160); 455 mm (CX180/CX210); 514 mm (CX230/
CX240)

Shock absorber spring yoke screw* ................................................................................................... 267 to 312 Nm
Tension cylinder screw* ...................................................................................................................... 267 to 312 Nm
Tension cylinder non-return valve..................................................................................................................... 59 Nm
* Apply Loctite 262 to the threads
SPECIAL TOOLS
B407320M
Use CAS 1450 and CAS 1682 to check for leaks as
below

5005-4
REMOVAL AND INSTALLATION OF THE IDLER WHEEL

AND THE TENSION SHOCK ABSORBER
Removal STEP 4
STEP 1
See "Removing and installing a set of tracks",
Section 5001.
STEP 2
JD00341A
Using a crowbar, move the idler wheel and the shock
absorber spring assembly out of the housing in the
undercarriage.
STEP 5
JD00339A
Start the engine. Move the machine until the track
chain is disengaged from the idler wheel. Shut down
the engine.
STEP 3
JD00342A
Move the idler wheel and the shock absorber spring
assembly out of the housing in the undercarriage,
using a crowbar, until the nylon sling can be attached
to the shock absorber spring assembly.
JD00340A
Attach the nylon sling from the lifting equipment to
the idler wheel.

5005-5
STEP 6 STEP 8
JD01077A JD00345A
Raise and remove the idler wheel and the shock Connect the lifting equipment to the idler wheel.
absorber spring assembly. Remove the four screws and hardened washers
which attach the idler wheel to the yoke. Remove the
NOTE: On CX180/CX210 machines, the tension
idler wheel from the yoke.
cylinder is linked to the shock absorber spring.
STEP 7
JD01078A
Place the idler wheel and the shock absorber spring
on wooden blocks. Remove the lifting equipment
from the shock absorber spring assembly.

5005-6
Installation STEP 3
STEP 1
JD00342A
Raise the idler wheel and the tension shock absorber
JD00362A and install them in the undercarriage housing. Push
Attach a suitable lifting device to the idler wheel and the idler wheel and the tension shock absorber into
bring it into position on the yoke. Apply Loctite 262 to the undercarriage. Remove the lifting device from the
the threads of the idler wheel retaining screws. Install idler wheel and from the back of the tension shock
four hardened washers and screws to fasten the idler absorber.
wheel to the tension shock absorber yoke. Tighten
the screws to torque (see specifications). STEP 4
STEP 2
JD00363A
Insert the lifting device Nylon sling into the central
JD01078A orifice of the tension shock absorber yoke.
Attach the lifting device Nylon sling to the assembly.

5005-7
STEP 5
JD00365A
Raise the assembly and slide it into the
undercarriage, with the help of a crowbar. Remove
the lifting equipment.
STEP 6
See "Removing and installing a set of tracks",
(section 5001), for installing the track.

5005-8
DISASSEMBLY AND ASSEMBLY OF THE IDLER WHEEL

Description
A
B
8 7 5 6 4
CS01B544
1 DRAIN PLUG 5 O-RING
2 IDLER WHEEL 6 SHAFT
3 SNAP RING 7 FACE SEAL
4 HUB 8 BUSHING
CX130 CX160 CX180/CX210 CX230/CX240

A ................................. 263.6 to 265.5 mm 283.6 to 285.6 mm 283.6 to 285.6 mm 283.6 to 285.6 mm
B ................................. 185.8 to 189.3 mm 199.8 to 203.3 mm 199.8 to 203.3 mm 199.8 to 203.3 mm
Reconditioning
If the idler wheel is worn to the indicated limits or if it shows traces of leaks, it must be reconditioned or changed.
See section 1002 for limits of wear.

5005-9
Disassembly STEP 3
STEP 1 2
2
6 4
4 JS00350A
Remove and scrap the O-ring (5) from the shaft (6).
JS00348A Remove the shaft (6) with the hub (4) from the idler
Clean the idler wheel (2) with a suitable solvent. wheel (2).
Install the idler wheel (2) on stands, with the drain
plug (1) at the bottom. Remove the drain plug (1) STEP 4
from the hub (4) and drain the oil.
STEP 2 6
2
5 4
6
4 3
3
JS00351A
Remove and scrap the other snap ring (3). Remove
the hub (4) from the shaft (6), remove and scrap the
JS00349A O-ring (5) from the shaft (6).
Remove and scrap the snap ring (3) at one end.
Remove the hub (4) from the shaft (6). STEP 5
7
7
JS00352A
Remove and scrap the face seal (7) from the hub (4)
using a screwdriver or equivalent tool. Make sure you
do not damage the hub seal bore. Scrap the face
seal.

5005-10
STEP 6 Inspection
STEP 1
7 Clean all the components with cleaning solvent. Also
clean the cavity in the idler wheel. Dry all the
7 7 components with compressed air at low pressure and
apply clean oil to all the components.
STEP 2
2 Inspect the bushing surfaces on the shaft for scoring,
2 pitting, and other damage. Measure the diameter of
the shaft at four opposing points. Compare the values
7 with the specifications. Change them if necessary.
JS00353A STEP 3
Remove and scrap the face seal (7) from the idler
wheel (2) using a screwdriver or suitable tool. Make Check for wear and damage to the bushings.
sure you do not damage the idler wheel seal bore. Measure the inner diameter and width of the bushing.
Compare the values with the specifications. Change
STEP 7 them if necessary.
8 2 STEP 4
Check for damage which could give rise to leaks at
the hub seal and idler wheel bores. Replace the
components with new components as required.
Measure the depth of the hub seal bores. Compare
8 the values with the specifications. Change them if
necessary.
JS00354A
NOTE: Carry out this step only if the inspection in

step 3 reveals that the bushings (8) have to be
changed.
Using a hammer and a brass drift, drive the bushings
(8) out of the idler wheel (2). Make sure you do not
damage the idler wheel seal bore.

5005-11
Assembly STEP 3
STEP 1
7
8 2
7
8 4
A JS00352A
Install the remaining O-rings and face seal (7) metal
bushing in the hub seal bore (4). Apply clean oil
copiously to the face seals.
8
STEP 4
6
2 5
4
3
JS00356A
A. Clean the inside
Carefully install the bushings (8) in the idler wheel
using a press and a suitable rod.
STEP 2
JS00358A
Lubricate the O-rings (5) with clean grease. Install an
O-ring on the shaft (6), then install the shaft in the
hub (4). Fasten the hub and seal with a new snap
7 ring (3).
7
2
2 7
7
JS00357A
Install an O-ring and a face seal metal bushing in the
idler wheel bore (2). Apply clean oil to the face seal
lips. Repeat this step to install the face seal on the
other side of the idler wheel.

5005-12
STEP 5 STEP 8
2 2
6 4 4
JS00359A JS00361A
Apply clean grease around the shaft (6). Install the Fill the idler wheel (2) with clean oil (see
shaft and hub (4) assembly in the idler wheel (2). specifications). Install the drain plug (1) in the hub
(4).
STEP 6
5 4
3
1
JS00360A
Apply clean grease on the O-ring (5) if this has not
already been done and install the O-ring on the shaft
(6). Install the hub (4) on the shaft and install a new
snap ring (3) to fasten the hub and shaft. Install a
drain plug (1).
NOTE: Check the pitch of the retaining ports of the
tension shock absorber yoke, see page 8.
STEP 7
Check for leaks to ensure that the idler wheel has
been correctly reassembled and check for any
damage which could give rise to leaks at seals and
other components.

5005-13
Leakage test STEP 5

Use CAS 1450 and CAS 1682 for the leak checks Make sure that the shut-off valve (1) is open.
shown below.
STEP 6
Open the pressure regulator (2) until the pressure
1 gauge shows 1.9 bar.
STEP 7
The shaft being checked should now be rotated four
times.
STEP 8
Close the regulator until the pressure gauge shows
1 bar.
2 STEP 9
B407320M Close the shut-off valve. Maintain the air pressure of
STEP 1 step 8 for 10 seconds. A reduction in air pressure
during this period shows a defective component or
Connect the shut-off valve (1) to the pressure incorrect assembling.
regulator (2). Connect a union for the air supply hose
to the shut-off valve.
STEP 2
Install the adaptor and a quick coupler to the oil filler
orifice. Install a seal with the adaptor.
STEP 3
Turn the knob anti-clockwise to close the pressure
regulator (2).
STEP 4
Connect the pressure gauge pipe to the quick
coupler.

5005-14
DISASSEMBLY AND ASSEMBLY OF THE TENSION SHOCK ABSORBER

Description
6
CS01B546
1 SHOCK ABSORBER SPRING 4 YOKE
2 ROLL PIN 5 SPRING GUIDE (CX180/CX160/CX230/CX240)
3 SLOTTED NUT 5 TENSION CYLINDER BARREL (CX180/CX210)
6 PRE-STRESS VALUE (SEE SPECIFICATIONS)

5005-15
Disassembly Assembly
STEP 1 STEP 1
Clean the shock absorber spring assembly. Fix the spring guide (5) in a hydraulic press.
STEP 2
WARNING: The shock absorber spring is
! highly compressed. Place the shock absorber spring (1) and the yoke (4)
in the hydraulic press on the spring guide (5).
STEP 2 STEP 3
Place the shock absorber spring in a hydraulic press. Operate the hydraulic press to compress the shock
Use the press to compress the shock absorber spring absorber spring (see specifications for the value).
(1).
STEP 4
STEP 3 Install the slotted nut (3) and install a new roll pin (2)
Drive out the roll pin (2) from the slotted nut (3). in the slotted nut and the spring guide shaft (5).
Remove the slotted nut from the spring guide (5).
STEP 5
STEP 4 Remove the shock absorber spring from the
Operate the hydraulic press to release tension in the hydraulic press.
shock absorber spring (1).
STEP 5
Remove the yoke (4) and the shock absorber spring
(1) from the spring guide (5).

5005-16
TRACK TENSION CYLINDER (CX130, CX160, CX230 AND CX240)

Description
1
2
3
15
14
4
13
12
5
11
7
6
8
9
10
JS01084A
1 SCREW 9 BALL
2 FLAT WASHER 10 NON-RETURN CHECK VALVE BODY
3 SCREW 11 CYLINDER ROD
4 LOCKING WASHER 12 WIPER SEAL
5 BRACKET 13 THRUST RING
6 GREASE FITTING 14 O-RING
7 CHECK VALVE 15 CYLINDER BARREL
8 SPRING

5005-17
Removal STEP 3
STEP 1
JD01082A
Using a crowbar, push the track tension cylinder
JD01080A piston rod into the cylinder barrel. The grease will
See Section 5003 "Removing the lower roller" and flow out of the non-return check valve. Remove the
remove the roller (A) located under the track tension track tension cylinder from the machine.
cylinder.
STEP 2
Disassembly
STEP 1
Using a suitable cleaning solvent and clean cloths,
remove impurities and grease from the outside of the
track tension cylinder.
STEP 2
Remove the two screws (3) and the locking washers
(4). Remove the bracket (5).
STEP 3
Remove the grease fitting (6) from the non-return
check valve.
JD01081A
STEP 4
NOTE: Do not allow any part of your body to pass
under the tension cylinder. You could be seriously Remove the non-return check valve from the cylinder
injured by the tension cylinder falling, when the barrel (15).
screws are removed which fasten it to the machine.
STEP 5
Loosen the tension cylinder non-return check valve.
Place wooden blocks under the tension cylinder to If necessary, disassemble the non-return check valve
prevent it falling off the machine when the two screws by removing the poppet (7), spring (8) and the ball (9)
which attach it to the machine are removed. Remove from the non-return check valve (10).
the two screws and the flat washers (2).

5005-18
STEP 6 Assembly
STEP 1
Apply clean grease to a new O-ring (14) and new
thrust ring (13). Install the O-ring and the thrust ring in
the cylinder barrel (15).
11 15
12 14
STEP 2
A
13
JS01083A
Remove the cylinder rod (11) from the cylinder barrel
(15).
STEP 7
Using a screwdriver, remove the wiper seal (12) from
the cylinder barrel (15). Scrap the wiper seal.
JS00372A
STEP 8 Apply clean grease to a new wiper seal (12). Using a
hammer and a sleeve (A), drive the wiper seal into
Remove and scrap the thrust ring (13) and the O-ring
the cylinder barrel (15) with the lip orientated towards
(14).
the outside of the cylinder barrel. Drive the wiper seal
Inspection into the cylinder barrel until it touches the cylinder
barrel shoulder. Apply clean grease to the wiper seal
STEP 1 lip.
Clean all the components with cleaning solvent. STEP 3
STEP 2 Apply clean grease around the cylinder rod (11).
Install the cylinder rod in the cylinder barrel (15).
Check for deep grooves, scratches or other damage
inside the cylinder. If necessary, use a lamp to look STEP 4
inside the cylinder. Use medium abrasive emery
paper to eliminate grooves or scratches. If the If the non-return check valve has been disassembled,
grooves or scratches are too deep or if there is other install the ball (9), spring (8) and poppet (7) in the
damage, change the cylinder. non-return check valve body (10). Install the grease
fitting (6) in the non-return check valve body.
STEP 3
STEP 5
Check for deep grooves, scratches or other signs of
wear or damage on the cylinder rod. Use medium Install the non-return check valve assembly on the
abrasive emery paper to eliminate grooves or cylinder barrel (15). Tighten the non-return check
scratches. If the cylinder rod is worn or damaged, valve to torque (see specifications).
replace the cylinder rod. STEP 6
STEP 4 Install the bracket (5) on the cylinder barrel (15).
Check for wear or damage on the non-return check Install two locking washers (4) and screws (3) to
valve assembly. Check for signs of irreparable fasten the bracket to the cylinder barrel.
seizure of the spring. Change all defective
components.

5005-19
Installation STEP 3
STEP 1
Check that the cylinder rod (11) is driven as far as
possible into the cylinder barrel (15).
STEP 2
JD01080A
See "Installing the lower roller" for installing the roller
(A) under the track tension cylinder.
JD01082A
JD01081A
Move the tension cylinder into position. Apply
Loctite 262 to the threads of the two screws (1).
Support the tension cylinder while an assistant
installs two flat washers (2) and screws (1) to fasten
the tension cylinder. Tighten the screws to torque
(see specifications).

5005-20
TRACK TENSION CYLINDER (CX180/CX210)

Description
1
11 2
12
13 10
14
15 3
9
5
6
7
4 8
5002-108
1 SCREW 9 GREASE FITTING
2 LOCKING WASHER 10 SCREW
3 BRACKET 11 CYLINDER ROD
4 NON-RETURN CHECK VALVE ASSEMBLY 12 WIPER SEAL
5 POPPET 13 THRUST RING
6 SPRING 14 O-RING
7 BALL 15 CYLINDER BARREL
8 BODY
Removal
STEP 1 STEP 2
Carry out the procedure for the removal of the idler Carry out the procedure for the removal of the
wheel and the tension shock absorber. tension shock absorber.

5005-21
Disassembly STEP 3
STEP 1
1 12
2
11
15 15
3
4
9 5002-106
Using a screwdriver or a suitable tool, carefully
5002-104 remove the wiper seal (12) from the tension cylinder
Clean the track adjustment cylinder rod and the (15). Scrap the wiper seal.
tension cylinder barrel. Remove the screws (1) and
the locking washers (2) which fasten the bracket (3) STEP 4
to the cylinder rod (11). Remove the bracket. Remove
the non-return check valve assembly (4) with the
grease fitting (9). Remove the non-return check valve
grease fitting. Disassemble the non-return check
13
valve assembly by removing the check valve (5), the
spring (6), the ball (7), and the body (8). 14
STEP 2
15
5002-107
Remove and scrap the thrust ring (13) and the O-ring
(14) from the tension cylinder (15).
15 11
5002-105
Remove the cylinder rod (11) from the tension
cylinder barrel (15).

5005-22
Inspection STEP 2
STEP 1
Clean all the components with cleaning solvent. 12
STEP 2
Check for deep grooves, scratches or other damage
inside the cylinder. If necessary, use a lamp to look
inside the cylinder. Use medium abrasive emery
paper to eliminate grooves or scratches. If the
grooves or scratches are too deep or if there is other 15
damage, change the cylinder.
STEP 3
5002-106
Check for deep grooves, scratches or other signs of
wear or damage on the cylinder rod. Use medium
abrasive emery paper to eliminate grooves or
scratches. If the cylinder rod is worn or damaged,
replace the cylinder rod.
STEP 4
Check for wear or damage on the non-return check
valve assembly. Check for signs of irreparable
seizure of the spring. Change all defective
5002-109
components. Apply clean grease to a new wiper seal (12). Using a
sleeve and a hammer, drive the wiper seal into the
Assembly tension cylinder with the seal lip orientated towards
STEP 1 the outside of the tension cylinder.
STEP 3
13
14
15
15
11
5002-107
Apply clean grease to a new O-ring (14). Install the
5002-105
O-ring and the thrust ring (13) in the tension cylinder Apply clean grease around the cylinder rod (11).
barrel (15). Install the cylinder rod in the tension cylinder barrel
(15).

5005-23
STEP 4
1
11 2
10
3
4
9
5002-104
Install the screws (10) in the tension cylinder (15).
Install the ball (7), the spring (6) and the check valve
(5) in the body (8). Install the grease fitting (9) in the
body (8). Install the non-return check valve (4) on the
tension cylinder barrel (15). Tighten the non-return
check valve to torque, see specifications. Assemble
the bracket (3) on the tension cylinder. Assemble and
tighten the screws (1) and washers (2) to torque.
Installation
STEP 1
Carry out the procedure for installing the tension
shock absorber.
STEP 2
Carry out the procedure for installing the idler wheel
and the tension shock absorber.

5005-24

6001
Section
6001
DRIVE MOTOR AND FINAL DRIVE TRANSMISSION


Printed in France
6001-2
TABLE OF CONTENTS
SPECIFICATIONS .................................................................................................................................................. 2
SPECIAL TORQUES .............................................................................................................................................. 2
DRIVE MOTOR AND FINAL DRIVE TRANSMISSION .......................................................................................... 3
Removal and installation ..................................................................................................................................... 3
SPECIFICATIONS
Hydraulic oil .................................................................................................................................... See Section 1002
Reduction gear lubricant
Type ........................................................................................................................................... See Section 1002
Quantity ...................................................................................................................................... See Section 1002
Weight of the drive motor and final drive transmission................................................................... See Section 1002
SPECIAL TORQUES
Cap screws securing drive motor and final drive transmission to the machine .............................. See Section 1002
(Loctite 262 must be applied to the threads of the cap screws)
Oil level, fill plug and oil drain plug .............................................................................................................5 to 11 Nm
(Teflon tape must be wrapped on threads)
Cre 7-27841GB Edition 04-01

6001-3
DRIVE MOTOR AND FINAL DRIVE TRANSMISSION

Removal and installation
STEP 1 STEP 5
To prevent fluid loss when disconnecting hydraulic
lines, connect a vacuum pump to the hydraulic reser-
voir (see Section 8000).
STEP 6
1
JS00163A
STEP 2
Release pressure in the hydraulic system and in the CD00F067
hydraulic reservoir (see Section 8000). Remove the four cap screws and washers (1) holding
the access cover to the drive motor.
STEP 3 STEP 7
1
CD00F068
Install indentification tags on the hoses connected to
CD00F069
the drive motor to aid in installation.
Remove the oil fill plug and oil lever plug (1) and oil
drain plug (2) and drain the oil. STEP 8
NOTE: When installing, refer to Section 1002 for the Start the vacuum pump.
correct type and quantity of oil to use. Tighten the
plugs to a torque of 5 to 11 Nm.
STEP 4
Wrap Teflon tape on the oil drain plug and install it.
Install the fill plug.

6001-4
STEP 9 STEP 13
1
1
CD00F068 CD00F068
Disconnect the hoses (1) from the drive motor. Install Remove the screws and washers (1) that hold the
a plug in each hose and a cap on each fitting. final drive transmission (2) to the track frame (3).
STEP 10 NOTE: When installing, tighten the screws to the
torque specified in Section 1002.
Stop the vacuum pump.
STEP 14
STEP 11
Refer to Section 5004 and carry out the sprocket
removal procedure.
STEP 12
JD00838A
Remove the drive motor and final drive transmission
from the machine.
JD00836A
Connect suitable lifting equipment to the drive motor
and final drive transmission.
NOTE: For the combined weight of the drive motor
and final drive transmission, see Section 1002.

6001-5
STEP 15
6002-11
Place the drive motor and final drive transmission on
a flat surface with the final drive transmission pointing
upwards. Remove the lifting equipment.
NOTE: For installation, follow the same procedure in
reverse order. Systematically replace all O-rings with
new ones. Fill the final drive casing via the leak off
orifice with hydraulic oil. Before using the machine,
check there are no leaks from the circuit. Check the
oil level in the hydraulic reservoir and the final drive
casing. Add oil if necessary.

6001-6
NOTES
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
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....................................................................................................................................................................................
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....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
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....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
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6002
Section
6002
DISASSEMBLY AND ASSEMBLY OF

THE TRAVEL MOTOR/REDUCTION GEAR ASSEMBLY

Printed in France
6002-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 2
INTERCHANGEABLE PRODUCTS ......................................................................................................................... 2
TRAVEL MOTOR/REDUCTION GEAR ASSEMBLY ............................................................................................... 3
Description ........................................................................................................................................................... 3
HYDRAULIC MOTOR .............................................................................................................................................. 4
Disassembly ......................................................................................................................................................... 4
Inspection............................................................................................................................................................. 8
Assembly.............................................................................................................................................................. 8
SPECIFICATIONS
Hydraulic motor
Manufacturer ................................................................................................................................................ KAYABA
Type...................................................................................................................................................MSF-170VP-E2
Displacement.........................................................................................................................................95/162.2 cm3
Braking torque .......................................................................................................................................... 25 100 Nm
Reduction gear
Manufacturer ................................................................................................................................................ KAYABA
Type............................................................................................................................................. RGC-170VP-43E-1
Reduction ratio .............................................................................................................................................. 1/43246
Type of oil ...................................................................................................... API GL5 grade 80W90 or ISO VG 150
Capacity........................................................................................................................................................... 5 litres
Weight of motor and reduction gear assembly ................................................................................................ 280 kg

Hydraulic motor
Screw 1/16 NPTF ...................................................................................................................................... 10 ± 1 Nm
Cover screw........................................................................................................................................... 205 ± 10 Nm
Non-return check valve spool plugs ...................................................................................................... 140 ± 10 Nm
Spool plugs...............................................................................................................................................118 ± 6 Nm
Secondary relief valve ........................................................................................................................... 373 ± 20 Nm
Non-return check valve spool cap screw............................................................................................... 108 ± 10 Nm
Calibrated orifice screw Ø 2 mm ....................................................................................................... 2.45 ± 0.49 Nm
Calibrated orifice screw Ø 0.8 mm .................................................................................................... 2.45 ± 0.49 Nm
Reduction gear
Cover retaining screws ........................................................................................................................ 73.5 ± 3.5 Nm
Planetary carrier short retaining screws ................................................................................................ 540 ± 25 Nm
Planetary carrier long retaining screws ................................................................................................. 540 ± 25 Nm
Planetary pinion retaining screws.............................................................................................................. 59 ± 5 Nm
Drain, level and filler plugs ...................................................................................................................... 157 ± 8 Nm
INTERCHANGEABLE PRODUCTS
Thread lock fluid ....................................................................................................................................... Loctite 262
Liquid sealing compound.......................................................................................................................... Loctite 504
Reduction gear oil.......................................................................................... API GL5 grade 80W90 or ISO VG 150
Hydraulic oil ...............................................................................................................................................ISO VG 46

6002-3
TRAVEL MOTOR/REDUCTION GEAR ASSEMBLY

Description
40 42 1 2 3 4 5 6 7
41
39
8
38 9
37 10
11
36
12
34 13
35 16
14
33
15
32
17
31
18
19
30
22
20
29 28 27 26 25 24 21 23
CI00G510
1 CONTROL COVER 22 REDUCTION GEAR HUB
2 BALL BEARING 23 SCREW
3 CYLINDER BLOCK FACE 24 REDUCTION GEAR COVER
4 STOP STUD 25 THRUST PLATE
5 STOP STUD 26 1ST STAGE SUN GEAR
6 SCREW 27 SHIM
7 BRAKE PISTON 28 THRUST PLATE
8 CYLINDER BLOCK 29 2ND STAGE SUN GEAR
9 STEEL BRAKE DISC 30 SCREW
10 SINTERED BRAKE DISC 31 STOP STUD
11 PISTON 32 SHIM
12 THRUST PLATE 33 LIP SEAL
13 PAD 34 FACE SEAL
14 BALL BEARING 35 PIVOT BALLS
15 CONTROL PISTON FOR 1ST AND 2ND SPEED 36 PISTON FACE
16 BALL BEARING 37 BODY
17 SCREW 38 SPRING STOP
18 PLANETARY CARRIER 39 SPRING
19 PLANETARY 40 SPRING STOP
20 PLANETARY CARRIER 41 BRAKE SPRING
21 PLANETARY 42 SNAP RING

6002-4
HYDRAULIC MOTOR
Disassembly
STEP 1
2 1
CI00G510
Install the motor/reduction gear assembly on a tripod,
with the reduction gear downwards. Make identification
marks between the reduction gear cover and housing.
Disassemble the screws (1), remove the cover (2) and
scrap the O-ring (3).
STEP 2
22 1 11 13
21 30
8 10 12
20
31
19
23 14 9
18 15
23
24 27 16 10
17 29 8
26
2 3 4
34 5
28
31 33
32 2 6
33 34 32 2
1
31 7
21
30 25 29 20
27
28 19
26 24
22 18
23 17
CI00G512
Disassemble the two valves (1). Remove the seals and the back-up rings (2) and scrap them. Disassemble the seat
and the check valve (3). Remove the body of the valve (4) and the piston (5). Remove the spring guides (6) and the
spring (7). Remove the plugs (8) from the spool valve (9) and scrap the seals (10). Extract the spring guide (11), the
shim (12) and the spring (13). Remove the spool (9) and the spool (14). Remove the piston (15) and scrap the seals
and back-up rings (16).
6002-5
Remove the plug (17) and scrap the seal (18), STEP 4
remove the screw (19). Disassemble the screws (20),
remove the covers (21) and scrap the seals (22). 1 5 4 3 2 6
Remove the spring guides (23) and the spring (24).
Extract the spool (25). Disassemble the plugs (26),
scrap the O-ring (27), remove the spring (28) and the
check valve (29). Disassemble the screws (30) and
the calibrated orifice screws (31). Remove the seals
(32), the springs (33) and the valves (34).
STEP 3
1 2 7 8 9 3
4
5
6
10
CI00G514
Extract the cylinder block (1). Label and remove the
pistons (2) complete with guide plate (3) from the
cylinder block. Remove the spherical bushing (4) and
the thrust rods (5). Remove the piston face plate (6).
STEP 5
1 3
CI00G513
Remove the springs (1) and the distribution plate (2). 5 2 4
Extract the brake piston (3) and scrap the seals (4).
Remove the steel discs (5) and the friction discs (6).
Compress the spring (9) to free up the snap ring (7).
Disassemble the snap ring (7), the thrust stop (8), the
spring (9) and the shim (10).
CI00G515
Extract the shaft (1) complete with bearing (2).
Remove the pistons (3) and the springs (4). Remove
the balls (5). Extract the bearing (2) from the shaft (1).

6002-6
STEP 6 STEP 8
2 3 4 1 2 1
3
4
CI00G516 CI00G518
Disassemble the three plugs (1) and scrap the seals. Remove the planetary pinions (1) with the needle
Disassemble the retaining screws (2). Separate and roller bearings (2). Remove the washer (3). Remove
remove the cover (3). Remove the shim (4). the planetary carrier (4).
STEP 7 STEP 9
2 1 3 1 2 3
3
4
CI00G517 CI00G519
Disassemble the screws (1). Remove the retaining Remove the sun gear (1), 1st stage, the sun gear (2)
plate (2). Remove the plates (3). 2nd stage. Disassemble the retaining screws (3) for
the planetaries (5). Remove the thrust plates (4), the
planetaries (5) and the washers (6).

6002-7
STEP 10 STEP 12
3 2
4
1
CI00G520 CIG00522
Disassemble the screws (1). Extract the planetary The following operation needs to be performed only if
carrier (2). Remove the centring studs (3) and retain the bearings are changed: Remove the two bearings
the shims (4). (1), driving them out using a bronze drift (arrow).
STEP 11 STEP 13
CI00G521 CI00G523
Install the housing under a press and on blocks so as Disassemble and scrap the lip seal (1) (arrows).
to allow the body to be driven out (1). Drive out the
body (1). Remove the face seal (2), taking care not to
damage the steel contact faces.

6002-8
Inspection Assembly
STEP 1 STEP 1
Check for cracks, breakage and pitting on the
planetary and sun gears, planetary carriers, hub, body, 1 3
cylinder block, pistons and pads.
STEP 2 2
Check for heavy wear, cracks, pitting, deep scratches, 2
rough areas on the distribution plate, piston face plate,
thrust rings, pistons, piston housings in the cylinder
block and control spools.
STEP 3
Turn the bearings, check that they do not have any
hard spots or places where they are too loose. Check
for flattened areas, corrosion, bursting, scaling or
indented, grazed or corroded paths on the bearings
and the inner and outer bushings.
STEP 4
CI00G524
If one of these conditions is present, change the Assemble the lip seals (1). Position the half face seal
component. (2) on the body (3).
STEP 2
CI00G525
Assemble the bearings (1) hard up against the hub.
Position the half face seal (2) on the hub. Coat the
steel faces of the face seals with oil.

6002-9
STEP 3 STEP 4
1 2
3
2
A
X
CI00G526 CI00G520
Position the shims (X). Assemble the centring studs
(1). Position the planetary carrier (2). Assemble and
3 tighten the screws (3) to torque.
STEP 5
B
5 4
CI00G527
Assemble the body (1) in the hub (2). Apply a load of 2
3 tonnes on the inner bearing cage (arrows). Read
and note the dimension (A) on the planetary carrier 1
(3). Read and note dimension (B).
Calculation of shims (X) to be placed between the
bearing and the planetary carrier: A - B = X
NOTE: Shims are available as spare parts in the
following thicknesses (0.05), (0.1), (0.3), (0.5) and (1.0).
CI00G528
Assemble the thrust washers (1), with the rounded
part towards the planetary carrier. Assemble the
planetaries (3) complete with needle roller bearings
(2). Assemble the thrust washers (4), with the
rounded part towards the screw head. Assemble and
tighten the screws (5) to torque.

6002-10
STEP 6 STEP 8
2
1 2
A
CI00G519 CI00G529
Position the 2nd stage sun gear (1) with its spring Measure the dimension (A) between the hub (1) and
ring. Position the 1st stage sun gear shaft (2). the retaining plate (2).
Calculate the shims to be installed between the cover
STEP 7 and the 1st stage sun gear.
7 6 Dimension in mm
5
Value A Place the shim
4
3 between 1.2 and 0.67 2.3
2
between 0.66 and 0.04 2.8
1
between 0.03 and -0.16 3.0
between -0.17 and -0.41 3.2
between -0.42 and 0.80 3.6
CI00G517
Position the 1st stage planetary carriers (1).
Assemble the plate (2) with the rounded end towards
the planetary carriers. Assemble the planetaries (3)
complete with needle roller bearings (4). Assemble
the plates (5) with their rounded ends towards the
planetary. Position the retaining plates (6). Assemble
and tighten the screws (7) to torque.

6002-11
STEP 9 STEP 11
4 2 1 5 5
6 4
2
3 7
9
8
3
1
CI00G516 CI00G530
Position the shim(s) (1) calculated in step 8. Coat the Position the spring stop (1) with the chamfer
face of the cover seal (2) with Loctite 504. Position orientated towards the barrel (2). Assemble the
the cover (2) on the hub (3) in accordance with the spring (3), the shim (4) and the spring ring (5) using a
marks made on disassembly. Assemble and tighten press. Oil and assemble the push-rods (6) in the
the screws (4) to torque. Assemble and tighten the cylinder block (2). Assemble the spherical bushing
plugs (5) to torque. Turn the reduction gear the other (7) on the cylinder block (2). Oil and assemble the
way up. pistons (8) on the thrust plate (9). Assemble all the
pistons (8) and the plate (9) in the cylinder block
STEP 10 (identification marks made before disassembly).
6 4 3 1 STEP 12
5 5
2 1 4
3
2
CI00G515
Oil the parts before assembling them. Assemble the
pistons (1) complete with springs (2). Assemble the CI00G511
ball bearing (3) on the shaft (4) using a press. Oil and assemble the piston face plate (1) on the
Assemble the shaft (4) complete with bearing (3) in the balls (2). Tilt the reduction gear (3). Hold the pistons
body (5) using a plastic mallet. Grease and position (4) in the barrel (5) and position the whole assembly
the balls (6). on the reduction gear (3) taking care not to drop the
piston face plate (1) or the balls (2).

6002-12
STEP 13
5 4 3
CI00G513
Assemble the brake discs, alternating one steel disc (1)
and one friction disc (2) and so on. Oil and assemble
new seals (3) on the brake piston (4). Assemble the
brake piston (4). Position the brake springs (5).
STEP 14
31 1 21 19
32 38
22 23 20
33
37
34
29 15 14 13
35 12 16
29
30 26 11 17
36 24
27
2 3 4 18
39 5
25
37 40
41 2 6
40 39 41 2
8
37 7 10 9
32
38 28 24 33
26
25 34
27 30
31 35
29 36
CI00G512
Oil and assemble the new seals and back-up rings (2). Assemble the seat and the check valve (3) on the valve
body (4). Assemble the piston (5) on the valve body (4). Position the spring guides (6) and the spring (7). Assemble
the valve body (4) in the plug (8). Assemble the adjusting screw (9) and its lock-nut (10). Assemble the valves (1)
and tighten to torque. Assemble the seals and back-up ring (11) on the piston (12), oil and place the whole
assembly in the spool (13).

6002-13
Assemble the spool (14) in the spool (13), assemble STEP 16
the spool assembly (13) in the cover (15). Assemble
the seal (16) on the piston (12). Assemble the seal 3 8 5 4 6
(17) on the plug (18). Assemble the plug and tighten
9 7
to torque (18). Position the spring (19), the shim (20)
and the spring guide (21). Fit the seal (23) on the
plug (22), assemble the plug (22) and tighten to
torque. Assemble the check valves (24) and the
1
springs (25) in the spool (28). Fit seals (26) on the
plugs (27). Assemble and tighten the plugs (27) to 2
torque. Position the spring guides (29) and the
springs (30). Fit the plugs (32) on the cover (15) and
tighten the screws (33) to torque. Assemble the bleed
screw (34) and the seal (35) and tighten the plug (36)
to torque. Assemble the calibrated orifice screws
(37), tighten the plugs (38) au couple. Assemble the
valves (39), the springs (40) and the seals (41).
STEP 15
1 2 3 4 5
CI00G510
Assemble one O-ring (1) on the reduction gear (2).
Assemble the cover (3) on the reduction gear (2) as
per the identification marks made during
disassembly. Make sure you align the stud (4) with
the face (5), the studs (6) in the brake piston (7), and
the bearing (8) on the reduction gear primary shaft.
Assemble and tighten the screws (9) to torque.
CI00G531
Assemble the four centring studs (1). Assemble the
distribution plate (3) positioning stud (2). Assemble
the ball bearing (4) in the control cover (5). Grease
the face of the distribution plate (3) which is in contact
with the cover (5).

6002-14

Section
6003
6003
OF THE SWING REDUCTION GEAR

Printed in France
6003-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 2
TOOLS REQUIRED ................................................................................................................................................. 2
SWING REDUCTION GEAR.................................................................................................................................... 3
Removal ............................................................................................................................................................... 3
Installation ............................................................................................................................................................ 4
SPECIFICATIONS
Swing motor and swing reduction gear
Weight ........................................................................................................................................ See Section 1002
Swing reduction gear
Capacity ..................................................................................................................................... See Section 1002
Type of oil................................................................................................................................... See Section 1002

Retaining screws for upper panel and central frame ............................................................................. 88 to 107 Nm
(apply Loctite 262 to the threads)
+20
Screws which attach swing motor to swing reduction gear ...................................................................117.7 -0 Nm
Screws which attach swing reduction gear to the upperstructure frame ........................................ See Section 1002
TOOLS REQUIRED
Hand pump CAS-10090.

6003-3
SWING REDUCTION GEAR

Removal STEP 5
STEP 1
Carry out steps 1 to 11 of "Removing the swing
motor" (see Section 8008).
STEP 2
Mark the position of the swing reduction gear on the
upperstructure frame by making alignment marks on
the swing reduction gear and the upperstructure
frame.
1
STEP 3
6003-014
Place a receptacle of 7.5 litres capacity under the
swing reduction gear drain plug (1). Remove the
drain plug (1) and drain the oil. Install the drain plug.
STEP 6
Lower the swing motor/reduction gear assembly to
the ground and place it on suitable stands.
1
NOTE: The stands must be high enough to prevent
the pinion touching the ground.
STEP 7
6003-110
Remove the eleven swing reduction gear retaining
screws (1) and the centring pin.
STEP 4
6003-018
To facilitate assembly, make an alignment mark on
the swing motor and the reduction gear. Remove the
sixteen swing motor retaining screws (1).
6003-084 STEP 8
Using a suitable lifting device, carefully raise the
swing motor/reduction gear assembly from the Carefully raise the swing motor and move it away
upperstructure and move it away from the machine. from the swing reduction gear. Place it in a clean
area.

6003-4
Installation STEP 4
STEP 1
A
6003-084
Raise the swing motor/reduction gear assembly off
JD00446A the ground. Apply No. 2 EP lithium grease over the
Connect a suitable lifting device to the swing motor pinion (A).
and move it into position above the reduction gear.
Carefully lower the swing motor onto the reduction NOTE: Before installing the swing motor/reduction
gear. gear assembly, check that the drain hose (B) is
installed on the side of the reduction gear housing.
STEP 2
STEP 5
6003-018
Assemble the sixteen swing motor retaining screws 6003-085
(1). Raise the swing motor/reduction gear assembly and
+20 bring it into position above the upperstructure mating
NOTE: Tighten the screws to a torque of 117.7 -0 Nm. surface, ensuring that it is in line with the alignment
STEP 3 marks previously made.
Clean the upperstructure mating surface.

6003-5
STEP 6 STEP 10
6003-109 6003-110
Connect the hand pump CAS-10090 to the swing Apply Loctite 262 to the screw threads and tighten
motor brake release orifice (A). them to the torque specified in Section 1002.
STEP 7 STEP 11
Check that the hand pump is filled with fluid.
STEP 8
Operate the hand pump until the pressure gauge
shows 19.4 bar. The swing motor brake should be A
released, thus allowing the reduction gear output
shaft to turn.
STEP 9
Lower the swing motor/reduction gear assembly onto
the upperstructure mating surface, using a centring
stud.
6003-109
NOTE: Make sure that the reduction gear pinion is
Release the hydraulic pressure in the hand pump
correctly engaged with the upperstructure ring gear.
CAS-10090 and disconnect it from the swing motor
brake release orifice (A). Remove the lifting
equipment from the swing motor.

6003-6
STEP 12 STEP 13
2
1
3
2
CD00E093 CD00E101
1 AIR BLEED PLUG
2 LUBRICATION ORIFICE
Remove the air bleed plug on the side of the swing

reduction gear. Pump No. 2 EP lithium grease into
the reduction gear until grease comes out of the air
bleed orifice. Install the air bleed plug.
STEP 14
Connect a vacuum pump to the hydraulic reservoir
(see Section 8000). Start the vacuum pump.
STEP 15
1
CD00E118
Check that the swing reduction gear oil drain plug (1)
is correctly tightened. Remove the oil level dipstick
(2) and the oil filler plug (3). Fill the swing reduction
gear with the quantity (capacity) and type of oil
specified in Section 1002. Install the oil dipstick and
check the oil level. The oil level should be on the
lower part of the dipstick. Add oil as required and
install and tighten the oil filler plug.
CD00F094
Remove the hose plugs and the union caps and
connect the hydraulic hoses to the swing motor, using
new O-rings.

6003-7
STEP 16 STEP 20
CP99A021 CD00F093
Remove the plug on the top of the swing motor. Fill Install the central frame (1).
the swing motor with hydraulic fluid via the plug
NOTE: Tighten the screws to a torque of between 88
orifice until the fluid starts to spill over. Then install
and 107 Nm (apply Loctite 262 to the threads).
the plug.
STEP 21
STEP 17
Stop and disconnect the vacuum pump from the
STEP 18
A
CD00F092
Install the upper access panel (1).
NOTE: Tighten the screws to a torque of between 88
and 107 Nm (apply Loctite 262 to the threads).
CD00F091 NOTE: Before operating the machine, start the
Connect the earth cable (-) (A) to the battery. engine, check the system for leaks and check the
STEP 19 level of hydraulic fluid in the reservoir, top up if
necessary.
See Section 8001 and adjust the swing motor safety
valves.

6003-8

Section
6004
6004
CX210 - CX230
Copyright © 2005 CNH France.SA.

Printed in France
6004-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 3

Description .......................................................................................................................................................... 4
Disassembly ........................................................................................................................................................ 5
Assembly ............................................................................................................................................................. 8

6004-3
SPECIFICATIONS
See Section 1002

+20
Motor retaining screw on the reduction gear ........................................................................................117.7 -0 Nm

6004-4

Description
12 13
14
11
15
10
16
9
17
8
18
7
19
6
5
4
3
2
CI00K508
1 PINION SHAFT 11 SECOND STAGE SUN GEAR
2 STOP 12 FIRST STAGE SUN GEAR
3 SNAP RING 13 PLANETARY GEAR
4 RETAINING PLATE 14 FIRST STAGE PLANET WHEEL CARRIER
5 SPHERICAL ROLLER BEARING 15 PLANETARY GEAR
6 HOUSING 16 ROLL PIN
7 LIP-SEAL 17 SECOND STAGE PLANET WHEEL CARRIER
8 SPHERICAL ROLLER BEARING 18 SNAP RING
9 DOWEL PIN 19 SPACER
10 RING GEAR

6004-5
Disassembly STEP 4
NOTE: The swing reduction gear is extremely heavy.
Use suitable lifting equipment to lift and move the
components.
STEP 1
Place the reduction gear in a clean working area. 1
STEP 2
JD00452A
Remove the second stage sun gear.
1
STEP 5
JD00450A
Remove the first stage sun gear (1) and the thrust
ring (2).
1
STEP 3
JD00453A
Remove the second stage planet wheel carrier (1).
NOTE: The planetary gear axles are assembled in
two ways: A = assembly by hubbing the axle; B =
assembly by blocking the axle (roll pin). Replace the
whole planet wheel carrier or the spare parts
separately.
JD00451A
Remove the first stage planet wheel carrier (1). If first
stage planetary gears are worn or have broken or
missing teeth replace the complete assembly.

6004-6
STEP 6 STEP 9
Place the planetary gear assembly on a suitable
workbench.
STEP 7
6003-105
Remove the planetary gears.
STEP 10
6003-103
Push the roll pins into the shafts so that the shafts
can be removed.
STEP 8
6003-106
Remove the thrust washers from under the planetary
gears.
STEP 11
6003-104 1
Support the planetary gears and remove the planet
wheel carrier shafts. Remove the roll pins completely 2
from the shafts and discard them.
JD00454A
To aid in assembly, put alignment marks on the ring
gear (1) and the gear housing (2). Remove the ring
gear from the gear housing by tapping lightly with a
plastic mallet.

6004-7
STEP 12 STEP 15
2
1
JD00455A JD00458A
Remove the four dowel pins (1) from the ring gear Remove the roller bearing (1) from the gear housing.
(2).
STEP 16
STEP 13
1
1
A
B
JD00459A
JD00456A Using a suitable tool remove the lip seal (1) from the
(A) Gap gear housing. Discard the lip seal.
(B) Notch
STEP 17
Take the retaining ring out of its groove using the
notch in the housing for leverage. Remove the
retaining ring (1).
STEP 14
2
1
JD00460A
Remove the retaining ring (1) and the spacer (2).
JD00457A
Use a puller or a press to remove the equipped shaft.

6004-8
STEP 18 Assembly
STEP 1
1
JD00461A
Press the bearing (1) from the shaft.
JD00462A
STEP 19 Install the stop (1), the retaining plate (2) on the
pinion shaft.
2 WARNING: Take precautions (gloves), risk of

! burns.
1 STEP 2
3
2
JD00462A
Remove the thrust plate (1) and the retaining plate 1
(2) from the shaft.
JD00463A
Secure the pinion gear shaft in a press. Heat the
bearing (1) to 50°C above the ambient temperature
before pushing it in the press on the shaft.
NOTE: Do not heat the bearing to a temperature
greater than 100°C. Assemble the spacer (2) and the
snap ring (3).

6004-9
STEP 3 STEP 5
JD00464A JD00466A
Fill the roller bearings with 600 cc of No. 2 EP lithium Install a M16 eyebolt into the pinion gear (1) and
grease. reposition the housing under a press. Align the shaft
to keep it straight and plumb. Press the pinion gear
NOTE: The total grease capacity is 1000 cc. The
assembly into the reduction gear housing.
remainder is added after assembly.
STEP 6
STEP 4
1 1
JD00467A
JD00465A
Install the retaining ring (1) with the gap
Remove the grease from the reduction gear housing
approximately 30 mm away from the notch in the
and apply Loctite 504. Fix the reduction gear housing
reduction gear housing.
in a press, install the lip seal (1) in the reduction gear
housing. Lubricate the lip seal with No. 2 EP lithium
grease.

6004-10
STEP 7 STEP 10
1 Place the first stage planet wheel carrier on a clean
workbench.
2
STEP 11
JD00468A
Oil and assemble the bearing (1) in the housing (2)
using a plastic mallet.
STEP 8
6003-106
1 Install the planetary gears and the thrust washers in

the planet wheel carrier, washers under the pinions
(boom).
1 STEP 12
JD00469A
Degrease the mating surfaces of the gear housing,
ring gear, and the four dowel pins. Install the four
dowel pins (1) into the gear housing. Apply
Loctite 504 liquid packing to the mating surfaces.
STEP 9 6003-105
Align the ports of the pinions with the ports of the
planet wheel carrier and install the shafts.
2
JD00470A
Install the ring gear (1) ensuring the alignment marks
are aligned. Assemble four screws (2) in opposition
to hold the ring gear (1).

6004-11
STEP 13 STEP 15
6003-107 JD00452A
With a suitable tool, install a new roll pin (A). Install the second stage sun gear so that it meshes
B = 1 mm, recess dimension with the planetary gears.
Brake using two awl strokes (booms).
STEP 16
STEP 14
JD00451A
JD00453A Install the first stage planet wheel carrier so that it

Install the second stage planet wheel carrier so that it meshes with the internal teeth of the ring gear. Turn
meshes correctly with the internal teeth of the ring the planetary assembly slightly to mesh the teeth of
gear. Turn the planetary assembly slightly to engage the planetary gears with the teeth of the second
the splines of the pinion shaft. stage sun gear.

6004-12
STEP 17
JD00450A
Install the first stage sun gear (1) and the thrust ring
(2). Mesh the teeth of the sun gear with those of the
planetary gears. Turn the first stage planet wheel
carriers by hand to check that the output shaft rotates
smoothly.
STEP 18
1
A
CI00K509
Measure the dimension A
+1.7
A = 2.5 -0.5 mm
Adjust or change the shim (1) if necessary.

Section
6004
6004
CX240

Printed in France
6004-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 3

Description .......................................................................................................................................................... 4
Disassembly ........................................................................................................................................................ 5
Assembly ............................................................................................................................................................. 8

6004-3
SPECIFICATIONS
See Section 1002

+50
Motor retaining screw on the reduction gear ....................................................................................... 294.3 -0 Nm

6004-4

Description
15 16 17
14 18
13 19
12
20
11
21
10
9
22
7
6
5
4
3
2 1
CS00K510
1 SCREW 12 SPHERICAL ROLLER BEARING
2 STOP PLATE 13 DOWEL PIN
3 PINION 14 RING GEAR
4 SHIM 15 FIRST STAGE SUN GEAR
5 SPACER 16 SHIM
6 SNAP RING 17 FIRST STAGE PLANETARY GEAR
7 PLATE 18 FIRST STAGE PLANET WHEEL CARRIER
8 SPHERICAL ROLLER BEARING 19 SECOND STAGE PLANETARY GEAR
9 HOUSING 20 ROLL PIN
10 SHAFT 21 SECOND STAGE PLANET WHEEL CARRIER
11 LIP-SEAL 22 SPACER

6004-5
Disassembly STEP 4
NOTE: The swing reduction gear is extremely heavy.
Use suitable lifting equipment to lift and move the
components.
STEP 1
Place the reduction gear in a clean working area. 1
STEP 2
2 1
6003-088
Remove the second stage sun gear (1).
STEP 5
6003-086
Remove the first stage sun gear (1) and thrust ring
(2).
STEP 3
1
6003-089
Remove the second stage planet wheel carrier (1).
6003-087
Remove the first stage planet wheel carrier (1).

6004-6
STEP 6 STEP 8
4 3
5
6
7
1
2
2 1
6003-090 JD01465A
Remove the ring gear (1) from the reduction gear Remove the two screws (1), the brake plate (2), the
housing (2) using the notch in the housing for end plate (3) and the pinion (4). Remove the snap
leverage. ring (5), the stop (6) and the plate (7).
NOTE: The planetary gear axles are assembled in STEP 9
two ways: A = assembly by hubbing the axle;
B = assembly by blocking the axle (roll pin).
According to the type of assembly, replace the entire
planet wheel carriers or individual spare parts.
STEP 7
1
3
6003-096
Install the swing reduction gear in a suitable press.
Place shims under the flange on the housing to hold
the shaft upright.
STEP 10
JD01464A
Turn the swing reduction gear upside down to be able
to access the pinion (1). Straighten up the corners of
the brake plate (2) to free the screws (3).
2
1
A
6003-097
Place a jack (A) under the shaft (1) and the bearing
(2) under the press to hold and support the shaft
when it has been pressed out of the housing. Press
the shaft from the housing. Remove the shaft and the
bearings from the press.

6004-7
STEP 11 STEP 13
1
1
4
JD00458A
Remove the roller bearing (1) from the gear housing.
STEP 12
2
2
CS00K511
Place the shaft (1) under a press. Insert two shims
1 (2), press the shaft (1) from the bearings (3). Remove
the spacer (4).
STEP 14
2
JD00459A
Using a suitable tool remove the lip seal (1) from the
gear housing. Discard the lip seal.
6003-103
Place the planetary gear assembly on a workbench.
Press the pins (1) in the axles (2) just enough to
remove the axles (2).

6004-8
STEP 15 Assembly
1 STEP 1
2 Place the planet wheel carrier on a clean workbench.
STEP 2
2 1
6003-104
Support the planetary gears and remove the axles
from the planet wheel carrier (2). Press the pins
completely from the axles (1). Remove the pins.
STEP 16 6003-106
Assemble the planetary gears (1), slide the thrust
washers (2) under the pinions (boom).
STEP 3
1
1
6003-105
Remove the planetary gears (1).
STEP 17
1 6003-105
Align the pinions with the bores of the planet wheel
carrier and install the axles. Take care to position the
axle retaining bore correctly (1) with respect to the
bore of the planet wheel carrier.
6003-106
Remove the thrust washers (1) from the planetary
gears.

6004-9
STEP 4 STEP 6
WARNING: Take precautions (gloves), risk of

B ! burns.
6003-107
Install a new pin (A) in the shaft using a suitable tool.
2
Recess dimension in the plane wheel carrier:
B = 1 mm.
Hammer by two awl strokes. 1
STEP 5
Position the pins in the second stage planet wheel
carrier.
CS00K513
Install the spacer (1) on the shaft (2). Heat the
bearing (3) to 50°C above the ambient temperature.
Assemble the hot bearing on the shaft (2), use
protective gloves.
STEP 7
CS00K512
Boom: direction of rotation.
JD00465A
Degrease the reduction gear housing and apply
Loctite 504. Fix the reduction gear housing in a
press, install the lip seal in the reduction gear
housing. Lubricate the lip seal with No. 2 EP lithium
grease. Assemble the bearing on the reduction gear
side.

6004-10
STEP 8 STEP 10
6 7 1
5
1
2
JD00469A
3 Degrease the mating surfaces of the gear housing,

ring gear, and the four dowel pins. Install the four
4 4 dowel pins (1) into the gear housing. Apply
Loctite 504 liquid packing to the mating surfaces.
CS00K514
Coat the roller bearings (1) with 800 grams of No. 2 STEP 11
EP lithium grease (2). Place the shaft assembled (3)
on the shims (4) under a press. Position the housing
(5) equipped with the bearing and the lip seal on the 2
shaft (3). Position the shims (6) on the bearing (7).
Assemble the housing using the press (booms).
STEP 9
JD00470A
1 Install the ring gear (1) ensuring the alignment marks
are aligned. Assemble four screws (2) in opposition
to hold the ring gear (1).
2
3
4
5
6
8 7
CS00K515
Assemble the plate (1). Assemble the snap ring (2)
with a gap of about 30 mm with respect to the notch
on the housing. Assemble the spacer (3), the shim
(4). Lubricate and assemble the pinion (5). Assemble
the stop plate (6). Install the brake plate (7),
assemble and tighten the screws (8). Bend the
corners of the brake plate (7) on the screw heads (8).

6004-11
STEP 12 STEP 14
1
1
6003-089 6003-087
Install the second stage planet wheel carrier (1) so Install the first stage planetary assembly (1) so that it
that it meshes correctly with the internal teeth of the meshes with the internal teeth of the ring gear. Turn
ring gear. Turn the planetary assembly slightly to the planetary assembly slightly to mesh the teeth of
engage the splines of the pinion shaft. the planetary gears with the teeth of the second
stage sun gear.
STEP 13
STEP 15
1
2
6003-088
Install the second stage sun gear (1) so that it 6003-086
meshes with the planetary gear assembly. Install the thrust shim (1) on the second stage sun
gear. Install the first stage sun gear (2) so that it
meshes correctly with the teeth of the planetary
gears. Turn the first stage planetary assembly by
hand and check that the output shaft rotates
smoothly.

6004-12
STEP 16
A 1
CS00K516
Measure the dimension (A), position of the sun gear.
+1.6
A=4 -1.4 mm.
Adjust or change the shim (1) if necessary.

Section
8000
DEPRESSURISING AND DECONTAMINATING THE

HYDRAULIC SYSTEM, USE OF THE VACUUM PUMP
AND BLEEDING THE COMPONENTS
8000

Printed in France
8000-2
TABLE OF CONTENTS
SPECIAL TOOLS ..................................................................................................................................................... 3
RELEASING PRESSURE IN THE HYDRAULIC SYSTEM...................................................................................... 4
BLEEDING AIR FROM THE MAIN HYDRAULIC SYSTEM COMPONENTS .......................................................... 5

Hydraulic pump .................................................................................................................................................... 5
Attachment cylinders ............................................................................................................................................ 5
Hydraulic swing motor .......................................................................................................................................... 5
VACUUM PUMP....................................................................................................................................................... 6
Installation ............................................................................................................................................................ 6
Removal ............................................................................................................................................................... 6
CLEANING THE HYDRAULIC SYSTEM ................................................................................................................. 7

General ................................................................................................................................................................ 7
Types of contamination ........................................................................................................................................ 7
Decontamination of the hydraulic system ............................................................................................................ 8

8000-3
SPECIAL TOOLS
806128
CAS 10508 - Kit for unions
806127
CAS 10162A - Portable filter
CS99B532
CAS 30038 - Set of hydraulic flow and pressure test
unions
M1325
CAS 10193 - Kit for vacuum pump

8000-4
RELEASING PRESSURE IN THE HYDRAULIC SYSTEM

IMPORTANT: Before carrying out any operation on STEP 4
the hydraulic system, pressure in all the hydraulic
circuits must first be at zero.
STEP 1
Place the machine on flat, level ground, with the
attachment lowered to the ground, then shut down
the engine.
STEP 2
CD00E111
Operate the control levers ten times to right and left
and backwards and forwards.
STEP 5
CD00E060
Place the starter switch key in the "ON" position.
STEP 3
CD00E080
Place the starter switch key in the "OFF" position.
STEP 6
CD00E006
Lower the function cancellation control arm (exit
safety bar).
CD00E112
Press the button located above the breather to
release any remaining pressure.

8000-5
BLEEDING AIR FROM THE MAIN HYDRAULIC SYSTEM COMPONENTS

IMPORTANT: After having bled the air from the Attachment cylinders
components, shut down the engine for five minutes
and then check that no air bubbles appear in the Start the engine and run it at idle. Extend and retract
hydraulic fluid reservoir. all the cylinder rods four or five times without bringing
them against the stops, then do the same again three
Hydraulic pump or four times, but this time bringing the cylinder rods
against the stops.
CX130/CX160
Hydraulic swing motor
CX130/CX160
CD00E181
CX210/CX230/CX240
CD00F055
CX210/CX230/CX240
CD00E134
Using a solvent, clean the upper surface of the pump
and the air bleed plug. Remove the air bleed plug.
CD00F056
Fill the pump with hydraulic fluid via that orifice. Start the engine and run it at idle. Loosen the air
Install and tighten the air bleed plug. bleed plug and make sure that hydraulic fluid flows
Start the engine and run it at idle speed. Loosen the out of that orifice. If necessary, shut down the engine
pump air bleed plug. Retighten the plug when fluid and top up via that orifice. Install the plug, without
flows out of the orifice with no air bubbles. Carefully tightening it, then start the engine and run it at idle.
clean around the plug. Let it run until hydraulic fluid flows out of the orifice.
Completely retighten the air bleed plug. Perform at
least two complete swings of the upperstructure, both
to right and to left.

8000-6
VACUUM PUMP
Installation STEP 4
STEP 1
Release pressure in the hydraulic system, see page 4.
STEP 2
JD00020A
Connect the vacuum pump CAS 10193 to the elbow
union of the adaptor plate. Connect the vacuum
pump harness to the batteries.
CD00E112
Removal
Remove the plate (A) on top of the hydraulic
reservoir.
STEP 1
NOTE: Do not remove the O-ring from the reservoir. Disconnect the vacuum pump harness from the
batteries.
STEP 3
STEP 2
B Disconnect the vacuum pump from the elbow union
of the adaptor plate (B).
STEP 3
Remove the adaptor plate (B) from the hydraulic
reservoir and scrap the O-ring.
STEP 4
Install a new O-ring on the hydraulic reservoir and
install the plate (A).
JD00019A
Install the adaptor plate (B) from the kit CAS 30028
on the hydraulic reservoir.

8000-7
CLEANING THE HYDRAULIC SYSTEM

General Types of contamination
Contamination of the hydraulic system is a major Contamination exists basically in two forms:
cause of incorrect operation of hydraulic microscopic or visible.
components. Contamination manifests itself by the
1. We speak of microscopic contamination when
presence of foreign bodies in the hydraulic fluid.
very small particles of foreign bodies are in
Contamination of the hydraulic system can occur in
suspension in the hydraulic fluid. These particles
any of the following situations:
are too small to be seen or felt. Microscopic
1. When draining fluid or disconnecting a hydraulic contamination can be identified by the problems
line. connected with microscopic contamination or by
tests in the laboratory. Here are a few examples
2. When disassembling a component.
of the problems caused by microscopic
3. Due to normal component wear. contamination:
4. Due to damaged or worn seals. A. Cylinder rod seals leak.
5. Due to a damaged component in the hydraulic B. Control valve spools do not return to the neutral
system. position.
All hydraulic systems can still operate even when C. The hydraulic system working temperature is
slightly contaminated. Components of the hydraulic high.
system are designed to withstand a slight degree of D. Components wear quickly.
contamination. Any increase in the degree of
contamination causes serious problems in the 2. We speak of visible contamination when the
hydraulic system. presence of foreign bodies can be detected visually
or by touch or smell. Visible contamination can
Here is a non-exhaustive list of these problems: cause a sudden failure of a component. Here are a
1. Cylinder rod seals leak. few examples of problems caused by visible
contamination:
2. Control valve spools do not return to the neutral
position. A. The fluid contains metal or other debris.
3. Control valve spools are hard to move. B. The fluid contains air.
4. Hydraulic fluid is too hot. C. The fluid is dark and thick.
5. Hydraulic components wear quickly. D. The fluid smells burnt.
6. Safety valves or non-return check valves do not E. The fluid contains water.
close, due to contamination.
7. Repaired components soon fail again.
8. Cycles are slow; the machine does not have
enough power.
If one of the above situations occurs, it shows
excessive contamination of the hydraulic system. To
eliminate this contamination effectively, use the
portable filter CAS 10162A.

8000-8
Decontamination of the hydraulic STEP 7

system
STEP 1 2
Prepare the portable filter CAS 10162A as follows:

1
1. Eliminate all hydraulic fluid from the inlet and
outlet hoses of the portable filter.
2. Remove the element from the portable filter.
3. Eliminate all the hydraulic fluid from the portable
filter.
4. Clean the inside of the element housing.
5. Install a new filter element. CD00E178
Remove the bleed lever valve (1) under the hydraulic
STEP 2 reservoir. Do not remove the adaptor (2).
Release the pressure in the hydraulic system, see STEP 8
page 4.
Install the shut-off valve from the union kit CAS 10508
STEP 3 on the adaptor (2).
Drain the hydraulic fluid from the reservoir and clean NOTE: Make sure that the shut-off valve is closed.
the reservoir. See the Operator’s Manual.
STEP 9
NOTE: Do not install the access panel under the
hydraulic reservoir. Fill the hydraulic reservoir with clean hydraulic fluid.
See the Operator’s Manual.
STEP 4
STEP 10
Change the breather element, the return filter and
clean the inlet filter. Install the inlet hose from the portable filter on the
shut-off valve under the hydraulic reservoir.
NOTE: Do not install the plate complete with
breather. STEP 11
STEP 5 Install the long pipe from the union kit CAS 10508 on
the portable filter return hose.
Change the pilot circuit filter. See the Operator’s
Manual. STEP 12
STEP 6 Insert the long pipe in the hydraulic reservoir. Move
the inlet filter long pipe as far away as possible.
Change the Ultra Clean filter. See the Operator’s
Manual. STEP 13
Open the shut-off valve under the hydraulic reservoir.

8000-9
STEP 14 STEP 20
Install the portable filter on the upperstructure in such With the engine at full speed; operate the swing
a manner that the machine can be operated. Attach control several times 180° to the left and then to the
the portable filter firmly to the machine. right.
STEP 15 STEP 21
Connect the electric cable from the portable filter to With the engine at full speed; position the attachment
the batteries. Make sure that the electric cable is at right angles to the undercarriage. Use the
away from any moving components. attachment to raise the track off the ground. Operate
the travel pedal, in one direction for two minutes and
STEP 16 then in the other direction for two minutes. Repeat
Start the portable filter running. this cycle for ten minutes.
STEP 17 STEP 22
Start the engine, run it at half maximum speed for ten Repeat Step 21 for the other track.
minutes. During those ten minutes, stir the hydraulic
STEP 23
fluid in the hydraulic reservoir with the long pipe.
Reduce the engine speed to idle.
STEP 18
STEP 24
Set engine speed to maximum and bring the
hydraulic fluid up to its operating temperature by the Stir the hydraulic fluid in the hydraulic reservoir for
following procedure: 10 minutes with the long pipe.
1. Operate the bucket and dipper controls in one STEP 25
direction (against the cylinder stops) for
30 seconds. Stop the portable filter and the engine.
2. Operate the bucket and dipper controls in the other STEP 26

direction (against the cylinder stops) for 30 seconds. Close the shut-off valve under the hydraulic reservoir.
3. Repeat steps 1 and 2 until the hydraulic fluid
STEP 27
temperature reaches 45 to 55°C (third bar on the
hydraulic fluid temperature gauge on the illuminated Remove the inlet pipe from the shut-off valve under
instrument panel control screen). the hydraulic reservoir.
STEP 19 STEP 28
With the engine at full speed; operate each cylinder Remove the long pipe from the hydraulic reservoir.
(retract, extend) two times, one after another, for
45 minutes. STEP 29
Disconnect the portable filter electric cable from the
batteries and remove the portable filter from the
machine.
STEP 30
Install a vacuum pump on the hydraulic reservoir.
See page 6.
STEP 31
Start the vacuum pump.

8000-10
STEP 32
2
1
CD00E178
Remove the shut-off valve from the adaptor (2) and
install the bleed lever valve (1).
NOTE: Make sure that the bleed lever valve is
closed.
STEP 33
Stop the vacuum pump and remove it from the
hydraulic reservoir. See page 6.
STEP 34
Install the access panel under the hydraulic reservoir.
STEP 35
Change the return filter and clean the inlet filter. See
the Operator’s Manual.
STEP 36
Change the pilot system filter. See the Operator’s
Manual.
STEP 37
Change the Ultra-Clean filter. See the Operator’s
Manual.
STEP 38
Check the level of the hydraulic fluid. Top up as
necessary. See the Operator’s Manual.

8001
Section
8001
SPECIFICATIONS, TROUBLESHOOTING, CHECKS

AND HYDRAULIC PRESSURE SETTINGS

Printed in France
8001-2
TABLE OF CONTENTS
SPECIFICATIONS..................................................................................................................................................... 4
SPECIAL TOOLS ...................................................................................................................................................... 4

Tester .................................................................................................................................................................... 4
IDENTIFICATION OF HYDRAULIC COMPONENTS ............................................................................................... 6

Pump CX130/CX160 (Uchida) ............................................................................................................................. 6
Pump CX130/CX160/CX180/CX210/CX230/CX240 (Kawasaki) ......................................................................... 7
Control valve CX130/CX160/CX180 .................................................................................................................... 8
Control valve CX210/CX230/CX240 .................................................................................................................. 10
6 solenoid valve manifold................................................................................................................................... 11
PREPARATION BEFORE INSPECTION ................................................................................................................12

Releasing pressure in the hydraulic system....................................................................................................... 12
Installing the pilot pressure test point ..................................................................................................................13
Installing the flowmeter .......................................................................................................................................13
Display on diagnostic screen "CHK1" .................................................................................................................14
Warming up the engine .......................................................................................................................................15
Warming up the hydraulic fluid............................................................................................................................15
CHECKING AND PRESSURE SETTING PROCEDURE........................................................................................16

Pilot system secondary relief valve (H) ...............................................................................................................17
Checking the pilot accumulator ...........................................................................................................................17
Main relief valve (A) ............................................................................................................................................18
Secondary control valve attachment relief valves ...............................................................................................19
Secondary relief valves of the boom safety valves (B1 and B2) .........................................................................20
Dipper secondary relief valve (D1) ......................................................................................................................21
Swing secondary relief valves .............................................................................................................................22
Checking the swing braking pressure .................................................................................................................23
Travel secondary relief valve (K, L).....................................................................................................................23
Checking the pressure delivered by the proportional valve ................................................................................25
By-pass travel checking ......................................................................................................................................26
Checking for leaks on the travel motor................................................................................................................26
Checking the swing motor for leaks ....................................................................................................................27

8001-3
TROUBLESHOOTING ............................................................................................................................................29
Travel drift .......................................................................................................................................................... 29
Not possible to select 2nd travel speed ............................................................................................................. 30
No swing or slow swing ...................................................................................................................................... 31
With the excavator on a slope, the swing brake does not hold .......................................................................... 31
No movement on any function ........................................................................................................................... 32
Lack of power or speed on one of the attachment movements ......................................................................... 32
Not possible to select hard/soft shock absorbing system................................................................................... 33
The boom or the dipper does not lower ............................................................................................................. 33
WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see this
! symbol, carefully read the message that follows, as there is a risk of serious injury.

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

8001-5
CS99B532
4. SET OF UNIONS FOR PRESSURE TEST AND
HYDRAULIC FLOW CAS 30038
CD99C002
5. SET OF HIGH PRESSURE HYDRAULIC
HOSES CAS 30036 (INCLUDING TWO HIGH
PRESSURE HOSES)

8001-6
IDENTIFICATION OF HYDRAULIC COMPONENTS

Pump CX130/CX160 (Uchida)
PZ1 R2 X3
PZ2
G2
R1
G1 A1
A2
CS00E543
G4 G7
G5
G3
G6
X8
S T
S3
CS00E516 CS00E542
Port Description Location

A1-A2 Pump output (P1-P2) SAE 6000 3/4"
X8 Pilot pump output G 3/8
S Main pump intake SAE 6000 3/4"
S3 Pilot pump intake G 3/4
T Return from pilot circuit secondary relief valve G 3/8
PZ1-PZ2 Negative pressure (P1-P2) G 1/4
X3 Negative pressure detector G 1/4
G1-G2 Pressure P1-P2 (plugged) G 1/4
G3 Plugged (proportional pressure valve) G 1/4
G4-G5 Pressure P1-P2 (plugged) G 1/8
G6-G7 Pressure detector P1-P2 G 1/4
R1-R2 Filling and bleeding orifices

8001-7
Pump CX130/CX160/CX180/CX210/CX230/CX240 (Kawasaki)
B3
A3
Dr
Pi1
A2 A1
Pi2 a2 a1
a4 PSv
B1
CS00E547

A1-A2 Pump output (P1-P2) SAE 6000 3/4"
B1 Main pump intake SAE 2500 2-1/2"
Dr Filling and bleeding orifice G 3/4
PSv Accumulator pressure information G 1/4
Pi1-Pi2 Negative pressure G 1/4
a1-a2 Pressure detector P1-P2 G 1/4
a3-a4 Plugged (proportional pressure valve) G 1/4
A3 Pilot pump output G 1/2
B3 Pilot pump intake G 3/4

8001-8
Control valve CX130/CX160/CX180
Ps2
R2 R5
4B3 4B2 4B1
R4
PI3
PR
a
4A3 4A2 4A1
FR
PO
Px2
FL
Px1
5B4 5B2 5B1
5B5 PS1
Dr1 OPT
Dr2
Pi1
PL
Pi2 5A1
5A5 5A4 5A2
CI00J501

8001-9

4A3 Bucket closing
4B3 Bucket opening
4A2 Boom lowering
4B2 Boom raising
4A1 LH forward travel
4B1 LH reverse travel
5A5 Dipper retracting
5B5 Dipper extending
5B2 RH swing
5A2 LH swing
5A4 Option circuit
5B4 Option circuit G 3/4
5A1 RH forward travel
5B1 RH reverse travel G 3/4
PR-PL Inlet - pump P1-P2 G 3/4
P0-OPT Supply to option spool G 1/2
R2 Check valve return 2.9 bar
FL-FR Negative pressure (N)
PX1 Attachment and swing pressure switch G 1/4
PX2 Travel pressure switch G 1/4
PS1 39 bar supply (travel drift) G 1/4
DR1-DR2 Leak-off return G 1/4
PS2 Boom/dipper load holding pilot pressure
R5 By-pass return G 1/4
R4 To shock absorber (heating) G 1/4
Pi1 Priority to swing G 1/4
Pi2 Cancel priority to swing G 1/4
Pi3 Dipper parallel flow variation

8001-10
Control valve CX210/CX230/CX240
Pbu
Ps2 T1 Ps1
T2 Pc3 A5
T3 Pc1
T5
Dr
A3
B5
Pc2 B8
A2
B3
B7
B2 PT
A8
B6 B1
A7 PH
P3 T4
A6
P4 P1 PP
P2 A1 PA
CS00E549 CS00E548
Port Description Port Description

P3
B7 Bucket opening Option circuit
P4
A7 Bucket closing T1 T2 Return
B8 Boom lowering Ps1
Check negative signal
A8 Boom raising Ps2
A6 LH forward travel PT Travel pressure switch
Higher pressure - 2-stage control of the relief
B6 LH reverse travel PH
valve
A5 Dipper extending PA Attachment and swing pressure switch
B5 Dipper retracting Dr Leak-off return
B3 RH swing Pc1 Dipper load holding
A3 LH swing Pc2 Boom load holding
A2 Option circuit T4 By-pass return
B2 Option circuit T5 To shock absorber (pre-heating)
A1 LH forward travel T3 Swing return
B1 LH reverse travel Pc3 Priority to swing
P1
Pump pressure Pbu Cancel priority to swing
P2
PP Pilot pressure

8001-11
6 solenoid valve manifold
Y5 Y4
Y1
Y2
Y6 Y3
CD00E143
Port Description
B Supply to pilot manifold
T Return to reservoir
Y4 Select 2nd travel speed
Y3 Swing brake control
Y5 Higher pressure - 2-stage relief
Y6 Cancel pilot system shock absorbing
Y1 Cancel swing piloting
Y2 Pilot pressure cancellation control

8001-12
PREPARATION BEFORE INSPECTION
WARNING: Hydraulic fluid output under pressure can penetrate the skin. Hydraulic fluid can also cause or
infect a slight skin cut. In the event of being injured by hydraulic fluid under pressure, consult a doctor immedi-
ately. Any delay in obtaining treatment for an injury can cause a serious infection or reaction. Before pressuris-
ing the circuits, make sure that all the outlets are correctly tightened and that the hoses and pipes are in good
! condition. Release pressure in the circuits completely before disconnecting pipes or carrying out any operation
on the hydraulic system. Always use a small piece of cardboard or wood to detect leaks of fluid under pressure.
Never use your hands.
WARNING: Any incorrect use or maintenance WARNING: The accumulator of this machine
of a construction machine can cause acci- is charged with nitrogen under pressure. In the
dents. Only persons who have read, under- event of incorrect operation of the circuit,
! stood and who observe the instructions in the
! change the accumulator. Never try to repair it.
operator’s manual are accredited to use or Non-observance of these instructions and the
maintain this machine. procedure shown below can cause serious or
fatal injury.
Releasing pressure in the hydraulic system

NOTE: Process to be followed before every opera- 7. Lower the pilot control cancellation lever.
tion on the hydraulic circuit. 8. Operate each control 10 times in both directions
1. Position the machine on hard, flat ground. to release pressure in the circuits.
2. Open the bucket until the cylinder rod is com-
pletely retracted.
3. Extend the dipper until the cylinder rod is com-
pletely retracted. Lower the boom so that the end
of the dipper is resting on the ground. Lower the
tool to the ground.
4. Check in "S" mode on the diagnostic screen that
the following values are respected.
CS00E544
CHK MODE II S ENG 1950 rpm
1 9. Press the button located on the hydraulic reser-
P1 030.0 MPa I 0450 mA voir breather to release pressure in the reservoir.
P2 030.0 MPa WT 0080 °C
N 03.00 MPa OT 0055 °C
CX160 CX210
CX130 CX240
CX180 CX230
1950 2050 1800 2000
Engine speed
rpm rpm rpm rpm
Amperage
450 490/369 292 307
(mA)
5. Lower the engine speed to idle for 30 seconds,

then shut down the engine.
6. Turn the starter key switch to "ON", without start-
ing the engine.

8001-13
Installing the pilot pressure test Installing the flowmeter

point (Checking hydraulic pump flows)
CX130/CX160 Pump Uchida
1
3
4 2
M3 4
CD00E191
Install a pressure test point (M3) on the pilot circuit CD00F008
using the T-union and quick coupling supplied in the CX130/CX160/CX180/CX210/CX230/CX240
kit CAS 30038. Pump Kawasaki
4
2
CD00F004
1. Remove the hose (1) from the pump outlet to be

checked.
2. Install the flange (2) (CAS 2764) on the hose (1).
3. Connect the elbow union (3) (CAS 2764) on the
pump outlet to be checked.
4. Install the hoses (4) (CAS 30036) on the elbow
union (3) and on the flange (2).

8001-14
CX130/CX160 Pump Uchida Display on diagnostic screen
"CHK1"
To access this screen: Select work mode "H" or "S"
using the control (2).
6 4
5
CD00F007
CX130/CX160/CX180/CX210/CX230/CX240 1
2
Pump Kawasaki
CM00E001
Press simultaneously on the travel speed control (1)
and on the work mode selector control (2) as shown
above until the diagnostic screen "CHK1" appears
(3 seconds).
6
CHK MODE II H ENG 2000 rpm
4
1
P1 030.0 MPa I 0300 mA
4 P2 030.0 MPa WT 0080 °C

5
CD00F005
N 03.00 MPa OT 0055 °C
5. Install the flowmeter (5) on the hoses (4).
6. Fasten the flowmeter to the upperstructure. P1: P1 pump pressure in MPa
7. Connect the Multi-Handy 2051 connecting cable
to the plug on the flowmeter detector (6). CX130/CX160/ CX210/CX230/
CX180 CX240
Inspection orifice G6 a1
Boom Dipper
Pressure checked Bucket RH travel
LH travel Swing
P2: P2 pump pressure in MPa
CX130/CX160 CX210/CX230/
CX180 CX240
Inspection orifice G7 a2
Dipper Boom
Pressure checked RH travel Bucket
Swing LH travel

8001-15
N: Negative pump pressure in MPa. The pres- Warming up the engine
sure detector at this test point is located on
the pump (port X3 on CX130/CX160 pump 1. Start the engine. The engine will have warmed
Uchida and port PI1 on the hose on (CX130/ up in 10-15 minutes.
CX160/CX180/CX210/CX230/CX240) pump 2. Run the engine until the message "AUTO WARM
Kawasaki. It helps check the negative pump UP" disappears from the display monitor.
pressure.
ENG: Engine speed in rpm. Warming up the hydraulic fluid
I: Amperage in mA (Proportional valve). 1. Actuate the bucket and dipper controls in one
WT: Engine water temperature in °C. direction (against the cylinder stops) for 30 sec-
onds.
OT: Hydraulic oil temperature in °C.
2. Actuate the bucket and dipper controls in the
other direction (against the cylinder stops) for
30 seconds.
3. Repeat Steps 1 and 2 until the hydraulic fluid
temperature reached 45-55°C.
4. Actuate the boom, swing and travel controls in
both directions to warm up all the circuits to
45-55°C.

8001-16
CHECKING AND PRESSURE SETTING PROCEDURE

Location of secondary relief valves
CX130/CX160/CX180
D1 B2 B1
E
D
G
C
B
A CI00E506
CI01B555
CI00E504
CI01B556
J I
H L
CS00E545
CS00E516 CS00M501
CX210/CX230/CX240
D B D1 B2 B1
C
G A
CS00E548
CS00E549
CI01B555
CI01B556
H
J I
CS00E545 L
CS00E552 CS00M501

8001-17
Pressure for 1 turn of the screw (or for 1 shim*)

Item Description CX130 CX160 CX180 CX210/CX230 CX240
---- ---- 213 bar 213 bar
Main relief valve (standard pressure)
(21.3 MPa) (21.3 MPa)
A
Main relief valve (higher pressure - 2-stage 284 bar 284 bar
---- ----
relief) (28.4 MPa) (28.4 MPa)
196 bar 196 bar 212 bar 212 bar
B Boom raising secondary relief valve
(19.6 MPa) (19.6 MPa) (21.2 MPa) (21.2 MPa)
196 bar 196 bar 212 bar 212 bar
C Boom lowering secondary relief valve
(19.6 MPa) (19.6 MPa) (21.2 MPa) (21.2 MPa)
196 bar 196 bar 212 bar 212 bar
D Dipper extending secondary relief valve
(19.6 MPa) (19.6 MPa) (21.2 MPa) (21.2 MPa)
196 bar 196 bar 212 bar 212 bar
E Dipper retracting secondary relief valve
(19.6 MPa) (19.6 MPa) (21.2 MPa) (21.2 MPa)
196 bar 196 bar 212 bar 212 bar
F Bucket opening secondary relief valve
(19.6 MPa) (19.6 MPa) (21.2 MPa) (21.2 MPa)
196 bar 196 bar 212 bar 212 bar
G Bucket closing secondary relief valve
(19.6 MPa) (19.6 MPa) (21.2 MPa) (21.2 MPa)
15.6 bar 16 bar 20 bar 20 bar
H Pilot circuit secondary relief valve
(1.56 MPa) (1.6 MPa) (2 MPa) (2 MPa)
5 bar * 5 bar * 5 bar * 115 bar
I RH swing secondary relief valve
(0.5 MPa) (0.5 MPa) (0.5 MPa) (11.5 MPa)
5 bar * 5 bar * 5 bar * 115 bar
J LH swing secondary relief valve
(0.5 MPa) (0.5 MPa) (0.5 MPa) (11.5 MPa)
10 bar * 86 bar 60 bar 60 bar
K Rear travel secondary relief valve
(1 MPa) (8.6 MPa) (6 MPa) (6 MPa)
10 bar * 86 bar 60 bar 60 bar
L Forward travel secondary relief valve
(1 MPa) (8.6 MPa) (6 MPa) (6 MPa)
Pilot system secondary relief valve Checking the pilot accumulator

(H) 1. Raise the boom completely and extend the dip-
per.
Test
2. Shut down the engine, with the starter key switch
1. Connect a 0-100 bar pressure gauge to pressure on "ON".
test point M3.
3. Operate the boom lowering or dipper retracting
2. With the engine at full speed, select mode "S". control several times consecutively.
3. Move the pilot cancellation lever to its low posi- 4. The pressure in the accumulator should enable
tion. the boom lowering or dipper retracting function to
4. With the swing and travel attachment controls in be performed about six times.
neutral, read the value on the pressure gauge:
The value should be 39±1 bar (3.9±0.1 MPa).
Adjustment
1. Loosen the lock nut and turn the valve adjusting
screw (H) until 39±1 bar (3.9±0.1 MPa) is
reached.
2. Tighten the lock nut while holding the adjusting
screw in position.
3. When the adjusting screw has been tightened,
check the pressure again and make sure there
are no leaks.

8001-18
Main relief valve (A) CX210/CX230/CX240

Test
1. Display the diagnostic screen "CHK1".
2. With the engine at full speed, select mode "S". 2
1
3. Operate and hold in position the dipper retracting
control (against cylinder stops).
4. Read the pressure on the diagnostic screen:
When the dipper cylinder is against the stops,
the pressure is the standard value for 2 seconds,
then at the higher pressure - 2-stage relief value
for 8 seconds before falling back to standard 3 4
pressure.
CS00E550
Standard Higher
Pump 1. Disconnect and plug the 2-stage relief level pilot
pressure pressure level
CX130 hose from the main relief valve.
343±3 bar 363±5 bar
CX160 P2 2. Using a key, hold the adjusting screw (3) in posi-
(34.3±0.3 MPa) (36.3±0.5 MPa)
CX180 tion and loosen the lock nut (4).
CX210
343±3 bar 373±5 bar
3. Tighten the adjusting screw (3) until it is against
CX230 P1 the stops.
(34.3±0.3 MPa) (37.3±0.5 MPa)
CX240
4. Tighten the lock nut (4).
5. Start and run the engine at the maximum speed,
NOTE: To read the higher pressure - 2-stage relief
select the mode "S".
level again, the control lever should be released, then
operated against the cylinder stops. 6. Operate and hold in position the dipper retracting
Adjusting the higher pressure level 7. Loosen the lock nut (2) and turn the adjusting
CX130/CX160/CX180 screw (1) until the higher pressure - 2-stage relief
level is reached.
NOTE: Tighten the screw (1) to increase the pres-
sure. Loosen the screw (1) to reduce the pressure.
1 2 8. Using a key, hold the adjusting screw (1) and
tighten the lock nut (2).
9. Check the pressure once again. If the desired
value is not obtained, repeat steps 6 to 9.
10. Carry out the standard pressure adjustment
(steps 2 to 9).
3 4
CS00E551

8001-19
Adjusting the standard pressure Secondary control valve
NOTE: Carry out the procedure mentioned below attachment relief valves
only if the higher pressure level is correct, otherwise (B, C, D, E, F and G)
carry out adjustment of the higher pressure level.
NOTE: If the excavator is equipped with secondary
CX130/CX160/CX180 relief valves on the boom and the dipper, the second-
ary relief valves (B) and (D) are not assembled or
they are reset. In this case the valves (B1-B2 and D1)
assembled on the secondary relief valves must be
tared.
NOTE: The secondary attachment relief valves are
tared at a pressure higher than that in the main relief
valves. To check or set the secondary attachment
relief valves, the main relief valve must be reset.
3 4 Checking and setting
CS00E551
CX130/CX160/CX180
CX210/CX230/CX240
1 2
3 4
CS00E551
CS00E550
1. Disconnect and plug the 2-stage relief level pilot CX210/CX230/CX240

hose from the main relief valve.
2. Using a key, hold the adjusting screw (3) in posi- 1 2
tion and loosen the lock nut (4).
3. Start and run the engine at maximum speed,
select mode "S".
5. Turn the adjusting screw (3) until the standard
pressure is obtained. CS00E550
NOTE: Tighten the screw (3) to increase the pres- 1. Disconnect and plug the 2-stage relief level pilot
sure. Loosen the screw (3) to reduce the pressure. hose from the main relief valve.
6. Using a key, hold the adjusting screw (3) in posi- 2. Using a key, hold the adjusting screw (1) in posi-
tion and tighten the lock nut (4). tion and loosen the lock nut (2).
7. Check the pressure once again. If the desired 3. Tighten the adjusting screw (1) by 180°.
value is not obtained, repeat steps 2 to 6. 4. Using a key, hold the adjusting screw (1) in posi-
8. Shut down the engine. tion and tighten the lock nut (2).
9. Reconnect the 2-stage relief level pilot hose to 5. Start and run the engine at maximum speed,
the main relief valve. select mode "S".
7. Operate and hold in position the corresponding
attachment control (against the cylinder stops).

8001-20
8. Read the pressure on the diagnostic screen, the 18. Using a key, hold the adjusting screw (1) in posi-
pressure should be: tion and tighten the lock nut (2).
19. Check that the standard pressure of the main
CX130/CX160/ CX210/CX230/ relief valve is correct, if not repeat steps 15 to 19.
Function
CX180 CX240
20. Shut down the engine.
Boom 383±5 bar 392±5 bar
P1 P2 21. Reconnect the 2-stage relief level pilot hose to
raising (38.3±0.5 MPa) (39.2±0.5 MPa)
the main relief valve.
Boom 383±5 bar 392±5 bar
P1 P2
lowering (38.3±0.5 MPa) (39.2±0.5 MPa)
Secondary relief valves of the
Dipper 383±5 bar 392±5 bar
retracting
P2
(38.3±0.5 MPa)
P1
(39.2±0.5 MPa)
boom safety valves (B1 and B2)
Dipper
P2 383±5 bar P1 392±5 bar Checking and setting right-hand side
extending (38.3±0.5 MPa) (39.2±0.5 MPa)
Bucket 383±5 bar 392±5 bar

P1 P2
opening (38.3±0.5 MPa) (39.2±0.5 MPa)
Bucket
9
383±5 bar 392±5 bar
closing
P1
(38.3±0.5 MPa)
P2
(39.2±0.5 MPa)
8
9. Carry out steps 10 to 14 only if one of the sec-
ondary attachment relief valves needs to be 5 3
tared. Otherwise go to step 15.
4
3
1
4
2
CD01B008
Disconnect the balancing hose (1). Assemble on the
hose a male coupling joint equipped with its union
(2). Plug the elbow union (3). Connect to the hose (1)
a female coupling joint equipped with a pressure
CI00E508 detector (4). Connect the Multi-Handy tester or a
10. Using a key, hold the adjusting screw (4) of the 0-600 bar pressure gauge (5) to the pressure detec-
corresponding secondary relief valve in position tor (4).
and loosen the lock nut (3).
11. Operate and hold in position the corresponding
attachment control (against the cylinder stops).
12. Turn the adjusting screw (4) of the corresponding
secondary relief valve until the correct pressure
is obtained.
13. Using a key, hold the adjusting screw (4) in posi-
tion and tighten the lock nut (3).
14. Check the pressure once again. If the desired
value is not obtained, repeat steps 10 to 14.
15. Using a key, hold the adjusting screw (1) of the
main relief valve in position and tighten the lock
nut (2).
17. Turn the adjusting screw (1) until the correct
value of the main relief valve standard pressure
is obtained.
NOTE: Tighten the screw (1) to increase the pres-
sure. Loosen the screw (1) to reduce the pressure.

8001-21
Dipper secondary relief valve (D1)

Checking and setting
7 6
2
3
CD01B007
Disconnect and plug the pilot hose (6) corresponding
4
to the valve to be adjusted located behind the boom
foot. Put the hose (6) in a receptacle in order to CD01B017
retrieve possible leaks. Plug the elbow union (7). Disconnect and plug the pilot hose (1). Put a recepta-
Start the engine. Set the rotational velocity to cle under the union (2) to collect possible leaks.
1000 rpm using the potentiometer on the instrument Remove the plug (3) and install a pressure detector
panel. Move the boom to half-height. Turn the boom union (4) (location 21G). Connect the Multi-Handy
lowering control and raise pressure settings of the tester or a 0-600 bar pressure gauge to the pressure
valve (B+). Repeat the operation several times rais- detector (4). Start the engine. Set the rotational
ing the pressure each time. velocity to 1000 rpm using the potentiometer on the
instrument panel. Lower the boom to half-height.
Machines Pressure settings Turn the dipper retracting control and raise the pres-
CX130/CX160/CX180 383 to 388 bar sure settings of the valve. Repeat the operation sev-
eral times while raising the pressure each time.
CX210/CX230/CX240 392 to 397 bar
If the value is not correct, loosen the lock nut (8) and Machines Pressure settings
turn the screw (9) in order to adjust the pressure CX130/CX160/CX180 383 to 388 bar
while turning the boom lowering control. Tighten to CX210/CX230/CX240 392 to 397 bar
increase, loosen to decrease the pressure. Tighten
again the lock nut (8). Shut down the engine. To
decompress the large chamber cylinder, first recon-
nect the pilot hose (6). Start the engine in order to fill
the accumulator. Shut down the engine. Decompress
the hydraulic system. Remove the union plug (3).
Débrancher le raccord d'accouplement (2). Recon-
nect the balancing hose (1).
Checking and setting the right-hand side
Carry out the same operations as those on the right-
hand side. The difference between the two valves
should be less than 5 bar.

8001-22
5. Slowly operate the swing lever to the right, then
gradually increase engine speed to full speed to
ensure that the swing is locked.
6. Repeat Step 5 for the LH swing, the pressures
should be:
Function CX130/CX160/CX180
RH swing P2 279±4 bar

5 6 (27.9±0.4 MPa)
LH swing P2 279±4 bar

(27.9±0.4 MPa)
Function CX210/CX230 CX240

CD01B016
RH swing P1 279±4 bar P1 290±4 bar
If the value is not correct, loosen the lock nut (5) and (27.9±0.4 MPa) (29±0.4 MPa)
turn the setting screw (6) in order to adjust the pres-
LH swing P1 279±4 bar P1 290±4 bar
sure. Tighten to increase, loosen to reduce the pres- (27.9±0.4 MPa) (29±0.4 MPa)
sure. While turning the dipper retracting control,
tighten the lock nut again (5). Shut down the engine. For the machines CX130, CX160, CX180, CX210
To decompress the small chamber dipper cylinder, and CX230, note down the pressures if they are not
first reconnect the pilot hose (1). Start the engine in correct in order to determine the number of shims
order to fill the accumulator. Shut down the engine. required for adjustment. One 0.1 mm shim corre-
Decompress the hydraulic system. Disconnect the sponds to 5 bar of pressure.
pressure detector union (4). Fit the plug again (3).
Adjustment
Swing secondary relief valves CX130/CX160/CX180/CX210/CX230
(I, J)
Test
J
I
CS99B596
(I) RH swing secondary relief valve

(J) LH swing secondary relief valve
CD00E143
1. Disconnect the swing solenoid valve connector 1. Remove the secondary relief valve concerned
(green). from the swing motor. If both secondary relief
valves have to be removed, mark them ready for
2. Display the diagnostic screen "CHK1". reassembly.
3. Start the engine and select the mode "S".
4. Switch on the swing brake control on the instru-
ment panel (indicator lamp ON).

8001-23
Checking the swing braking

4 5 6
pressure
1 2 3 7
CS99B598
2. Tighten the body of the valve in a vice and
remove the plug (1), guide (2), liner (3), spacer
CD00E192
(4), shims (5), spring (6) and the check valve (7).
1. Disconnect the hose swing brake supply hose at
3. Remove (to reduce the pressure) or add (to
the reduction gear end and connect a pressure
increase the pressure) the number of shims (5)
test point and a 0-100 bar pressure gauge to the
required to reach the correct pressure.
hose.
4. Reassemble the parts (1 to 7) of the valve and
2. With the engine at full speed, select mode "S".
tighten the plug (1) to 157 Nm.
3. With the swing control in the neutral position,
5. Reassemble the valve on the swing motor and
switch on the swing brake control on the instru-
the tighten to 78 Nm.
ment panel (indicator lamp ON), the pressure
6. Check the pressure of the valves again and should be between 0 and 3 bar.
make sure there are no leaks.
4. With the swing control in the neutral position,
CX240 switch off the swing brake control on the instru-
ment panel (indicator lamp OFF), the brake
1 release pressure should be about 39 bar.
2
Travel secondary relief valve (K, L)
Tools required
CS00G515
1. Carry out steps 1 to 5 from the "Checking" sec-

tion.
tion and loosen the lock nut (1).
3. Slowly operate the swing lever to side to be set,
then gradually increase engine speed to full
speed to ensure that the swing is locked.
4. Turn the adjusting screw (2) until the correct CS99B579
pressure is obtained. - 1 locking rod of the above dimensions

6. Check the pressure again. If the desired value is
not obtained, repeat steps 2 to 6.

8001-24
Checking and adjustment Adjustment CX130
1. Reset the main relief valve (steps 1 to 4 page 19.
Section on attachment secondary relief valves).
K
2. Start the engine.
L
TRAVEL
K. Reverse secondary relief valve
L. Forward secondary relief valve
9. Remove the secondary relief valve concerned
CS99B580
from the travel motor. If both secondary relief
3. Mechanically block the travel to be checked
valves have to be removed, mark them ready for
carefully in the locking rod position (A) in
reassembly.
between the sprocket and the undercarriage as
shown above.
D
5. Display the diagnostic screen "CHK1". F
6. Operate and maintain the corresponding travel
control (locking the sprocket).
H
7. Read the pressure on the diagnostic screen, the
pressure should be:
E
I
G
Machines Pressure
CX130 430±5 bar (43.0±0.5 MPa)
CX160/CX180/
CX210/CX230/ 353±5 bar (35.3±0.5 MPa)
CX240 JD00857A
10. Tighten the body of the valve (I) in a vice and
For the CX130 machines, note down the pressures if remove the plug (D), the adjusting shims (E), the
they are not correct in order to determine the number seat (F), the spring (G) and the valve (H).
of shims required for adjustment. One 0.1 mm shim
corresponds to 10 bar of pressure.
8. Go to step 9 if one of the secondary relief valves
needs to be tared. Otherwise reset the main
relief valve (steps 15 to 21 page 20).

8001-25
11. Remove (to reduce the pressure) or add (to Checking the pressure delivered by
increase the pressure) the number of adjusting
shims (E) required to reach the correct pressure.
the proportional valve
12. Reassemble the parts (D to H) of the valve and CX130/CX160 (Pump Uchida)
tighten the plug (D) to a torque of 57 to 95 Nm.
13. Reassemble the secondary relief valve on the
travel engine and tighten it to a torque of 107 to
148 Nm.
15. Reset the main relief valve (steps 15 to 21
page 20).
Adjustment CX160/CX180/CX210/CX230/
G3
CX240
3
CS00E542
K
CX130/CX160/CX180/CX210/CX230/
4 CX240 (Kawasaki)
6002-03
K. Reverse secondary relief valve
L. Forward secondary relief valve
a4
9. Using a key, hold the adjusting screw (3) of the
concerned secondary relief valve in position and
loosen the lock nut (4).
CS00E552
10. Operate and hold the corresponding travel con-
1. Connect a pressure test point and a 0-100 bar
trol (locking the sprocket).
pressure gauge to port G3 (CX130/CX160) or a4
11. Turn the adjusting screw (3) of the concerned (CX180/CX210/CX230/CX240) on the pump.
secondary relief valve until the correct pressure
is obtained.
3. With the engine at full speed, select mode "H".
Pump Uchida CX130 CX160
Pressure 15 to 19 bar xx to xx bar
Amperage 600 mA 600 mA
14. Reset the main relief valve (steps 15 to 21
page 20).
Pump Kawasaki CX130 CX160/CX180
Pressure XX to XX bar XX to XX bar
Pump Kawasaki CX210/CX230 CX240

Pressure 18 to 21 bar 16 to 20 bar

8001-26
4. With the engine at full speed, select mode "S". Checking for leaks on the travel
Pump Uchida CX130 CX160
motor
Pressure 9 to 13 bar xx to xx bar Tools required
Pump Kawasaki CX130 CX160/CX180

Pressure XX to XX bar XX to XX bar
Pump Kawasaki CX210/CX230 CX240

Pressure 25 to 29 bar 23 to 28 bar
By-pass travel checking CS99B579
Ensure that the tension of the tracks is correct. 1 blocking rod of the above dimensions
1 receptacle with a capacity of 10 litres
This test should be carried out with the hydraulic oil 1 hose
temperature at 50°C and on flat and hard ground of 1 plug
about 30 m length.
Checking for leaks
With the engine running at full speed in mode "H",
press and hold the travel pedals against the stops. (With the hydraulic oil between 45 and 55°C)
Forward travel for a distance of 25 metres. 1. Press the breather to release pressure in the
hydraulic reservoir.
Raise the drift value over the last 20 metres of travel.
2. Remove the travel motor protective shield.
If this value is greater than 1 m:
1. Check the pilot pressure values on the two travel
spools (should be greater than 30 bar).
2. Check the leak-off values of the travel motors.
CS00E546
3. Disconnect the hydraulic motor drain hose and
plug it.
4. Use a hose to connect the drain port to the
receptacle.

8001-27
Checking the swing motor for leaks

A B
Tools required
1 receptacle with a capacity of 10 litres
1 hose
1 plug
Checking for leaks
(With the hydraulic oil between 45 and 55°C)
CS99B580
A Locking pin
B Forward
5. Lock the travel on the side to be checked by
positioning the locking pin (A) between the
sprocket and the undercarriage as shown above.
7. Operate the travel control of the hydraulic motor
to be checked and measure the quantity of oil
which leaves the drain during 1 min. CD00E143
8. Repeat Steps 1 to 7 to check the other motor. 1. Disconnect the swing solenoid valve connector
9. Compare the quantities of oil collected; if the dif- (green).
ference between the two motors is greater than 2. Display the diagnostic screen "CHK1".
1 l/min, repair or change the motor which has 3. Start the engine and select the mode "S".
output the greatest quantity of oil. 4. Switch on the swing brake control on the instru-
ment panel (indicator lamp ON).
5. Slowly operate the swing control lever and grad-
ually increase the engine speed to full speed to
ensure that the swing is locked.
6. Shut down the engine.
7. Press the breather to release pressure in the
hydraulic reservoir.

8001-28
CD00E192
8. Disconnect the hydraulic motor drain hose and
plug it.
9. Use a hose to connect the drain port to the
receptacle.
10. Start the engine at full speed in mode "S". Oper-
ate the swing control to the right or left and
measure the quantity of oil that leaves the drain
during 1 min.
11. Since the quantity of oil can vary depending on
the test point used, repeat the measurement
(Step 10) with the upperstructure at 90°, then at
180°.

8001-29
TROUBLESHOOTING
Travel drift
(Pressures P1 and P2 correct)
No. Tests Results Repairs

With the tracks lifted, check the Difference in speed between the two
1 Check travel motor leaks (No. 4)
rotating speed at the sprockets sprockets
Check pressures P1 and P2 during The pressure difference between P1 Check the negative pressure (N) of
2
travel and P2 is greater than 30 bar (3 MPa) the pump (No. 3)
Check the main valve:
Adjust or change
Pressure greater than 6 bar
(0.6 MPa) Check the pump regulator or body
which is at fault:
Adjust or change
Check the travel spool pilot pressure
Check the negative pressure (N) of
3 on the side which is at fault
the pump
Pressure below 30 bar (3 MPa):
Check the operation of the control
Pressure below 6 bar (0.6 MPa)
pedal spool, replace or repair
Pressure greater than 30 bar (3 MPa):
Check the travel spool (sticking,
scratched ...)
Greater than the permitted value Replace or repair the travel motor
Check the travel pressure without
load (with track raised)
Normal pressure:
Change the central seal
4 Check the travel motors for leaks
Lower than the permitted value Higher than normal pressure:
Drain the reduction gear and check if
there is any contamination (metal
particles).
Replace or repair the travel reduction
gear

8001-30
Not possible to select 2nd travel speed

Press the travel speed control and
Refer to troubleshooting electrical
1 check that the speed changes from I Speed II is not displayed
failures
to II on the console screen
Check pressures P1 and P2 on
diagnostic screen "CHK1" when the
machine is travelling
Check on diagnostic screen "CHK2" if
1) Both pressures are less than
2 the information changes to "ON" Information stays on "OFF"
40 bar: refer to troubleshooting
when the machine is travelling
electrical failures
2) Both pressures are higher than
40 bar: refer to point No. 3
Check the negative pressure (N) of
3 Too high Adjust the pressure
the pump
Check electrical supply and the
Pressure too low
solenoid valve coil (No. 5 and 6)
Check the pilot pressure at the output
4 Check the pilot pressure at the travel
from solenoid valve (C1)
Pressure correct (39 bar - 3.9 MPa) motor displacement change spool
(No. 7)
Check the voltage at the electrical
5 plug on the displacement change Voltage < 24 V Check the electrical harness
solenoid valve
Check the displacement change Infinite or 0 Ohm Change the solenoid valve
6
solenoid valve coil About 40 Ohm Change the solenoid valve coil
Internal leak at hydraulic swivel,
Pressure too low
repair or change the hydraulic swivel
Check the pilot pressure at the travel
7 Check the travel motor displacement
motor displacement change spool
Pressure correct (39 bar - 3.9 MPa) change spool.
Repair or change the travel motor

8001-31
No swing or slow swing

(No problems with other functions)

Adjust or change the secondary relief
1 Check the swing pressure Pressure too low
valves
Reconnect the solenoid valve and
check the swing brake release
Disconnect the swing brake solenoid No swing or slow swing
pressure at the output from the
2 valve (pink connector) and operate solenoid valve (No. 3)
the swing
Check the solenoid valve supply
The swing operates normally
electrical circuit
Check or change the swing brake
With the engine running and the Pressure below 30 bar
solenoid valve
3 swing brake deactivated, check the
swing brake release pressure Check the swing motor for leaks
Pressure greater than 30 bar
(No. 5)
Check or change the swing
Disconnect the swing cancellation No swing or slow swing
cancellation solenoid valve
4 solenoid valve (green connector) and
operate the swing Check the solenoid valve supply
The swing operates normally
electrical circuit
With the engine at full speed, and Greater than the permitted value Change or repair the swing motor
5 hydraulic oil at 50°C, check for leaks Check the swing brake, repair or
on the swing motor during the swing Lower than the permitted value
change
With the excavator on a slope, the swing brake does not hold
Incident on the brake, repair or
1 Check the swing braking system Abrasion
change
Adjust or change the secondary relief
2 Check the swing pressure Pressure too low
valves
With the engine at full speed, and
3 hydraulic oil at 50°C, check for leaks Greater than the permitted value Change or repair the swing motor
on the swing motor during the swing
Check the swing brake pilot pressure Pressure greater than 1 bar Check electrical supply and the
4
at the solenoid valve output (0.1 MPa) solenoid valve coil (No. 5 and 6)
5 plug on the swing brake pilot solenoid Voltage < 24 V Check the electrical harness
valve
Infinite or 0 Ohm Change the solenoid valve
6 Check the pilot solenoid valve coil
About 40 Ohm Change the solenoid valve coil

8001-32
No movement on any function

(Control cancellation lever in the low position)

1 Check the hydraulic oil level Lack of hydraulic oil Top up as required
Adjust the pilot circuit secondary relief
2 Check the pilot pressure at M3 Pressure below 30 bar (3.0 MPa)
valve, change it if necessary
Check the pilot pressure at outlet port Check electrical supply and the
3 Pressure below 30 bar (3.0 MPa)
B on the 6 solenoid valve block solenoid valve coil (No. 4 and 5)
Check the electrical supply and
mechanical adjustment of the controls
Check the voltage at the pilot
4 Voltage < 24 V cancellation contact switch.
solenoid valve connector (blue)
Check the harness between the
contact switch and the solenoid valve
Infinite or 0 Ohm Change the solenoid valve
5 Check the pilot solenoid valve coil
About 40 Ohm Change the solenoid valve coil
Lack of power or speed on one of the attachment movements

(No problems with other movements)

Incident on the secondary relief valve
1 Check the P1 or P2 pressure Pressure too low of the faulty movement, adjust or
change
With the engine at full speed (in mode
"H"), and the hydraulic oil at 50°C, Lower than the specifications. Leak at the non-return check valve,
2
check the speed of the movement See section 1002 adjust or change
concerned
With a load on the end of the
Leak at attachment cylinders, change
attachment and 1 m above the Greater than the specifications.
3 the piston seals or change the
ground, check the retracting and See section 1002
cylinder
extending of the cylinder rods
Manually check the movement of the
Spool stuck or scratched, spring
4 pilot spool in the control valve for the Difficult to move
broken
faulty movement
Check the pilot pressure of the control Check the operation of the control
5 Pressure below 30 bar
valve spool lever spool, change or repair

8001-33
Not possible to select hard/soft shock absorbing system

Check on diagnostic screen "CHK3" if Check the signal at the electronic box
information displayed changes to input:
1 Information stays on "OFF"
"ON" when shock absorption is Below 5 volts: change the control box
selected/deselected 5 volts: change the electronic box
Check the electrical supply and the
Check the pilot pressure at the hard/ Pressure too low
solenoid valve coil (No. 3 and 4)
2 soft shock absorption solenoid valve
(Y6) Repair or change the hard/soft shock
Pressure correct (39 bar - 3.9 MPa)
absorption valve
3 plug on the hard/soft shock Voltage < 24 V Check the electrical harness
absorption solenoid valve
Check the hard/soft shock absorption Infinite or 0 Ohm Change the solenoid valve
4
solenoid valve coil About 40 Ohm Change the solenoid valve coil
The boom or the dipper does not lower

(No problems with other movements)

Manually check the movement of the
1 Difficult to move Spool stuck or spring broken
pilot spool
Repair or change the load holding
2 Check the load holding operation Sticking
valve
Check the pilot pressure at the control Check the operation of the control
3 Pressure below 30 bar
valve spool lever spool, change or repair

8001-34

8002
Section
8002

OF THE HYDRAULIC RESERVOIR

Printed in France
8002-2
TABLE OF CONTENTS
SPECIFICATIONS .................................................................................................................................................. 2
HYDRAULIC RESERVOIR ..................................................................................................................................... 3
Removal .............................................................................................................................................................. 3
Installation ........................................................................................................................................................... 4
Description .......................................................................................................................................................... 5
SPECIFICATIONS
See Section 1002

8002-3
HYDRAULIC RESERVOIR
Removal
STEP 1 STEP 8
on top of the control valve.
STEP 9
Loosen the two screws (9) located under the
machine. Open the side door on the right of the
machine and remove the two screws (10). Remove
the screw (10) located on the right of the fuel
reservoir. Remove the protective plate of the
reservoir (11).
STEP 10
JS00163A Loosen the circlips (12) and disconnect the suction
Park the machine on hard, flat ground. Lower the hoses (13) under the hydraulic reservoir.
STEP 11
STEP 2
Attach identification tags to the output hoses.
Release pressure in the hydraulic system and in the Disconnect the hoses.
STEP 12
STEP 3
Remove the screws (14) and the retaining shims
Attach a "DO NOT OPERATE" tag to the ignition key (15).
in the cab.
STEP 13
STEP 4
Using a hoist, remove the hydraulic reservoir (1) from
NOTE: The numbers within brackets refer to the the machine.
figures on pages 5 and 6.
Remove the screws and the access panels under the
hydraulic reservoir (1).
STEP 5
Using a container of sufficient capacity, empty the
hydraulic reservoir (1) using the valve (2) and remove
the latter.
STEP 6
Remove the screws (4) on top and then inside the
front boot, then remove the protective housing (3).
STEP 7
on top of the hydraulic reservoir (1).

8002-4
Installation
STEP 1
NOTE: The numbers within brackets refer to the
figures on pages 5 and 6.
Using a hoist, position the hydraulic reservoir (1) on
the machine.
STEP 2
Install the screws (14) and the retaining shims (15) to
hold the hydraulic reservoir (1) to the machine
undercarriage, tighten the screws to a torque, see the
specifications. Install the oil change valve (2).
STEP 3
Connect the suction hose (13) using two circlips (12).
Tighten the nut.
STEP 4
Connect the output hoses taking help of the tags
installed during removal.
STEP 5
Install the reservoir protective plate (11) using screws
(9) and (10).
STEP 6
Install the protective plate (6) under the hydraulic
reservoir using retaining screws (5).
STEP 7
Install the protective plate (8) under the control valve
using screws (7).
STEP 8
Install the protective housing (3) using screws (4),
then install the screw mask inside the front boot.
STEP 9
Fill the hydraulic reservoir, see the section "Filling the
reservoir" in the operator’s manual and check for
leaks.
STEP 10
Start the engine. Pressurise the hydraulic reservoir
then stop the engine. Check again for leaks.
STEP 11
Install the protective plate under the machine using
screws and flat washers.

8002-5
Description
Location
10
10
4
11 9
CS00F539
6 5 4 3
CS00F540
3 PROTECTIVE HOUSING
4 SCREW
5 SCREW
6 HYDRAULIC RESERVOIR PROTECTIVE PLATE
7 SCREW
8 CONTROL VALVE PROTECTIVE PLATE
9 SCREW
10 SCREW
11 RESERVOIR PROTECTIVE PLATE

8002-6
Hydraulic reservoir
13
12
2
15
14
CI00F507
1 HYDRAULIC RESERVOIR 13 HOSE
2 VALVE 14 SCREW
12 CIRCLIP 15 SHIM

Section
8003
8003
REMOVAL AND INSTALLATION OF THE MAIN
HYDRAULIC PUMP AND THE PILOT PUMP

Printed in France
8003-2
TABLE OF CONTENTS
SPECIFICATIONS ................................................................................................................................................... 3
SPECIAL TORQUE SETTINGS .............................................................................................................................. 3
MAIN HYDRAULIC PUMP ...................................................................................................................................... 4
PILOT PUMP ........................................................................................................................................................... 9
HYDRAULIC PUMP COUPLING ........................................................................................................................... 10
Description ........................................................................................................................................................ 10
Removal and installation ................................................................................................................................... 11

8003-3
SPECIFICATIONS
Filling capacity of the hydraulic reservoir........................................................................................See Section 1002
Total capacity of the hydraulic system ............................................................................................See Section 1002
Hydraulic oil ....................................................................................................................................See Section 1002
Weight ............................................................................................................................................See Section 1002

Screw for fixing the hydraulic pump flange to the engine hand-wheel crankcase ..........................See Section 1002
Screw for fixing the hydraulic reservoir cover....................................................................................... 2.9 to 4.9 Nm
Nuts for tightening the silencer retaining collars .............................................................................................. 39 Nm
Screw for fixing the silencer bracket to the motor................................................................................... 64 to 74 Nm
Dowel blocks retaining screw ............................................................................................................. 205 to 225 Nm
Splined sleeve locking screw.................................................................................................................. 96 to 98 Nm

8003-4
MAIN HYDRAULIC PUMP

STEP 1
JS00163A
STEP 2 6003-011
Remove the access panel (1) retaining screws from
Release pressure in the hydraulic system and underneath the hydraulic reservoir, then remove the
release pressure in the hydraulic reservoir (see panel.
section 8000).
STEP 5
STEP 3
Place a container of 200 litres capacity under the oil
change valve of the hydraulic reservoir. Empty the
hydraulic fluid and close the valve.
STEP 6
1
CD00F091
Disconnect the earth cable (1) from the battery.
CD00F099
Unlock the two engine hood locking latches (1) and
raise the hood to the raised, locked position.
STEP 7
Attach suitable lifting slings to the hood.

8003-5
STEP 8 STEP 12
1 1
2 1
CD00F100 CD00F102
Remove the retaining hardware (1) from the retaining Remove the six retaining screws (1) from the hinges
bar (2) and remove the retaining bar. (2).
STEP 9 STEP 13
Lift the hood using the hoist, then move it away from
the machine.
STEP 14
2
1 1
1
CD00F101
Remove the split pin (1) and the flat washer (2) from 2
the engine hood safety side support bracket.
STEP 10
CD00F103
Remove the engine hood safety side support bracket. Remove the six retaining screws (1) from the metal
Lower the hood. plate (2), then remove the metal plate (2).
NOTE: Have an assistant help you with this step.
STEP 11
Attach the lifting slings to the hoist.

8003-6
STEP 15 STEP 18
3 4
4 3
2
1
CD00F104 CD00F107
Remove the two retaining screws (3) from the metal Remove the engine stop control cable (1) from the
plate (4). cable grommet (2). Remove the retaining screw (4)
from the metal plate (3), then remove the metal plate.
STEP 16
STEP 19
1 1
CD00F105
Remove the four retaining screws (1) from the grille CD00F108
(2), then remove the grille. Loosen the circlip (1) fastening the silencer pipe to
the turbocompressor.
STEP 17
NOTE: Let the engine and the exhaust system cool
before trying to remove the silencer.
1 2
CD00F106
Loosen the nut (1) from its bracket, free the cable (2)
from the engine stop control lever (3).

8003-7
torque specified on page 3.
STEP 23
CD00F110
Remove the four retaining nuts from the silencer
circlips, then remove the two circlips (1).
CD00F113
NOTE: When installing, tighten the nuts to the torque To aid proper installation, attach identification tags to
specified on page 3. all hoses and electrical connections of the main
hydraulic pump and the pilot pump.
STEP 21
STEP 24
Remove the pipes, the hydraulic hoses and the
electrical connections. Seal all hoses and union of
the main pump as well as those of the pilot pump.
STEP 25
Install suitable lifting apparatus on the lifting eyes of
the hydraulic pump. Do not leave any slack so that
the pump can be supported when the coupling
screws are removed.
STEP 26
CD00F111 Remove the screws that fasten the hydraulic pump
Remove the silencer assembly from the machine. flange to the engine hand-wheel housing.
STEP 27
1 Remove the hydraulic pump from the motor and put it
away from the machine. Place the hydraulic pump on
a clean workbench using suitable brackets.
NOTE: Carry out the following step only if a new
hydraulic pump needs to be installed.
CD00F112
Remove the three screws (1) and the retaining
washers from the silencer bracket, then remove the
silencer bracket.

8003-8
STEP 28 NOTE: Always drain the air out from the hydraulic
pump before starting the engine. If the air has not
Remove the connections of the hydraulic pump that been drained out, the pump can get damaged.
has just been removed and install them on the new
hydraulic pump. Remove and install the connections NOTE: Before working with the machine, operate the
one after another to avoid improper installation of the swing, travel and attachment for five minutes with the
connections on the new hydraulic pump. engine at idle. Check that there are no leaks in the
system, check the level of oil in the hydraulic
NOTE: For installing the hydraulic pump, proceed in reservoir, top up if necessary. Adjust the hydraulic
the reverse order to that of removal. Replace all rings pump, refer to section 8001.
with new rings.
STEP 29
CD00F176
Remove the four screws and washers (1). Remove
the cover (2) and the O-ring from on top of the
hydraulic reservoir. Scrap the O-ring. Fill the
hydraulic reservoir with hydraulic fluid (see section
1002) up to a level in between the "high" and "low"
marks on the visual gauge. Install the cover with a
new O-ring, fasten it using four screws and washers
(1), tighten the screws to the torque specified on
page 3.
STEP 30
CD00F091
Connect the earth (-) cable (1) of the battery.

8003-9
PILOT PUMP
STEP 1 Shut off the vacuum pump.
Refer to the removal of the hydraulic pump in this NOTE: When installing, proceed in the reverse order
section and carry out steps 1 to 3. to that of removal. Replace the O-rings with new
O-rings.
STEP 2
STEP 6
To prevent any fluid leaks when disconnecting
hydraulic hoses, connect a vacuum pump to the Remove the air bleed plug located on top of the pilot
hydraulic reservoir (see section 8000). Start the pump. Fill the pump with clean hydraulic fluid. Install
vacuum pump. the air bleed plug.
STEP 3 NOTE: Before working with the machine, operate the

swing, travel and attachment for five minutes with the
1 engine at idle. Check that there are no leaks in the
system, check the oil level in the hydraulic reservoir.
Top up if necessary. Adjust the hydraulic pump, refer
to section 8001.
CD00F114
Place a 10-litre container below the hydraulic pump
to recover any oil that might escape from one of the
hoses when it is disconnected or from the pilot pump
when the latter is removed. Label and disconnect the
hoses from the pilot pump (1), seal the hoses and
unions.
STEP 4
Remove the four retaining screws (and the flat
washers) from the pilot pump, then remove the pilot
pump.

8003-10
HYDRAULIC PUMP COUPLING

Description
1 5
2
6
3
7
4
9
11
10
CS00M509
1 SCREW 6 ELASTIC COUPLING
2 ROLL PIN 7 SPLINED SLEEVE
3 LOCKING SCREW 8 ENGINE HAND-WHEEL
4 HYDRAULIC PUMP SHAFT 9 HYDRAULIC PUMP
5 DOWEL BLOCK 10 FLANGE
11 SCREW

8003-11

NOTE: The numbers in brackets refer to the Remove the screws (1), then remove the dowel
specification on page 10. blocks (5). Visually check the state of the dowel
blocks for wear, replace them if necessary.
STEP 1
NOTE: If wear of the elastic coupling and dowel
Refer to the removal of the hydraulic pump in this blocks requires them to be replaced, replace the
section and remove the hydraulic pump. splined sleeve as well. When installing, apply
STEP 2 Loctite 262 on the threads of the dowel block
retaining screws, position the dowel blocks correctly
Remove the two locking screws (3), remove the and tighten to the torque specified on page 3.
splined sleeve (7) from the hydraulic pump shaft (4).
STEP 5
NOTE: When installing, replace the splined sleeve if
necessary. Install the splined sleeve on the pump Remove the four roll pins from the engine hand-
shaft. The splined sleeve should be stopped against wheel, when installing, replace them if necessary.
the pump shaft shoulder. The depth between the face NOTE: When installing the hydraulic pump coupling,
of the end of shaft and the outer face of the splined proceed in the reverse order to that of removal.
sleeve should be 6±3 mm (see illustration below).
6+-3 mm
CS00M510
Apply Loctite 262 on the threads and tighten the
locking screws (3) of the splined sleeve to the torque
specified on page 3.
STEP 3
Remove the elastic coupling (6), check visually the
elastic coupling for wear, replace if necessary.

8003-12

Section
8004
8004
OF THE MAIN HYDRAULIC CONTROL VALVE

Printed in France
8004-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 2
MAIN HYDRAULIC CONTROL VALVE.................................................................................................................... 3

SPECIFICATIONS
Weight of control valve ................................................................................................................... See Section 1002

Retaining screws for central frame and upper access panel................................................................. 88 to 107 Nm
Control valve mounting on upperstructure frame ........................................................................... See Section 1002

8004-3
MAIN HYDRAULIC CONTROL VALVE

STEP 1
CD00F092
Remove the retaining screws for the upper access
JS00163A panel (1) and remove the panel.
attachment to the ground. NOTE: When installing, tighten the screws to a
torque of between 88 and 107 Nm (apply Loctite 262
STEP 2 to the threads).
Release pressure in the hydraulic system and in the STEP 6
STEP 3
1
1
CD00F093
Remove the central frame (1) retaining screws and
remove the central frame.
CD00F091
Disconnect the earth cable (1) (-) from the battery. NOTE: When installing, tighten the screws to a
STEP 4 to the threads).
Connect a vacuum pump to the hydraulic reservoir to
prevent any fluid leaks when disconnecting hydraulic
lines (see Section 8000).

8004-4
STEP 7 STEP 11
2
CD00F116 CD00G180
Remove the screws (1) then remove the flange (2). Attach identification labels to all the control valve
hoses, pipes and electric wires. Disconnect and plug
STEP 8 the hoses and pipes. Plug the control valve orifices.
Start the vacuum pump. Disconnect the electrical connections.
STEP 9 STEP 12
STEP 13
Install lifting rings in the threaded orifices on the top
of the control valve.
2 STEP 14
1
Connect a suitable lifting device to the control valve.
See Section 1002 for the weight of the control valve.
CD00G182
Remove the two hose clips (1) from the hose (2) and
remove the hose from the manifold.
STEP 10
1
2
CD00G181
Remove the four retaining screws (1) from the flange (2).

8004-5
STEP 15 STEP 17
Remove the unions and manifolds from the control
valve which has just been removed and mount them
on the new control valve. Remove and install the
unions and manifolds one after another to make sure
that they are correctly installed on the new control
valve.
NOTE: For the installation, follow the same
procedure in the reverse order. Replace all seals with
new seals.
NOTE: Before carrying out any work with the
machine, operate the swing, travel and the
attachment for five minutes with the engine at idle
speed. Check that there are no leaks in the system,
check the oil level in the hydraulic reservoir. Top up if
necessary. Adjust the valves in the control valve (see
Section 8001).
1
CS00E521
Remove the retaining screws (1) and washers from
the control valve.
NOTE: When installing, tighten the screws to the
STEP 16
Carefully raise and guide the control valve out of the
upperstructure frame. Move all the hoses and pipes
out of the way. Remove the control valve from the
machine and place it on suitable stands.
NOTE: The following step is to be performed only if
the control valve has to be changed.

8004-6

Section
8005

OF THE ATTACHMENT CYLINDERS
8005

Printed in France
8005-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 2
PREPARATION BEFORE REMOVAL/INSTALLATION........................................................................................... 2
BOOM CYLINDER ................................................................................................................................................... 3

Description ........................................................................................................................................................... 3
Removal ............................................................................................................................................................... 4
Installation ............................................................................................................................................................ 6
DIPPER CYLINDER ................................................................................................................................................. 9

Description ........................................................................................................................................................... 9
Removal ............................................................................................................................................................. 10
Installation .......................................................................................................................................................... 12
BUCKET CYLINDER.............................................................................................................................................. 16
Description ......................................................................................................................................................... 16
Removal ............................................................................................................................................................. 17
Installation .......................................................................................................................................................... 18
SPECIFICATIONS
See Section 1002
PREPARATION BEFORE REMOVAL/INSTALLATION

- Completely retract the bucket and dipper cylinder rods and lower the attachment to the ground.
- Release pressure in the hydraulic system and install a vacuum pump on the hydraulic reservoir (see Section 8000).

8005-3
BOOM CYLINDER
Description
2
4 1
3
6
10
1
6
10
9
5 8
11
7
2
4
3
JS00593
1 LUBRICATING HOSE 7 NUT
2 NUT 8 SCREW
3 SCREW 9 PIN
4 LOCKING BUSHING 10 BOOM CYLINDER
5 SHIM 11 PIN
6 HYDRAULIC HOSE

8005-4
Removal STEP 3
NOTE: The number sin brackets in the following 3 3
steps refer to the boom cylinder schematic on page
11
3.
STEP 1
5
4
1 2
JS00579A
Remove the nuts (2) from the screws (3). Remove
the screws from the pin (11) and the locking bushings
(4). Push the pin far enough to prevent it interfering
with the removal of the boom cylinder. Remove the
shims (5) and the locking bushings.
JS00577A
Disconnect the lubrication hose (1) from the boom STEP 4
cylinder.
NOTE: Lift the cylinder carefully. The cylinder is
heavy, the weight should be carefully distributed on
the slings when lifting.
STEP 2
JS00580A
Place a stand (A) at the front of the boom cylinder.
Place the front of the boom cylinder on the stand.
STEP 5
JS00578A
Attach a suitable lifting device to the boom cylinder.
Take up all the slack to ensure the boom cylinder is
fully supported before starting to remove the boom
cylinder.
B
JS00581A
Attach a strap (B) to hold the cylinder rod to the
cylinder barrel.

8005-5
STEP 6 STEP 10
Start the vacuum pump. 7
8
STEP 7
9
6 A C
JS00583A
Remove the nuts (7) from the screw (8). Remove the
screw from the pin (9). Install a suitable screw (C) in
JS00582A
the threaded orifice in the pin. Use a suitable sliding
Disconnect the hydraulic supply hoses (6) from the hammer fastened to the screw to remove the pin.
boom cylinder. Unscrew the screw from the pin.
STEP 8 STEP 11
(Only if the machine is equipped with cylinder
safety valves)
JS00584A
Carefully raise the boom cylinder and move it away
from the machine. Place the boom cylinder on
suitable stands. Remove the strap which was holding
CS00G501
Disconnect the safety valve piloting hydraulic hoses the cylinder rod to the cylinder barrel.
and disconnect the harness from the pressure
detector.
STEP 9
Plug the hoses with plugs and the unions with caps.

8005-6
STEP 12 STEP 2
(Only if the machine is equipped with cylinder (Only if the machine is equipped with cylinder
safety valves) safety valves)
E E
D D
A B C A B C
CS00G502 CS00G502
Disconnect the pipe (A) from the safety valve (B). Install a new O-ring (E) on the boom cylinder and
Remove the screws (C), the base (D) and the safety install the safety valve (B) and the base (D) with the
valve (B) from the boom cylinder. Scrap the O-ring (E). screws (C). Connect the pipe (A).
STEP 13 NOTE: Carefully raise the cylinder. The cylinder is
heavy, the weight must be carefully distributed over
Repeat steps 1 to 13 to remove the other cylinder. the slings during lifting.
Installation STEP 3
STEP 1
JS00587A
Using a suitable lifting device, raise the boom
JS00586A
cylinder. Align the boom cylinder with the chassis
Attach a suitable strap (B) to the boom cylinder to
mounting brackets. Place a suitable stand under the
hold the cylinder rod to the cylinder barrel.
boom cylinder to support it.

8005-7
STEP 4 STEP 6
7 (Only if the machine is equipped with cylinder
8 safety valves)
9
A C
JS00588A
Install the pin (9) and the screw (8). Using a feeler
gauge, check that there is a clearance of 1 to 2.5 mm
between the mounting bracket and the cylinder barrel CS00G501
mounting eye. If necessary, remove the screw and Connect the hydraulic piloting hoses to the safety
the pin and add one or more shims as required to valve and connect the harness to the pressure
obtain the correct clearance. Install the pin and the detector. Stop the vacuum pump. Remove the strap
screw. Install the first nut (7) on the screw and tighten which is holding the cylinder rod to the cylinder barrel.
until the nut touches the mounting bracket boss.
Loosen the nut a quarter turn and, using two STEP 7
wrenches, install the second nut (7) to lock the first
one in position.
STEP 5
JS00590A
Raise the boom cylinder and align the cylinder rod
end with the boom mounting orifice.
STEP 8
JS00589A
Start the vacuum pump. Remove the plugs from the Repeat steps 1 to 7 to install the second boom cylinder.
hydraulic hoses (6) and the caps from the unions.
Connect the two hydraulic supply hoses to the boom
cylinder.

8005-8
STEP 9 STEP 11
11
JS00591A JS00656A
Install the pin (11) and the shims (5). Connect the lubricating hoses (1) to the boom
cylinders.
STEP 10
STEP 12
3
Remove the vacuum pump and bleed air from the
boom cylinders (see Section 8000).
STEP 13
Check the level of hydraulic fluid in the reservoir. Top
4 up as necessary.
STEP 14
2 Lubricate the linkages.
JS00592A
Install the locking bushings (4). Install the screws (3)
through the locking bushings and the pin. Using a set
of feeler gauges, check that there is a clearance of 1
to 2.5 mm between the mounting bracket and the
cylinder rod mounting eye. If necessary, remove the
screws and the pin and add or remove one or more
shim(s) as required to obtain the correct clearance.
Install the pin and the screws. Install the first nut (2)
on the screw and tighten until the nut touches the
locking bushing. Loosen the nut a quarter of a turn
and, using two wrenches, install the second nut (2) to
lock the first nut in position. Remove the sling from
the boom cylinder.

8005-9
DIPPER CYLINDER
Description
4 5
8
10
7
3 10
6
2
1
JS00603A
1 NUT 6 NUT
2 SCREW 7 SCREW
3 PIN 8 PIN
4 HYDRAULIC HOSE 9 DIPPER CYLINDER
5 LUBRICATION HOSE 10 SHIM

8005-10
Removal STEP 4
NOTE: The numbers in brackets in the following steps
refer to the dipper cylinder schematic on page 9.
STEP 1
B
A
JS00586A
9 Attach a suitable strap (B) to hold the cylinder rod to
the cylinder barrel.
STEP 5
JS00594A
Place a wooden block (A) under the dipper cylinder (9). Start the vacuum pump.
STEP 2 STEP 6
JS00595A JS00598A
Remove the nuts (1) and the screw (2) at the cylinder Disconnect both hydraulic supply hoses (4) from the
rod end. dipper cylinder.
STEP 3
JS00596A
Carefully remove the pin (3).

8005-11
STEP 7 STEP 10
(Only if the machine is equipped with cylinder A
safety valves)
JS00600A
Attach a suitable lifting device to the dipper cylinder.
Take up all the slack in the lifting equipment so as to
CS00G503
support the dipper cylinder before starting to remove it.
Disconnect the hydraulic piloting hoses from the
cylinder safety valve.
STEP 11
STEP 8
Plug the hydraulic hoses with plugs and the unions
with caps. Stop the vacuum pump.
STEP 9
5 8
7
6
JS00601A
Remove the nuts (6) and the screw (7) from the pin
(8) at the cylinder barrel end and carefully remove the
pin (8).
JS00599A
Disconnect the lubrication hose (5) from the dipper
cylinder.
NOTE: Raise the cylinder carefully, the cylinder is
heavy and the weight must be carefully distributed
over the slings when lifting.

8005-12
STEP 12 STEP 14
10 (Only if the machine is equipped with cylinder
safety valves)
A B
C
JS00602A E
Carefully raise the dipper cylinder and move it away
from the dipper. Remove the shims (10). Place the D
dipper cylinder on suitable stands. CS00G504
Disconnect the pipe (A) from the cylinder safety valve
STEP 13 (B). Remove the screws (C), the base (D) and the
cylinder safety valve (B) from the dipper cylinder.
Scrap the O-ring (E).
Installation
B STEP 1
JS00586A
Remove the strap (B) which holds the cylinder rod to
the cylinder barrel.
JS00586A
Attach a suitable strap (B) to the dipper cylinder to
hold the cylinder rod to the cylinder barrel.

8005-13
STEP 2 STEP 4
safety valves)
A B 8
7
6
C
E JS00601A
Install the pin (8) and fasten the pin with the screw
D (7). Using a set of feeler gauges, check that there is a
CS00G504
clearance of 0.5 to 3 mm between the mounting
Install a new O-ring (E) on the dipper cylinder and bracket and the cylinder barrel mounting eye. If
install the cylinder safety valve (B) and the base (D) necessary, remove the screw and the pin and add or
with the screws (C). Connect the pipe (A). remove one or more shims (10) as required to obtain
the correct clearance. Install the pin and the screw.
NOTE: Carefully raise the cylinder. The cylinder is Install the first nut (6) on the screw and tighten until
heavy and the weight must be carefully distributed the nut touches the bracket boss. Loosen the nut a
over the slings when lifting. quarter of a turn and, using two wrenches, install the
STEP 3 second nut (6) to lock the first nut in position.
10 STEP 5
JS00602A
Attach a suitable lifting device to the dipper cylinder,
JS00604A
lift the dipper cylinder and bring it into position. Align
Connect the lubrication hose (5) to the dipper
the dipper cylinder mounting orifices with the boom
cylinder.
brackets and install the shims (10).

8005-14
STEP 6 STEP 8
4
B
JS00605A JS00586A
Start the vacuum pump. Remove the plugs from the Remove the sling (B) which holds the cylinder rod to
hydraulic hoses (4) and the caps from the unions. the cylinder barrel.
Connect the hydraulic supply hoses to the dipper
cylinder. STEP 9
STEP 7
safety valves)
JS00606A
Align the dipper cylinder mounting orifices with the
dipper orifices.
CS00G503
Connect the hydraulic piloting hoses on the cylinder
safety valve. Stop the vacuum pump.

8005-15
STEP 10
3 2
JS00607A
Install the pin (3) and the screw (2). Using a set of
feeler gauges, check that there is a clearance of 0.5
to 3 mm between the mounting bracket and the
cylinder rod mounting eye. If necessary, remove the
screw and the pin and add one or more shims as
required to obtain the correct clearance. Install the
pin and the screw. Install the first nut (1) on the screw
and tighten until the nut touches the boss. Loosen the
nut a quarter of a turn and, using two wrenches,
install the second nut (1) to lock the first nut in
position. Remove the sling from the dipper cylinder.
STEP 11
Remove the vacuum pump and bleed the air from the
dipper cylinder (see Section 8000).
STEP 12
Check the level of hydraulic fluid in the reservoir. Top
up as required.
STEP 13
Lubricate the linkages.

8005-16
BUCKET CYLINDER
Description
9
10
3
4 8
9
11
5
6
4
11
1
CS00F534
1 NUT 7 SCREW
2 SCREW 8 PIN
3 PIN 9 SHIM
4 SHIM 10 BUCKET CYLINDER
5 HYDRAULIC HOSE 11 CONNECTING ROD
6 NUT

8005-17
Removal STEP 3
NOTE: The numbers in brackets in the following steps 2
refer to the bucket cylinder schematic on page 16.
STEP 1 1
11
JS00609A
Remove the nuts (1) from the screw (2) and remove
10
the screw from the connecting rod (11).
STEP 4
JS00597A
Place a wooden block (A) under the bucket cylinder
(10).
NOTE: Carefully raise the cylinder. The cylinder is 3
heavy and its weight must be distributed over the
slings when lifting.
STEP 2
JS00610A
Carefully remove the pin (3).
STEP 5
B
JS00608A
Attach a suitable lifting device to the bucket cylinder.
Take up any slack so that the cylinder is fully
supported when removed.
4
JS00611A
Lift the bucket cylinder, at the same time moving it
away from the connecting rods. Attach a suitable
sling (B) to the bucket cylinder to hold the cylinder rod
onto the cylinder barrel. Remove the shims (4).
NOTE: Remove the wooden block once the bucket
cylinder is lifted.

8005-18
STEP 6 STEP 9
JS00612A JS00586A
Start the vacuum pump. Disconnect the two hydraulic Remove the sling (B) which was holding the cylinder
hoses (5) from the bucket cylinder. Plug the hydraulic rod onto the cylinder barrel.
hoses with plugs and the unions with caps. Stop the
vacuum pump. Installation
STEP 7 STEP 1
7
8 B
JS00613A JS00586A
Remove the nuts (6) and the screw (7). Remove the Attach a suitable strap (B) to the bucket cylinder to
dipper pin (8). hold the cylinder rod onto the cylinder barrel.
STEP 8 NOTE: Carefully raise the cylinder. The cylinder is

heavy and its weight must be distributed over the
9 slings when lifting.
STEP 2
9
B
JS00614A
Carefully raise the bucket cylinder and move it away
from the dipper. Remove the shims (9). Place the
bucket cylinder on suitable stands.
JS00614A
Install the bucket cylinder on the dipper and install
the shims (9).

8005-19
STEP 3 STEP 5
8
7
6 B
JS00616A JS00586A
With the cylinder and the shims in position, install the Remove the sling (B) which was holding the cylinder
pin (8) and the screw (7). Using a set of feeler rod onto the cylinder barrel.
gauges, check that there is a clearance of 0.5 to
3 mm between the mounting bracket and the cylinder STEP 6
barrel. If necessary, remove the screw and the pin
and add or remove one or more shims (9) as required
to obtain the correct clearance. Install the pin and the
screw. Install the first nut (6) on the screw and tighten 10
until the nut touches the boss. Unscrew a quarter of a
turn and, using two wrenches, install the second nut
to lock the first nut in position.
STEP 4
11
5
JS00618A
Raise the bucket cylinder (10) to align the cylinder
rod and the connecting rods (11). Install the shims
(4).
JS00617A
Start the vacuum pump. Remove the plugs from the
hydraulic hoses (5) and the caps from the unions.
Connect the hydraulic hoses to the unions on the
bucket cylinder. Stop the vacuum pump.

8005-20
STEP 7
2
3
4
JS00619A
Install the pin (3) and the screw (2). Using a set of
feeler gauges, check that there is a clearance of 1 to
2 mm between the connecting rod and the mounting
eye on the cylinder rod. If necessary, remove the
screw and the pin and add or remove one or more
shims as required to obtain the correct clearance.
Install the pin and the screw. Install the first nut (4) on
the screw and tighten until the nut touches the boss.
Loosen the nut a quarter of a turn and, using two
wrenches, install the second nut (4) to lock the first
nut in position.
STEP 8
Remove the vacuum pump and bleed the air from the
bucket cylinder (see Section 8000).
STEP 9
Check the level of hydraulic fluid in the hydraulic
reservoir. Top up as required.
STEP 10
Lubricate the linkages.

Section
8006

OF THE HYDRAULIC SWIVEL
8006

Printed in France
8006-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 2
HYDRAULIC SWIVEL .............................................................................................................................................. 3
SPECIFICATIONS
Weight ............................................................................................................................................ See Section 1002

Capscrews for retaining locking bar ............................................................................................... See Section 1002
Capscrews for retaining hydraulic swivel outer sleeve on upperstructure...................................... See Section 1002

8006-3
HYDRAULIC SWIVEL
STEP 1
JS00163A
Park the machine on flat, hard ground. Lower the
attachment to the floor.
STEP 2 CI00F500
Remove the retaining hardware (1) from the lower
Release pressure in the hydraulic system and plates (2) then remove the plates.
release pressure in the hydraulic reservoir (see
Section 8000).
STEP 3
Disconnect the earth cable from the battery.
STEP 4
To prevent any fluid loss when disconnecting hydraulic
lines, connect a vacuum pump to the reservoir (see
Section 8000).

8006-4
STEP 6 STEP 11
3
2
CD00F058 CD00F060
Remove the retaining hardware (1), the locking bar
(2) and the retaining hardware (3) from the hydraulic
swivel outer component.
NOTE: When installing, tighten to the torque
specified in Section 1002.
STEP 12
Raise the hydraulic swivel sufficiently to free it from
its bracket, so that it can be pivoted 90°. Place the
hydraulic swivel on the ground.
NOTE: When installing, use the same procedure in
the reverse order. Replace all O-rings with new
O-rings. Before operating the machine, operate the
CD00F059
To facilitate installation, attach identification labels to travel, stop the engine and check that there are no
all the hydraulic swivel hoses (outer and inner). leaks. If there is a leak, tighten the hose connections,
check the level of hydraulic oil in the reservoir and top
STEP 7 up if necessary.
STEP 8
Disconnect the hoses from the hydraulic swivel. Plug
the hydraulic swivel hoses and orifices.
STEP 9
STEP 10
Connect suitable lifting equipment to the hydraulic
swivel. Do not leave any slack since the hydraulic
swivel has to be supported once the retaining screws
are removed.

Section
8007

OF THE PILOT FUNCTION BLOCKS
8007

Printed in France
8007-2
TABLE OF CONTENTS
PILOT FUNCTION BLOCKS ................................................................................................................................... 3
Travel pedal block ............................................................................................................................................... 3
LH control lever ................................................................................................................................................... 4
RH control lever .................................................................................................................................................. 8
Swing shuttle block ........................................................................................................................................... 11
Cushion control valve ........................................................................................................................................ 12
Servo control and return manifold block ............................................................................................................ 13
6 solenoid valve block ....................................................................................................................................... 14

Manipulator block control lever locknut ............................................................................................................ 41 Nm

8007-3
PILOT FUNCTION BLOCKS

Travel pedal block STEP 5
Removal and installation Attach identification tags on all hoses of the control
pedal block.
STEP 1
STEP 6
STEP 7
Provide for a container to recover any possible
hydraulic fluid leaks.
STEP 8
JS00163A
STEP 2
Release pressure in the hydraulic system and in the
STEP 3
CD00G165
Remove and seal the hydraulic hoses (1). Remove
the junction joints (2), put plugs on the ports of the
1 control pedal, then discard the O-rings.
NOTE: When installing, replace all O-rings with new
O-rings.
STEP 9
Shut off the vacuum pump.
CD00F091
Disconnect the earth (-) cable (1) from the battery.
STEP 4
To prevent any fluid leaks when disconnecting
hydraulic lines, connect a vacuum pump to the

8007-4
STEP 10 LH control lever
1 NOTE: Refer to page 3 and carry out steps 1 to 4.
STEP 1
4
5
2
3 6
CD00G047
Remove the retainers (1), then remove the lever (4).
Remove the retainers (2), then remove the pedal (5).
Remove the retainers (3), then remove the bracket
(6). Proceed in the same manner for the second
pedal. CD00G048
Lift the grommet. Loosen and remove the four
STEP 11 retaining screws from the front upper portion of the
control arm.
STEP 2
1
CD00E046
1
Put the floor carpet away from the pedals. Remove
the four screws (1) that fasten the control pedal block
to the cab floor, then remove the control pedal block. CD00G049
Loosen and remove the retaining screw (1) from the
NOTE: When installing, proceed in the reverse order function cancellation lever (2), then remove the lever.
to that of removal. Start the engine and operate the
control levers. Stop the engine, check the circuit for
leaks and the hydraulic oil level in the reservoir, top
up if necessary.

8007-5
STEP 3 STEP 6
CD00G050 CD00G053
Loosen and remove the three retaining screws from Loosen and remove the two retaining screws from
the inner cab access bar, then remove the access the arm angle adjustment and function cancellation
bar. lever, then remove the lever.
STEP 4 STEP 7
2
1
CD00G051 CD00G054
Label and disconnect the electrical connections (1), Lift the upper portion of the control arm, label and
remove the compartment control casing assembly disconnect the electrical connections.
(2).
STEP 8
STEP 5
CD00G055
CD00G052
Loosen the locknut, unscrew the control lever and
Loosen and remove the four retaining screws from remove the upper portion of the control arm.
the rear upper portion of the control arm.
NOTE: When installing, tighten the locknut to a
torque of 41 Nm.

8007-6
STEP 9 STEP 11
4
3
5
2
6 1
2
JD00764A CD00G057
1 CLIP Loosen and remove the retaining screws from the
2 NUT left-hand side of the control arm.
3 HANDLE
4 GROMMET STEP 12
5 CONNECTOR
6 LEVER
Cut the clip (1) and discard it. Loosen the nut (2).
Unscrew and remove the handle (3) and the
connector (5) from the lever (6). Remove the nut (2)
to remove the grommet (4).
NOTE: Replace the grommet if it is damaged. The
grommet protects the unions from all types of
contamination.
1
STEP 10
CD00G058
Remove from the safety bar side, the rod (1) that
links the function cancellation lever to the safety bar.
STEP 13
CD00G056
Loosen and remove the two upper screws as well as
the two lower retaining screws from the front portion
of the control arm.
CD00G059
Loosen and remove the four retaining screws from
the plate (1).

8007-7
STEP 14 STEP 18
1
1
CD00G060 CD00G062
Loosen and remove the four screws that fasten the Attach identification tags to all hoses of the control
retaining plate of the control lever (1) to the bracket lever block. Remove and seal the hydraulic hoses.
(2). Remove the junction unions, put plugs on the ports of
the control lever block, then discard the O-rings.
STEP 15 Loosen and remove the two retaining screws (1) from
the plate (2).
O-rings.
STEP 19
2 NOTE: When installing, proceed in the reverse order
1 control levers. Stop the engine, check the circuit for
up if necessary.
CD00G061
Take the control lever block (1) out from the bracket
(2).
STEP 16
STEP 17

8007-8
RH control lever STEP 3

NOTE: Refer to page 3 and carry out steps 1 to 4.
STEP 1
CD00G068
Loosen and remove the two retaining screws from
the arm angle adjustment lever.
STEP 4
CD00G065
CD00G069
Lift the grommet. Loosen and remove the four
CD00G066 retaining screws from the front upper portion of the
Remove the trim panel (1) then remove the retaining control arm.
screws from the air-conditioning control box.
STEP 5
STEP 2
1
2
CD00G070
CD00G067 Loosen and remove the four retaining screws from
Label and disconnect the electrical connection (1) the rear upper portion of the control arm.
then remove the air-conditioning control box (2).

8007-9
STEP 6 STEP 8
4
3
5
2
6 1
2
CD00G071 JD00764A
Lift the upper portion of the control arm, label and 1 CLIP
disconnect the electrical connections. 2 NUT
3 HANDLE
STEP 7 4 GROMMET
5 CONNECTOR
6 LEVER
Cut the clip (1) and discard it. Loosen the nut (2).
Unscrew and remove the handle (3) and the
connector (5) from the lever (6). Remove the nut (2)
to remove the grommet (4).
NOTE: Replace the grommet if it is damaged. The
grommet protects the unions from all types of
contamination.
STEP 9
CD00G072
Loosen the locknut, unscrew the control lever and
remove the upper portion of the control arm.
NOTE: When installing, tighten the locknut to a
torque of 41 Nm.
CD00G073
Loosen and remove the two upper retaining screws
as well as the two lower retaining screws from the
front portion of the control arm.

8007-10
STEP 10 STEP 13
STEP 14
1 STEP 15
2
CD00G074
Loosen and remove the four retaining screws from
the plate (1).
STEP 11
1
1
CD00G07
Attach identification tags to all hoses of the control
lever block. Remove and seal the hydraulic hoses.
Remove the junction unions, put plugs on the ports of
the control lever block, then discard the O-rings.
Loosen and remove the two retaining screws (1) from
the plate (2).
2 NOTE: When installing, replace all O-rings with new
O-rings.
CD00G075 STEP 16
Loosen and remove the four screws that fasten the
retaining plate of the control valve (1) to the bracket
(2). NOTE: When installing, proceed in the reverse order
STEP 12 control levers. Stop the engine, check the circuit for
1 up if necessary.
CD00G076
Take the control lever block (1) out from the bracket
(2).

8007-11
Swing shuttle block STEP 6

Removal and installation 1
STEP 1
To make installation easier, attach identification tags
to all hydraulic hoses and electrical connections of
the shuttle block.
STEP 2
2
STEP 3
CD00G064
Provide for a container to recover any possible Remove the screws (1), then remove the shuttle
hydraulic fluid leaks. block (2) from its bracket.
STEP 4 NOTE: When installing, proceed in the reverse order
to that of removal. Start the engine, operate the
control levers, stop the engine, check the circuit for
up if necessary.
CD00G166
Remove and seal the hydraulic hoses (1), remove the
pressure detector (2), remove the junction unions (3),
put plugs on the ports of the shuttle block, then
discard the O-rings.
O-rings.
STEP 5

8007-12
Cushion control valve STEP 6

1
STEP 1
Open the left-hand side doors.
STEP 2
CD00G164
Remove the four retaining screws (1) from the access
panel (2), then remove the access panel.
STEP 7
Loosen the cushion control valve retaining screws
behind the partition. Remove the cushion valve (raise
it until the screws and the flat washers are clear of
CD00G008 the key hole slots in the bracket then pull it from the
To aid installation, put identification tags on the bracket).
hydraulic hoses. Seal the ports of the cushion control
valve and the ends of the hydraulic hoses. STEP 8
STEP 3 Install the cushion control valve in a vice with
protective jaws. Loosen then remove the adaptors
Start the vacuum pump. and the elbow union.
STEP 4 NOTE: When installing, proceed in the reverse order
Disconnect the hydraulic hoses from the cushion
valve. Seal the hydraulic hoses and the ports of the
cushion control valve.
up if necessary.
STEP 5

8007-13
Servo control and return manifold STEP 6

block
STEP 1 3
To aid installation, put identification tags on all the
hydraulic hoses.
STEP 2 2
Start the vacuum pump. 1
STEP 3
CD00G163
Provide for a container to recover any possible Remove the screws (1) then remove the block (2).
hydraulic fluid leaks. Remove the junction unions (3), discard the O-rings,
put plugs on the ports of the block.
STEP 4
O-rings.
NOTE: When installing, proceed in the reverse order
up if necessary.
CD00G162
Remove and seal the hydraulic hoses.
STEP 5

8007-14
6 solenoid valve block STEP 5

Removal and installation To aid installation, put identification tags on the
hydraulic hoses.
STEP 6
STEP 1
Open the right-hand side door of the machine.
STEP 7
STEP 2
CD00F051
CD00F049 Disconnect the hydraulic hoses connected to the
Remove the two screws and the washers from the solenoid valve block. Seal the ports with caps and the
protective housing. hoses with plugs.
STEP 3 STEP 8
Put the protective housing away to make it easier to Shut off the vacuum pump.
disconnect the connectors from the protective
housing. STEP 9
STEP 4 Loosen the retaining screws from the solenoid valve
block. While supporting the solenoid valve block,
remove the screws and the washers. Remove the
solenoid valve block from its bracket.
STEP 10
For proper installation of the connections, mark the
locations of the elbow unions. Hold the solenoid valve
in a vice. Remove the elbow unions and the straight
unions from the ports of the solenoid valve. Seal the
ports of the solenoid valve with plugs to avoid any
penetration of foreign bodies into the block.
NOTE: When installing, proceed in the reverse order
to that of removal. Start the engine. Activate several
CD00F050
Disconnect the connectors by pressing on the tongue times the solenoid valves (selection of the second
fastener then by pulling to separate them (the speed, swing brake control, power boost, cushion
connectors are identified by rings of different pilot cancellation, swing pilot cancellation, pilot
colours). pressure cancellation control). Stop the engine,
check the circuit for leaks and the hydraulic oil level in
the reservoir, top up if necessary.

Section
8008

OF THE SWING MOTOR
CX210 - CX230
8008

Printed in France
8008-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 2
SWING MOTOR ....................................................................................................................................................... 3
SPECIFICATIONS
Weight ................................................................................................................................................................ 46 kg

Upper panel and central frame retaining screws ................................................................................... 88 to 107 Nm
(apply Loctite 262 to the threads) +20
Swing motor retaining screws................................................................................................................117.7 -0 Nm

8008-3
SWING MOTOR
STEP 1 STEP 5
JS00163A CD00F061
Park the machine on flat, hard ground. Lower the Remove the upper panel (1) retaining screws, then
attachment to the ground. remove the panel.
STEP 2 NOTE: When installing, tighten the screws to a
Release pressure in the hydraulic system and in the to the threads).
STEP 6
STEP 3
1 1
CD00F093
JD00375A Remove the retaining screws from the central frame
Disconnect the earth cable (1) (-) from the battery. (1) then remove the central frame.
STEP 4 NOTE: When installing, tighten the screws to a
To prevent any fluid leaks when disconnecting torque of between 88 and 107 Nm (apply Loctite 262
hydraulic lines, connect a vacuum pump to the to the threads).
hydraulic reservoir (see Section 8000). STEP 7
To facilitate installation, attach labels to all the hoses
and hydraulic unions which are disconnected during
removal.

8008-4
STEP 8 STEP 12
STEP 9
6003-018
To facilitate reassembly, make an alignment mark on
the swing motor and on the reduction gear. Remove
CD00F094
the sixteen retaining screws (1) from the hydraulic
Disconnect all the hoses from the swing motor. Plug swing motor.
the hoses with a plug and the unions with a cap. NOTE: When installing, tighten the screws to a
+20
NOTE: When installing, replace all O-rings with new torque of 117.7 -0 Nm.
O-rings.
STEP 13
STEP 10 Carefully raise the swing motor and move it away
Stop the vacuum pump. from the reduction gear. Move the swing motor away
from the machine and place it on a clean bench.
STEP 11
NOTE: When installing, apply Loctite 504 to the
mating surfaces between the reduction gear and the
swing motor.
STEP 14
To prevent any contamination of the gear oil, cover
the reduction gear with a cloth or a suitable
protection.
NOTE: When installing, follow the same procedure in
the reverse order.
6003-085
Connect a suitable lifting device to the swing motor.

8008-5
STEP 15
CP93A021
Remove the plug from the top of the swing motor. Fill
the swing motor with hydraulic fluid via the plug
orifice until the fluid starts to overflow. Then install the
plug.
STEP 16
See Section 8001 and adjust the swing motor
secondary relief valves.
NOTE: Before operating the machine, start the
engine, check the system for leaks and check the
fluid level in the hydraulic reservoir, top up if
necessary.

8008-6

Section
8010
MAIN HYDRAULIC PUMP
8010

Printed in France
8010-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 2
WEAR INSPECTION................................................................................................................................................ 3
IDENTIFYING THE COMPONENTS........................................................................................................................ 4

Description ............................................................................................................................................................ 5
DISASSEMBLY ........................................................................................................................................................ 6
ASSEMBLY ............................................................................................................................................................ 10
SPECIFICATIONS
See Section 1002.

8010-3

Cover retaining screws ..................................................................................................................................... 29 Nm
Body retaining screws .................................................................................................................................... 431 Nm
Power take-off housing retaining screws ....................................................................................................... 33.3 Nm
Control unit retaining screws ......................................................................................................................... 29.4 Nm
WEAR INSPECTION
Pump K3V112 DTP

Description of parts Standard dimension/ Action
maximum dimension
Play between the piston and the
0.039 / 0.067 Replace the cylinder assembly
cylinder bore
Replace the piston or the plate
Play at the shoe piston and the guide 0-0.1 / 0.3
assembly
Shoe thickness 4.9 / 4.7 Replace the pistons
Free height of cylinder springs 41.1 / 40.3 Replace the springs
Height of the base plate and the Replace the base plate and the
12.0 / 11.0
spherical bushing spherical bushing
Overhaul dimension of the cylinder, the distribution machined plate and the swash plate
(machined surface)
Distribution machined plate (sliding contact surface) Standard roughness
0.1 RA or less
Swash plate (at the plate) after grinding
Cylinder (sliding contact surface) Roughness of the surface
Irregularity of each surface 0.8 RA
at the wear limit

8010-4
IDENTIFYING THE COMPONENTS
1
2 3
41 4
5 6 7
34 8
A 40 9
36 33 10
35
32 11
37
31 12
30 13
38 39
29 14
15
16
28
17
18
19
B
20
27
21
22
26 25 24 23
CI01G501

8010-5
Description
1 DRIVING SHAFT
2 LIP-SEAL
3 COVER
4 SHIM
5 BEARING
6 FLANGE - FRONT BRACKET
7 ROLL PIN
8 STOP SCREW
9 FRONT HOUSING
10 CONTROL PISTON
11 SWASH PLATE
12 PLATE
13 PISTON
14 CONTROL PIVOT
15 CYLINDER PLATE
16 NEEDLE BEARINGS
17 INTERMEDIATE HOUSING
18 STOP SCREW
19 MAIN PINION
20 SEAL PLATE
21 REAR HOUSING
22 SEAL PLATE
23 REAR FLANGE
24 COVER
25 BEARING
26 SNAP RING
27 REAR CYLINDER BLOCK
28 STOP DOWEL
29 FRONT CYLINDER BLOCK
30 SPRING
31 SPHERICAL BUSHING
32 BASE PLATE
33 SNAP RING
34 SHIM
35 LP PUMP POWER TAKE-OFF HOUSING
36 BEARING
37 SECONDARY PINION
38 SHAFT
39 INTERMEDIATE PINION
40 REGULATOR BLOCK
41 SOLENOID VALVE BLOCK

8010-6
DISASSEMBLY
STEP 1 STEP 3
NOTE: Always keep the components from different
pumps separate from one another. During
disassembly of the pump, place the components on a
rubber mat. Handle the components carefully, always
mark the position of the parts.
1
1
2
CD01G105
Remove the cylinder assembly (1), the spherical
bushing, the thrust springs, the piston plate.
NOTE: Do not loosen the stop screws of the control
piston, the front and rear flanges and the
intermediate housing, as doing so will alter the flow.
CD01G103
Remove the oil drain plug located in the low pressure STEP 4
pump gear housing and drain the pump. Remove the
retaining screws (1) and remove the regulator block (2).
STEP 2
2
1
4
3
CD01G106
1 Remove the retaining screws (1) from the cover (2).
Install two screws in the extraction holes (3). Protect
the shaft splines (4) with adhesive tape. Remove the
CD01G104 cover (2), remove and discard the O-ring and the lip
Place the pump on a table, with the regulators facing seal.
downwards. Remove the retaining screws and
remove the front pump housing (1). Retain the
cylinder plate. Remove the main pinion.

8010-7
STEP 5 STEP 8
NOTE: Operation to be carried out in case of wear of
the piston or the control pivot.
1 4
1
5
6
7
CD01G107 3
Remove the front flange (1) by gently tapping it with a
plastic mallet. Discard the seal. 2
STEP 6 Remove the seal plates (1) and (2), discard the seals
CI01G502
(3) and (4). Drive out the control pivot (6) blocking pin
(5). Remove the control pivot (6).
2 NOTE: The control pivot is installed using Loctite.

Extract the control piston (7).
STEP 9
1
CD01G108
Remove the swash plate (1) from the pump housing (2). 3
STEP 7
2
1
2
1
4
5
CD01G109
Remove the shaft (1) from the flange (2) using a
plastic mallet.
CI01G503
Remove the snap ring (1). Remove the shim (2),
drive out the shaft (3). Remove the bearing (4) and
the shim (5). Proceed in the same manner when
removing the other pump body.

8010-8
STEP 10
CD01G110
Remove the low pressure pump. Remove the
retaining screws and extract the power take-off
housing (1) from the low pressure pump.
STEP 11
CD01G111
Remove the snap ring, drive out the shaft and
remove the intermediate pinion (1). Remove the two
shims.
STEP 12
CD01G112
Remove the snap ring, drive out the bearing
assembly and the secondary pinion (1).

8010-9
STEP 13
4
9
8
D1 10
37 B1
36 31
F1
35
30 29 15 5
41 32 G1 C1 1
34 6 7
42 28 11
22 12 7
20 A1 13 3
40 E1 2
18 33
21
27
17
19 15 D
E
G
43
39
F
15 25
23
14
A
B C 26 24
CI01G560
Removing the regulator

In order to avoid changing the pump settings, the Remove the side lever (27) without removing the axle
cover (1) is equipped with adjusting screws (2) and (28).
(3), a push-rod (4), a lock nut (5), an adjusting screw
Remove the shaft (29) and remove the control lever
(6) and a nut (7).
(30).
Do not loosen these screws and nuts, failure to
comply with this instruction will cause maladjustment Remove the side lever (31) without removing the
of pressure and flow. shaft (32).
Compensation section Remove the pilot piston (33) and the spool (34).
Remove the cover (1) by removing the screws (15). Remove the sleeve (35) by pushing the
Remove the outer spring (8), the inner spring (9) and compensating rod (37) to the opposite side.
the spring seat (10).
Remove and discard the seals.
Pilot section
Replace all defective parts.
Remove the spring guide (11), the spring (12) and the
spring seat (13).
Remove the screws (14) and (15) and remove the
cover (16) and the spring (17). Extract the snap ring
(18), the spring seat (19), the spring (20) and the
sleeve (21) and remove the outer snap ring (22) from
the sleeve (21).
Extract the snap rings (23) and (24), the support plug
(25) and the adjustment plug (26).
8010-10
ASSEMBLY
STEP 1
38 33 13 12 11 15
15
16 16
7
14
C 1
B-B
40
29 39
28 25 20 17 22 21 34 38 10 9
31 19 8 1
5
32 33
18 2
26 16
37 3
24
27 42
33 7
41
4
43 35
30 36
37
A-A
CI01H504
Regulator assembly instructions

Assembly is done in the reverse order of Assembly
disassembly, taking into account the following
Press the shaft (28) into the housing (38).
instructions:
Press the shaft (32) into the lever (31).
- Clean the components with detergent and dry them
with compressed air. Install the compensating rod (37) in the housing (38).
- Tighten the screws and plugs to the recommended
Install the lever (31) on the shaft (28) by engaging the
torque.
gear (32) in the groove of the compensating rod (37).
- Coat the moving parts with clean oil before
assembling them. Install the snap ring (22) on the sleeve (21), grease
- Install new seals and O-rings. and install the spool (34) in the sleeve (21), install the
assembly in the housing (38) at port (A) by adjusting
the spool (34). Check that the sleeve and the spool
are sliding freely.
Install the control lever (30) complete with its shaft
(40), maintaining the orientation (reference mark
made during disassembly), align the bores of the
lever (30) and the spool (34) and install the shaft (29).

8010-11
Install the pilot spool (33) at (C) in the housing (38). Pump assembly instructions
Install the lever (27), engaging the shaft (28) in the Assembly is done in the reverse order of
groove on the spool (33). disassembly, however, the following instructions need
to be followed:
Install the plug (25) complete with the shaft (39) in the
housing (38). Position the lever (27) correctly so that - Respect the reference marks made during
the shaft (39) is engaged in the orifice on the lever disassembly.
(27), then install the snap ring (23). - Lubricate the seals and the sliding parts.
- Do not mix the parts of the front and rear pumps.
Install the plug (26) and the snap ring (24).
- Use light Loctite when installing the control pivot.
Install the spring (20), the spring seat (19) on the
spool (34) and install the snap ring (18). STEP 2
Install the spring (17). 5
Install the compensating piston (36), the sleeve (35), 3
the spacer (41) and the piston (42) at orifice (B).
Install the cover (16) and tighten the screws (14). 2
Install the spring seat (13), the spring (12) and the
spring guide (11) in the housing at (E) (see 4
disassembly). 1
Install the spring seat (10), the inner spring (9), the
outer spring (8) in the housing at (D) (see 6
disassembly).
CI01G502
Install the cover (1) complete with adjusting screws
Install the control piston (1) and the control pivot (2)
(2), (3) and (6), the push-rod (4), the lock nuts (5)
in the housing (3), coat with light Loctite that part of
and (7).
the control piston that is in contact with the control
Install and tighten the retaining screws (15). pivot (arrow). Position the pivot in such a way that the
locking pin (4) is installed, wipe off excess Loctite.
Lubricate the control piston (1) and its housing, fit
new seals on the seal plates (5), (6) and install them
in the housing (3).
STEP 3
2 1
CD01G113
Fit a new O-ring on the flange (1). Install the flange
(1) on the housing (2), respecting the reference
marks made during disassembly.

8010-12
STEP 4 NOTE: The bearing locking shim (4) is oriented
towards the shaft splines.
Adjust the bearing (3) properly. Install the bearing (3)
on the shaft (2) using heat protective gloves. Install
1 the shim (5). Install the snap ring (6).
STEP 6
2
2
CD01G114
Place the pump housing (1) with the regulator side
facing downwards. Coat the swash plate bearings (2)
with grease. Install the swash plate (2) by engaging 1
the housing of the plate in the control pivot. Check
that the swash plate (2) is fully home against the
CD01G115
housing bearings (1). Ensure that the swash plate (2)
Install the shaft assembly (1) in the flange (2) while
is able to move freely by pressing on each side with
supporting the swash plate. Tap with a plastic mallet.
fingers of both hands.
STEP 7
STEP 5
1
2
6
CD01G116
Grease the cover (1) lip seal. Install the cover (1)
5 taking care not to damage the lip seal on the splines
of the shaft (2). Install and tighten the screws (3) to a
3 torque of 29 Nm.
1
4
2
CI01G504
Install the shim (1) on the shaft (2). Heat the bearing
(3) to 80°C in an oven.

8010-13
STEP 8 STEP 10
3 1
CD01G117 CD01G119
Install the springs, the spherical bushing, the pistons Install and tighten the screws (1) alternately to a
complete with the thrust ring on the cylinder block. torque of 431 Nm. Install the coupling pinion in the
Install the piston plate on the swash plate. Install the intermediate housing. Proceed in the same manner
cylinder block assembly (1) in the housing (2) by to install the second pump body.
engaging the splines of the spherical bushing and the
cylinder block on the shaft (3). STEP 11
STEP 9
4 1
2
3
1 CD01G112
Position the pinion complete (1) with two bearings on
CD01G118 the power take-off housing, install the assembly
Install new needle bearings (1) in the intermediate under a press and push in until stopped. Install the
housing (2). Use grease to stick the cylinder plate (3) snap ring.
on the intermediate housing (2) by adjusting it so that
the retaining pin is engaged in the plate housing.
Install a new seal (4). Position the intermediate
housing on the pump body according to the reference
marks made during disassembly.

8010-14
STEP 12 STEP 14
1
3
2
1 4
CD01G111 CD01G103
Install the intermediate pinion (1) complete with its Install a new O-ring (1) on the regulator block (2).
bearing (2). Install a shim on each side of the pinion. Align the control lever (3) with the axle (4) of the
Install the shaft (arrow). Install the snap ring. control pivot and install the regulator block (2). Install
and tighten the retaining screws to a torque of
STEP 13 29.4 Nm.
Proceed in the same manner when assembling the
second regulator block.
CD01G110
Install a new seal on the intermediate housing. Install
the power take-off housing (1). Install and tighten the
screws to a torque of 33.3 Nm.

8011
Section
8011

OF THE CONTROL VALVE

Printed in France
Case Cre 9-36270GB November 2001
8011-2
TABLE OF CONTENTS
SPECIFICATIONS .................................................................................................................................................. 2
TOOLS REQUIRED ............................................................................................................................................... 2
SPECIAL TORQUE SETTINGS ............................................................................................................................. 3
CONTROL VALVE .................................................................................................................................................. 4
Description .......................................................................................................................................................... 4
Identifying the ports .............................................................................................................................................. 9
Disassembly .......................................................................................................................................................10
General instructions ...........................................................................................................................................10
Separating the sections ..................................................................................................................................... 10
Load holding block ............................................................................................................................................ 11
Cleaning ............................................................................................................................................................ 14
Inspection .......................................................................................................................................................... 14
Precautions before assembly ............................................................................................................................ 14
Assembly ........................................................................................................................................................... 14
SPECIFICATIONS
Weight of the control valve ............................................................................................................. See Section 1002
Safety valve settings....................................................................................................................... See Section 8001
TOOLS REQUIRED
1. Loctite 262
2. Torque wrench OEM 6472, OEM 6474 and OEM 6476

8011-3

Spool assembly
Screws (D) for spools (2) to (6) and (14) to (17) ................................................................................. 20 to 22 Nm
Screws (22) for the spool (19) ............................................................................................................. 19 to 22 Nm
Load holding valve (67)
Plug (N) and (B) .............................................................................................................................. 147 to 157 Nm
Plug (P) ............................................................................................................................................... 14 to 18 Nm
Retaining screw (76) ........................................................................................................................... 39 to 44 Nm
Control valve assembly
Relief valve (68) .................................................................................................................................. 78 to 88 Nm
Safety valves (69) ............................................................................................................................... 78 to 88 Nm
Safety valves (70) ........................................................................................................................... 103 to 113 Nm
Retaining screws (77) of the control valve sections ........................................................................ 167 to 177 Nm
Plugs (92) ........................................................................................................................................ 205 to 227 Nm
Plug (46).......................................................................................................................................... 107 to 117 Nm
Plugs (72) ............................................................................................................................................ 73 to 79 Nm
Plugs (87) ............................................................................................................................................ 78 to 88 Nm
Plugs (24) and (60) ......................................................................................................................... 103 to 113 Nm
Plug (61).............................................................................................................................................. 39 to 44 Nm
Plug (63).............................................................................................................................................. 14 to 18 Nm
Plugs (72) ............................................................................................................................................ 73 to 79 Nm
Cap retaining screws (37), (43) and (88) ............................................................................................ 58 to 64 Nm
Cap retaining screws (10), (12), (8) and (9) ........................................................................................ 39 to 44 Nm
Cap retaining screw (18) ................................................................................................................. 8.8 to 10.8 Nm
Plugs (73), (97) and (91) ..................................................................................................................... 19 to 22 Nm

8011-4
CONTROL VALVE
Description
72
L
74 B 72
13
1 A 69 75
78 37 69 76 M 74 N
C C
76
D D
E E
37
F F
43
G G
H 87 J H
I75 I
89 88
K 68 52
72 A 96 92 87 75
72 93 52 M
B 75 N
77 81
69 75
69
37 92
N-N
77 81
CI01K536

8011-5
92
44 45
36
97
64
91
50
36 51
35
49 G-G
47
48 46
73 73
34 35 53 54
55 H-H
92 I-I 34 35 53 54 55
CI01K537

8011-6
67
36 34 38 39 40
35
35 36 72
34
34
D-D 35 73
36
36
35
34
34
36 35 67
E-E 40
39 38
F-F
36 35 34
CI01K538

8011-7
13 70
A1 A2
41
7
9 42
14
10 8
15
10
16 8
17 12 8
12 8
5
12
A-A A2 - A2
65 66
60
63
66
65 J-J
A1 - A1
72
65
66
57
33
65 65
32
L-L
M-M
CI01K539

8011-8
1 70
B1
7
8 2
12
42 9
3
10
8
41 4
8 12
5
8 12
6
12
B1
B1 - B1
B-B
72
31
33 32 30 27 26
20 24 61
18
22 21 25
62
23
19 K-K
C-C
CI01K540

8011-9
Identifying the ports

NOTE: Refer to Section 8001.
Description 57. Spacer
60. Plug assembly
1. Control valve housing 61. Plug
2. Dipper spool 2 62. O-ring
3. Boom spool 1 63. Port plug
4. Bucket spool 64. O-ring
5. Travel spool 65. O-ring
6. Straight-line travel spool 66. O-ring
7. O-ring 67. Load holding valve
8. Cap 68. Relief valve
9. Cap 69. Safety valves
10. Cap 70. Safety valves
12. Cap
72. Plug
13. Control valve housing
73. Plug
14. Dipper spool 1
74. Screw M10x1.5 L=28
15. Boom spool 2
75. Screw M10x1.5 L=40
16. Swing spool
76. Screw M10x1.5 L=70
17. Option spool
77. Screw M16x2 L=130
18. Cap
78. Screw M6x1 L=20
19. Spool
81. Washer
20. Spring seat
87. Plug
21. Spring
88. Cap
22. Spool end screw
89. O-ring
23. O-ring
91. Plug
24. Plug
92. Plug
25. O-ring
93. Plug
26. Spring
96. Screw
27. Spool
96. Plug
30. O-ring
31. Back up ring
32. Check valve
33. Spring
34. Check valve
35. Spring
36. O-ring
37. Flange
38. Check valve
39. Spring
40. Spacer assembly
41. O-ring
42. O-ring
43. Flange
44. Check valve
45. Spring
46. Plug
47. O-ring
48. Spring
49. Check valve
50. Steel ball
51. Check valve
52. Flange
53. Spacer
54. O-ring
55. Back up ring

8011-10
Disassembly STEP 3
NOTE: Remove the control valve from the machine, 65 66
see Section 8004.
General instructions
66
- Clean around the component to be removed and 65
take care to ensure that no foreign matter enters the
control valve.
- Label the parts removed and arrange them in a 65
manner that makes installation easier. 65
- Since the spool is an integral part of the control
valve body and the sleeve, do not replace the spool.
66
NOTE: The numbers in brackets refer to the views on
pages 4 to 8. 65
Separating the sections 65
NOTE: Remove the sections only if required. If
removal is required, place the control valve body in a
CI01K542
horizontal plane. Remove the O-rings (65) and (66).
STEP 1 Spool assembly
Clean the outside of the control valve with a suitable STEP 1
cleaning solvent to eliminate all traces of impurities,
grease and other foreign bodies. Dry, using low Loosen and remove the twenty screws (74) that
pressure compressed air. fasten the caps (8) and (9) and remove the caps.
STEP 2 NOTE: If necessary, remove the plug assembly (73)

and the plug (91) complete with the O-ring (64).
77 81
STEP 2
Remove the ten O-rings (7) from sections (1) and
(13) of the control valve.
STEP 3
Remove the spools (2) to (6) and (14) to (17) from the
control valve body as sub-assemblies, taking care
not to damage them.
NOTE: Identify each spool so that they can be put
back in their respective housings during assembly.
STEP 4
Loosen and remove the twenty screws (74) that
fasten the caps (10) and (12) and remove the caps.
77 81
NOTE: If required, remove the plug assembly (73)
CI01K541 and the plug (97).
Separate the two sections (1) and (13) from the
control valve by removing the screws (77) and the
washers (81).

8011-11
STEP 5 STEP 4
Remove the O-rings (7) froms sections (1) and (13) Loosen, then remove the end (22) of the spool (19),
of the control valve. then remove the spring seats (20) and the spring
(21).
NOTE: To avoid abrasion of the spool surface during
removal of the spool assembly, use a vice with Spool assembly (27)
protective jaws and tighten the spool as close as
possible to the head in order to avoid any deformity. NOTE: When removing the plug (24), make sure that
When the threaded portion of the screw is coated you do not drop parts which under pressure from the
with Loctite, heat the head of the screw using an springs.
industrial drier until removal becomes easy (normally STEP 1
the temperature should be in between 200 and
250°C). If this operation causes the spring to be Loosen and remove the plug (24) and remove the
deformed and malfunction, replace the spring. O-ring (25).
STEP 6 STEP 2
C B Remove the spring (26).
B D
STEP 3
31 B
A
CS01K596
Remove the spool screws (D) on the spring side of
the spools (2) to (6) and (14) to (17). Remove the
spring seats (B) as well as the springs (C). 30 C
NOTE: In the spools (3) and (14), only remove the CS01K597
Remove the spool (A) from the sleeve (B). Extract the
check valves, the springs, the O-rings, the back up
sleeve (B) from the control valve body. Remove the
rings and the plugs if it is necessary. If it is necessary
piston (C), the O-ring (30) and the back up rings (31).
to remove them, heat the periphery of the spool in
order to make it easier to remove the plug. Load holding block
Dipper load holding valve NOTE: Be careful when removing the components,
decompression spool 1 some parts are subject to spring pressure.
STEP 1 STEP 1
Loosen and remove the screws (78) that fasten the Loosen and remove the screws (75) and remove the
cap (18) and remove the cap (18). caps (37).
STEP 2 STEP 2
Remove the O-ring (23) from the cap (18). Remove the springs (35), the check valves (34) and
STEP 3 (51), the O-rings (36) from the control valve body.
Remove the spool (19) from the control valve body NOTE: The straight-line travel valve does not have
taking care not to damage it. springs or check valves (see section H-H).
NOTE: For removal of the spool, refer to the STEP 3

instructions previously cited for removal of spool Loosen and remove the screws (75) and remove the
assemblies. caps (52).

8011-12
STEP 4 Spacer assembly (40)
Remove the spacer (53) from the control valve body, NOTE: Be careful when removing components, some
then remove the O-ring (54), the back-up ring (55) parts are subject to spring pressure.
from the spacer (53).
STEP 1
STEP 5
Loosen and remove the screws (76) from the load
Remove the spring (35) and the check valve (34) holding valve (67) then remove the load holding
from the control valve body. valve.
STEP 6 STEP 2
Loosen and remove the plug (72) (see section C-C). Remove the O-rings (41) and (42) from the control
valve body.
STEP 7
STEP 3
Remove the spring (33) and the check valve (32)
from the control valve body. C B
STEP 8 40
Loosen and remove the plug (72) (see section L-L).

STEP 9
Remove the spacer (57), the spring (33) and the A
check valve (32) from the control valve body.
STEP 10
Loosen and remove the plug (92) (see section G-G).
STEP 11 CS01K598
Remove the O-ring (A).
Loosen and remove the screws (96) and remove the
cap (43). STEP 4
STEP 12 Use the screw (78) M6 x 1 as an extracting screw to
remove the spacer (40).
Remove the spring (45), the check valve (44) and the
O-ring (36) from the control valve body. STEP 5
STEP 13 Remove the O-ring (C) and the back-up ring (B).
Loosen and remove the plug (46) and the O-ring (47). STEP 6
STEP 14 Remove the spring (39) and the check valve (38)
from the control valve body.
Remove the spring (48) and the check valve (49)
from the control valve body.

8011-13
Load holding valve (67) Valves
NOTE: Do not operate on the components of the
67 P safety valve, as this will affect the pressure.
E
STEP 1
Loosen and remove the six safety valves (69) from
the control valve body.
G
STEP 2
A Loosen and remove the relief valve (68) from the
control valve body.
STEP 3
A 70 B
Q L H J K R M F D C B N
CS01K599
NOTE: Be careful when removing components, some
parts are subject to spring pressure.
STEP 1
Loosen and remove the plug (N) and remove the
O-ring.
STEP 2
Remove the piston (C), the spool (D) and the spring CS01K600
(F). Loosen and remove the two safety valves (70) and
remove the O-rings (A) and (B).
STEP 3
Loosen and remove the plug (B) and remove the
Auxiliary assembly
O-ring (M). STEP 1
STEP 4 Loosen and remove the screws (75) from the caps
Remove the sleeve (E), the check valve (A) from the (88) and remove the O-rings (89).
load holding valve body (67). Remove the O-rings (H) STEP 2
and (J), the back-up rings (K) and (L) from the
periphery of the sleeve (E). Loosen and remove the two plugs (87) and remove
the O-rings and the back up rings.
STEP 5
Plug assembly
Remove the spring seat (Q) and the spring (G).
STEP 1
STEP 6
Loosen and remove the plug (60) and remove the
Loosen and remove the plug (P), if this is required. O-ring (see section J-J).
NOTE: The steel ball (R) is a press fit, do not remove STEP 2
it.
Loosen and remove the plug (61) and remove the
O-ring (62) (see section K-K).

8011-14
STEP 3 Precautions before assembly
Loosen and remove the plug (63) from its port (see Before beginning assembly, check the quantity of the
section A1-A1). parts, be sure of their final position and get all the
STEP 4 required tools ready.
Loosen and remove the plug (92) and remove the Assembly
O-ring (see section I-I).
Spool assembly
STEP 5
NOTE: Take care not to apply too much Loctite, it
Loosen and remove the plugs (72) and remove the could seep through inside the spool and cause it to
O-rings. malfunction.
Cleaning NOTE: If the spool (3) boom section 1 (opposite the
spring) and the spool (14) dipper section 1 (spring
Clean all the parts removed with clean oil. Dry with side) have been removed for assembly, proceed in
compressed air and place each part on a clean sheet the following manner:
of paper or vinyl for inspection.
STEP 1
Inspection Install the check valve and the spring in the spool,
Inspect the surface of each part for scratches, install the back up ring and the O-ring on the plug.
abrasion and other damage. Apply Loctite 242 on the threaded portion of the plug.
Install the spool in a vice with protective jaws and
1. Check that there are no scratches or dents on tighten the plug at the end of the spools (3) and (4).
the non-return load check valve seat in the
control valve body and that there are no traces STEP 2
of rust or contaminants.
Apply Loctite 242 on the spring side on the threaded
2. Check that there are no scratches or dents on portions of the spools (2) to (6) and (14) to (17).
the periphery of the spool. Remove small Install the spool in a vice with protective jaws.
scratches using a piece of cloth soaked in an
abrasive product. STEP 3
3. Check that all sliding surfaces are moving B C B D
freely. Check for the absence of foreign matter
in holes and in grooves.
4. Replace the springs in case of damage,
deformity or wear and tear.
5. Replace all O-rings and back up rings with new
ones.
CS01K596
6. After removing the caps and plugs, ensure that Install the spring seat (B), the spring (C), the spring
there is no trace of paint at the level of the port seat (B) on the screw (D) and tighten it on the spool
of the body or on the rim of the plug. (Any trace to a torque of 20 to 22 Nm.
of residual paint is likely to cause contamination
that could cause the system to malfunction and
lead to possible leaks).

8011-15
Dipper load holding valve STEP 4
decompression spool 1 Install the spring (F) and the piston (C) in the plug
STEP 1 (B).
Apply Loctite 242 on the threaded portions of the STEP 5

spool (19) and install the spring seats (20), the spring Install the plug (N) equipped with an O-ring on the
(21) and the spool end (22). plug (B). Tighten to a torque of 147 to 157 Nm.
STEP 2 STEP 6
Install the spool in a vice with protective jaws. Tighten Install the plug (B) equipped with a new O-ring (M) on
the end of the spool to a torque of 19 to 22 Nm. the load holding valve body (67). Tighten to a torque
Load holding valve (67) of 147 to 157 Nm.
STEP 7
67 P Install the plug (P) equipped with a new O-ring on the
E load holding valve body (67). Tighten to a torque of
14 to 18 Nm.
Valves
G
NOTE: Do not act on the components of the safety
valve, as this will affect the pressure.
A
STEP 1
Install the relief valve (68). Tighten to a torque of 78
to 88 Nm.
STEP 2
Q L H J K R M F D C B N
Install the six safety valves (69). Tighten to a torque
CS01K599
of 78 to 88 Nm.
STEP 1
STEP 3
Install the O-rings (H) and (J) and the back up rings
(K) and (L) on the peripheral grooves of the sleeve A 70 B
(E).
NOTE: Respect the position of the O-rings and the
back up rings. Any wrong installation will cause
lacerations to the O-rings and will encourage the
cylinder to drift.
STEP 2
Install the check valve (A) and the spool (D) in the
port of the sleeve (E).
STEP 3
CS01K600
Install the spring seat (Q) at the end of the check
Install the two safety valves (70) equipped with an
valve (A), install the spring (G). Insert the assembly
O-ring (A) and (B). Tighten to a torque of 103 to
into the load holding valve body (67).
113 Nm.
NOTE: Apply grease on the spring seats to make
installation easier.

8011-16
Load holding block STEP 10
STEP 1 Install the plug assembly (92) equipped with an
O-ring. Tighten to a torque of 205 to 227 Nm.
Install the O-rings (36) in the control valve housing,
dipper sections 1 and 2 (see section D-D), boom STEP 11
section 1 and 2 (see section E-E), swing and bucket
Install the check valve (49) and the spring (48) on the
section (see section F-F), install the check valves
travel portion (see section G-G). Install the plug (46)
(34) and the springs (35).
equipped with an O-ring (47). Tighten to a torque of
STEP 2 107 to 117 Nm.
Install the caps (37) and fasten them using screws STEP 12
(75). Tighten to a torque of 58 to 64 Nm.
Install the check valve (32) and the spring (33) on the
STEP 3 dipper portion 1 (see section C-C). Install the plug
(72) equipped with an O-ring. Tighten to a torque of
Install the O-rings (36) in the housing of the travel 73 to 79 Nm.
control valve section (see section H-H), install the
check valves (51) and the springs (35). STEP 13
STEP 4 Install the check valve (32), the spring (33) and the
spacer (57) on the dipper portion 2 (see section L-L).
Install the caps (37) and fasten them using screws Install the plug (72) equipped with an O-ring. Tighten
(75). Tighten to a torque of 58 to 64 Nm. to a torque of 73 to 79 Nm.
STEP 5 Load holding valve
Install the O-ring (36) in the housing of the straight-
STEP 1
line travel control valve section (see section H-H).
Install the O-rings (41) and (42) on the dipper control
NOTE: The straight-line travel valve is not equipped
valve body 1 (see sections D-D and A2-A2) and
with springs or check valves.
boom 1 (see sections E-E and B1-B1).
STEP 6 STEP 2
Install the cap (37) using screws (75). Tighten to a
Install the check valve (38) and the spring (39).
torque of 58 to 64 Nm.
STEP 3
STEP 7
Install the check valve (34) and the spring (35) (see C B
section I-I), install the spacer (53) complete with an 40
O-ring (54) and a back up ring (55).
NOTE: Respect the position of the O-rings and back
up rings. Any wrong installation will cause lacerations
to the O-rings and will encourage the cylinder to drift. A
STEP 8
Install the cap (52) using screws (75) and tighten to a
STEP 9
CS01K598
Install the O-ring in the option section (see section Install an O-ring (A) on the spacer (40), install the
G-G), install the check valve (44) and the spring (45). O-ring (C) and the back up ring (B).
Install the cap (43) and fasten it using screws (96).
NOTE: Respect the positions of the O-rings and back
Tighten to a torque of 58 to 64 Nm.
up rings. Any wrong installation will cause lacerations
and external leaks.

8011-17
STEP 4 STEP 2
Install the spacer assembly (40). Install the cap (18) equipped with an O-ring (23) and
fasten it using screws (78). Tighten to a torque of 8.8
STEP 5 to 10.8 Nm.
Install the load holding valve (67) and fasten it using
Spool assemblies (2) to (6) and (14) to (17)
screws (76). Tighten to a torque of 39 to 44 Nm.
Auxiliary assembly STEP 1
Install the O-rings (7) on the control valve body.
STEP 1
STEP 2
Install the caps (88) equipped with an O-ring (89) and
fasten them using the screws (75). Tighten to a Install the assembled spools (2) to (6) and (14) to
torque of 58 to 64 Nm. (17) in the ports of the control valve body.
STEP 2 NOTE: Ensure that the spool is installed in its original
port, install it without pressing too hard. After
Install the plugs (87) complete with an O-ring and a installing the spool, make it slide manually to check
back up ring. Tighten to a torque of 78 to 88 Nm. its proper functioning.
Spool assembly (27) STEP 3
STEP 1 Install the caps (10) and the caps (12) on the control
31 valve body and fasten them using screws (74).
B
A
STEP 4
Install the caps (8) and the caps (9) on the control
valve body and fasten them using screws (74).
30 C NOTE: Check the proper positioning of the caps (9)
CS01K597 and (10).
Install the O-ring (30) and the back up rings (31) on
the sleeve (B). Install the piston (C) and the spool (A) STEP 5
in the sleeve (B). Install the assembly in the control Install the plugs (73) equipped with an O-ring on the
valve body. long cap of the boom section 2 (see section E-E), on
STEP 2 the long cap of the straight-line travel section (see
section H-H). Tighten to a torque of 19 to 22 Nm.
Install the spring (26) inside the plug (24) equipped
with an O-ring (25). Screw the plug on the control STEP 6
valve body. Tighten to a torque of 103 to 113 Nm. Install the plug (97) equipped with an O-ring on the
Dipper load holding valve short cap of the option section (see section G-G).
decompression spool 1
STEP 7
STEP 1
Install the plug (73) equipped with an O-ring on the
Install the spool assembly (19) in the control valve
short cap of the straight-line travel section (see
body without forcing it.
section H-H). Tighten to a torque of 19 to 22 Nm.
NOTE: Ensure that it is functioning properly by
making it slide manually.

8011-18
STEP 8 STEP 2
Install the plug (91) equipped with an O-ring (64) on 77 81
the long cap of the option section (see section G-G).
Plug assembly
STEP 1
Install the plug (60) equipped with an O-ring. Tighten
to a torque of 103 to 113 Nm (see section J-J).
STEP 2
Install the plug (61) equipped with an O-ring (62).
Tighten to a torque of 39 to 44 Nm (see section K-K).
STEP 3
Install the plug (63) in its port. Tighten to a torque of
14 to 18 Nm (see section A1-A1). 77 81
STEP 4 CI01K541
Assemble the two sections (1) and (13) using screws
Install the plugs (92) equipped with an O-ring. (77) and washers (81). Tighten to a torque of 167 to
Tighten to a torque of 205 to 227 Nm. 177 Nm.
STEP 5 NOTE: For installation of the control valve, see

Section 8004.
Install the plugs (72) equipped with an O-ring.
Assembling the sections
STEP 1
65 66
66
65
65
65
66
65
65
CI01K542
Install new O-rings (65) and (66).

8012
Section
8012
DISASSEMBLY AND ASSEMBLY

OF THE ATTACHMENT CYLINDERS

Printed in France
8012-2
TABLE OF CONTENTS
SPECIFICATIONS ................................................................................................................................................... 2
SPECIAL TOOLS .................................................................................................................................................... 4
CYLINDERS ............................................................................................................................................................ 6
Boom cylinder description ................................................................................................................................... 6
Dipper cylinder description .................................................................................................................................. 8
Bucket cylinder description ................................................................................................................................10
Disassembly .......................................................................................................................................................12
Inspection ...........................................................................................................................................................20
Assembly ............................................................................................................................................................21
SPECIFICATIONS
See Section 1002.

8012-3

CX130 CX160 CX210 CX240
CX180 CX230
Boom cylinder
Piston nut ...................................................................... 3150 Nm .......... 4130 Nm ..........4820 Nm........ 5500 Nm
Bearing retaining screw................................................... 171 Nm ............ 267 Nm ............267 Nm.............xx Nm
Clamp screw (11) .............................................................. 32 Nm .............. 32 Nm .............. 32 Nm.............xx Nm
Clamp screw (9) ................................................................ 40 Nm .............. 63 Nm .............. 63 Nm.............xx Nm
Hydraulic pipes retaining screws (4) ................................. 26 Nm .............. 51 Nm .............. 51 Nm.............xx Nm
Hydraulic pipes end plugs (2)............................................ 98 Nm ............ 226 Nm ............226 Nm.............xx Nm
Piston nut screw (16) ........................................................ 32 Nm .............. 57 Nm .............. 57 Nm.............xx Nm
Dipper cylinder
Piston nut ...................................................................... 6160 Nm .......... 8200 Nm ....... 10 300 Nm..... 13 600 Nm
Hydraulic pipes retaining screws (4) ................................. 51 Nm .............. 92 Nm .............. 92 Nm.............xx Nm
Barrel end plug ................................................................ 226 Nm ............ 226 Nm ............226 Nm.............xx Nm
Bucket cylinder
Piston nut ...................................................................... 3580 Nm .......... 4810 Nm ..........6650 Nm........ 9600 Nm
Hydraulic pipe retaining screw cylinder head side ............ 26 Nm .............. 51 Nm .............. 51 Nm.............xx Nm
Pipe retaining screw cylinder foot side .............................. 52 Nm .............. 51 Nm .............. 51 Nm.............xx Nm

8012-4
SPECIAL TOOLS
OEM 9797 Hydraulic cylinder repair bench
OEM 9798 Piston nut screw
PE.174E-220 Hydraulic/electric pump
or
CAS 10918 Hydraulic cylinder repairing bench

8012-5
OEM 9797 PE-174E-220
OEM 9798
CAS10918
CAS 10918

8012-6
CYLINDERS
Boom cylinder description
3 4 44
43
10
2
34
35
15
36 30 4 3 2
29 42 41
37
38
14
31 32 33
5 6
24
11
42
12
13
41
1
18
17
16
7 23
20
8 21
9 22
5 19
39
40
45
JS00664A

8012-7
1 LUBRICATION FITTING
2 PLUG
3 O-RING
4 SCREW
5 HYDRAULIC PIPE
6 O-RING
7 SCREW
8 WASHER
9 PIPE CLAMP
10 HYDRAULIC PIPE
11 SCREW
12 LOCKING WASHER
13 RETAINING CLIP
14 SCREW
15 BEARING
16 SCREW
17 STEEL BALL
18 PISTON NUT
19 PISTON
20 SEAL RING
21 BACK UP RING
22 WEARING RING
23 WEARING RING
24 SHIM
25 NOT USED
26 NOT USED
27 NOT USED
28 NOT USED
29 O-RING
30 BACK UP RING
31 WEARING RING
32 BACK UP RING
33 SQUARE SEAL
34 U-RING
35 BACK UP RING
36 WIPER SEAL
37 STOPPING RING
38 BUSHING
39 SEAL RING
40 CUSHION BUSHING
41 WIPER SEAL
42 BUSHING
43 CYLINDER ROD
44 CYLINDER BARREL
45 O-RING

8012-8
Dipper cylinder description
38 37 29 30
31 32 33
34 43
44
5
35
6
36 4
3
2
42
15
41 4
1
14
5
6
7 8 9
18 42
19 41
12
11
13
20 23 17 27
21 16 26
22
39
40 28
25
45 24
JS00657A

8012-9
2 PLUG
3 O-RING
4 SCREW
5 HYDRAULIC PIPE
6 O-RING
7 SCREW
8 WASHER
9 PIPE CLAMP
10 NOT USED
11 SCREW
12 WASHER
13 RETAINING CLIP
14 SCREW
15 BEARING
16 SCREW
17 STEEL BALL
18 PISTON NUT
19 PISTON
20 SEAL RING
21 BACK UP RING
22 WEARING RING
23 WEARING RING
24 SHIM
25 RING
26 SNAP RING
27 CUSHION BUSHING
28 CUSHION SEAL
29 O-RING
30 BACK UP RING
31 WEARING RING
32 BACK UP RING
33 SQUARE SEAL
34 U-RING
35 BACK UP RING
36 WIPER SEAL
37 STOPPING RING
38 BUSHING
39 SEAL RING
40 CUSHION BUSHING
41 WIPER SEAL
42 BUSHING
43 CYLINDER ROD
44 CYLINDER BARREL
45 O-RING

8012-10
Bucket cylinder description
29
31 32 33 37 30
44
34 38
43
35
36
5
42
4
15 6
41 14
4
1
5 1
6
42
18 41
19
7
8
9
13
12
11
20 24 16 17
21
22
23
40
45
JS00658A

8012-11
2 NOT USED
3 NOT USED
4 SCREW
5 HYDRAULIC PIPE
6 O-RING
7 SCREW
8 WASHER
9 RETAINING CLIP
10 NOT USED
11 SCREW
12 WASHER
13 RETAINING CLIP
14 SCREW
15 BEARING
16 SCREW
17 STEEL BALL
18 PISTON NUT
19 PISTON
20 SEAL RING
21 BACK UP RING
22 WEARING RING
23 WEARING RING
24 SHIM
25 NOT USED
26 NOT USED
27 NOT USED
28 NOT USED
29 O-RING
30 BACK UP RING
31 WEARING RING
32 BACK UP RING
33 SQUARE SEAL
34 U-RING
35 BACK UP RING
36 WIPER SEAL
37 STOPPING RING
38 BUSHING
39 NOT USED
40 CUSHION BUSHING
41 WIPER SEAL
42 BUSHING
43 CYLINDER ROD
44 CYLINDER BARREL
45 O-RING

8012-12
Disassembly STEP 3
NOTE: The boom, dipper and bucket cylinders are Bucket cylinder
basically identical in construction. What changes is
the hydraulic tube connections. Before installing the
cylinder in the repair stand, remove the hydraulic
tubes. 1. Remove the two lubrication fittings (1) from the
cylinder.
STEP 1
2. Remove the screws (4). Disconnect the hydraulic
Boom cylinder tubes (5) from the cylinder. Remove and discard
NOTE: The numbers in brackets in the following steps the two O-rings (6).
refer to the boom cylinder schematic on page 6. 3. Remove the screw (7), the washer (8) and the
1. Remove the lubrication fitting (1) from the clamp (9) from the cylinder.
cylinder. 4. Remove the screws (11), the washers (12) and
2. Remove the two plugs (2). Remove and discard the clamp (13) from the cylinder. Remove the
the two O-rings (3). hydraulic tube (5) from the cylinder.
3. Remove the screws (4) and disconnect the NOTE: As an example, the repairing bench
hydraulic tubes (5) and (10) from the cylinder. CAS 10918 is used.
Remove and discard the two O-rings (6). STEP 4
4. Remove the screw (7), the washer (8) and the
clamp (9) from the tubes. Remove the hydraulic
tubes (5) and (10) from the cylinder.
5. Remove the screws (11), the washers (12) and
the clamp (13) from the cylinder.
STEP 2
Dipper cylinder
1. Remove the lubrication fitting (1) from the
cylinder. JD00620A
Install suitable bushings on the cylinder head stock
2. Remove the plug (2) from the hydraulic tube.
chuck wings.
Remove and discard the O-ring (3).
3. Remove the screws (4) and disconnect the STEP 5
hydraulic tube (5) and the clamp from the cylinder.
Remove and discard the two O-rings (6).
4. Remove the screw (7), the washer (8) and the
clamp (9) from the cylinder.
5. Remove the screws (11), the washers (12).
Remove the clamp (13) from the cylinder.
Remove the hydraulic tube (5) from the cylinder.
JD00621A
Tighten the bushing retaining screws.

8012-13
STEP 6 STEP 8
JD00623A JD00625A
Install the stop pins on the boom tail stock. Connect lifting equipment, if necessary, to the
cylinder. Position the cylinder in the repair stand with
STEP 7 the rod end of the cylinder at the head stock chuck.
Loosen the retaining screws of the tail stock chuck
wings. When positioning the cylinder rod end on the
head stock chuck wing, be sure that the chuck wing
bushings are centred in the rod bushing. Install the
screw and nuts to secure the cylinder rod end to the
repair stand.
STEP 9
JD00624A
Install suitable bushings on the cylinder tail stock
chuck wings. Tighten the retaining screws. Install the
chuck wings on the cylinder tail chuck. Tighten the
locking screws. Use the scale on the face of the
chuck to aid in centering the chuck wings.
JD00626A
On the cylinder repair stand, loosen the retaining
screws of the tail stock chuck wings. When
positioning the cylinder barrel end on the head stock
chuck wing, be sure that the bushings are centred in
the cylinder barrel bushing. Install the screw and nuts
to secure the cylinder barrel end to the repair stand.

8012-14
STEP 10 STEP 12
JD00627A JD00629A
Check and ensure that the chuck wings are centred Raise the cylinder barrel (44) support to support the
on the repair stand centre line using scales scribed cylinder barrel. Tighten the nuts to lock the support in
on the head and tail stock chucks. position. Remove the lifting equipment.
NOTE: The numbers in brackets in the following STEP 13
steps refer to the boom cylinder, dipper cylinder and
bucket cylinder schematics on pages 6, 8 and 10.
STEP 11
JD00630A
To make reassembly easier, draw alignment marks
on the cylinder barrel (44) and the bearing (15).
Remove the screws (14).
JD00628A
Raise the cylinder rod (43) support to support the STEP 14
cylinder rod. Tighten the nuts to lock the support in
position.
JD00631A
Place a container beneath the bearing and cylinder
barrel to catch any hydraulic oil that may still be
inside the cylinder. Start the hydraulic pump to
remove the rod from the cylinder barrel.

8012-15
STEP 15 STEP 18
Connect lifting equipment, if necessary, to the D
cylinder barrel (44) and remove from the repair stand. B
STEP 16
A
C
A
JD00635A
Check that both stop bars (A) are installed to prevent
the head stock (B) chuck from turning. Remove the
tail stock chuck wings and install the wrench (C) on
JD00632A
the tail stock. Check that the wrench is centred on the
Move the bearing (15) away from the piston (19). chuck and tighten the screws (D).
STEP 17 STEP 19
E
18
JD00633A JD00636A
Push the head stock chuck towards the piston nut
(18) and, if necessary, remove the stop bars (A) and
turn the chuck until the wrench (E) engages the
piston nut.
JD00634A
Remove the screws (16) from the piston nut (18).
Turn the cylinder rod and remove the ball (17).

8012-16
STEP 20 STEP 22
JD00637A JD00639A
Loosen the tail stock chuck screws. Tighten the Start the hydraulic pump by pressing on the pedal to
wrench nuts on the piston nut (18). Check that the loosen the piston nut. At the end of the stroke,
wrench is centred by using the scale on the chuck. remove the two stop bars; if necessary, depress the
rear of the pedal to retract the cylinder rod just
STEP 21 enough to enable removal of the stop bars. Depress
the rear of the pedal to retract the cylinder rod to
B lower the toggle assembly as far as possible on the
circular plate then install the stop bars.
STEP 23
Repeat step 22, if necessary, until the piston nut has
been loosened.
STEP 24
JD00638A
Lower the toggle assembly (B) as far as possible on
the circular plate and install the stop bars (A).
JD00640A
Remove the piston nut (18) from the rod.

8012-17
STEP 25 STEP 28
JD00641A JD00644A
Remove the shim (24) from the rod. Remove the two inner wear rings (22) from the
piston.
STEP 26
STEP 29
20 22 23
19
B
A
45 21
JD00642A
Remove the piston (19) then remove the bearing rod. JS00645A
Install the piston (19) in a vice (A) with protective jaws
STEP 27 (B). Using a suitable tool, cut or break the seal ring
(20). Remove the seal ring and discard. Remove and
discard the two back up rings (21). Remove the
piston from the vice.
JD00643A
Remove the two outer wear rings (23) from the
piston.

8012-18
STEP 30
JD00647A
JD00646A Use a suitable tool to remove the O-ring (45). Scrap
the O-ring.
NOTE: Step 31 applies only to the dipper cylinder.
STEP 31
18
27
26
25
43
28
JS00648A
18 PISTON NUT Remove the ring (25). Push the cushion bushing (27)
25 RING away from the stopper (26). Remove the stopper
26 STOPPER
27 CUSHION BUSHING
(26). Remove the cushion bushing (27). Widen the
28 CUSHION RING slit of the cushion ring (28) then remove and discard
43 CYLINDER ROD the cushion ring (28).

8012-19
STEP 32
30 29
36
38
35 34 A 37
JS00649A
JD00650A JD00652A
Remove and discard the O-ring (29) and back up ring
(30). Remove and discard the back up ring (35) and
U-ring (34). Remove and discard the buffer ring (A)
which consists of a wear ring (31), a back up ring
(32), and a square ring (33). Remove and discard the
wiper ring (36).
STEP 33
38
JD00651A
37
JS00653A
With a suitable tool, remove the stop ring (37) from
the bearing. Place the bearing on a press and with a
suitable driver, force the ring (38) out of the bearing.

8012-20
STEP 34 Inspection
NOTE: The bucket cylinder does not incorporate a STEP 1
seal on the cushion ring.
Inspect the seals, U-rings, back up rings, and O-rings
Remove the seal (39) from the cushion ring (40) and prior to installation for any imperfections, tears, or
discard the seal. Remove the cushion ring (40). other damage. If the seals or the bushings are worn
STEP 35 out or damaged, replace the component(s). Ensure
seals and bushings are installed correctly with no
NOTE: Do the following step only if inspection twisting of the seal or bushing. Install all new seals
indicates that the bushings (42) require replacement. and rings wet with hydraulic oil.
STEP 2
41 Check the sliding parts for wear or damage such as
scratches, dents, or bent parts. Small scratches can
be removed with a hone or crocus cloth.
STEP 3
Check for cracks in the welding or other damage.
STEP 4
Measure the internal diameter of the bushings (42). If
the internal diameter of the bushings is greater than
the specifications, replace the bushing(s).
JD00654A
41
JD00655A
Remove the four wipers (41) from the cylinder rod
and cylinder barrel. Use a suitable press and driver
and remove the two bushings (42) from the cylinder
rod and cylinder barrel.

8012-21
Assembly STEP 3
NOTE: The numbers in brackets in the following
steps refer to boom cylinder, dipper cylinder and 38
bucket cylinder schematics in this section on
pages 6, 8 and 10.
STEP 1
41
15
JS00659A
Using a suitable press and driver, install the bushing
(38) in the bore of the bearing (15).
JD00655A STEP 4
41
38
15
JD00654A JS00653A
Using a suitable press and driver, install the two Install the stop ring (37) in the bearing groove (15).
bushings (42). Install the four new wipers (41) with
the lip side of the wipers facing out.
STEP 2
NOTE: The bucket cylinder does not incorporate a
seal in the cushion ring.
Install the cushion bushing (40) on the cylinder rod
(43). Install a new seal (39) in the cushion bushing.

8012-22
STEP 5
JD00650A
JD00652A Install a new O-ring (29) and back up ring (30). Install
a new wiper ring (36). Install a new U-ring (34) and
back up ring (35). Install a new buffer ring (A) which
consists of a wear ring (31), a back up ring (32), and
a square ring (33).
JD00651A
30 29
36
38
35 34 A 37
JS00649A

8012-23
NOTE: Step 6 applies only to the dipper cylinder.
STEP 6
18
27
26
43
25
28
JS00648A
18 PISTON NUT Install a new cushion ring (28) on the cylinder rod
25 RING (43). Install the stopper (26) in the groove of the
26 STOPPER
27 CUSHION BUSHING
cylinder rod (43). Install the cushion bushing (27) on
28 CUSHION RING the cylinder rod (43) and install the ring (25) to hold
43 CYLINDER ROD the cushion bushing (27).

8012-24
STEP 7 STEP 9
JD00647A JD00642A
Install the bearing (15) then the piston (19) on the
cylinder rod.
STEP 10
JD00646A
Coat a new O-ring (45) with clean hydraulic oil. Install
the O-ring in the center groove of the piston.
STEP 8 JD00641A
Install the shim (24) on the piston rod behind the
piston.
20 22 23
STEP 11
19 B
A
45 21
JS00645A
(A) VICE
(B) HARD WOOD
Place a tapered tool over the piston (19). Coat a new JD00640A
seal ring (20) with clean hydraulic fluid. Slide the seal Install the piston nut (18) on the cylinder rod and
onto the tool and install it in the groove of the piston hand tighten.
on top of the O-ring (45). Install two new back up
rings (21). Install four new wear rings (22) and (23) in
the grooves of the piston.

8012-25
STEP 12 STEP 14
Carry out steps 4 to 12 of disassembly to install the
cylinder rod in the repair stand. A
STEP 13 C
B
JD00660A
Remove the toggle assembly (A) and the cylinder (D)
on the RH side of the repair stand, by removing the
stop bars (B) and the pins (C). Install the toggle
JD00637A
assembly and cylinder (D) on the left side of the
repair stand. Operate the hydraulic pump by
depressing the foot pedal to extend the rod end of the
E
hydraulic cylinder to rotate the circular plate
18 clockwise to tighten the piston nut. At the end of the
stroke, remove the two stop bars; if necessary,
depress the rear of the pedal to retract the cylinder
rod just enough to enable removal of the stop bars.
Depress the rear of the pedal to retract the cylinder
rod to lower the toggle assembly as far as possible
then install the stop bars. Repeat this step as
required to tighten the piston nut to torque (see
"Specifications").
JD00636A
Carry out steps 19 to 21 of disassembly to install
wrench (E) on the piston nut (18).

8012-26
STEP 15 STEP 16
16
17
JD00634A JS00661A
(A) AWL
After tightening the screw (16) to the required torque,

caulk the screw at two places.
STEP 17
JD00633A
Install the steel ball (17) in the piston nut (18). Install
the screw (16) in the nut. Tighten the screw to torque
(see "Specifications").
JD00637A
Loosen the nuts to remove the wrench from the
piston nut (18). Move the repair stand support away
from the cylinder rod.

8012-27
STEP 18 STEP 20
Attach a suitable lifting device to the cylinder.
Remove the screws and chuck wings to free the
cylinder from the repair stand.
STEP 21
Boom cylinder
refer to the boom cylinder schematic on page 6.
1. Install the clamp (13) on the cylinder, the washer
(12) and the screw (11). Tighten the screws to
torque (see "Specifications").
JD00662A 2. Install the two hydraulic pipes (5) and (10), the
Using suitable means of lifting, install the tube on the clamp (9), the washer (8) and the screw (7).
repair stand in order to align the cylinder rod (43) and Tighten the screw to torque (see "Specifications").
the bearing. Install the tube and the bearing (15) by
aligning the markers. 3. Install two new O-rings (6) on the cylinder.
Connect the hydraulic pipes (5) and (10) to the
STEP 19 cylinders. Fasten the pipes using screws (4).
Tighten the screws to torque (see
"Specifications").
4. Install two new O-rings (3) on the pipes. Install
two plugs (2) and tighten the plugs to torque (see
"Specifications").
5. Install the lubrication fitting (1) in the cylinder.
STEP 22
Dipper cylinder
JD00630A
1. Install the clamp (13), the screw (11) and the
washer (12) on the cylinder. Tighten the screw to
torque (see "Specifications").
2. Install the hydraulic pipe (5), the clamp (9), the
washer (8) and the screw (7). Tighten the screw
to torque (see "Specifications").
3. Install two new O-rings (6) on the cylinder.
Connect the pipe (5) and the clamp to the cylinder
with screws (4). Tighten the screws to torque (see
"Specifications").
4. Install a new O-ring (3) on the pipe. Install the
plug (2). Tighten the plug to torque (see
"Specifications").
JS00663A
Start the pump on the machine to bring the tube into 5. Install the lubrication fitting (1) in the cylinder.
contact with the bearing. Install 12 screws (14) and
tighten the screws to torques (see "Specifications").

8012-28
STEP 23
Bucket cylinder
1. Install the clamp (13) on the cylinder tube. Secure
the clamp with two washers (12) and screws (11).
Tighten the screws to torque (see
"Specifications").
2. Install the clamp (9) and tube (5) on the clamp
(13). Secure the clamp (9) with the washer (8)
and the screw (7). Tighten the screws to torque
(see "Specifications").
3. Install two new O-rings (6). Connect the hydraulic
pipe (5) to the cylinder and secure the pipes with
the screws (4). Tighten the screws to torque (see
"Specifications").
4. Install two lubrication fittings (1) on the cylinder.

Section
8013
8013
OF THE CONTROL LEVERS

Printed in France
8013-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 2
CONTROL LEVER ................................................................................................................................................... 3
Description ........................................................................................................................................................... 3
Disassembly ......................................................................................................................................................... 4
Inspection............................................................................................................................................................. 7
Assembly.............................................................................................................................................................. 8
SPECIFICATIONS
Torque settings
Orifice plate retaining screws ........................................................................................................... 29.4 ± 1.5 Nm
Universal joint on control lever ......................................................................................................... 47.1 ± 2.9 Nm
Lock-nut on universal joint ............................................................................................................... 68.6 ± 4.9 Nm

8013-3
CONTROL LEVER
Description
20
3
19
4
18 5
6
17 8
22 10
11
12
16
15
13
21
14
CI00G508
1 LOCK-NUT 12 CONTROL LEVER BODY
2 PROTECTIVE BOOT 13 ORIFICE PLATE
3 DISC 14 HEXAGONAL ALLEN-TYPE SCREW
4 PUSH-ROD 15 O-RING
5 PLATE 16 BUSHING
6 PLUNGER ASSEMBLY 17 SPOOL
7 O-RING 18 SPRING
8 SPRING SEAT 19 LIP-SEAL
9 SPRING 20 UNIVERSAL JOINT
10 SPRING 21 PLASTIC PIN
11 SPOOL 22 WASHER

8013-4
Disassembly STEP 3
steps refer to the schematic on page 3.
Always handle high precision parts with the greatest
care to prevent them being damaged by being
knocked or dropped. The components of the control
lever may rust due to contamination and humidity if
they are left without protection after disassembly. If
work has to be stopped, the components must be
protected against contamination or corrosion.
STEP 1
CD00G089
Remove the disc from the control lever.
STEP 4
CD00G087
Install the control lever in a soft-jawed vice. Remove
the protective boot.
STEP 2
JD00767A
Install two nuts on the universal joint and tighten them
fully. While holding the upper nut, turn the lower nut
anti-clockwise to unscrew the universal joint. Remove
the universal joint from the control lever.
NOTE: Carefully remove the universal joint to prevent
the plate and the push-rods, which are under
pressure from the springs, from flying out too quickly.
CD00G088
Remove the lock-nut from the control lever.

8013-5
STEP 5 STEP 7
CD00G091 CD00G093
Remove the plate. Remove the spool assembly from the control lever.
NOTE: Mark the components removed in the STEP 8
following steps to facilitate their insertion in the
correct bore during assembly.
STEP 6
CD00G094
Turn the control valve the other way up in the vice.
Unscrew and remove the six screws and the sealing
washers.
CD00G092
Depending on the condition of the return springs, the STEP 9
friction of the O-rings can keep the plunger
assemblies in place in the body. In this case, use a
flat screwdriver to remove the plunger assemblies.
Slide the screwdriver into the external groove of the
plunger assembly, taking care not to damage the
plunger assembly. This must be done carefully, since
the plunger assembly can be thrown out suddenly,
due to the action of the return springs.
CD00G095
Remove the orifice plates and the O-ring from the
body. Scrap the O-ring.

8013-6
STEP 10 STEP 12
JD00774A CD00G098
Remove the bushing from the body of the control Remove the spool (17) and the spring (18) from the
lever. plunger assembly (6).
STEP 11 STEP 13
CD00G096 CD00G099
Remove the push-rod (4) from the plunger assembly
(6).
STEP 14
CD00G097
Press the spring down a few millimetres so as to free
the spool (11) from the spring seat (8). Separate the
spool (11) from the spring (10) and the washer (22). CD00G100
Keep these components together for the reassembly Remove and scrap the plunger assembly O-ring.
procedure.

8013-7
STEP 15 Inspection
Change all the seals and O-rings which have been
removed. Also change the washers on all screws
which have been removed.
STEP 1
Inspect the spools to ensure that the finish is not
damaged, that they are not bent or damaged in any
other manner. Make sure that the spool slides freely
in the control valve body bore. If defects are found,
change the entire control valve.
STEP 2
CD00G101
Remove and scrap the plunger assembly seal.
STEP 16
Cleaning the components:
1. Soak them in a suitable cleaning solvent until
contamination and oil are removed. Components can
be damaged if they are washed while they are still
contaminated.
2. Final washing: Immerse the components in a
clean receptacle containing a suitable cleaning
solvent. Impart a rotary motion to the receptacle so
JS00784A
as to wash the inner surface of the components as Inspecting the controls. Change the components if
well. Dry the components with a clean cloth. wear on the shaft pin and seal create play in the
NOTE: Never dry them with compressed air. Dust controls greater than 2 mm.
and water contained in the air will damage and STEP 3
corrode their surfaces.
If it is impossible after inspection of the parts to
3. Corrosion prevention: Apply an anti-rust product
determine the cause of an abnormal noise or a
to all the components.
reduction in primary pressure, change the control
NOTE: Components can rust if left in the open air lever.
after cleaning.

8013-8
Assembly STEP 3
Carry out the assembly with the very greatest care.
Do not hit or force the components, since that will
damage them and cause seizure or oil leaks which
would result in impaired performance of the machine.
Before reassembly, remove all traces of metal
particles or foreign bodies from all components.
Check that there are no burrs on the components and
remove them with an oil stone. Replace all O-rings
and thrust rings with new components. Lubricate the
O-rings and thrust rings to prevent any damage
during assembly. Tighten all cap screws to the
specified torque. Plug all orifices with plugs to prevent A
any contamination of the control lever by dust after
CD00G103
reassembly. Install the orifice plate (13) with the plastic pin (21) in
the orifice (A) in the control lever body.
STEP 1
STEP 4
JD00774A
Install the control lever body bushing.
CD00G104
Install the hexagonal Allen-type cap screws and the
STEP 2
sealing washers in the orifice plate (13). Tighten the
screws and retighten them alternately to a torque of
29.4 ± 1.5 Nm.
STEP 5
CD00G102
Install the O-ring in the groove in the control lever
body.
CD00G105
Assemble the spool assembly by installing the
washer (22), the spring (10) and the spring seat (8)
on the spool (11).

8013-9
STEP 6 STEP 8
CD00G106 CD00G108
Turn the control lever the other way up in the vice.
Install the return spring and the complete spool
assembly in the body, respecting the positions noted
during steps 5 to 7 (disassembly).
STEP 7
19
CI00G509
Install the lip seals (19) with their ends as shown
above.
STEP 9
CD00G107
Install the O-ring on the plunger.
CD00G109
Coat the surfaces of the push-rod (4) with hydraulic
fluid and install it in the plunger (6).

8013-10
STEP 10 STEP 13
CD00G110 CD00G112
Install the spool (17) and the spring (18) in the Install the plate and retain it by means of the
plunger (6). universal joint. Tighten the universal joint to a torque
of 47.1 ± 2.9 Nm.
STEP 11
STEP 14
CD00G111
Install the plunger in the body. Depending on the CD00G113
condition of the return springs, the friction of the Install the disc on the universal joint. Tighten until the
O-rings may keep the plungers in place in the body. disc touches the four push-rods equally.
STEP 12 STEP 15
Repeat steps 5 to 11 for the other three bodies.
CD00G114
Install the lock-nut and tighten it to a torque of
68.6 ± 4.9 Nm while holding the flats on the disc (3)
with a flat wrench.

8013-11
STEP 16
CD00G115
Place a few spots of grease on the push-rods.
STEP 17
CD00G116
Install the protective boot (2) on the control lever.

8013-12

Section
8014
8014
OF THE CONTROL PEDALS

Printed in France
8014-2
TABLE OF CONTENTS
SPECIFICATIONS ................................................................................................................................................... 3
TORQUE SETTING ................................................................................................................................................. 3
SPECIAL TOOLS .................................................................................................................................................... 3
CONTROL PEDAL .................................................................................................................................................. 4
Description .......................................................................................................................................................... 4
Disassembly ........................................................................................................................................................ 5
Inspection ............................................................................................................................................................ 9
Assembly ............................................................................................................................................................. 9
Troubleshooting ................................................................................................................................................ 15

8014-3
SPECIFICATIONS
Primary coolant pressure....................................................................................... Maximum 9.8 MPa (100 kgf/cm2)
Secondary coolant pressure.........................................................0 ~ 4.4 MPa (Max end of stroke control pressure)
Permissible return pressure........................................................................................................ 0.3 MPa (3 kgf/cm2)
Rated flow..................................................................................................................................................... 10 L/min
Operating angle .............................................................................................................................................. ± 12.4°
Hydraulic fluid .......................................................................................................................... Mineral hydraulic fluid
Working temperature range ................................................................................................................ -20°C ~ +75°C
TORQUE SETTING
Cover retaining screws ........................................................................................................................... 79 to 81 Nm
Cam joint pin locking screw (apply Loctite 241) ......................................................................................... 6 to 8 Nm
Cam setting screw locking nut.......................................................................................................... 31.5 to 37.5 Nm
SPECIAL TOOLS
70
Special tool Dimensions mm 29
9
Ø12
Ø10
Ø 25
Ø 32
Ø 40
20 2
32
CM99E005 CS01C525
Tool for removing the cover bushing. Tool for installing the stopping ring.

8014-4
CONTROL PEDAL
Description
28 29 27 23
26
22
25
19
24
18
21
17
20
14 16
13 15
9 12
8 11
7 10
6
3
2 5
4
1
CI00J500
1 BODY 16 COVER
2 SPOOL 17 O-RING
3 SHIM 18 TAPPET GUIDE
4 SPRING SEAT 19 BUSHING
5 RECOIL SPRING 20 WIPER SEAL
6 CALIBRATED SPRING 21 PUSH-ROD
7 SPRING SEAT 22 NUT
8 LOCKING HALF-WASHER 23 SETTING SCREW
9 STOPPING RING 24 SCREW
10 BALL SEAT 25 GROMMET
11 BALL 26 CAM
12 SPRING SEAT 27 CAM SHAFT
13 SPRING 28 BUSHING
14 SPRING 29 SCREW
15 PISTON

8014-5
Disassembly STEP 3
Always handle high precision parts with the greatest
care to prevent them being damaged by being
knocked or dropped. The components of the control
lever may rust due to contamination and humidity if
they are left without protection after disassembly. If
work has to be stopped, the components must be
protected against contamination or corrosion.
STEP 1
CI01B519
Remove the cam shaft using a 8 mm diameter drift
punch.
STEP 4
CI01B517
Tighten the control pedal in a vice with protective
jaws. Remove the grommet.
STEP 2
CI01B520
Mark the position of the cam with respect to the cover
and remove the cam assembly.
STEP 5
CI01B518
Remove the locking screw from the cam shaft.
CI01B521
Remove the cover retaining screw.

8014-6
STEP 6 STEP 9
CI01B522 CI01B525
Mark the position of the cover with respect to the Mark the position of the piston with respect to the port
control pedal body and remove the cover. of the control pedal body and remove the piston.
NOTE: Repeat the steps 2 to 6 for the second control STEP 10
pedal body.
STEP 7
CI01B526
Mark the position of the springs with respect to the
port of the control pedal body, then remove the outer
CI01B523 spring and the inner spring.
Mark the position of the push-rod with respect to the
guide and remove the push-rod. STEP 11
STEP 8
CI01B527
Mark the position of the spring seat with respect to
CI01B524 the port of the control pedal body and remove the
Mark the position of the guide with respect to the
spring seat.
control pedal body and remove the guide assembly.

8014-7
STEP 12 STEP 15
CI01B528 CI01B531
Mark the location of the balls and remove the four Mark and remove the spool assembly.
balls using a magnet. STEP 16
STEP 13
CI01B532
Mark and remove the spring.
CI01B529
Remove the stopping ring using pliers. STEP 17
NOTE: Be careful not to scratch the inner part of the
body. When installing, make sure that the stopping
ring is put back in its original port.
STEP 14
CI01B535
Compress the spring with the seat so that the two
locking half-washers can be removed.
NOTE: Be careful not to damage the spool surface.
Do not compress the spring by more than 4 mm.
CI01B530
Mark and remove the ball seat.

8014-8
STEP 18 STEP 21
CI01B536 CI01B539
Mark and remove the spool, the spring seat, the Remove the O-ring from the tappet guide.
calibrated spring, the spring seat and the shim.
NOTE: Repeat the steps 7 to 21 for the three other
STEP 19 control pedal ports.
STEP 22
CI01B537
Mark and remove the bushing from the tappet guide.
CI01B533
STEP 20 Position each cover on a flat surface and remove the
bushings using a special tool and a hammer.
STEP 23
CI01B538
Remove the wiper seal from the tappet guide.
NOTE: Make sure you do not damage the inner CI01B534
portion of the tappet guide. Fasten each cam assembly in a vice with protective
jaws, loosen and remove the nuts and the setting
screws.

8014-9
Inspection STEP 1
STEP 1
Check for cracks, distortion or blocking of the springs.
If any one of the defects is found, replace the spring.
STEP 2
Check the spools to ensure that their finish is not
damaged, that they are not twisted, or chipped etc.
Ensure that the spools slide smoothly in the bore of
the control pedal body. If defects are found, change
the entire control pedal.
STEP 3
CI01B536
Check the sleeves and the clips to ensure that their Assemble the shim, the spring seat, the calibrated
finish is not damaged, that they are not twisted, spring and the spring seat in their original positions
cracked or chipped. If any one of the defects is found, on the spool.
replace the damaged part.
STEP 2
STEP 4
Check the bores for damage, internal damage of
housings, or signs of internal wear at the level of the
control pedal. If the control pedal is damaged,
replace the entire assembly.
STEP 5
Discard all the O-rings and use new O-rings.
Assembly
NOTE: Immerse all parts in clean hydraulic fluid in
order to guarantee proper lubrication when installing
and restarting operation.
CI01B540
Compress the spring with the seat so that the two
locking half-washers can be engaged.
CS01C526
NOTE: Assemble the two locking half-washers with
the right angle side (A) directed towards the top.

8014-10
STEP 3 STEP 6
CI01B532 CI01B529
Assemble the recoil spring. Using pliers, insert the stopping ring in the port of the
control pedal body with the right angle directed
STEP 4 towards the top.
NOTE: Be careful not to damage the inside of the
body.
STEP 7
CI01B531
Assemble the spool assembly in the bore of the
control pedal body and ensure that it is positioned
correctly.
STEP 5 CI01B542
Using a special tool, position the stopping ring in its
groove by applying pressure on the recoil spring and
the ball seat.
NOTE: Be careful not to damage the inside of the
body.
CI01B541
Assemble the ball seat.

8014-11
STEP 8 STEP 11
CI01B528 CI01B543
Install the four steel balls on their seats. Assemble the large diameter spring.
STEP 9 STEP 12
CI01B527 CI01B544
Assemble the spring seat. Assemble the piston.
STEP 10 STEP 13
CI01B526 CI01B539
Assemble the small diameter spring. Assemble the O-ring on the tappet guide.

8014-12
STEP 14 STEP 16
CI01B538 CI01B545
Apply a thin coat of grease on the wiper seal and Oil and install the push-rod in the guide.
install it in the tappet guide.
NOTE: Make sure that the wiper seal does not get
NOTE: Respect the position of the wiper seal (A) damaged.
according to the illustration below.
STEP 17
CS01C527
STEP 15
CI01B546
Assemble the tappet guide assembly.
NOTE: Repeat the steps 1 to 17 for the three other
ports of the control pedal.
CI01B537
Assemble the bushing on the tappet guide.

8014-13
STEP 18 STEP 21
CI01B547 CI01B550
Place the cover on a flat surface and install the Assemble the nuts and the screws on the cam.
bushings using the special tool and a hammer.
STEP 22
STEP 19
CI01B520
CI01B548
Position the cam on the cover; assemble the cam
Assemble the cover on the control pedal body. shaft while holding it.
STEP 20 NOTE: Repeat the steps 18 to 22 for the other control
pedal body.
STEP 23
CI01B549
Tighten the cover retaining screw to the torque
specified on page 3.
CI01B551
NOTE: Check the proper positioning of the cover on Apply Loctite 241 on the threads of the cam pin
the control pedal body. locking screw and tighten it to the torque specified on
page 3.

8014-14
STEP 24 STEP 26
CI01B552 CD01B554
Adjust the height of the setting screws until the upper Assemble the upper portion of the grommet on the
surface of the cam is level. Check there is no play cam, apply a humidity inhibitor in the groove of the
between the screws and the push-rods by operating cover in order to avoid oxidation, then assemble the
the cam. Tighten the nuts to the torque specified on lower portion of the grommet on the cover.
page 3.
STEP 25
CI01B553
Tilt the cam and apply grease at the ends of the
push-rods and inject grease in the tappet guide
bushings.

8014-15
Troubleshooting
The following table draws up a list of common problems, reasons for them and action that needs to be taken.
However, in most cases, the problems are not due to the malfunction of only a single component but the
malfunction of this and other related components. It is important to note that this list of measures is not exhaustive.
Problem Cause Action to be taken

The secondary coolant pressure 1. Insufficient primary coolant 1. Getting the correct primary
does not increase. pressure. coolant pressure.
2. Secondary coolant pressure 2. Use a new component.
control spring is worn or broken.
3. Excessive play between the spool 3. Replace the spool or the guides
and the guides. assembly.
4. End play in working component. 4. Removal, installation and
replacement of parts.
The secondary coolant pressure is 1. The sliding parts are jammed. 1. Repair the jammed part.
unstable.
2. Variation in the line pressure at 2. Return directly to the reservoir.
the reservoir.
3. Mixture of air in the line. 3. Operate several times to drain the
air.
The secondary coolant pressure is 1. Line pressure at the reservoir is 1. Return directly to the reservoir.
high. too high.
2. The sliding parts are jammed. 2. Repair the jammed part.
No discharge function. 1. Air trapped in the piston. 1. Operate several times and
release the air.
2. Sliding parts seized up. 2. Repair or replace the defective
part.
3. The seat of the springs (13) and 3. Replace the part.
(16) is defective (see section).
4. Gap between the discharge 4. Replace the spring as well as the
spring and the housing is housing.
abnormally large.
5. Malfunction of the non-return 5. Repair or replace the non-return
check valve. check valve.
6. Calibrated port of the discharge 6. Replace the discharge piston.
piston is abnormally large.
Discharge pressure is too high. 1. Sliding parts are seized up. 1. Repair or replace the defective
part.
2. Calibrated port of the discharge 2. Repair or replace the piston.
piston is blocked.

8014-16

Section
8015

OF THE SIX SOLENOID VALVES BLOCK
8015

Printed in France
CNH Cre 7-27911GB April 2003
8015-2
TABLE OF CONTENTS
SIX SOLENOID VALVES BLOCK .......................................................................................................................... 3
Identifying the ports and the solenoid valves ...................................................................................................... 3
Section ................................................................................................................................................................ 4
Disassembly and assembly ................................................................................................................................. 5
Inspection ............................................................................................................................................................ 6

8015-3
SIX SOLENOID VALVES BLOCK

Identifying the ports and the solenoid valves
C5 C3 C1
B T
Y1 Y5 Y4
Y6 Y3 Y2
C4 C2 P
CS01C519
C1 HIGH SPEED CONTROL Y4 2 STAGE TRAVEL SOLENOID VALVE (RED RING)
C2 SWING BRAKE CONTROL Y3 SWING BRAKE SOLENOID VALVE (PINK RING)
C3 POWER BOOST CONTROL Y5 POWER BOOST SOLENOID VALVE (YELLOW RING)
C4 CUSHION CANCELLATION CONTROL Y6 CUSHION CONTROL SOLENOID VALVE (LIGHT GREEN
C5 SWING CANCELLATION CONTROL RING)
P SIX SOLENOID VALVES BLOCK POWER SUPPLY Y1 SWING CANCELLATION SOLENOID VALVE (GREEN
B MACHINE CONTROL POWER SUPPLY RING)
T RETURN TO THE RESERVOIR Y2 PILOT PRESSURE SOLENOID VALVE

8015-4
Section
5 6
CS01C521
1 NUT 4 O-RING
2 COIL 5 SPOOL
3 CORE 6 SPRING

8015-5
Disassembly and assembly
4
2
3
6
CS01C522
NOTE: During disassembly, identify each part of STEP 5
every component in order to make assembly easier.
The spool of the component Y3 is different from the Remove the spring (6) from the solenoid valve block
components Y1, Y2, Y4, Y5 and Y6. housing.
STEP 1 STEP 6
Remove the connections of the solenoid valve block. Repeat steps 2 to 5 for the disassembly of the other
components.
STEP 2
STEP 7
Remove the retaining nut (1) from the coil (2) and
remove the coil from the core (3). Carry out inspection of the components.
NOTE: During assembly, tighten the nut (1) to a NOTE: During assembly, proceed in the reverse
torque of 4.9 Nm. order to that of disassembly.
STEP 3
Remove the core (3) from the solenoid valve housing.
Discard the O-ring (4).
NOTE: During assembly, install a new O-ring (4) on
the core (3), tighten the core (3) to a torque of 30 to
37 Nm.
STEP 4
Remove the spool (5) from the solenoid valve block
housing.

8015-6
Inspection
1. Clean all parts using suitable cleaning solvent.
Immerse the solenoid valve housing in a
cleaning solvent for several minutes to dissolve
dirt or other foreign matter inside the solenoid
valve housing. Use low pressure compressed air
to blow out any foreign matter from interior of
valve housing. Dry parts using clean cloths.
2. Inspect springs for cracks, distortion, or evidence
of permanent set. Replace a spring if any of
these defects are observed.
3. Check for cracks, holes, deformities and other
signs of wear on the spools. Check that the
spools slide easily into the grooves of the
solenoid valve block spools. If any of these
conditions are seen, replace the solenoid valve
block.
4. Check that the internal threading is not worn out
and that the solenoid valve block is not damaged
inside. If any of these conditions are seen,
replace the solenoid valve block.
5. Measure the play between the spool groove and
the spool. The play must be approximately
0.01 mm. If this is not the case, replace the
solenoid valve block.

Section
8016

OF THE CUSHION CONTROL VALVE
8016
Copyright Ó 2002 Case France

Printed in France
Case Cre 7-27942GB March 2002
8016-2
TABLE OF CONTENTS
CUSHION CONTROL VALVE ................................................................................................................................ 2
Description .......................................................................................................................................................... 2
Disassembly ........................................................................................................................................................ 4
Inspection ............................................................................................................................................................ 6
Assembly ............................................................................................................................................................. 6
CUSHION CONTROL VALVE

Description
Identifying the ports
T G H R
E F
B
A
C D
CS01C518
A DIPPER RETRACTION (TOWARDS CONTROL LEVER) G BOOM LIFTING (TOWARDS CONTROL VALVE)
B DIPPER EXTENSION (TOWARDS CONTROL LEVER) H BOOM LOWERING (TOWARDS CONTROL VALVE)
C DIPPER RETRACTION (TOWARD CONTROL VALVE) R RETURN TO RESERVOIR
D DIPPER EXTENSION (TOWARDS CONTROL VALVE) S CUSHION FUNCTION CANCELLATION
E BOOM LIFTING (TOWARDS CONTROL LEVER) T LEAK RETURN
F BOOM LOWERING (TOWARDS CONTROL LEVER)
NOTE: The cushion control valve can have a machined or moulded body. This manual deals with only the machined
body.

8016-3
Section
10 11 12 13
6 5 4 3 2 1
JS00567A
1 CONTROL VALVE HOUSING 8 PLUNGER ASSEMBLY
2 SPRING 9 O-RING
3 SPOOL 10 SPRING
4 SPRING 11 SPRING GUIDE
5 SPACER 12 O-RING
6 O-RING 13 SPOOL
7 FLOW RESTRICTION ADAPTOR

8016-4
Disassembly STEP 3
NOTE: The numbers within brackets in the following
STEP 1 10
8
9
7
7
JD00551A
Remove the spring (10) and the O-ring (9) from the
plug (8). Scrap the O-ring.
STEP 4
JD00549A
If the cushion control valve has to be replaced,
remove the adaptors and elbow unions and install
them on the new control valve. Do not remove the
four flow restriction adapters (7) installed in the sides 10
of the valve.
NOTE: Mark parts to ensure correct assembly in 13
same valve bore as removed from.
STEP 2
10
9 JD00552A
Remove the spool (13) and the spring (10) from the
8 control valve.
STEP 5
11
13
JD00550A
Remove the plug (8) with the O-ring (9) and the
spring (10).
JD00553A
NOTE: Removal to be carried out in case of a leak
between the spool (13) and the spring guide (11).
Put the spool (13) in a vice using wooden shims to
protect the spool. Remove the spring guide (11) from
the spool (13).

8016-5
STEP 6 STEP 10
11
12
4
JD00554A JD00557A
Remove the O-ring (12) from the spring guide (11). Remove the spring (4).
Scrap the O-ring.
STEP 11
STEP 7
Repeat steps 2 through 6 for the other spool.
3
STEP 8
5
A
6
7 JD00558A
Install an M4 cap screw (A) in the tapped hole of the
spool (3). Remove the spool (3) with the spacer (5)
and the spring (2). Remove the M4 cap screw.
JD00555A STEP 12
Remove the flow restriction adaptor (7) and the
O-ring (6).
3
STEP 9
2
6
5
7
JD00559A
Remove the spring (2) and the spacer (5) from the
spool (3).
JD00556A STEP 13
Remove and discard the O-ring (6) and the flow
restriction adaptor (7). Repeat steps 9 through 12 for the remaining three
spools.

8016-6
Inspection Assembly
STEP 1 NOTE: The numbers within brackets in the following
Clean all parts using suitable cleaning solvent.
Immerse valve housing in cleaning solvent for several NOTE: Lubricate all parts with clean hydraulic oil.
minutes to dissolve dirt or other foreign matter inside Ensure that parts are assembled in the same groove
valve housing. Use low pressure compressed air to as they were removed from.
blow out any foreign matter from interior of valve
STEP 1
housing. Dry parts using clean cloths.
STEP 2 3
Inspect springs for cracks, distortion, or evidence of
permanent set. Replace a spring if any of these
defects are observed.
STEP 3
Check the spools for cracks, holes, distortion or other
damage. Check that the spools slide easily in the
groove of the control valve housing. If any defects are 5
observed replace the cushion valve.
STEP 4
JD00559A
Check the plugs, flow restriction adapters, and spring Install the spacer (5) on the spool (3).
guides for damaged threads. Check the ports in flow STEP 2
restriction adapters for foreign matter, chipping, or
other damage. Check spring guides for bent condi-
tion. Replace a defective part.
STEP 5
Check the spacer for chipping, wear and signs of
damage. If any of these conditions are seen replace
2
the spacer.
STEP 6 3
Check for damaged threads and signs of internal
wear on the control valve housing. If any defects are
seen, replace the cushion valve. 5
JD00560A
Install the spring (2), the spool (3) and the spacer (5)
in the control valve housing.

8016-7
STEP 3 STEP 7
11
3
4 13
JD00561A JD00563A
Install the spring (4) in the spool (3). Place the spool (13) in a vice using wooden shims to
protect it and tighten the spring guide (11).
STEP 4
STEP 8
10
11
6 13
7
JD00562A
Install a new O-ring (6) on the flow restriction adaptor JD00564A
(7). Install the flow restriction adaptor in the control Install the spring (10), the spring guide (11) and the
valve housing. spool (13) in the groove of the control valve housing.
STEP 5 STEP 9
Repeat steps 1 through 4 for remaining three spools.
STEP 6 10
11
12
13
JD00565A
Install the spring (10).
JD00554A
Install the spring guide (11) using a new O-ring (12)
on the spool (13).

8016-8
STEP 10
9
8
JD00566A
Install a new O-ring (9) on the plug (8). Install the
plug and O-ring in the housing.
STEP 11
Repeat steps 6 through 10 for the other spool.
STEP 12
JD00549A
If removed, install the adapters and elbows on the
control valve.

Section
8017
HOSE BURST CHECK VALVE
8017

Printed in France
Case Cre 7-29631GB June 2002
8017-2
TABLE OF CONTENTS
TORQUE SETTINGS ............................................................................................................................................. 2
BOOM RELIEF VALVE .......................................................................................................................................... 3
Marking the ports ................................................................................................................................................ 3
Removal .............................................................................................................................................................. 3
Installation ........................................................................................................................................................... 3
Disassembly ........................................................................................................................................................ 4
Assembly ............................................................................................................................................................. 6
ARM RELIEF VALVE ............................................................................................................................................. 8
Marking the ports ................................................................................................................................................ 8
Removal .............................................................................................................................................................. 8
Installation ........................................................................................................................................................... 8
Disassembly ........................................................................................................................................................ 9
Assembly ........................................................................................................................................................... 11
TORQUE SETTINGS
Boom relief valve
Spool cap (3) ......................................................................................................................................... 274,6 ± 3 Nm
Spool stop cap (1) ................................................................................................................................ 78,5 ± 0,7 Nm
Plug (11) ................................................................................................................................................ 215,8 ± 2 Nm
Plug (15) ............................................................................................................................................... 78,5 ± 0,7 Nm
Safety valve (10)................................................................................................................................... 58,8 ± 0,6 Nm
Arm relief valve
Plug (1) and (5)...................................................................................................................................... 215,8 ± 2 Nm
Spool cap (9) and (11) retaining screws ............................................................................................... 39,2 ± 0,4 Nm
Safety valve (18)................................................................................................................................... 58,8 ± 0,6 Nm

8017-3
BOOM RELIEF VALVE

Marking the ports Installation
When installing, use the same procedure in the
reverse order of removal by assembling new seal
2 rings.
1 For valve adjustment, refer to section 8001.
4 5
CD00K000
1 PILOT SPOOL
2 LEAK RETURN
3 HIGH PRESSURE CIRCUIT BYPASS TOWARDS THE
OTHER VALVE
4 VALVE POWER SUPPLY
Removal
NOTE: Before performing any operation on the
machine, carry out the following operations in the
order shown.
- Depressurise the hydraulic circuit (see
Section 8000).
1. Remove the hoses (1), (2) and (3) and seal the
unions and the hoses.
2. Remove the tube (4) and seal the ports.
3. Remove the screws (5) and remove the relief
valve (6).
4. Seal the cylinder port.

8017-4
Disassembly
9 7 4 5 6 3
10
14 13 11 12 18 17 15 16 36
CI00K505
1. Remove the spool stop cap (1) and discard the 5. Remove the plug (11), discard the joint (12),
joint (2). remove the spring (13) and the check valve (14)
by marking their positions.
2. Remove the spool cap (3), discard the joint (4)
and remove the springs (5) and (6). 6. Remove the plug (15), discard the joint (16),
remove the spring (17) and the check valve (18)
3. Remove the seat from the springs (7).
by marking their positions.
4. Remove the spool (9).
7. Remove the valve (10) and discard the joint (36).

8017-5
21 22 23 24 26 28 25 27
19
20
32
30 29 31 34 35 33
CI00K504
8. Remove the locknut (19), the pressure setting
screw (20) and discard the joint (21).
9. Remove the spring (22) and the check valve
(23).
10. Remove the valve cap (24) from the sheath (25)
and discard the joint (26).
11. Remove the valve nose (27) and remove the
spring (28).
12. Discard the joint (29) and the back up rings (30).
(32).
14. Remove the awl (33), discard the joint (34) and
the back up rings (35).

8017-6
Assembly
21 22 23 24 26 28 25 27
19
20
32
30 29 31 34 35 33
CI00K504
NOTE: When installing, install new seal rings. 7. Oil the cap (24) and the inside of the valve nose
(27).
1. Install a joint (34) and back up rings (35) on the
awl (33). 8. Install the cap (24) taking care not to damage the
joints (29) and (30).
2. Oil and install the awl (33) in the valve nose (27).
9. Install the check valve (23) and the spring (22).
3. Oil and install the valve nose (27) in the sheath
(25). 10. Install a joint (21) on the screw (20).
4. Install the check valve (32) and the spring (31). 11. Install the screw (20) without tightening it too
much, the final tightening will be done with
5. Install a joint (29), the back up rings (30) and a
pressure setting.
joint (26) on the cap (24).
12. Install the blank nut (19).
6. Put the spring (28) in place.

8017-7
9 7 4 5 6 3
10
14 13 11 12 18 17 15 16 36
CI00K505
13. Install an O-ring (2) on the spool stop cap (1). NOTE: Take care in respecting the position of each
14. Install the cap (1) on the relief valve. check valve assembly marked during removal.
15. Oil and install the spool (9). 20. Install an O-ring (16) on the plug (15).
16. Install the springs (5) and (6). 21. Oil and install the check valve (18) and the spring
(17).
17. Install an O-ring (4) on the spool cap (3).
22. Install and tighten the plug (15).
18. Install the spool cap (3).
23. Install an O-ring (12) on the plug (11).
19. Install a joint (36) and install the valve (10).
24. Oil and install the check valve (14) and the spring
(13).
25. Install and tighten the plug (11).

8017-8
ARM RELIEF VALVE

Marking the ports Installation
When installing, use the same procedure in the
reverse order of removal, by assembling new seal
2 rings.
3
For valve adjustment, refer to section 8001.
4
5
1
CD00K001
1 PILOT SPOOL
2 VALVE POWER SUPPLY
3 SPOOL LEAK RETURN
4 VALVE LEAK RETURN
Removal
NOTE: Before performing any operation on the
machine, carry out the following operations in the
order shown.
- Park the machine on the ground.
- Depressurise the hydraulic circuit (see
Section 8000).
1. Remove the hoses (1), (3) and (4) and seal the
unions and the hoses.
2. Remove the tube (2), seal the tube and the
union.
3. Remove the screws (5) and remove the relief
valve (6).
4. Seal the cylinder port.

8017-9
Disassembly
2 3 4 5 6 7 8
36 1
18
10
14
13 11 12 15 16 17
CI00K503
1. Remove the plug (1) and discard the joint (2).
2. Remove the spring (3) and the check valve (4)
after marking their positions.
3. Remove the plug (5) and discard the joint (6).
4. Remove the spring (7) and the check valve (8)
after marking their positions.
5. Remove the retaining screws from the spool stop
cap (9), remove it and discard the joint (10).
6. Remove the screws and remove the spool cap
(11), discard the joint (12).
7. Remove the springs (13) and (14).
8. Remove the seats from the spring (15) and (16).
9. Remove the spool (17).
10. Remove the valve (18) and discard the joint (36).

8017-10
22 23 24 26 28 25 27
21
19
20
32
30 29 31 34 35 33
CI00K504
11. Remove the locknut (19), and the pressure
setting screw (20) and discard the joint (21).
(23).
13. Remove the valve cap (24) from the sheath (25)
and discard the joint (26).
14. Remove the valve nose (27) and remove the
spring (28).
15. Discard the joint (29) and the back up rings (30).
(32).
17. Remove the awl (33), discard the joint (34) and
the back up rings (17).

8017-11
Assembly
22 23 24 26 28 25 27
21
19
20
32
30 29 31 34 35 33
CI00K504
NOTE: When installing, install new seal rings.
1. Install a joint (34) and back up rings (35) on the
awl (33).
2. Oil and install the awl (33) in the valve nose (27).
3. Oil and install the valve nose (27) in the sheath
(25).
5. Install a joint (29), back up rings (30) and a joint
(26) on the cap (24).
6. Install the spring (28).
7. Oil the cap (24) and the inside of the valve nose
(27).
8. Install the cap (24) taking care not to damage the
joints (29) and (30).
10. Install a joint (21) on the screw (20).
11. Install the screw (20) without tightening it too
much, the final tightening will be done with
pressure setting.
12. Install the blank nut (19).

8017-12
2 3 4 5 6 7 8
36 1
18
10
14
13 11 12 15 16 17
CI00K503
13. Install a joint (36) on the valve (18).
14. Install the valve (18).
(3) according to the markings made during
disassembly, install the plug (1) equipped with a
joint (2).
(7) according to the markings made during
disassembly, install the plug (5) equipped with a
joint (6).
17. Install a joint (10) and install the spool stop cap
(9) using four retaining screws.
18. Oil and install the spool (17).
19. Install the spring seats (16) and (15).
20. Install the springs (13) and (14).
21. Install a joint (12) on the spool cap (11).
22. Install and fasten the spool cap (11) using the
four screws.

Section
8018

OF THE HYDRAULIC SWIVEL
8018

Printed in France
8018-2
TABLE OF CONTENTS
HYDRAULIC SWIVEL .............................................................................................................................................. 3
Description ........................................................................................................................................................... 3
Disassembly ......................................................................................................................................................... 4
Assembly.............................................................................................................................................................. 6

Cover retaining screws ...................................................................................................................... 32.2 to 38.2 Nm

8018-3
HYDRAULIC SWIVEL
Description
7 8
1
6
2
3 8
12
11
14
15
9 13
10
JS00031A
1 CAP SCREW 9 THRUST PLATE
2 WASHER 10 HEXAGONAL ALLEN TYPE CAP SCREW
3 LOCKING BAR 11 O-RING
4 PIVOT 12 COVER
5 "V" SEAL 13 HEXAGONAL ALLEN TYPE CAP SCREW
6 BUSHING 14 CAP SCREW
7 O-RING 15 WASHER
8 SEALING RING

8018-4
NOTE: To remove the hydraulic swivel, refer to STEP 3
Section 8006.
Disassembly 10
Always handle the components carefully. Never force,
9
hit or drop components. Prevent any contamination
from dust, water or foreign bodies. Work in a clean
area with clean tools. Always use a press to
disassemble the inner and outer components of the
4
hydraulic swivel.
STEP 1 6
13
JS00027A
Remove the screws (10) and the thrust plate (9).
STEP 4
12
6
6
JS00025A
Remove the screws (13) and the cover (12).
STEP 2 4
JS00028A
Using a press, separate the inner component (4) from
11 the outer component (6).
STEP 5
6
5
4
JS00026A
Remove the O-ring (11) and scrap it.
JS00029A
Remove the "V" seal (5) from the inner component
(4) and scrap it.

8018-5
STEP 6
7
8
8
8
JS00030A
Remove the O-ring (7) and the sealing rings (8) from
inside the outer component (6). Scrap the sealing
rings and the O-ring.

8018-6
Assembly
Clean all the components. Use an oil stone to polish 7
out scratches and rough areas. Use new seals,
O-rings and sealing rings. Take the same precautions
as during disassembly. 8
STEP 1
8
JS00034A
Coat the O-ring (7) with hydraulic fluid and insert it in
the upper groove in the outer component. Coat the
six sealing rings (8) with hydraulic fluid and insert
them, starting from the second groove down from the
JS00032A
top of the outer component.
Clean the outer component in cleaning solvent or low
pressure compressed air. STEP 3
STEP 2
7 A
8
8
B 8
6
JS00035A
Use a mirror to check that the O-ring and sealing
rings are correctly installed. Apply hydraulic fluid,
make sure that the components are not protruding,
twisted, etc.
JS00033A
A: 1 O-ring
B: 6 sealing rings

8018-7
STEP 4 STEP 7
5
11
4 6
CS00G519 JS00039A
Install a new "V" seal (5) on the inner component (4) Install the O-ring (11).
and coat it with clean hydraulic fluid.
STEP 8
STEP 5
13
12
6
4
JS00040A
JS00037A
Install the cover (12) and the screws (13). Tighten the
Insert the inner component (4) in the outer screws to torque (see page 2).
component (6).
NOTE: Do not cut through the "V" seal, or graze it.
STEP 6
10
JS00038A
Install the thrust plate (9) and the screws (10).

8018-8

Section
8019

OF THE HYDRAULIC SWING MOTOR
8019
Copyright  2005 CNH France.SA.

Printed in France
8019-2
TABLE OF CONTENTS
SPECIFICATIONS ................................................................................................................................................... 3
TORQUE SETTINGS .............................................................................................................................................. 3
HYDRAULIC SWING MOTOR ................................................................................................................................ 4
Description .......................................................................................................................................................... 4
Disassembly ........................................................................................................................................................ 6
Inspection .......................................................................................................................................................... 13
Assembly ........................................................................................................................................................... 14
RELIEF VALVE ..................................................................................................................................................... 21
Disassembly ...................................................................................................................................................... 21
Inspection .......................................................................................................................................................... 22
Assembly ........................................................................................................................................................... 22

8019-3
SPECIFICATIONS
See Section 1002
TORQUE SETTINGS
Cover plug .................................................................................................................................................... 23.8 Nm
Bypass valve plug......................................................................................................................................... 23.8 Nm
Non return check valve plug ......................................................................................................................... 23.8 Nm
Cover screw................................................................................................................................................... 157 Nm
Safety valve ..................................................................................................................................................... 78 Nm

8019-4
HYDRAULIC SWING MOTOR

Description
1 SLEEVE
2 SPY JOINT
3 BEARING
4 OIL GAUGE
5 SPRING
6 PISTON PLATE
7 BASE PLATE
8 PISTON ASSEMBLY
9 FRICTION PLATE
10 DISK PLATE
11 O-RING
12 BRAKE PISTON
13 O-RING
14 SPRING
15 RETAINING PIN
16 COVER
17 O-RING
18 PLUNGER ASSEMBLY
19 PISTON
20 SPRING
21 TEFLON RING
22 BUSHING
23 DISTRIBUTION PLATE
24 BEARING
25 CYLINDER
26 HOUSING
27 PLUNGER ASSEMBLY
28 SPRING
29 BY PASS VALVE
30 CHECK VALVE
31 SPRING
32 O-RING
33 BACKUP RING
34 O-RING
35 NON RETURN CHECK VALVE
36 SEAT
37 PLUNGER ASSEMBLY
38 CHECK VALVE
39 SPRING
40 O-RING
41 SHIM
42 SPACER
43 VALVE HOUSING
44 PISTON
45 O-RING
46 BACKUP RING
47 PLUNGER ASSEMBLY
48 SLEEVE
49 SAFETY VALVE ASSEMBLY
50 HEXAGONAL ALLEN TYPE CAP SCREW
51 O-RING
52 BACKUP RING
53 PLUNGER ASSEMBLY
A SHOE
B BRAKE PILOT PORT

8019-5
32 33 34 35 36 38 39 40 42 41 43 45
31 46
15 47
30
44
48
37
28
49
29
50
53 52 51
16 19 18
17
14
13
20
12
21
11
22
10
9 23
B
8
7 24
A
25
6 26
27
4 5 3 2 1
CI00G504

8019-6
Disassembly
STEP 1 STEP 3
JD00387A JD00390A
Remove the oil level dipstick (4) and dipstick tube Remove the large joint on top of the motor. Remove
(A). and discard O-rings.
NOTE: If the swing motor is being replaced, do steps STEP 4
2 through 4 below. If the swing motor is not being
replaced, disregard steps 2 through 4.
NOTE: Install the plugs in the ports of the motor.
STEP 2
JD00391A
To make reassembly easier, mark the location of the
safety valve assemblies (1) on the lid so that they can
be put back in their original place.
JD00388A
Remove the two elbow joints from the motor. Remove
and discard O-rings.

8019-7
STEP 5 STEP 8
1
2
JD00392A JD00395A
Remove relief valve assemblies (1) from swing Place the cover with the shaft on top and remove the
motor. Remove and discard the O-rings (2). retaining ring (1) from the shaft (2).
STEP 6 STEP 9
1
1
JD00393A JD00396A
To aid assembly, put alignment marks (A) on the Remove the internal needle bearing ring (1).
cover and motor housing. Remove the four cover
retaining screws (1). STEP 10
STEP 7
JD00397A
A ALIGNMENT MARK
JD00394A
Remove large O-ring (1) from cover. Discard the
Remove the cover from the motor housing. O-ring.
NOTE: Mark the distribution plate and cover with an
indelible ink felt tip pen prior to removal to ensure
correct alignment when reassembling.

8019-8
STEP 11 STEP 13
2
1
JD00398A JD00400A
Remove the cover distribution plate. Remove the four bushings (1) with teflon rings (2)
from the cover. Discard teflon rings.
STEP 12
STEP 14
1 1
JD00399A
To aid assembly, mark the location of pistons (1) to JD00401A
ensure installation in the same bore as removed Remove the four Belleville washers (1) from bushing
from. Remove the pistons from the balance plate. recesses in the cover.
STEP 15
JD00403A
Remove the plug (1) from cover.

8019-9
STEP 16 STEP 19
3
3
2 2
1
1
JD00403A JD00407A
Remove the O-ring (1) and back-up ring (2) from the Remove the two O-rings (1) and (2) and the teflon
plug (3). Discard the O-ring and back-up ring. back-up ring (3) from the bypass valve plug. Discard
O-rings and back-up ring.
STEP 17
STEP 20
1
2
JD00404A
Remove the spring (1) from cover. JD00408A
Remove the spring (1) and valve assembly (2) from
STEP 18 cover.
STEP 21
Rotate cover 180 degrees and repeat steps 15
1 through 20 to remove the other check valve and
bypass valve plug.
JD00405A
Remove the check valve (1) from the cover.

8019-10
STEP 22 STEP 24
NOTE: Protect the housing and the piston surfaces
with rags when you lever the piston out of the
housing.
JD00409A
JD00412A
JD00410A
Remove the plug (1) from cover. Remove O-ring from
plug. Discard the O-ring.
STEP 23
JD00413A
Install two M6 screws (A) in tapped holes in piston.
1 Lever these screws and free the piston from the
housing.
JD00411A
Remove the springs (1) from the brake piston (2).

8019-11
STEP 25 STEP 27
1
JD00414A JD00417A
Remove the cylinder assembly from the motor
2 housing.
STEP 28
3 1
JD00415A
Remove the O-rings (1) and (2) from the swing motor
housing (3) and the brake piston (4). Discard O-rings.
Remove the two M6 screws from the brake piston. JD00418A
Remove the external bearing ring (1) from the motor
STEP 26 housing.
2
STEP 29
1
JD00416A
Remove the three friction plates (1) and the three
disc plates (2) from the motor housing. JD00419A
Position the motor housing in a press. With a sleeve
or a suitable guiding pin, force the lip seal out of the
housing. Discard the lip seal.

8019-12
STEP 30 STEP 33
NOTE: Mark the location of the pistons on the base
1
plate and on the cylinder. Pistons must be installed in
same positions during assembly.
1
2
JD00420A
Remove the retaining ring (1) from the fluted shaft
(2).
STEP 31
JD00423A
Remove the piston plate (1), the piston assembly (2)
and the base plate (3) from the cylinder.
STEP 34
1
JD00421A
Remove the tapered roller bearing and the spacer 3
with an extractor separator.
STEP 32
JD00424A
2 Slip the piston plate (1) out of the sliding surfaces of
the piston assemblies (2), while ensuring that it does
not get damaged. Remove the pistons from the base
1 plate (3).
JD00422A
Remove the tapered roller bearing (1) and the spacer
(2) from the shaft (3).

8019-13
STEP 35 Inspection
STEP 1
Check the distribution plate sliding surfaces for signs
of seizing or wear. If there is evidence of seizing or
wear, the plate should be replaced.
STEP 2
1 Check for wear of the pistons. Replace the motor if
2 the depth of any shoe sliding surface is less than
0.45 mm, if the shoe surfaces are seriously damaged
or if a piston assembly shows any sign of seizing.
There should be no wear of the external surfaces of
the piston assemblies.
JD00425A
Using an extractor, remove the spacer (1) from the STEP 3
fluted shaft. Remove the spring (2) from the cylinder.
Check for signs of seizing or wear on the piston plate
sliding surface. The plate should be replaced if there
is evidence of seizing or wear.
STEP 4
Check for signs of seizing, wear or damage on the
cylinder piston bores. The motor should be replaced
if there is evidence of seizing or if the piston bores
are damaged.
Inspect the needle bearing and tapered roller bearing
for damage. The bearings should be replaced if any
damage is found, or after 3000 hours of operation.

8019-14
Assembly
STEP 1 STEP 3
JD00427A JD00429A
Apply grease (No. 2 EP lithium grease) to the curved Apply clean hydraulic fluid on the sliding surfaces of
part of the cylinder shaft that contacts the spring and the piston assemblies (A) and install the piston plate.
install the spring.
STEP 4
STEP 2
2 3
3
1
JD00432A
JD00428A Install the spacer (1) and a new tapered roller bearing
Apply clean hydraulic fluid to the cylinder (1) bores. (2) on the shaft. Using a proper size sleeve on the
Install the piston assemblies (2) at the ports of the inner race of the tapered roller bearing, press the
base plate (3). Install the piston assemblies and the bearing and sleeve (3) on the shaft.
base plate on the cylinders. Be sure that the pistons
are installed in the same bores as removed from.

8019-15
STEP 5 STEP 8
JD00430A JD00418A
Apply a thin coat of Loctite 515 or 518 where the Install the new external roller ring (1) in the motor
sleeve is installed on the cylinder shaft. Press the housing.
sleeve on the shaft.
STEP 9
STEP 6
JD00417A
JD00420A Carefully install the cylinder assembly in the housing.

Install the retaining ring (1). Be careful when installing the cylinder assembly not
to damage the splines on the shaft.
STEP 7
STEP 10
2
A 1
JD00431A
Before removal, apply grease to the lip of the lip seal. JD00416A
Position housing in a press. Apply Loctite 504 to the Apply clean hydraulic fluid to both faces of the friction
periphery of the lip seal. Install and centre the lip seal plates (1) and the disc plates (2). Install a disc plate
in the housing bore. With a suitable sleeve (A), press first, then a friction plate, then a disc plate, then a
the lip seal in the bore of the housing. friction plate, then the last disc plate, then the last
friction plate.

8019-16
STEP 11 STEP 13
1
1
3
2
JD00415A JD00411A
Install the springs (1) in the brake piston (2) in their
2 original locations.
STEP 14
4
1
JD00414A
Apply grease to the new O-rings (1) and (2); install
the O-rings in the motor housing (3) and on the brake
piston (4). Install two M6 screws (A) in tapped holes JD00410A
in piston to assist in installing the brake piston in the
motor housing.
STEP 12
JD00409A
Install a new O-ring on the plug (1). Install the plug
(1) on the cover. Tighten the plug to a torque of
JD00433A 23.8 Nm.
Apply clean hydraulic fluid on the periphery of the
piston. Push the piston in the housing. Remove the
two M6 screws.

8019-17
STEP 15 STEP 18
Repeat steps 15 through 17 to install second bypass
1 valve on other side of cover.
STEP 19
2 1
JD00408A
Reposition the cover and install the spring (1) and
valve assembly (2) in bypass valve port of cover.
STEP 16
JD00405A
Install the check valve (1) in the cover.
4
STEP 20
3
2 1
JD00407A
Install two new O-rings (1) and (2) and a new teflon
back-up ring (3) on bypass valve plug (4).
STEP 17 JD00404A
Install the spring (1) in the cover.
STEP 21
1 3
2
1
JD00406A
Install bypass valve plug (1) in cover. Tighten the plug
to a torque of 23.8 Nm. JD00403A
Install a new O-ring (1) and a new back-up ring (2) on
the plug (3).

8019-18
STEP 22 STEP 25
1 1
JD00403A JD00400A
Install the plug (1) in cover. Tighten the plug to a Apply No. 2 EP lithium grease to the bushings (1),
torque of 23.8 Nm. new teflon rings (2), and the pins (3) in the cover.
Install a teflon ring on each of the bushings. Install
STEP 23 the bushings with rings in the bushing ports on the
Repeat steps 19 through 22 to install second make cover.
up check valve.
STEP 26
STEP 24
1
2 1
JD00399A
JD00401A
Apply No. 2 EP lithium grease to the pistons and
Install the Belleville washers (1). install the pistons (1) in the balance plate (2). Be sure
that the pistons are installed in same bore as
removed from. Install pistons and balance plate on
the cover ensuring that marks made in step 10 of
disassembly are aligned.

8019-19
STEP 27 STEP 30
2 1
1 2
JD00395A JD00394A
Install the new needle bearing inner race (1) on the Install carefully the cover (1) and the distribution plate
shaft and install the retaining ring (2). (2) on the housing, by making sure that the
distribution plate and bushings do not fall off the
STEP 28 cover. Align the motor housing and cover alignment
marks.
1 STEP 31
JD00397A
Install a new, greased O-ring (1) on the cover.
STEP 29
JD00393A
Install the four retaining screws (1) on the cover and
tighten to a torque.
JD00434A
Apply Loctite 504 to the mating surfaces of the motor
housing and cover.

8019-20
STEP 32 STEP 34
JD00435A JD00388A
Install new O-rings on elbows. Install the elbow
unions in the motor cover.
STEP 35
JD00392A
Install a new O-ring (1) on the safety valve assembly
(2). Install the safety valve assemblies in the cover
and tighten to a torque. JS00436A
Install the oil level gauge tube (A) (L = 116 mm), and
STEP 33 the oil level gauge.
STEP 36
Apply a pilot pressure of 30 bar at the brake port.
Check that the drive shaft can be rotated smoothly at
least one full revolution by applying a torque of
approximately 39 Nm.
NOTE: If the shaft does not turn, the unit has not
been assembled correctly. Disassemble and repeat
assembly steps.
JD00390A
Install a new O-ring on the large fitting and install the
fitting in the swing motor cover.

8019-21
RELIEF VALVE
Disassembly
STEP 1 STEP 4
JD00438A JD00441A
Loosen the plug on the relief valve. Remove the relief valve assembly from the housing.
STEP 2 STEP 5
JD00439A JD00435A
Remove the plug from the relief valve housing. Remove O-ring from housing, if not previously
removed. Discard the O-ring.
STEP 3
STEP 6
JD00440A
If necessary, remove the O-ring and back-up ring JD00442A
from plug. Do not discard the rings; rings are not Remove the piston from the poppet.
available separately.

8019-22
STEP 7 Inspection
NOTE: Individual relief valve assembly parts cannot
be replaced. If a relief valve assembly fails to operate
properly for any reason other than dirt or foreign
matter, the entire assembly must be replaced.
STEP 1
Clean the disassembled components with clean
hydraulic fluid and dry them with compressed air at
low pressure.
Assembly
STEP 1
JD00443A
Remove the poppet sleeve.
STEP 8
A B JD00445A
Install the seat and the spring on the poppet.
STEP 2
JD00444A
Remove the spacer (A) and the shim (B) from the
poppet.
STEP 9
JD00444A
Install the spacer (A) and the shim (B) on the poppet.
JD00445A
Remove the spring and the seat from the poppet.

8019-23
STEP 3 STEP 6
JD00443A JD00441A
Install the sleeve on the poppet. Install relief valve assembly in housing.
STEP 4 STEP 7
JD00442A JD00440A
Install the piston on the poppet. Install O-ring and back-up ring on plug if removed.
STEP 5 STEP 8
JD00435A JD00439A
Install new O-ring on the housing. Assemble and tighten the plug in the relief valve
housing.

8019-24

Section
8019

OF THE SWING HYDRAULIC MOTOR
8019

Printed in France
8019-2
TABLE OF CONTENTS
SPECIFICATIONS ................................................................................................................................................... 2
TOOL TO BE MANUFACTURED ............................................................................................................................ 3
HYDRAULIC SWING MOTOR ................................................................................................................................ 4
Description .......................................................................................................................................................... 4
Disassembly ........................................................................................................................................................ 6
Inspection .......................................................................................................................................................... 10
Wear limit .......................................................................................................................................................... 11
Assembly ........................................................................................................................................................... 12
SPECIFICATIONS
See Section 1002

Safety valve (8)............................................................................................................................................... 177 Nm
Anti-rebound suction (1) ................................................................................................................................... 69 Nm
Cover (9) retaining screw (16) on the housing (12) ........................................................................................ 431 Nm
Booster check valve plug (13) ........................................................................................................................ 539 Nm
Anti-rebound valve (2) retaining screw (5)........................................................................................................ 29 Nm
Plug (40) ........................................................................................................................................................... 36 Nm
Plug (42) ........................................................................................................................................................... 36 Nm

8019-3
TOOL TO BE MANUFACTURED
For removal of the brake piston
40
Ø 40
100
250
Ø 11
10
M10
189
210
CS01D501

8019-4
HYDRAULIC SWING MOTOR

Description
13 10
11
44
8
14
15
16
2
40
5 41 4 1
6 7 19 18 37
36
2
17
20 38 39
21 29
22 30
23 38
26 42
43
28
27
24 12
34 32
25 35 33 31
CS01D502

8019-5
1. Anti-rebound suction 23. Barrel
2. Anti-rebound valve 24. Plate
3. O-ring 25. Spherical bearing
4. Back up ring 26. Piston
5. Screw 27. Thrust pad
6. O-ring 28. Connecting rod
7. O-ring 29. Friction plate
8. Safety valve 30. Disk plate
9. Motor cover 31. Shaft
10. O-ring 32. Bearing
11. Back up ring 33. Retaining ring
12. Motor housing 34. Thrust plate
13. Plug 35. Lip seal
14. Spring 36. Bearing
15. Booster check valve 37. Retaining ring
16. Screw 38. Shim
17. O-ring 39. Spring
18. Port plate 40. Plug
19. Spring 41. O-ring
20. Brake piston 42. Plug
21. O-ring 43. O-ring
22. O-ring 44. O-ring

8019-6
Disassembly STEP 4
NOTE: The numbers in brackets refer to the drawing 9
on page 4.
NOTE: Carry out step 1, only if the motor needs to be
replaced.
STEP 1
Remove all the installation joints from the motor. A
12
STEP 2
5
CD01D002
To make installation easier, draw alignment marks (A)
6 7 between the cover (9) and the motor housing (12).
1 STEP 5
2
3
1
4
8
CS01D503
To make installation easier, mark the location of the
anti-rebound suctions (1) on the anti-rebound valve
(2). Remove the anti-rebound suctions (1) from the
anti-rebound valve (2). Remove and discard the
O-rings (3) and the back up rings (4) from the anti- CD01D001
rebound suctions (1). To make installation easier, mark the location of the
safety valves (8). Remove the safety valves (8) from
STEP 3 the cover (9) of the motor. Remove and discard the
O-rings (10) and the back up ring (11).
Remove the screws (5) and remove the anti-rebound
valve (2) from the motor. Remove and discard the
O-rings (6) and (7). Remove the plugs (40) and
discard the O-rings (41).

8019-7
STEP 6 STEP 11
CD01D003 CD01D005
Remove the plug (13) and the booster check valve Remove the springs (19) from the brake piston (20).
assembly from the cover (9). Remove the spring (14)
and the check valve (15) from the cover. Discard the STEP 12
O-ring (44) from the plug (13).
STEP 7
Rotate the cover by 180° and repeat step 6 to remove
the other booster check valve assembly.
STEP 8
CD01D006
Install the manufactured tool on the brake piston (20)
and remove the brake piston from the motor housing
(12).
STEP 13
Remove and discard the O-rings (21) and (22) from
CD01D004 the motor housing (12).
Remove the retaining screws (16) from the cover (9)
and remove the cover (9) from the housing (12).
NOTE: When loosening the screws (16), the brake
springs will gently push the cover (9) back.
STEP 9
Remove and discard the O-ring (17) from the cover
(9).
STEP 10
Remove the port plate (18) from the housing (12).
NOTE: Be careful not to scratch the plate during
removal.

8019-8
STEP 14 STEP 17
CD01D007 CS01D504
Remove the barrel assembly (23) equipped with the Install the shaft (31) in a press. Using a sleeve or a
plate (24), the spherical bearing (25), the pistons suitable guiding pin, remove the inner bushing from
(26), the connecting rod (27) and the thrust pads (28) the bearing (32).
from the housing (12).
STEP 18
STEP 15
CD01D010
CD01D008 Remove the retaining ring (33), the thrust plate (34)
Remove the friction plates (29) and the disk plates and the lip seal (35) from the housing (12). Discard
(30) from the housing (12). the lip seal (35).
STEP 16 STEP 19
CD01D009 CD01D011
Protect the splines on the shaft (31) and remove the Remove the outer bushing of the bearing (32) from
shaft (31) from the motor housing (12). the housing (12).

8019-9
STEP 20 STEP 21
NOTE: Mark the location of the pistons in the thrust
pad and in the barrel. Pistons must be installed in
same positions during assembly.
25 28
24
26
27
38
23 39
37 38
CS01D505
Remove, all in one piece, the plate (24), the piston
assembly (26) and the thrust pad (27) from the barrel
(23). Taking care not to damage it, slide the plate (24)
out of the friction surfaces of the piston assemblies
(26). Remove the pistons (26) from the thrust pad
(27).
STEP 22
CD01D012 Remove the spherical bearing (25) and the
Using a slide hammer puller, remove the bearing (36) connecting rods (28) from the barrel (23).
from the cover (9).
STEP 23
Remove the retaining ring (37), the shims (38) and
the spring (39) from the barrel (23).
STEP 24
If necessary, remove the plug (42) from the housing
(12) and discard the O-ring (43).

8019-10
Inspection STEP 5
STEP 1 The bearing is normally replaced after 3000 hours of
operation.
The port plate (18) includes crescent-shaped
apertures that ensure modulation between oil at high The bearings are also replaced if damage to the roller
pressure and oil at low pressure. Any damage to the contact surfaces is noticed when removing the motor
contact surface between the port plate and the end before the 3000 hours period.
plate of the barrel will cause leaks and lead to a drop It is advised that the bearings be replaced
in volumetric efficiency that will possibly be systematically during installation of the motor. Insofar
accompanied by increased spinning. as they get damaged easily when the motor is
Possible seizing at these two contact surfaces may removed.
result in a loss of mechanical efficiency and can lead STEP 6
to significant damage.
Replace all seal rings whose edges show signs of
A wear of more than 0.03 mm requires the plate to be
damage. In addition, the seal rings are also replaced
replaced. The plate should also be replaced if it
after 3000 hours of operation, even though there may
shows signs of seizing.
be no leaks or signs of wear and tear. Use new seals
STEP 2 when installing the motor.
Repair all damage to the contact surface of the piston STEP 7

shoes (26).
Replace all O-rings that show signs of damage. The
If the depth of the sliding surface of one of the shoes O-rings are replaced after 3000 hours of operation,
is less than 0.45 mm, or if the shoe surfaces are even though there may be no leaks or signs of wear
badly damaged, replace the entire motor. and tear. Use new O-rings when installing the motor.
STEP 3 STEP 8
The outer surface of the piston assembly should The back up rings should also be replaced when
present practically no signs of wear. If a piston installing the motor.
assembly shows signs of seizing, replace the whole
motor.
STEP 4
The barrel bores should present practically no signs
of wear. If the bores show signs of seizing or
abnormal wear, replace the entire motor.

8019-11
Wear limit
Standard dimensions Minimum dimensions

Description Solution
(mm) (mm)
Play between piston and Replace the barrel and the
0.027 0.052
barrel bore pistons
Play between piston and Replace the pistons and
0 0.3
shoe (A) the shoes
Replace the pistons and
Thickness of shoes (B) 5.5 5.3
the shoes
Assembled height of the
Replace the thrust pad and
thrust pad and the 6 5.5
the spherical bearing
spherical bearing (H - h)
Thickness of the friction
1.8 1.6 Replace the plate
plate
CS99J556 CS99J557

8019-12
Assembly STEP 3
NOTE: The numbers in brackets refer to the drawing
on page 4.
Carry out the assembly with the very greatest care.
Do not hit or force the components, since that will
damage them and cause seizure or oil leaks which
would result in impaired performance of the machine.
Before installing the components, clean them with a
suitable solvent and remove all metallic particles and
foreign bodies from all components. Replace all
O-rings and back up rings with new ones.
STEP 1
CD01D015
Install the retaining ring (33) in the housing (12).
STEP 4
CD01D013
Install the new inner bearing (32) bushing on the
shaft (31).
STEP 2 CD01D016
Install the thrust plate (34) in the housing (12). Apply
grease on the lip seal (35) and using a suitable
guiding pin, install the lip seal (35) in the housing
(12). Guide the lip towards the interior of the housing.
STEP 5
CD01D014
Install the new internal bearing (36) bushing on the
shaft (31).
CD01D017
Using a suitable tool, install the external bearing (32)
bushing in the housing (12).

8019-13
STEP 6 STEP 10
Install the pistons (26) on the thrust pad (27). Apply
clean hydraulic oil in the bores of the barrel (23) and
install the plate/piston assembly in the barrel (23)
respecting their original ports marked at the time of
removal.
STEP 11
CD01D018
Protect the splines and install the shaft (31) in the
housing (12) taking care not to damage the lip seal
(35).
STEP 7
Apply a thin coat of grease on the plate (24) (chamfer
side in contact with the housing) and install the plate CD01D019
in the housing (12). Install the equipped barrel (23) on the shaft (31).
STEP 8 STEP 12
25 27
26 A
28
38
23
39
39 38 A
CS01D506 CD01D020
Install a shim (38), the spring (39) and a shim (38) in Apply clean hydraulic fluid to the two faces of the
the barrel (23). Install the retaining ring (37) on the friction and disk plates. Install the disk brakes, start
barrel (23). with a disk plate (30) then a friction plate (29) and so
on. Take care in aligning the notches (A) of the
STEP 9 friction plates.
Install the connecting rods (28) and the spherical
STEP 13
bearing (25) on the barrel (23).
Apply a thin coat of grease on the O-rings (21) and
(22) and install the O-rings (21) and (22) in the
housing (12).

8019-14
STEP 14 STEP 16
CD01D021 CD01D022
Using a suitable tool, install the outer bearing bushing
(36) in the cover (9).
A STEP 17
CS01D507
Apply clean hydraulic fluid around the brake piston
(20) and install the brake piston in the housing (12).
Put the brake in the housing (12). Take care in CD01D023
aligning the notches (A) as shown above. Install the port plate (18) on the cover (9). Apply a
thin coat of grease on the O-ring (17) and install the
STEP 15 O-ring (17) on the cover (9).
STEP 18
CD01D005
Install the springs (19) in the brake piston (20).
CD01D024
Install the cover (9) and the port plate (18) on the
housing (12) carefully.

8019-15
NOTE: Ensure that the port plate (18) and the STEP 23
springs (19) are installed correctly.
5
STEP 19
Install the cover retaining screws (16) and tighten to a
torque.
6 7
STEP 20
1
2
3
1
4
CS01D503
Apply a thin coat of grease on the O-rings (6) and (7)
and install the O-rings on the anti-rebound valve (2).
CD01D025 STEP 24
Install a booster check valve (15) and a spring (14) in
Install the anti-rebound valve on the cover (9), install
the cover (9). Install an O-ring (44) on the plug (13)
the screws (5) and tighten to a torque.
and install the plug on the cover (9). Tighten to a
torque. STEP 25
STEP 21 Install an O-ring (41) on the plugs (40) and install the
plugs (40) on the anti-rebound valve (2), tighten to a
Repeat step 20 to install the other booster check
torque.
valve assembly.
STEP 26
STEP 22
Install an O-ring (3) and a back up ring (4) on the anti-
rebound suctions (1) and install the suctions on the
anti-rebound valves (2), tighten to a torque.
STEP 27
Install an O-ring (43) on the plug (42) and install the
plug (42) on the housing (12), tighten to a torque.
STEP 28
Install installation joints on the motor.
CD01D026
Install an O-ring (10) and a back up ring (11) on the
safety valves (8) and install the valves (8) on the
cover (9). Tighten to a torque.

8019-16

Section
8020
HYDRAULIC FUNCTIONS
8020

Printed in France
Case Cre 7-28490GB December 2000
8020-2
TABLE OF CONTENTS
HYDRAULIC FUNCTIONS........................................................................................................................................ 3
Function List..........................................................................................................................................................3
Controls in Neutral ................................................................................................................................................ 6
High Speed Travel Circuit ..................................................................................................................................... 8
Low Speed Travel Circuit ....................................................................................................................................10
Straight Line Travel Circuit..................................................................................................................................12
Swing Circuit .......................................................................................................................................................14
Variable Priority Valve Circuit..............................................................................................................................16
Boom Raising Circuit...........................................................................................................................................18
Boom Lowering Circuit, Load Holding Valve.......................................................................................................20
Boom Lowering Reinjection Circuit .....................................................................................................................20
Boom Lowering Anti-vibration Circuit ..................................................................................................................20
Dipper Extending Circuit .....................................................................................................................................22
Dipper Retracting Circuit .....................................................................................................................................24
Dipper Retracting Reinjection Circuit ..................................................................................................................24
Bucket Opening Circuit .......................................................................................................................................26
Bucket Closing Circuit .........................................................................................................................................27
Crusher Circuit ....................................................................................................................................................28
Breaker Circuit ....................................................................................................................................................30
NOTES ....................................................................................................................................................................32

8020-3
HYDRAULIC FUNCTIONS
Function List
Description
Operation Description of function
of operation
Travel
High speed may be obtained by changing the displacement of the travel motors
from high to low.
When pressure becomes too high, the motors automatically change down to low
High speed speed. Page 8
When pressure drops, the motors automatically change up to high speed.
The machine returns to 1st speed when travel pressure drops to below
570 psi, to prevent snatching when turning on the spot in 2nd speed.
Low speed Low speed may be obtained by selecting high travel motor displacement. Page 10
Straight line If the attachment is used or swing operated during travel, the machine continues
Page 12
travel traveling in a straight line without hunting.
Swing
When the swing control is in neutral, swing is prevented by the motor reduction
gear brake.
When the swing control is operated, the moto-reduction gear brake is released.
Braking The brake will be applied once more within 5 seconds of returning the swing Page 14
control to neutral or of halting all attachment movement.
When the swing locking control is operated, the moto-reduction gear brake will
be applied.
Full swing power is maintained by a priority valve inside the control valve.
Priority Page 16
When digging trenches, the variable swing priority valve is actuated.
Anti-
This function allows the swing movement to come to a smooth halt.
shuddering
Attachment
Boom raising An internal spool makes two flows to the boom possible. Page 18
Boom
Boom can be lowered by releasing the load holding valve inside the control
lowering, Page 20
valve.
load holding
Boom By reinjecting hydraulic oil via the boom spool and maintaining permanent feed/
lowering return information feed back, higher speed and negative pressure prevention are Page 20
injection made possible.
Boom
lowering - Peak pressure is prevented by the bleed off circuit, thereby reducing extra
Page 20
vibration vibration.
prevention
Dipper
An internal spool makes two flows to the dipper possible. Page 22
extension
Dipper
Dipper retraction is made possible by releasing the load holding valve inside the
retraction - Page 24
control valve.
load holding
Dipper
retraction - The reinjection cancellation valve makes combined movements faster. Page 24
reinjection
Cushion The shocks encountered at the end of attachment movements are reduced by
valve the cushion valve, which has a built-in pilot heating circuit.

8020-4
Attachment (continued)
An option section is included in the control valve and can be used for special
Option Page 30
attachments such as a crusher or breaker.
Other features
Auto When the engine is under heavy load, the control valve inlet limiter is subjected
boosting to forced feeding for 8 seconds.
Negative This is designed to reduce power consumption by reducing flow from the pumps
control when the machine is not under load.

8020-5
This page is intentionally left blank

8020-6
Controls in Neutral
When the controls are in neutral, with the engine running, a part of the flow coming from the low pressure pump
arrives at PP and is divided by a battery of restrictors. Part of the flow goes through the travel control valves and
the other part goes to the remaining control valves before returning to the tank. When the spools are moved,
these circuits are closed, thereby closing the travel or upperstructure pressure switch contact points and
transmitting the electronic information.
The two flows from the HP pumps cross the control valve via the free passages. They are controlled by two
pressure limiters set at 370 psi for a flow of 13.2 gpm and two flow restrictors. Both pressures (PN) are sent to
the Pi1 and Pi2 ports on the pumps to regulate them to deliver minimum flow.

8020-7
Ps1 Dr T2 T1 T3 T5 T4 Ps2
405 psi 405 psi

28 bar 28 bar
Pc1
Pb9
A5
Pa9
B5
Pb5’
Pb5
Pa5’ Pc2
Pa5
A8
B8
Pc3’ Pb8’
Pc3 Pb8
Pa8’
Pbu
Pa8
Pb4 B7
Pb4’
A7
B3
Pb7
A3
Pb3 Pa7
Pa3
B6
B2 A6
Pb6
A2
Pb2
Pa6
Pa2
P4
B1
A1
Pb1
Pa1
P3
3 PT
33 PA
3 P3 PH
P0
10µ P
0.02 MPa
0.103 Mpa
14.5 psi
1 bar
P1 P2
A1 Psv a3 A2
a1 a2
3L 3L
3.92 MPa
568 psi a3
39.2 bar
A3
Dr B1 B3
CM00K026

8020-8
High Speed Travel Circuit

There are two flows of oil which supply the travel motors.
In high speed the travel motors are in low displacement position.
The travel motors have an internal circuit which enables them to change from low to high displacement when
supply pressure exceeds a certain level. If the pressure drops once more, the motors automatically revert to high
speed.
Oil from the A1 pump outlet enters the P1 port on the control valve, whereas oil from the A2 pump outlet enters
P2. One flow goes directly to the left-hand travel spool and the other goes to the right-hand travel spool.
The calculator sends a current to the cylinder displacement change electrovalve for high speed to be selected.
The 565 psi pilot pressure coming from the high speed electrovalve passes through the hydraulic swivel and
goes to pilot the travel motor cylinder displacement change spools.
C1. 2 stage travel (Red band)

C3. Power boost (Yellow band)
C5. Swing shut off (Green band)
Pa1/A1. RH forward travel
Pb1/B1. RH reverse travel
Pa6/A6. LH forward travel
Pb6/B6. LH reverse travel
1. Travel speed switch
2. Controller
3. Work mode switch

8020-9
Pm1 3V 3V Pm2
T2 T1
P2 P1
P1 P2
Pm2 Pm1
A
C E B
F D
405 psi 405 psi

28 bar 28 bar
Pc1
Pb9
A5
Pa9
B5
Pb5’
Pb5
Pa5’ Pc2
Pa5
A8
B8
Pc3’ Pb8’
Pc3 Pb8
Pa8’
Pbu
Pa8
Pb4 B7
Pb4’
A7
B3
Pb7
A3
Pb3 Pa7
Pa3
%
3E $
B2
A2
Pb2
Pa2
3D
P4
% B T
$ &
3E
3D
P
& C2
3 3
PT PP PA P3 PH
&
C4
$ $
2
1 , 2
3
CM00K013

8020-10
Low Speed Travel Circuit

Low speed is the normal speed for travel. Even if the machine is in high speed, if the starter switch key is turned
OFF and then turned ON again, the speed setting will always return to low speed.
Al pump flow enters port P1 of the control valve and A2 pump flow enters port P2. One flow goes directly to the
left-hand travel spool and the other goes to the right-hand travel spool. The high speed travel electrovalve is
switched OFF and the motor displacement change spools are in direct communication with the tank return line.
C1. 2 Stage travel (Red band)

Pa1/A1. RH forward travel
Pb1/B1. RH reverse travel
Pa6/B6. LH forward travel
Pb6/B6. LH reverse travel
2. Controller
3. Work mode switch

8020-11
Pm1 3V 3V Pm2
T2 T1
P2 P1
P1 P2
Pm2 Pm1
A
C E B
F D
405 psi 405 psi

28 bar 28 bar
Pc1
Pb9
A5
Pa9
B5
Pb5’
Pb5
Pa5’ Pc2
Pa5
A8
B8
Pc3’ Pb8’
Pc3 Pb8
Pa8’
Pbu
Pa8
Pb4 B7
Pb4’
A7
B3
Pb7
A3
Pb3 Pa7
Pa3
%
B2
$
A2
3E
Pb2
3D
Pa2
P4
%
$ B T
3E
3D &
P
3 PT PP PA
3 P3 PH
& C2
& C4
$ $
1
2
1 , 2
CM00K014

8020-12
Straight Line Travel Circuit

This chapter considers the situation whereby travel and boom raising operations are carried out at the same
time.
When the travel function is used, the low pressure circuit is closed and the pressure switch transmits this
information to the control unit, which in turn powers the pressure booster electrovalve.
When boom spool 2 is piloted, the control circuit coming from PP and going through all the attachment and swing
control valves is closed. The pressure in this circuit then rises to 565 psi and this pilots the straight line travel
valve. When this occurs, pump P1 supplies oil to both travel motors and pump P2 supplies oil to the attachment.
As oil is supplied to both travel motors in parallel the pressure is equal and the machine travels in a straight line.
If all the flow to the attachment is not used, the surplus is sent to the travel function, thereby keeping speed loss
to a minimum.
If other functions than the boom are used at the same time as the travel function, the operating principle is the
same.
C1. 2 stage travel (Red band)

Pa1/A1. RH Forward travel
Pb1/B1. RH Reverse travel
Pa6/A6. LH Forward travel
Pb6/B6. LH Reverse travel
Pb4. Boom spool 2
Pa8/A8. Boom up
Pb8/B8. Boom down
2. Controller
3. Work mode switch

8020-13
Pm1 Ps Ps Pm2
T2 T1
P2 P1
P1 P2
Pm2 Pm1
A
C E B
F D
405 psi 405 psi

28 bar 28 bar
Pc1
Pb9
A5
Pa9
B5
Pb5’
Pb5
Pa5’ Pc2
Pa5
$
%
Pc3’
Pb8’
Pc3
3E
3D
Pbu Pa8’
3E B7
Pb4’
A7
B3
Pb7
A3
Pb3 Pa7
Pa3
%
B2 $
A2
3E
Pb2
3D
Pa2
P4
B T
%
$ &
3E
3D P
& C2
3 PT
33 PA
3 P3 PH
& C4
$ $
2
1 , 2
CM00K015

8020-14
Swing Circuit
The swing function has one source of oil supply only.
When the engine is started and the swing control is in neutral, the swing brake electrovalve is powered and the
brake is applied.
When the swing function is operated, the swing pressure switch closes. Current to the swing brake electrovalve
is cut off and the swing moto-reduction gear brake is released. The upperstructure thereby becomes free to turn.
When the swing control is in neutral and the attachment is operated, lateral forces are exerted on the
attachment. To prevent the swing effect damaging the brake the swing brake is released.
When one of the HP pressure detectors situated on the pump outlets informs the calculator that pressure is
equal to or greater than 2132 psi, current to the swing brake electrovalve is cut off and the swing brake is
released.
When swing pressure switch or attachment pressure falls below 2932 psi, current flows to the swing brake
electrovalve after five seconds and the swing brake is applied.
If swing locking is solicited, even if the swing pressure is closed and pressure at both pumps is higher than
2132 psi, the swing brake will be applied. The swing spool is piloted on both sides. If the starter switch key is
turned to OFF position, the swing locking will be memorized and when the key is turned to ON position the swing
function will still be locked.
During travel, if pressure in one of the pumps rises to 2132 psi, the swing brake will be released for 5 seconds.
Outlet pressure on
Swing pressure Swing brake
Key switch A1 or A2 pump Swing brake
switch electrovalve
outlets
OFF OFF 0 OFF Applied
ON OFF 0 ON Applied
ON ON >0 OFF Released
ON OFF 2132 psi or more OFF Released
Pa3/A3. LH Swing
Pb3/B3. RH Swing
C2. Swing brake (Pink band)

8020-15
B T
Dr
P
&
GA GB C4
MU
A B
405 psi 405 psi

28 bar 28 bar
Pc1
Pb9
A5
Pa9
B5
Pb5’
Pb5
Pa5’ Pc2
Pa5
A8
B8
Pc3’ Pb8’
Pc3 Pb8
Pa8’
Pbu
Pa8
Pb4 B7
Pb4’
%
A7
Pb7
$ Pa7
3E B6
3D
A6
B2
Pb6
A2
Pb2
Pa6
Pa2
2S 3S 1S
P4
S2 S1
B1
A1
S3
Pb1
Pa1
3 PT PP PA
3 P3 PH
$ $
CM00K016

8020-16
Variable Priority Valve Circuit

After going through the selector the swing pilot pressure arrives at Pc3 and pilots the variable priority valve. This
makes it possible to have the maximum swing torque with high swing pressure, even if the dipper is being used
at the same time.
When the machine is digging, the boom raising pressure pilots the swing priority valve. Flow for the swing
function is then in parallel with the dipper via the priority valve and dipper speed is improved. Digging speed is
more constant, even if the free passage is closed by the boom (2) spool.
When the swing function and the dipper retracting or boom raising functions are operated simultaneously,
parallel working is reduced and swing pressure is maintained.
Pa5/A5. Dipper out

Pb5/B5. Dipper in
Pa9/Pb9. Dipper spool 2
Pa3/A3. LH swing
Pb3/B3. RH swing
Pc3. Priority to swing
Pb4. Boom spool 2

8020-17
Dr
GA GB
MU
A B
405 psi 405 psi

28 bar 28 bar
Pc1
$ 3E
% 3D
Pb5’
3E
Pa5’ Pc2
3D A8
B8
Pc3’ Pb8’
3F Pb8
Pa8’
Pbu
Pa8
3E B7
Pb4’
%
A7
Pb7
$ Pa7
3E
3D
B6
B2 A6
A2 Pb6
Pb2
Pa6
Pa2
2S 3S 1S
P4
S2 S1
B1
A1
S3
Pb1
Pa1
PT PP PA P3 PH
3 3
$ $
CM00K017

8020-18
Boom Raising Circuit

Two supply flows are used to raise the boom.
The P1 pump flow goes through the straight line travel valve or the right-hand travel spool, through the parallel
working passage and the boom (2) spool, before emerging from the boom (1) spool outlet.
The P2 pump flow goes through the second parallel working passage and the boom (1) spool and joins the flow
from pump P1 to go through the load holding valve and supply oil to the boom cylinders.
Pa8/A8. Boom up
Pb8/B8. Boom down
Pb4. Boom spool 2

8020-19
405 psi 405 psi

28 bar 28 bar
Pc1
Pb9
A5
Pa9
B5
Pb5’
Pb5
Pa5’ Pc2
$
Pa5
%
Pc3’ Pb8’
Pc3
3E
Pa8’
Pbu
3E 3D
B7
Pb4’ A7
B3 Pb7
A3
Pb3 Pa7
Pa3
B6
B2 A6
Pb6
A2
Pb2
Pa6
Pa2
P4
B1
A1
Pb1
Pa1
3 PT PP PA
3 P3 PH
$ $
CM00K018

8020-20
Boom Lowering Circuit, Load Holding Valve

A single supply flow is used to lower the boom.
When the boom lowering function is operated only the boom (1) spool is piloted.
At the same time, pilot pressure arrives at Pc2 and releases the load holding valve. This allows the oil discharge
from the boom cylinder large chambers to flow to the return circuit.
Boom Lowering Reinjection Circuit

When the boom is lowered, boom (1) spool is piloted. The load holding valve is released and part of the oil
discharged from the cylinder large chambers can go through a check valve and be reinjected in the cylinder
small chambers. The lower the supply pressure to the cylinder small chambers, the higher the flow reinjected in
this manner will be.
Even if the boom spool is completely closed, an orifice makes it possible for oil to reach the free passage and
develop pressure (PN) to inform the pump that flow must be reduced. Flow reduction is compensated for by the
reinjection circuit, thereby contributing towards a more efficient use of engine power.
Boom Lowering Anti-vibration Circuit

Due to the constant loss of oil from the supply source to the free passage, via the orifice, peak pressures and
vibrations are avoided, even if the boom lowering control is operated roughly.
Pa8/A8. Boom up
Pb8/B8. Boom down
Pc2. Boom load holding
1. Holding valve

8020-21
ø3
Dr T2 T1 T3 T5 T4 Ps2
405 psi
28 bar
Pb9
Pa9
3F
$
%
3E
3E
Pa8’
3D
B7
A7
Pb7
%
Pa7
B6
A6
Pb6
Pa6
$
3 P3 PH
$ 3E
A1 Psv a3 A2
a1 a2
(AVANT) (ARRIERE)
3D
Pi1 Pi2
3.92 MPa
568 psi a3
39.2 bar
A3
Dr B1 B3
CM00K019

8020-22
Dipper Extending Circuit

The dipper uses two supply flows.
When the dipper extends, flow from pump A1 arrives at the dipper (1) spool, either via the free passage or after
passing through the straight line travel valve via the parallel working passage.
Flow from pump A2 arrives at the dipper (2) spool, either via the free passage or after passing through the
straight line travel valve via the parallel working passage. It merges with the other flow just before the dipper (1)
spool. In this way, the two flows of oil go through the load holding valve and then on to the dipper cylinder small
chamber. Return to the large chamber is via the two dipper spools, thereby improving efficiency.
Pa5/A5. Dipper out

Pb5/B5. Dipper in
Pa9/A9. Dipper spool 2

8020-23
ø3
405 psi 405 psi

28 bar 28 bar
Pc1
$ 3E
% 3D
Pb5’
3E Pc2
Pa5’
3D A8
B8
Pc3’ Pb8’
Pc3 Pb8
Pa8’
Pbu
Pa8
Pb4 B7
Pb4’
A7
B3
Pb7
A3
Pb3 Pa7
Pa3
B6
B2 A6
Pb6
A2
Pb2
Pa6
Pa2
P4
B1
A1
Pb1
Pa1
3 PT PP PA
3 P3 PH
$ $
CM00K020

8020-24
Dipper Retracting Circuit

The dipper uses two supply flows.
When the dipper retracts flow from pump A1 arrives at the dipper (1) spool, either via the free passage or after
passing through the straight line travel valve via the parallel working passage.
A2 pump flow arrives at the dipper (2) spool, either via the free passage or after passing through the straight line
travel valve via the parallel working passage. It merges with the other flow just before the dipper (1) spool. In this
way, the two flows of oil go through the load holding valve and then on to the dipper cylinder large chamber.
Return to the large chamber is via the two dipper spools, thereby improving efficiency.
Dipper Retracting Reinjection Circuit

Oil discharging from the small chamber is fed back into the large chamber. The return flow goes through a
restrictor and a variable cancellation valve, which force the oil to re-enter the large chamber via a check valve.
When pressure in the large chamber increases, the cancellation valve is piloted by this pressure and reinjection
is progressively brought to a halt.
Pa5/A5. Dipper out

Pb5/B5. Dipper in

8020-25
ø3
405 psi 405 psi

28 bar 28 bar
3F
3E
$
% 3D
Pb5’
3E
Pc2
Pa5’
3D A8
B8
Pc3’ Pb8’
Pc3 Pb8
Pa8’
Pbu
Pa8
Pb4 B7
Pb4’
A7
B3
Pb7
A3
Pb3 Pa7
Pa3
B6
B2 A6
Pb6
A2
Pb2
Pa6
Pa2
P4
B1
A1
Pb1
Pa1
3 3
PT PP PA P3 PH
$ $
CM00K021

8020-26
Bucket Opening Circuit

The bucket uses one supply flow which arrives from pump A2 via the parallel working passage.
Pa7/A7. Bucket opening

Pb7/B7. Bucket closing
ø3
405 psi
28 bar
Pb9
Pa9
Pc2
A8
B8
Pb8’
Pb8
Pa8’
Pa8
%
$
3E
3D
B6
A6
Pb6
Pa6
3
P3 PH
$
CM00K022

8020-27
Bucket Closing Circuit

The bucket uses one supply flow which arrives from pump A2 via the parallel working passage.
Pa7/A7. Bucket opening

Pb7/B7. Bucket closing
ø3
405 psi
28 bar
Pb9
Pa9
Pc2
A8
B8
Pb8’
Pb8
Pa8’
Pa8
%
$
3E
3D
B6
A6
Pb6
Pa6
3 P3 PH
$
CM00K023

8020-28
Crusher Circuit
The crusher uses two supply flows.
One flow goes directly to the option, the other is forced into the reinjection valve and merges with the first flow
just before the inlet for the option spool.
When the switch in the cab is tilted to crusher position, current is sent to the second flow electrovalve.
When the option pedal is pressed, pilot pressure is sent through the selector and then the electrovalve. The
reinjection valve is released. This pressure also moves the dipper (2) spool and the latter seals off the free
passage. As a result, flow from pump P2 may be reinjected at the inlet for the option pedal.
P1 pump flow arrives directly at the inlet of the option spool.
The pilot pressure also acts on the reinjection valve priority valve. Dipper (2) spool pilot pressure return oil goes
back to the tank via the priority valve. The crusher thereby takes priority but, for example, should the dipper be
extended at the same time, one flow goes to the dipper and the other to the crusher.
Pa2/A2. Option circuit

Pb2/B2. Option circuit

8020-29
B A
T T
10µ
405 psi 405 psi

28 bar 28 bar
1 T 2
3E
Pc1
A5
B5 3D
Pb5'
Pb5
Pa5' Pc2
Pa5
A8
A1 S1 A2 P T B8
Pc3' Pb8'
Pc3 Pb8
Pa8'
B1 S2 B2 A Pbu
Pa8
Pb4 B7
Pb4'
A7
B3
Pb7
A3
Pb3 Pa7
Pa3
B6
A B
$ % A6
Pb6
3E Pa6
3D
T P4
B1
D
A1
E
C Pb1
Pa1
P
B
3 PT PP PA
3 P3 PH
$ $
CM00K024

8020-30
Breaker Circuit
The breaker uses one supply flow.
When the switch in the cab is in breaker position and the option pedal toed forward, the pressure switch closes
and sends the information to the calculator, which sets the breaker running at the preselected speed.
The option spool is piloted and pump A1 supplies the breaker with a flow of oil.
Pa2/A2. Option circuit

Pb2/B2. Option circuit

8020-31
B A
T T
10µ
405 psi 405 psi

28 bar 28 bar
1 T 2 Pc1
Pb9
A5
P
Pa9
B5
Pb5'
Pb5
Pa5' Pc2
Pa5
A8
A1 S1 A2 P T B8
Pc3' Pb8'
Pc3 Pb8
Pa8'
B1 S2 B2 A Pbu
Pa8
Pb4 B7
Pb4'
A7
B3
Pb7
A3
Pb3 Pa7
Pa3
B6
A B
% A6
$
Pb6
3E Pa6
3D
T P4
B1
D
A1
E
C Pb1
Pa1
P
B
3 PT PP PA
3 P3 PH
$ $
CM00K025

8020-32
NOTES
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Section
9000
9000
QUICK COUPLER

Printed in France
9000-2
TABLE OF CONTENTS
IDENTIFICATION OF COMPONENTS .................................................................................................................... 3

Description ..............................................................................................................................................................
Disassembly ......................................................................................................................................................... 4
Assembly .............................................................................................................................................................. 5
Inspection ............................................................................................................................................................. 5
this symbol, read carefully the message that follows, as it indicates that there is a risk of serious injury.

9000-3
IDENTIFICATION OF COMPONENTS
Description
BF9
BF4
BF4
BF11
BF5 BF10
BF14
BF9 BF3
BF9
BF2
BF1
BF6
BF9
CRPH05C008G
BF1 Cylinder BF9 Grease Nipple x 4

BF2 Hook BF10 Grub Screw
BF3 Cylinder Pin BF11 Blocking Bar Spring c/w bolts
BF4 Roll Pin BF12 Bush
BF5 Hook Pin BF13 Blocking Bar assembly
BF6 Cylinder Hook Pin BF14 Blockung Bar Spacer
BF7 n/a
BF8 n/a

9000-4
QUICK COUPLER
Removal STEP 6
WARNING: Please make sure you do not
contaminate any hydraulic fittings during the
! replacement procedure.
STEP 1
Uncouple the bucket/attachment/work tool from the
quick coupler (Refer to Operator’s Manual).
STEP 2
Lock the hook by moving the quick coupler switch to
the lock/on position (Refer to Operator’s Manual).
STEP 3 CRPH05C003A
Remove the quick coupleur from the machine (Refer Remove the roll pin (BF4) securing the cylinder pin
to Operator’s Manual). (BF3).
NOTE: For identifications of components, refer to the STEP 7

page 3.
STEP 4
CRPH05C004A
Remove the cylinder pin (BF3).
CRPH05C001A
STEP 8
Remove the grub screw (BF10) positioned on the
underside/rear face of the hook.
STEP 5
CRPH05C005A
Remove the hydraulic cylinder (BF1).
CRPH05C002A
Remove the cylinder hook pin (BF6).

9000-5
STEP 9 Inspection
NOTE: If the quick coupler frame becomes worn or
damaged in the area of the side plate rear, then the
following procedure must be followed for repair.
CRPH05C006A
Remove hydraulic hoses from the cylinder.
Hook and cylinder removal CRPH05C007A
STEP 1 The maximun wear allowed around this area is 5mm.

If the wear is more than this then repairs must be
Remove the small cylinder pin (BF6). carried out.
NOTE: On some quicks couplers the small cylinder STEP 1

pin (BF6) is inaccessible because of the quick
Contact your CASE Dealer for a template for the
coupler frame. To change this remove the long hook
coupler quoting serial number and quick coupler
pin (BF5) and lift out the hook and cylinder as one
type.
assembly then remove the small cylinder pin.
NOTE: When installing the hydraulic cylinder, use the STEP 2
same procedure in the reverse order. The area affected should be prepared with use of a
grinder before been built up with weld to match the
appropriate shape. Mig welding is recommended for
these repairs. Alternatively, welding with low
hydrogen electrodes (E7018 or equivalent) can be
used. All welds should be blended in and smooth to
avoid stress areas.
STEP 3
Once fully welded the repaired areas must be
allowed to cool slowly
STEP 4
Fully dress the welded areas by grinding and check
to ensure that they do not interfere with the
movement of the hook or other parts of the coupler.
Check that the dressed areas match that of the
template provided.
STEP 5
Clean off all sharp edges and repaint the coupler.
Carry out a maintenance check ( Refer to Operator’s
Manual) before refitting the quick coupler to the
machine.

9000-6

9002
Section
9002
UPPERSTRUCTURE, TURNTABLE
AND COUNTERWEIGHT

Printed in France
CNH Cre 7-27982GB Mai 2005
9002-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 2
UPPERSTRUCTURE ............................................................................................................................................... 3
Inspection............................................................................................................................................................. 3
Removal ............................................................................................................................................................... 4
Installation ............................................................................................................................................................ 6
COUNTERWEIGHT ............................................................................................................................................... 10
Description ......................................................................................................................................................... 10
Removal ............................................................................................................................................................. 11
Installation .......................................................................................................................................................... 13
WARNING: This symbol is used in the manual to indicate important safety messages. Whenever you see
! this symbol, carefully read the message that follows. It concerns your safety.

See Section 1002
SPECIFICATIONS
Weight ............................................................................................................................................See Section 1002
Quantity of grease to be applied
to the turntable.................................................. 190 cc (CX130); 400 cc (CX160, CX210); 500 cc (CX230, CX240)

9002-3
UPPERSTRUCTURE
Inspection
STEP 1 STEP 5
Inspecting the turntable
If the upperstructure no longer swings regularly or
makes a creaking noise, this shows that the turntable
is worn or damaged. If there is a time lapse before
the upperstructure starts to swing, this shows that the
ring gear of the turntable is damaged. When an
operator works with a machine, he must pay attention
to any unusual noises which could indicate turntable
wear. If the operator hears unusual noises and if the
upperstructure has a time lapse before it starts 1
swinging, he must carry out the following inspection.
STEP 2 2
Park the machine on hard, level ground. Lower the
attachment to the ground. 3
STEP 3 4
CI00F509
Reduce engine speed to idle for 30 seconds, then
Remove the three screws (1) and lock washers (2)
shut down the engine.
which fasten the access panel (3) to the machine.
STEP 4 Remove the access panel (3). Remove and scrap the
access panel seal (4).
STEP 6
WARNING: If you put your hand in the ring

gear access orifice when the upperstructure is
swinging, you could be serious injured. Before
applying grease by hand to the ring gear,
! always make sure that the bucket or the tool
is on the ground and that the engine is shut
down.
Request help from an assistant to operate the swing

gear. Check for scratches, a missing tooth, scaling,
cracks or other damage to the ring gear, using a
pocket torch. In the event of damage, refer to
1 "Removing the upperstructure" and change the
upperstructure turntable.
CI00F500
Remove the screws (1) which fasten the lower housing STEP 7
to the machine and remove the lower housing. Install a new seal on the access panel and install the
access panel on the machine using screws and lock
washers.

9002-4
STEP 8 STEP 7
Install the lower housing on the machine using (CX210/CX230/CX240)
screws and flat washers.
Removal 4
STEP 1
3
1
CD00G002
Open the left-hand side doors. Disconnect the earth
cable (1) from the battery, then the positive cable (2).
Disconnect and remove the battery cable (3).
JS00163A Remove the two screws (4), lock washers and the flat
Park the machine on hard, level ground. Lower the washers that fasten the battery protective cover.
attachment to the ground. Remove the cover and remove the battery. Close the
STEP 2 side doors.
Release pressure in hydraulic system in the hydraulic STEP 8

reservoir (see Section 8000).
STEP 3 2
1
(CX130/CX160)
2
1
1
2 CI00F508
3 1 FUEL TANK LOWER ACCESS PANEL
2 HYDRAULIC RESERVOIR LOWER ACCESS PANEL
CD00F052 Remove the lower access panel from the fuel tank (1)
Open the left-hand side door. Remove the two screws located at the front and to the right. Place a
(1), lock washers and flat washers that retain the receptacle under the fuel tank drain valve. Open the
battery housing (2). Remove the housing. Disconnect drain valve and drain the fuel.
the negative cable from the battery (3) then the
positive cable. Remove the batteries from the
machine. Close the left-hand side door.

9002-5
NOTE: See Section 1002 for the fuel tank capacity. STEP 14
STEP 9
Remove the lower access panel from the hydraulic
reservoir (2). Place a receptacle under the hydraulic
reservoir drain valve. Open the drain valve and drain
the hydraulic fluid into the receptacle.
NOTE: See Section 1002 for the capacity of the
hydraulic reservoir and of the total system.
STEP 10
4
Refer to Section 8006 and remove the hydraulic 1
swivel.
STEP 11 CD00G043
Using paint or another marking product, make marks
Refer to Section 9003 and remove the bucket, the on the upperstructure, turntable (4) and the
dipper and the boom. undercarriage, to facilitate re-assembly of the
upperstructure and the turntable.
STEP 12
Refer to the page 10 in this section and remove the steps refer to the schematic on page 6.
counterweight.
STEP 15
STEP 13
Remove the screws (1) which fasten the
Install lifting rings at the rear of the upperstructure. upperstructure to the turntable (4).
Connect a suitable lifting device to these lifting rings
and to the lifting rings located at the front of the STEP 16
upperstructure, above the boom brackets. Take up
Carefully lift the upperstructure while disengaging it
any slack in the lifting equipment, to ensure the
from the undercarriage. Place the upperstructure on
upperstructure is fully supported before lifting starts.
suitable stands to protect the swing pinion against
NOTE: Refer to specifications on page 2 for the any damage.
weight of the upperstructure. Make sure that the
lifting device has sufficient lifting and support
STEP 17
capacity for the upperstructure. Install lifting rings on the turntable (4). Connect a
suitable lifting device to the lifting rings. Take up any
slack in the lifting equipment, to ensure that the
turntable is fully supported before lifting starts.
NOTE: Refer to specifications on page 2 for the
weight of the turntable.
STEP 18
Remove the screws (2) and the flat washers (3)
which fasten the turntable to the undercarriage.
Carefully lift the turntable while disengaging it from
the undercarriage. Place the turntable on suitable
stands to protect the surfaces of the turntable against
any damage. Remove the lifting equipment from the
lifting rings and disassemble the lifting rings from the
turntable.

9002-6
Installation
Turntable
4 1
3
2
CI00F510
1 SCREW
2 SCREW
3 FLAT WASHER
4 TURNTABLE
STEP 1 STEP 3
Clean the mating surfaces of the undercarriage and Position the turntable (4) on the undercarriage. Align
the turntable. the marks on the turntable (4) and on the
undercarriage. Remove the lifting equipment and
disassemble the lifting rings from the turntable.
steps refer to the turntable schematic.
STEP 2
Install lifting rings on the turntable (4) and connect a
suitable lifting device to these rings. Take up any
slack in the lifting equipment, to ensure that the
turntable is fully supported before lifting starts.
weight of the turntable.

9002-7
STEP 4 STEP 7
Coat the screw threads (1) with Loctite 262. Install
the screws (1) in the turntable and the upperstructure
to fasten the upperstructure en position. Tighten the
screws (1) to the torques specified on page 2.
STEP 8
Remove the lifting equipment, then disassemble the
lifting rings.
STEP 9
4
1 Refer to Section 8006 and reassemble the hydraulic
swivel.
CD00G043
Coat the screw threads (2) with Loctite 262. Install STEP 10
the screws (2) and flat washers (3) to fasten the Refer to Section 9003 and reassemble the boom, the
turntable (4) to the undercarriage. Tighten the screws dipper and the bucket on the machine.
(2) to the torques shown on page 2.
STEP 11
STEP 5
Make sure that the hydraulic reservoir drain valve is
Connect a suitable lifting device to the lifting rings closed. To fill the reservoir, refer to the Section "Filling
located at the front of the upperstructure, above the the Reservoir" in the Operator’s Manual.
boom brackets, and to the rings mounted on the
frame at the rear of the upperstructure. NOTE: See Section 1002 for the capacity of the
hydraulic reservoir and the capacity of the total
NOTE: Refer to specifications on page 2 for the system.
weight of the upperstructure. Make sure that the
lifting equipment has sufficient lifting and support
capacity for the upperstructure.
NOTE: When the upperstructure is lowered and
touches the turntable and the ring gear, make sure
that the swing reduction gear pinion engages
perfectly with the teeth on the upperstructure ring
gear.
STEP 6
Carefully install the upperstructure in position on the
turntable. Align the marks on the upperstructure and
on the turntable. Check that the mounting orifices of
the upperstructure are aligned with those of the
turntable.

9002-8
STEP 12 STEP 14
2 (CX210/CX230/CX240)
1
4
1
2
2
1
3
5
CI00F508
1 FUEL TANK LOWER ACCESS PANEL
2 HYDRAULIC RESERVOIR LOWER ACCESS PANEL
CD00G002
Install the access panel (2) under the hydraulic Open the left-hand side doors and install the batteries.
reservoir. Install the battery protective cover (1), on the batteries
and fasten with the two screws (4), flat washers and
STEP 13 locking washers. Tighten the screws to the torque
Make sure that the fuel tank drain valve is closed, fill specified on page 2. Install and reconnect the battery
the tank (see the Operator’s Manual). cable (3). Connect the positive cable first (2) then the
negative cable (5). Close the left-hand side doors.
NOTE: See Section 1002 for the fuel tank capacity.
STEP 15
STEP 14
Refer to page 10, "Installing the counterweight" and
(CX130/CX160) install the counterweight.
WARNING: If you put your hand in the ring

gear access orifice when the upperstructure is
swinging, you can be seriously injured. Before
! applying grease by hand to the ring gear,
always check that the bucket or tool is on the
ground and that the engine is shut down.
1
2
3
CD00F052
Open the left-hand side door. Install the batteries in
the machine. Reconnect the battery cables (3), with
the positive cable always first. Install the battery
housing (2). Tighten using the screws (1). Close the
left-hand side door (see Section 4002).

9002-9
STEP 16 STEP 21
2 CD00G043
Apply grease to the three grease fittings on the
3 turntable. Install a new seal.
4 STEP 22
CI00F509 Install the access panel with its seal, on the machine.
Remove the three screws (1) and the locking
Fasten it in position with the three screws and the
washers (2) which fasten the access panel (3) to the
locking washers.
upperstructure. Remove the access panel (3). Scrap
the seal (4). STEP 23
STEP 17
Apply grease by hand to the ring gear.
STEP 18
Start the engine and swing the upperstructure an
eighth of a turn. Stop the engine.
STEP 19
Apply grease by hand to the ring gear again.
STEP 20
Repeat the operation until all the teeth of the ring
gear are perfectly greased.
quantity of grease to be applied.
CI00F500
Install the lower housing under the machine, using
screws and washers.

9002-10
COUNTERWEIGHT
Description
2 2
1
1
6 6
5
4
4
3 3
CS00F541 CI00F511
1 COUNTERWEIGHT 5 SHIM
2 PLUG 6 INSULATING MATERIAL
3 SCREW
4 WASHER

9002-11
Removal
STEP 1 STEP 4
1
1
1
CD00F099 CD00F101
Unlock the two engine hood locking latches (1) and Remove the split pin (1) and the flat washer (2) from
raise the hood to the raised, locked position. the engine hood safety side support bracket.
STEP 2 STEP 5
Attach suitable lifting slings to the hood. Remove the hood support strut. Lower the hood.
STEP 3 NOTE: Have an assistant help you with this step.
STEP 6
Connect a suitable lifting device.
STEP 7
2
1
2 2
CD00F100
Remove the retaining hardware (1) from the retaining
bar (2) and remove the retaining bar.
1 1
CD00F102
Remove the six screws (1) and the flat washers
which fasten the hinges (2).

9002-12
STEP 8
Install a lifting ring on the counterweight (1). Connect
suitable lifting equipment to the lifting rings. Take up
any slack in the lifting equipment to ensure that the
counterweight is fully supported before releasing the
retaining screws.
weight of the counterweight.
STEP 9
Remove the four screws (3) and the flat washers (4)
which attach the counterweight (1) to the chassis
frame.
STEP 10
Raise the counterweight (1) and remove it from the
machine. Place it on flat ground. Remove the lifting
device.
STEP 11
Remove the shims (5) from the chassis frame
anchorage points.
NOTE: Count the number of shims (5), as you
remove them from each anchorage point. Keep each
set of shims (5) to facilitate reassembly.
STEP 12
Check the condition of the insulating material (6)
installed on the counterweight. Change the insulating
material if it is damaged.

9002-13
Installation
NOTE: The numbers in brackets in the following STEP 8
NOTE: Have an assistant help you with this step.
STEP 1
Connect a suitable lifting device to the lifting rings
installed on the counterweight (1).
NOTE: Refer to the specifications on page 2 for the 2
weight of the counterweight.
STEP 2 1
Install the same number of shims (5) as were
removed during removal in step 11, at each
anchorage point of the counterweight on the chassis
frame.
STEP 3
CD00F101
Move the counterweight (1) into position on the Install the hood support strut, install the split pin (1)
chassis frame. Align the orifices of the counterweight and the flat washer on the engine hood safety side
with those on the chassis frame. support bracket.
STEP 4 STEP 9
Install the four screws (3) and flat washers (4) to
attach the counterweight (1). Tighten to the torque
settings specified on page 2.
STEP 5
Disconnect the lifting equipment from the lifting rings
on the counterweight (1), disassemble the lifting rings
and re-install the plugs. 2
STEP 6 1
Connect a suitable lifting device to the engine hood.
Move the engine hood into position.
CD00F100
STEP 7
Install the retaining bar (2) using the retaining
hardware (1).
STEP 10
Remove the lifting equipment from the engine hood.
2 2
1 1
CD00F102
Install the six washers (1) and flat washers which
attach the hood hinges (2).

9002-14
STEP 11
1
1
CD00F099
Lock the two engine hood locking latches (1).

Section
9003
9003
BOOM, DIPPER AND BUCKET

Printed in France
9003-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 2
BUCKET ................................................................................................................................................................... 3
Description ........................................................................................................................................................... 3
Removal ............................................................................................................................................................... 4
Installation ............................................................................................................................................................ 4
Shimming the bucket............................................................................................................................................ 6
DIPPER .................................................................................................................................................................... 7
Description ........................................................................................................................................................... 7
Removal ............................................................................................................................................................... 8
Installation ............................................................................................................................................................ 8
BOOM..................................................................................................................................................................... 10
Description ......................................................................................................................................................... 10
Removal ............................................................................................................................................................. 11
Installation .......................................................................................................................................................... 12
SPECIFICATIONS
See Section 1002

9003-3
BUCKET
Description
14 21 17
16
13 10 17
15
18
19 19
21 14
8 18 15
9
9 4
8
20
5 12
20
5
6 11
3 1 2
JS01273A
1 LOCKING PIN 12 SCREW
2 PIN 13 PIN
3 BUCKET 14 SHIM
4 YOKE 15 CONNECTING ROD
5 LINKAGE SEAL 16 GREASE FITTING
6 LOCKING PIN 17 BUSHING
7 PIN 18 BUSHING
8 LINKAGE SEAL 19 SHIM
9 DUST SEAL 20 DUST SEAL
10 GREASE FITTING 21 DUST SEAL
11 NUT

9003-4
Removal STEP 7
STEP 1 Remove the nuts (11) and the screw (12). Remove
the pin (13) and the shims (14) from the dipper.
Place the bucket flat on flat, level ground. Operate
the attachment controls so that the dipper/bucket STEP 8
connecting pin is not under load from the weight of
Remove and scrap the dust seals (21). Remove, if
the dipper. Shut down the engine.
necessary, the grease fitting (16) from the pin (13).
NOTE: Perform step 9 only if the bushings (17) and
steps refer to the bucket drawing on page 3.
(18) have to be changed. See Specifications.
STEP 2 STEP 9
Remove the locking pins (1) and (6). Remove the bushings (17) and (18) from the yoke (4)
STEP 3 using a hammer and a suitable drift on the outer
diameter of the bushing.
Installation
7 NOTE: Perform step 1 only if the bushings (17) and
(18) have been removed.
STEP 1
Using a suitable sleeve, install the bushings (17) and
(18) in the yoke (4).
NOTE: Perform steps 2 to 6 only if the yoke (4) and
2 the connecting rods (15) have been removed.
STEP 2
CD00E097
Remove the pins (2) and (7) and retain the shims Install new dust seals (21) on the dipper. Install the
(19). pin (13) in a connecting rod (15) and install the pin on
the dipper. Install the second connecting rod (15) on
STEP 4
the pin and install the screw (12).
Start the engine. Disengage the attachment from the
bucket and retain the linkage seals (5) and (8). STEP 3
Using a set of feeler gauges, check that the
STEP 5
clearance between the dipper and the connecting
Remove and scrap the dust seals (9) and (20). rods (15) is 1 to 1.5 mm. If necessary remove the
screw (12) and the pin (13) and add on or more
NOTE: Perform steps 6 to 9 only if the yoke (4) or the
shims as required to arrive at the correct clearance.
connecting rods (15) have to be changed.
Install the pin and the screw.
STEP 6 STEP 4
Attach a suitable lifting device to the yoke (4).
Install the first nut (11) on the screw and tighten until
Disconnect the bucket cylinder rod from the yoke (4)
the nut touches the boss on the connecting rod.
and from the connecting rods (15), see Section 8005.
Loosen a quarter of a turn and use two wrenches to
Remove the grease fittings (10) if necessary.
tighten the second nut on the first.
STEP 5
Install the grease fitting (16) on the pin (13).

9003-5
STEP 6 STEP 13
Attach a suitable lifting device to the yoke (4) and Using a set of feeler gauges, check that the
place the yoke in position on the dipper. Install the clearance between the yoke and the bucket is 1 to
bucket cylinder rod on the yoke (4) and the 3.5 mm. If necessary remove the locking pin (6) and
connecting rods (15), see Section 8005. Install the the pin (7) and add or more shims (19) as required to
grease fittings (10). arrive at the correct clearance. Install the pin (7) and
the locking pin (6).
STEP 7
STEP 14
Install new dust seals (9) on the yoke (4).
Push the linkage seals (5) and (8) into their housings.
STEP 8
STEP 15
Install new dust seals (20) on the dipper.
Grease the linkages.
STEP 9
NOTE: Perform step 16 only on CX160, CX180,
5 CX210, CX230, CX240 machines.
STEP 16
Carry out the shimming of the bucket, see page 6.
B9240128
Install new linkage seals (5) and (8) on the bucket
bosses.
STEP 10
Start the engine and align the dipper orifices with the
orifices in the bucket.
STEP 11
Install the pin (2) through the bucket and the dipper.
Install the locking pin (1).
STEP 12
Align the orifices of the yoke with the orifices in the
bucket and install the pin (7) through the bucket and
the yoke. Install the locking pin (6).

9003-6
Shimming the bucket NOTE: When the screws on the cap (1) are
tightened, the inner bushing moves towards the
The machine is equipped with a bucket play adjusting dipper and the play is eliminated.
system which eliminates play that develops at the
bucket/dipper linkage due to wear. This system IMPORTANT: The inner bushing has a stud which
delays the effects of wear and gives longer life to prevents the bushing from turning. The cap (1) has
bushings and pins. an orifice in its inner surface. Make sure that the stud
is inserted in that orifice when the cap is installed (1).
NOTE: Incorrect adjustment of the play can cause
friction, abnormal noises or excess play and damage
the O-rings.
Adjusting the play
Place the bucket flat, lying on the ground.
1
J
CD00E121
Check the play (J) between the dipper and the bucket
lug.
If the play (J) is considerable, remove the four screws
and the cap (1), then the shims (2).
Use the shims (2) as a feeler gauge and calculate the
number of shims necessary to eliminate the play (J).
Install the necessary number of new shims.
Reinstall the cap (1) and the four screws.

9003-7
DIPPER
Description
3
11 2
1
6 11
8
8
6
9 4
10
9
10
JS01274A
1 NUT 7 GREASE FITTING
2 SCREW 8 BUSHING
3 PIN 9 BUSHING
4 DIPPER 10 BUSHING
5 BOOM 11 BUSHING
6 DUST SEAL

9003-8
Removal NOTE: Perform step 9 only if the bushings (8), (9),

(10) or (11) have to be changed, see Specifications.
STEP 1
STEP 9
Remove the bucket, the connecting rods and the
yoke, see page 4. Remove the bushings (8), (9), (10) or (11) from the
dipper or from the boom, using a hammer and a
STEP 2 suitable drift on the outer diameter of the bushing.
Start the engine, retract the dipper cylinder rod and Installation
lower the attachment to the ground. Shut down the
engine. NOTE: Perform step 1 only if the bushings (8), (9),
(10) or (11) have been removed.
STEP 3
STEP 1
Remove the bucket cylinder and disconnect the
dipper cylinder rod from the dipper, see Section 8005. Using a suitable sleeve, install the bushings (8), (9),
Attach the dipper cylinder rod to the boom. (10) or (11).
NOTE: The numbers in the following steps refer to STEP 2
the dipper drawing on page 7.
Install new dust seals (6) on the dipper.
STEP 4
STEP 3
Attach a suitable lifting device to the dipper. Take up
any slack on the lifting slings, since the dipper has to Attach a suitable lifting device to the dipper. Move the
be supported before lifting. dipper into position near the machine.
STEP 5 STEP 4
Start the engine and move the machine forwards so
Remove the nuts (1), the screw (2) and remove the
that the boom is aligned with the dipper. Check the
pin (3).
alignment of the pin bores on the boom and the
STEP 6 dipper. Shut down the engine.
Start the engine, move the machine backwards to STEP 5
separate the dipper from the boom. Lower the boom
Install the pin (3).
to the ground and shut down the engine.
STEP 7 STEP 6
Lower the dipper to the ground and remove the lifting Using a set of feeler gauges, check that the play
equipment from the dipper. between the boom and the dipper is 0.5 to 1.1 mm . If
necessary, remove the pin (3) and add one or more
STEP 8 shims as required to arrive at the correct clearance.
Remove and scrap the dust seals (6).

9003-9
STEP 7
Install the screw (2), the first nut (1) and tighten the
nut until it touches the boss on the boom. Loosen the
nut a quarter of a turn and use two wrenches to lock
the second nut (1) onto the first.
STEP 8
Remove the lifting device from the dipper.
STEP 9
Connect the dipper cylinder rod to the dipper and
install the bucket cylinder, see Section 8005.
STEP 10
Install the bucket, see page 4.
STEP 11
Bleed the cylinders, see Section 8000.
STEP 12

9003-10
BOOM
Description
5 8
7
8
6
5
4 3 2
JS01275A
1 NUT
2 SCREW
3 PIN
4 BOOM
5 SHIM
6 DUST SEAL
7 GREASE FITTING
8 BUSHING

9003-11
Removal STEP 6
STEP 1 A
Remove the dipper, see page 8.
STEP 2
Start the engine and lower the boom to the ground.
Shut down the engine.
STEP 3
Remove the dipper cylinder, see Section 8005. Do
not remove the vacuum pump from the hydraulic
reservoir.
STEP 4 CS00F539
Remove the lid (A) on the front of the fuel tank.
A steps refer to the drawing on page 10.
C B STEP 7
Remove the nuts (1) and the screw (2).
E STEP 8
D Attach a suitable lifting device to the boom, take up
E all the slack on the lifting device.
STEP 9
CD00F117
Start the vacuum pump. Label and disconnect the
bucket (A) and dipper (B) supply hoses at the bottom of
the boom. If equipped, disconnect the option hoses (E). B A 3
Plug the hoses. Stop the vacuum pump. If equipped,
disconnect and move the dipper cylinder safety valve
pilot hoses (D) away from the boom. Disconnect the
boom working light electrical harness (C).
STEP 5
Disconnect the boom cylinder rods from the boom,
see Section 8005.
CD00F118
Install a screw (A) in the pin threaded orifice (3).
Install a sliding hammer (B) on the screw and remove
the pin (3).
STEP 10
Raise the boom and retain the shims (5). Lower the
boom to the ground and remove the lifting device.

9003-12
STEP 11 STEP 8
Remove and scrap the boom dust seals (6).
NOTE: Perform step 12 only if the bushings (8) have A
to be changed, see specifications. B
C
STEP 12
Remove the bushings (8) from the boom, using a E
hammer and a suitable drift on the outer diameter of
the bushing. D
Installation E
NOTE: Perform step 1 only if the bushings (8) have
been removed.
CD00F117
STEP 1 Start the vacuum pump and remove the plugs from
the hoses. Connect the bucket (A) and dipper (B)
Using a suitable sleeve, install the bushings (8) on supply hoses at the bottom of the boom. If equipped,
the boom. connect the option hoses (E). Stop the vacuum
pump. If equipped, clip the dipper cylinder safety
STEP 2 valve pilot hoses to the boom. Connect the boom
Install new dust seals (6) on the boom. working light electrical harness (C).
STEP 3 STEP 9
Attach a suitable lifting device to the boom. Raise the
boom and move it into position, check the alignment A
of the boom and chassis orifices.
STEP 4
STEP 5
Using a set of feeler gauges, check that the play
between the boom and the chassis is 0.5 to 3 mm. If
necessary, remove the pin (3) and add one or more
shims (5) as required to arrive at the correct
clearance. Install the pin (3). CS00F539
Install the lid (A) on the front of the fuel tank.
STEP 6
STEP 10
Install the screw (2), the first nut (1) and tighten the
nut until it touches the boss on the chassis. Loosen Install the dipper cylinder on the boom, see Section
the nut a quarter turn and use two wrenches to lock 8005.
the second nut (1) onto the first.
STEP 11
STEP 7 Install the dipper and the bucket, see page 8.
Connect the boom cylinder rods to the boom, see
STEP 12
Section 8005.
Bleed the cylinders, see Section 8000.
STEP 13

Section
9004
9004
SEAT AND SAFETY BELT

Printed in France
9004-2
TABLE OF CONTENTS
SPECIFICATIONS ................................................................................................................................................... 2
OPERATOR’S SEAT ............................................................................................................................................... 3
Description .......................................................................................................................................................... 3
Removal .............................................................................................................................................................. 4
Installation ........................................................................................................................................................... 7
SAFETY BELT ......................................................................................................................................................... 8
Removal .............................................................................................................................................................. 8
Installation ........................................................................................................................................................... 8
SPECIFICATIONS
Weight of the operator’s seat.............................................................................................................................. 46 kg

9004-3
OPERATOR’S SEAT
Description
3
5
2 8
CI00G507
1 OPERATOR’S SEAT
2 MASK
3 GROMMET
4 RAIL
5 REAR CONTROL ARM BRACKET
6 SHOCK ABSORBER
7 BRACKET
8 FRONT CONTROL ARM BRACKET

9004-4
Removal STEP 5
STEP 1
CD00G049
Loosen and remove the screw (1) that retains the
JS00163A function cancellation lever (2). Remove the lever.
Park the machine on hard, flat ground. Lower the tool
to the ground. STEP 6
STEP 2
Reduce the engine speed to idle for 30 seconds, then
STEP 3
Move the operator’s seat as far forward as possible.
STEP 4
CD00G050
Loosen and remove the three screws that hold the
inner cab access bar. Remove the access bar.
STEP 7
CD00G048
Lift the grommet. Loosen and remove the four screws
(1) from the front portion of the control arm.
2
NOTE: Steps 5 to 7 are to be carried out only for the
LH control arm. 1
CD00G051
Label and disconnect the electrical connectors (1),
remove the compartment control casing assembly
(2).

9004-5
NOTE: For the LH control arm, do not carry out STEP 11
step 8.
Lift the upper portion of the control arm and position it
STEP 8 on the side.
STEP 12
CD00G066
Remove the mask then remove the air-conditioning
box using the four screws. Remove the latter. CD00G117
Loosen and remove the two upper screws as well as
STEP 9 the two lower screws that hold the front portion of the
control arm.
NOTE: For the RH control arm, do not carry out
1
1 steps 13 and 14.
STEP 13
1
1
CD00G052
Loosen and remove the four screws (1) from the rear
portion of the control arm.
STEP 10
CD00G118
Loosen and remove the screws that hold the LH side
portion of the control arm.
CD00G053
Loosen and remove the two screws (1) that hold the
arm angle adjustment lever, then remove the lever.

9004-6
STEP 14 STEP 16
1 1
1
CD00G058 CD00G120
Remove from the LH side, the rod (1) that links the Loosen and remove the two front retaining screws (1)
function cancellation lever to the safety bar (2). of the control arm to the front seat bracket.
STEP 15 STEP 17
LH side
2
1
1
1
CD00G121
Loosen and remove the two rear retaining screws (1)
CD00G059 of the control arm to the rear seat bracket.
RH side
CD00G119
Loosen and remove the four screws that fasten the
plate (1) to the bracket (2).

9004-7
STEP 18 STEP 20
CD00G127 CD00G123
Move the LH control arm (1) on the cab side, keep it Remove the carpet, loosen then remove the eight
in this position using suitable lifting equipment. retaining screws from the seat. Remove the seat from
the cab, with the help of an assistant.
NOTE: For the RH control arm, position it behind the
cab. NOTE: The seat weighs 46 kg.
STEP 19 Installation
To install, proceed in the reverse order from that of
removal.
1
CD00G122
Remove the mask in front of the seat using the four
screws (1).

9004-8
SAFETY BELT
Removal STEP 4
STEP 1
CD00G125
Loosen then remove the screw (2) and the washer.
JS00163A Remove the inertia-reel.
Park the machine on hard, flat ground. Lower the tool
to the ground. Installation
STEP 2 To install, proceed in the reverse order from that of
removal.
STEP 3
CD00G124
Loosen then remove the retaining screw (1) and the
washer. Remove the seat fastener.

Section
9005
CAB AND CAB EQUIPMENT
9005

Printed in France
9005-2
TABLE OF CONTENTS
SPECIFICATIONS ................................................................................................................................................... 2
CAB ......................................................................................................................................................................... 3
Removal .............................................................................................................................................................. 3
Installation ........................................................................................................................................................... 5
HEATING BLOCK/AIR-CONDITIONING BLOCK ................................................................................................... 8
Description .......................................................................................................................................................... 8
Removal .............................................................................................................................................................. 9
Installation ......................................................................................................................................................... 11
WINDSHIELD WIPER MOTOR ............................................................................................................................. 13
Description ........................................................................................................................................................ 13
Removal ............................................................................................................................................................ 14
Installation ......................................................................................................................................................... 16
SPECIFICATIONS
Cab weight........................................................................................................................................................ 254 kg
Air-conditioning circuit capacity ...............................................................................................................1 kg +/- 0.05
Type of air-conditioning coolant............................................................................................................ HFC (R) 134a

Cab retaining screws ............................................................................................................................... 78 to 80 Nm
Battery housing retaining screws............................................................................................................ 20 to 29 Nm

9005-3
CAB
Removal STEP 3
(CX210/CX230/CX240)
STEP 1
JS00163A CD00G002
Park the machine on hard, flat ground. Lower the tool Open the left-hand side doors. Disconnect the earth
to the ground. cable (1) from the battery. Close the doors.
STEP 2 STEP 4
Reduce the engine speed to idle for 30 seconds, then Fold the operator’s seat-back down and move the
shut down the engine. seat as far as possible.
STEP 3 STEP 5
(CX130/CX160) Remove the floor mat from the cab.
STEP 6
1 Remove the thrust bar on the left-hand side of the
cab.
STEP 7
Remove the radio, if fitted.
STEP 8
2
3
CD00F052
Open the left-hand side door. Remove the two
screws (1) and washers which retain the battery
housing (2). Remove the battery housing. Disconnect
the earth cable from the battery (3). Close the door.
CD00G003
Remove the trim panel at the rear of the cab, taking
care to disconnect the connector for the cigarette
lighter and the solar radiation detector (only on air-
conditioned models).

9005-4
STEP 9 STEP 12
1
1
CD00G004 CD00G005
Remove the two electronic boxes (1) and (2) (see Remove the screws (1) which fasten the rear
Section 4003). ventilation and remove the two conduits.
STEP 10 STEP 13
3 Remove the connectors (2) at the rear of the cab.
STEP 14
CD00G006
Disconnect the windshield washer pipe and remove
the retaining clip.
STEP 15
Remove the windshield wiper motor, see page 13 in
this Section.
CI00G501
STEP 16
Remove the five relays and the relay retaining plate
Remove the upper right-hand side trim panel and
(3).
remove the display.
STEP 11
Remove the electronic control box support brackets
(4) and (5).

9005-5
STEP 17 STEP 20
CD00G007
Remove the pollen filter guard, remove the pollen
filter and remove the pollen filter conduit.
STEP 18
Remove the working light from the top of the cab.
Retract the radio aerial. Install suitable lifting rings on
the top of the cab. Install lifting equipment.
STEP 19
Remove the screws and washers which fasten the
cab to the upperstructure frame. CI99G501
Using the lifting equipment, carefully raise the cab
NOTE: Keep away from the cab while it is being until it is completely away from the machine, then
lowered. Make sure that the cab is not damaged lower it to the ground.
during lifting or lowering. Room for manoeuvre is very
limited at the rear, on the sides and inside the cab. NOTE: The cab weighs 254 kg.
Installation
NOTE: Keep away from the cab while it is being
lowered. Make sure that the cab is not damaged
during lifting or lowering. Room for manoeuvre is very
limited at the rear, on the sides and inside the cab.

9005-6
STEP 1 STEP 6
CD00G007
Install the pollen filter and the pollen filter conduit.
Using screws (1), fasten the pollen filter housing (2)
to the cab.
STEP 7
Reconnect the blower motor conduit to the ventilation
conduit at the front of the cab. Reconnect the
ventilation conduit at the rear of the cab.
STEP 8
CI99G501
Install suitable lifting rings on the top of the cab.
Using suitable lifting equipment, raise the cab. Guide
the cab so that it is correctly aligned with the
mounting studs and orifices in the upperstructure
frame.
NOTE: The cab weighs 254 kg.
STEP 2
Install the screws and washers which fasten the cab
to the upperstructure frame. Tighten them to a torque
of 78 to 80 Nm.
CD00G006
STEP 3 Connect the windshield washer pipes together and
Install the working light on the top of the cab. attach the circlip.
STEP 4 STEP 9
Install the windshield wiper motor, see page 13 in this Install the electronic control box support brackets.
Section. STEP 10
STEP 5 Connect the electrical harnesses.
Use the screws to install the display and connect it to
the electrical harness.

9005-7
STEP 11 STEP 16
(CX130/CX160)
CD00G004
Install the five relays and the two electronic control
boxes, see Section 4003. CD00G052
Open the left-hand side door. Reconnect the negative
STEP 12 cable (1) to the battery. Install the battery housing,
fasten it in place with the screws (2) and washers.
Tighten them to a torque of 20 to 29 Nm. Close the
door.
STEP 16
(CX210/CX230/CX240)
CD00G003
Install the trim panel at the rear of the cab, taking 1
care to reconnect the cigarette lighter connector and
the solar radiation detector (only on air-conditioned
models).
STEP 13
CD00G002
Install the radio, if fitted. Open the left-hand side doors. Reconnect the battery
cable (1) to the battery. Close the doors.
STEP 14
Install the access bar, using screws and washers.
STEP 15
Install the floor mat.

9005-8
HEATING BLOCK/AIR-CONDITIONING BLOCK

Description
3
1
10
9
4
6
11
8
2
CI00G503
1 CAB REAR VENTILATION CONDUIT 7 HEATER HOSE
2 CAB LOWER VENTILATION CONDUIT 8 RETAINING CLIP
3 CAB REAR VENTILATION CONDUIT 9 UNION
4 POLLEN FILTER 10 UNION
5 CONDUIT 11 HEATER ASSEMBLY
6 SCREW

9005-9
Removal STEP 3
(CX210/CX230/CX240)
STEP 1
JS00163A CD00G002
STEP 2 STEP 4
Reduce the engine speed to idle for 30 seconds, then Raise the engine hood and lock it in the raised
shut down the engine. position.
STEP 3 STEP 5
(CX130/CX160)
WARNING: Boiling cooling fluid can spurt out
when the radiator cap is removed. To remove
1 the cap, proceed as follows: Wait until the
system has cooled down and then turn the
cap slightly and wait for all the pressure to be
! released. You can be seriously scalded if the
radiator cap or expansion reservoir cap is
removed too quickly. For checking and
maintenance of the cooling system, refer to
2 the maintenance instructions.
3
Make sure that the radiator has cooled down and
remove the radiator cap.

CD00F052
STEP 6
screws (1) and washers which retain the battery Use a container of suitable capacity and empty the
housing (2). Remove the battery housing. Disconnect cooling system (see the operator’s manual).
STEP 7
Remove the operator's seat from the cab (see
Section 9004).

9005-10
STEP 8 NOTE: Carry out Steps 11 and 12 only for air-
conditioned machines.
STEP 11
Empty the air-conditioning system, contact an
authorised engineer.
STEP 12
CD00G003
Remove the trim panel at the rear of the cab, taking
care to disconnect the connector for the cigarette
lighter and the solar radiation detector (only on air- B
conditioned models).
STEP 9
Disconnect the electric blower supply harness. CD00G006
Remove the screw (A) and remove the hoses (B)
STEP 10 from the air-conditioner. Discard the O-rings. Block
the air-conditioner and the hoses with plugs in order
NOTE: The numbers in brackets refer to the
to avoid any risk of contaminating the system.
schematic on page 8.
STEP 13
Remove the ventilation conduits (1-2-3) from the cab.
8 STEP 14
7 7
CD00G044
Unscrew the hose clips (8) and disconnect the heater
hoses (7).
CD00G007
Remove the pollen filter guard, remove the filter (4)
and remove the conduit (5).
STEP 15
Remove the screws (6) that secure the heating or air-
conditioning block to the cab. Remove the block from
the cab.

9005-11
Installation NOTE: Carry out Steps 5 and 6 only on

air-conditioned machines.
NOTE: The numbers in brackets refer to the
schematic on page 8. STEP 5
STEP 1
Install the heating or air-conditioning block in the cab
using screws (6), brake washers and flat washers.
A
STEP 2
CD00G006
Remove the plugs from the air-conditioner and the
hoses (B), install new O-rings on the hoses (B) and
install the hoses (B) on the air-conditioner, tighten the
screw (A) to a torque of 7.8 to 11.8 Nm.
STEP 6
CD00G007
Install the conduit (5), the pollen filter (4) and the Fill the air-conditioning circuit, contact an authorized
pollen filter guard. engineer.
STEP 3 Type of coolant: HFC (R) 134a
Capacity of the circuit: 1 kg +/- 0.05
Install the heater ventilation conduits (1), (2) and (3).
STEP 4 STEP 7
Connect the blower supply electrical harness.
STEP 8
8
7 7
CD00G044
Install the heater hoses (7) and tighten the retaining
clips (8).
CD00G003
Install the trim at the rear of the cab, taking care to
reconnect the connector for the cigarette lighter and
the solar radiation detector (only on air-conditioned
models).

9005-12
STEP 9 STEP 14
Install the operator’s seat in the cab (see Add cooling fluid according to requirement in the
section 9004). expansion reservoir.
STEP 10
WARNING: Boiling cooling fluid can spurt out
Pour suitable cooling fluid in the radiator (see the when the radiator cap is removed. To remove
operator’s manual). the cap, proceed as follows: Wait until the
system has cooled down and then turn the
STEP 11 cap slightly and wait for all the pressure to be
(CX130/CX160)
! released. You can be seriously scalded if the
radiator cap or expansion reservoir cap is
removed too quickly. For checking and
1 maintenance of the cooling system, refer to
the maintenance instructions.
STEP 15
Start the engine and run it at maximum speed until it
reaches normal working temperature.
2
3 STEP 16
CD00F052
Open the left-hand side door. Connect the earth STEP 17
cable (1). Install the battery housing (2) using screws When the radiator feels cold, remove the caps from
(3) and washers. Tighten to a torque of between 20 the radiator and the expansion reservoir. Top up if
and 29 Nm. necessary.
STEP 12 STEP 18
(CX210/CX230/CX240)
Close the left-hand side doors.
CD00G002
Open the left-hand side doors. Reconnect the earth
cable (1). Close the doors.
STEP 13
Start the engine and run it at idle speed for one
minute. Shut down the engine.

9005-13
WINDSHIELD WIPER MOTOR

Description
11
9
8 10
1
7
6
3 5
CI00G502
1 PROTECTIVE FLAP 7 FLAT WASHER
2 WINDSHIELD WIPER ARM 8 PLASTIC SUPPORT
3 NUT 9 SCREW
4 WINDSHIELD WIPER MOTOR 10 ELECTRICAL HARNESS
5 RUBBER CAP 11 SCREW
6 NUT

9005-14
Removal STEP 3
(CX210/CX230/CX240)
STEP 1
JS00163A CD00G002
STEP 2 STEP 4
Reduce the engine speed to idle for 30 seconds, then NOTE: The numbers in brackets refer to the
shut down the engine. schematic on page 13.
STEP 3 From the front of the cab, raise the protective flap (1)
(CX130/CX160) located on the lower portion of the windshield wiper
arm (2).
STEP 5
1
Remove the nut (3).
STEP 6
Note the position of the windshield wiper arm (2).
Remove the windshield wiper arm (2) from the
windshield wiper motor (4) by pulling it off the
2 windshield wiper motor shaft.
3
STEP 7
Remove the rubber cap (5).
CD00F052 STEP 8
screws (1) and washers which retain the battery Remove the nuts (6), washer (7) and plastic support
housing (2). Remove the battery housing. Disconnect (8) from the windshield wiper motor shaft.

9005-15
STEP 9 STEP 11
Disconnect the electrical harness (10) from the
windshield wiper motor (4).
STEP 12
Remove the screws (9) and (11) from the windshield
wiper motor. Remove the windshield wiper motor.
CD00G133
Remove the upper right-hand trim.
STEP 10
CD00G134
Remove the lower front trim inside the cab, by the
screw(s) (A).

9005-16
Installation STEP 8
NOTE: The numbers in brackets refer to the Turn back the flap (1) located on the lower portion of
schematic on page 13. the windshield wiper arm (2).
STEP 1 STEP 9
(CX130/CX160)
Place the windshield wiper motor (4) in position on
the cab bracket. Connect the windshield wiper motor
connector (4) to the electrical harness (10).
3
STEP 2
Install the windshield wiper motor (4) on the cab
pillar, using the screws (9) and (11).
STEP 3
2
1
CD00F052
Open the left-hand side door. Connect the earth
cable (1). Install the battery housing (2) using the
screws (3) and washers. Tighten the screws (3) to a
STEP 9
(CX210/CX230/CX240)
CD00G134
Install the right-hand front trims in the cab using the
screws.
STEP 4
Install the support (8), washer (7) and the two nuts
(6). Tighten the nuts.
STEP 5
1
Install the rubber cap (5).
STEP 6
Install the windshield wiper arm (2) on the windshield
wiper motor shaft (4), positioning the windshield CD00G002
wiper arm (2) in the same position as was noted at Open the left-hand side doors. Connect the earth
disassembly. cable (1). Close the doors.
STEP 7 STEP 10
Install the nut (3) on the windshield wiper motor shaft. Switch on the windshield wiper motor and check that
Tighten the nut. everything is working correctly.

Section
9006
AIR CONDITIONER TROUBLESHOOTING AND

SYSTEM CHECKS
9006

Printed in France
9006-2
TABLE OF CONTENTS
SAFETY PROCEDURES ............................................................................................................................................... 2
SPECIAL TOOLS ........................................................................................................................................................ 3
OPERATION ............................................................................................................................................................... 4
Refrigerant schematic................................................................................................................................................ 5
Electrical schematic .................................................................................................................................................. 6
PRE-STUDIES ............................................................................................................................................................. 7
The Blow is not Cool ................................................................................................................................................. 7
The Speed of Blower motor is not changeable ............................................................................................................... 7
Magnetic Cluch does not work ................................................................................................................................... 8
Blow air is not changeable in fresh or recycle................................................................................................................ 8
A/C Mode is not changeable ....................................................................................................................................... 8
TROUBLESHOOTING .................................................................................................................................................. 9
The Blow is not Cool ................................................................................................................................................. 9
The Blow is not Hot ..................................................................................................................................................10
Blower motor does not work ..................................................................................................................................... 11
The speed of blower motor is not changeable .............................................................................................................. 12
Magnet Cluch does not work .................................................................................................................................... 12
Blow air is not changeable in fresh or recycle..............................................................................................................13
A/C Mode is not changeable ..................................................................................................................................... 13
TROUBLESHOOTING FOR COOLANT CIRCUIT ........................................................................................................... 14

9006-3
SAFETY PROCEDURES
THIS SAFETY ALERTY SYMBOL INDICATES
IMPORTANT SAFETY MESSAGES IN THIS
M A N U A L . W H E N Y O U S E E TH I S S Y M B O L ,
! CAREFULLY READ THE MESSAGE THAT
FOLLOWS AND BE ALERT TO THE POSSIBILITY
OF PERSONAL INJURY OR DEATH.
Safety procedures must be followed when working with 4. Always reclaim refrigerant from the system, if you are
Refrigerant R-134a to prevent possible personal injury. going to weld or steam clean near the air conditioner
system.
1. Always wear safety goggles when doing any service work
near an air conditioner system. Liquid refrigerant getting 5. Always check the temperature and pressure of the air
into the eyes can cause serious injury. Do the following if conditioner system before reclaiming refrigerant and
you get refrigerant near or in your eyes: when you test the system.
A. Flush your eyes immediately with water for 15 6. Dangerous gas can form when refrigerant comes in
minutes. contact with an open flame. Never permit fumes to be
inhaled.
B. See a physician immediately.
7. Never leak test with compressed air or flame testers.
2. A drop of liquid refrigerant on your skin will cause Te s t s h a v e i n d i c a t e d t h a t , a t p r e s s u r e s a b o v e
frostbite. Open the fittings carefully and slowly when it is atmospheric, and with air concentrations greater than
necessary to release pressure from the air conditioner 60% by volume, R-134a can form a combustible gas.
system. Your skin must be treated for frostbite or a
physician must be seen if you get refrigerant on you skin. 8. Do not steam clean any air conditioner system parts while
the system is charged. The heat can cause the refrigerant
3. Keep refrigerant containers in the correct upright position. to rise to a pressure that can cause the system to
Always keep refrigerant containers out of the sun away explode.
from any heat. The pressure in a container will increase
with heat.

9006-4
SPECIAL TOOLS
A22094 299L7B
Refrigerant Recovery, Recycling and 9 Inch Stem Type Thermometer

Charging Station OEM-1418 0°-250 CAS-10248
299L7A
Safety Goggles CAS10073-3

A22090
Electronic Leak Detector OEM-1437
299L7C
Belt Tension Tool CAS-10808

9006-5
OPERATION
The air conditioner system includes five major components: The receiver-drier is also a refrigerant reservoir for the air
condenser, evaporator, compressor, expansion valve, and conditioner system.
receiver-drier. These components are connected by tubes
and hoses to operate as a closed system. The air conditioner The refrigerant, still in a liquid form, flows to the expansion
system is charged with R-134a refrigerant. valve. The expansion valve causes a restriction in the flow of
refrigerant to the evaporator. Because of this restriction, the
The compressor receives the refrigerant in gas form. The refrigerant flowing out of the expansion valve is under less
compressor then compresses the refrigerant and sends the pressure than the refrigerant flowing in. As refrigerant flows
refrigerant, still in gas form, to the condenser. The air flow through the evaporator, the refrigerant takes heat from the air
th rou gh th e co nde ns er th en re mov es h ea t fro m t he around the evaporator. The combination of increased heat
refrigerant. As heat is removed the refrigerant changes into a an d de cr eas ed p r e ss ur e ca us es e va po r at io n of t he
liquid. refrigerant. The evaporation causes the air flowing over the
evaporation coil to cool. The cooled air is then used to keep
The liquid refrigerant flows from the condenser to the the operators cab cool.
receiver-drier. The receiver-drier is a container filled with a
drying material which removes moisture that has entered the The refrigerant, in a gas form again, flows back to the
air conditioner system. Moisture must be removed to prevent compressor, and the cycle is repeated.
corrosion of internal components of the air conditioner
system.

9006-6
REFRIGERANT SCHEMATIC
Low Pressure Gas 1. Typical Expansion Valve 4. Compressor

High Pressure Gas 2. Temperature Sensing Bulb 5. Condenser
Low Pressure Liquid 3. Evaporator 6. Receiver-Drier
High Pressure Liquid
JS01277A

9006-7
ELECTRICAL SCHEMATIC
2
1
3
9
5
10
6
11
7
12
8
13 14 15
16
17
19 17
17
18 cs03d527
1. A/C control panel 11. Therm-sensor for evaporator

2. Compressor 12. Therm-sensor for recycled air
3. Pressureswitch for A/C gas 13. Signal of anti-freeze temperature
4. Electric power source for compressor 14. Signal of front window (open or close)
5. Signal for blower RPM 15. Signal of CAB door (open or close)
6. Signal for switching fresch or recycle 16. SCM computer
7. Signal for air mix damper control 17. Motor actuator
8. Signal for switching outlet 18. Blower controler
9. Computer for A/C 19. Recycle air
10. Sun shine sensor

9006-8
PRE-STUDIES
The Blow is not cool
Control panel for Air Conditionner buzzing continuously
NO YES
See page «The blower is not Anti-Overheat Control Device is

COOL» working
The speed of blower motor is not changeable
NO YES
The AC blow mode (foot or face) and air mode

(open or close) are changeable
NO
YES
When the speed of blower motor does not work, is Anti-Overheat Control Device is
the AC in “Face”mode? working
NO YES
Is the door or window opened? See page “The speed of Blower

Motor is not changeable”
YES NO
Limit Control is working by the Door or the Limit control device is working by
front window “COOL MAX” situation

9006-9
Magnetic Clutch does not work
NO
YES
Does the Magnetic Clutch work in all
conditions except in “FOOT”air mode?
YES
NO
See the “Magnetic Clutch does not work Anti-Overheat Control Device is
trouble shooting”? working
Blow air is not changeable in fresh or recycle
NO YES
Quantity of air blow can not be adjusted
YES
NO
Door or the front window is opened Anti-Overheat Control Device is working
YES
NO
Limit Control Device is working by “COOL See page ”Blow air is not changeable
MAX” situation in fresh or recycle”
A/C Mode is not changeable
NO
YES
The mode “Fresh air” and “recycle air” are
changeable from one to the other
NO
YES
See page “A/C Mode is not changeable” Anti-Overheat Control Device is
working

9006-10
TROUBLESHOOTING
The Blow is not COOL
When auto switch or A/C switch are pushed, “HL.E” is
displayed on the panel
YES
NO
“HL.0” through “HL.9” are
1) Connector for Air Mix Motor Actuator is not
displayed
connected.
2) Failure of Air Mix Motor Actuator.
NO YES 3) Electrical current failure on Harness
“SNOW” mark on the panel is “SNOW” mark on the panel is
flashes flashes Repair or change the parts
NO YES
1) Thermosensor or harness are cut off or
1) Thermosensor in the cab and themosensor on
short-circuited
evaporator are shorting at the same time.
2) Connector of thermosensor is not
2) Failure on Controller
contacted
Refer to the Monitor Refer to the «Monitor Mode» section
Repair or change the parts
YES
NO
When “18.0” is set as a standard temperature and blow mode 1) Connector of thermosensor on
is changed to vent mode, blow is cooler than usual evaporator is not connected or cut off
2) Thermosensor on evaporator cut off or
shorting
NO YES
Refer to the Monitor
Air Mix Damper is located at the Cool Air is blowing into
“COOL MAX” thermosensor Repair or change the parts
NO YES NO
Repair the ON/ OFF switch of Controller failure and

If Motor actuator does not move,
Clutch of CompressorRepair the thermosensor failure
measure the blowing power after
checking the reason. Is the Power Circuit
blowing power less than 1.5 kgf?
See the trouble shooting for Repair
YES
freezing cycle
Check the duct and remove
NO YES factors causing cool air to
enter
1) Check, repair, and exchange lever on Motor Actuator failure or controller
Motor actuator failure
2) Spread the grease over the lever after
it is cleaned up Repair

9006-11
TROUBLESHOOTING
The Blow is not HOT
When auto switch or A/C switch are pushed, “HL.E” is
NO YES
“HL.0” through “HL.9” are

displayed
NO YES
1) Thermosensor or harness are cut off 1) Connector for Air Mix Motor Actuator is
When “32.0” is set as a standard
or short-circuited not connected.
temperature and blow mode is
2) Connector of thermosensor is not 2) Failure of Air Mix Motor Actuator.
«FOOT», blow is cooler than
contacted 3) Electrical current failure on Harness
usual
Repair or change the parts Repair or change the parts
NO YES
Air Mix Damper is located at the Hot Air is blowing into
“HOT MAX” thermosensor
NO
Controller failure and
NO thermosensor failure
YES
If Motor actuator does not move, See the trouble shooting for
measure the blowing power after freezing cycle Repair
checking the reason. Is the YES
blowing power less than 1.5 kgf?
Check the duct and remove
factors causing cool air to
enter
NO YES
1) Check, repair, and exchange Motor Actuator failure or
lever on Motor actuator controller failure
2) Spread the grease over the lever
after it is cleaned up
Exchange the Motor Actuator

9006-12
TROUBLESHOOTING
Blower Motor does not work
The amount of blow is “HIGH” and the both terminal(+)(-) are
connected to the battery. (See the “Note 1”)
NO YES
Red line of the blower motor (from Main Power) is Exchange the Blower
grounded on the battery Motor
NO YES
Blue / black color harness of the blower

1) Check the blower motor relay
amplifier are grounded by about 10 volts
2) When white / green line and red line of the
blower motor relay are connected to each other,
the blower motor starts to work
(See the “Note 2”) NO YES
Blue / black color harness of the blower

Repair or change the
amplifier are grounded by about 10
controller
volts
NO YES
Repair or exchange White / green color line of the blower

NO YES
the wire harness motor relay is connected to the
ground
Exchange the blower Repair or exchange the
amplifier after eliminating wire harness
the failure
YES
NO
1) Check, repair, and exchange lever on
Repair or exchange Motor actuator
the wire harness 2) Spread the grease over the lever after
it is cleaned up
NO YES
Exchange the relay Repair or exchange

the wire harness
(Note 1) measure the voltage on every harness connected
(Note 2) For safety, A/C switch, main power switch, and light must be off when you connect harness directly

9006-13
TROUBLESHOOTING
The speed of blower motor is not changeable
“HL.0” through “HL.9” is displayed on the panel
NO YES
1) Thermosensor or harness are cut off or short-

Exchange the blower amplifier circuited
controller 2) Connector of thermosensor is not contacted
Repair or change the parts
Magnet Clutch does not work
When “AUTO” switch or “A/C” switch is on, “SNOW” light is on
NO YES
The “Snow” symbol flashes and “E” is
The Clutch is connected with voltage
NO YES
1) Connector of thermosensor on
evaporator is not connected or cut off
2) Thermosensor on evaporator cut off or Harness is connected with pressure Exchange the compressor
shorting switch (Clutch failure)
Repair or change the parts NO YES

Failure of pressure switch or error
AC harness connector (white / red) connected of refrigerant pressure
to wheel is grounded to black line
See the “freeze cycle” trouble

NO shooting page
YES
A/C harness have some trouble
Check the clutch fuse
NO YES
Exchange harness Exchange control

9006-14
TROUBLESHOOTING
Blow air is not changeable in fresh or recycle
The indication for fresh/recycle on the control panel is flashed
NO YES
1) Contamination is on lever of Motor actuator 1) Motor Actuator connector for fresh/recycle air
2) Motor actuator lever is broken control is failed or not connected
2) Failure of Motor actuator
3) Failure of main harness
YES
NO
1) Remove the contamination
Exchange the motor actuator 2) Exchange the parts
A/C mode is not changeable
The indication of A/C mode (manual) on the control panel is

flashed
NO YES
Motor actuator rod is not released 1) Motor Actuator connector for fresh/recycle air
control is failed or not connected
2) Failure of Motor actuator
3) Failure of main harness
NO YES
Repair All of damper is not slipped
Ckeck or exchange
YES NO
Repair After removing the rod, can move cam but

difficult in (2 kgf over).
NO YES
Motor actuator failure or control 1) Contamination on the Cum or damper

failure 2) failure of Cum or damper
3) Movement failure caused by contamination
Repair
1) remove the contamination

2) exchange the parts
3) spread the grease after washing Cum

9006-15
Troubleshooting for coolant circuit
Phenomenon Result of diagnosis Estimated reason How to repair
Highest pressure is not If compressor switch is off, the Failure of compressor Exchange compressor
high and lowest pressure high pressure goes to the
is not low same pressure as the low
pressure
High and low pressure A/C blow is not kept cool Caused by water entering the Exchange the receiver dryer
changed at regular cooler circuit and add refrigerant after
intervals (When pressure removing the water
is not changed, their level
is normal)
Both high and low Air bubbles are found on the Gas is leaking from the parts Exchange the parts or pipes
pressure are lower than sight glass with pipes
usual Oil spreading into the pipe or
parts (Leak Tester reacts)
Air bubbles are found on the Refrigerant is low. Fill up refrigerant to the
sight glass appropriate level
Oil not spreading into the pipe
or parts (Leak Tester does not Gas is leaking from hose Fill up refrigerant to the
react) simply due to not adding appropriate level
refrigerant for a long time
The pipe for low pressure is Failure of expansion valve Repair the expansion valve
not cool
Expansion valve is clogged Remove the dust or exchange
the valve
Evaporator in the low pressure Remove the dust or exchange

line is clogged the valve
The blow volume drops when Evaporator fins are clogged Wash the evaporator
A/C has been working a long
time AC filter is clogged Clean or exchange the filter
Thermistor is on the incorrect Adjust the position of

position thermistor
Gas is leaking in AC unit Repair the pipe
Failure of thermistor or Repair the thermistor or

electrical circuit electrical circuit
It sometimes occured that Raise up the target

frost is formed on the temperature or adjust AC blow
evaporator when AC blow is volume
low at the same time as traget
temperature is lowest

9006-16
Troubleshooting for coolant circuit
Phenomenon Result of diagnosis Estimated reason How to repair
Both high and low Air bubbles do not occur even Air in piping Exchange the ceceiver dryer
pressure are higher than if water is placed on the and add refrigerant after
usual condenser (the receiver drier removing the water
is still cool)
The pipe for low pressure is Failure of expansion valve Adjust the poppet of valve or
cool and a lot of water or frost repair the valve
is attached to the pipe
Failure of expansion valve Repair the thermostat pipe so
(valve is not connected to the that it can be connected to the
thermostat pipe) valve
When water is placed on the Condenser fins are clogged Wash the condenser
condenser, condenser
becomes cooler (both low and Radiator fins are clogged Wash the radiator
high pressure go to the
normal level) Failure of the coolant fan or Repair the the coolant fan or
looseness of fan belt fan belt
The pipe for low pressure is Too much refrigerant Keep the refrigerant correct
not cool amount

1
BR 207 BR 207 2 BR 207 F23 F24 F25
F21 1.25 YR 208
1.25 W 209
6
1 1 1
ITEM DESCRIPTION
CN 20
2
1
1
1.25 R 206
F22
5
2 2 2
2
1
1
CN 26
A1. COMPUTER
3 4
2 BR 207
CN C1 CN C3 CN C4 A2. ENGINE CONTROLLER
2
1
1.25 YR 208
2
A3. ELECTRONIC ACCELERATION
CN C2 1.25 WR 209
1
A4. WIPER CONTROLLER
F8 F16 F15 F18 F3 F13 F7 F9 F2 F1 F10 F19 F17 F14 F5 F6 F4 F20 F11 F12 1
9 10 11 12 13 14
BrR 544
6
K7
1.25 R 206 BR 203
X3 2 BrW 545 B1. COOLANT TEMPERATURE SENSOR

15A 15A 15A 15A 20A 20A 20A 30A 20A 20A 10A 10A 5A 15A 10A 10A 15A 10A 10A
5
CN 29 10A 206, 208, 209 1.25 LR 204 1.25 LR 204
3 B2. HYDRAULIC OIL TEMPERATURE SENSOR
4
1.25 RW 202
CN 22
1.25 GR 205 1.25 GR 205
4
206, 208, 209

0.65 BrW 230
R 221
RW 220
0.85 LR 380
0.85 OR 375
0.85VR 370
0.85BrR 360
1.25 LgR 350
1.25 LW 340
1.25 GrR 330
2 WR 050
1.25 W 320
1.25 GR 310
GW290
VW 280
0.85 YW 270
0.85 YR 260
LR250
VR 240
B21. ENGINE OIL PRESSURE SWITCH
OW 300
5 60 R 200 60 R 201 60 R 001
2 1 B22. SWING PILOT PRESSURE SWITCH
1.25 W 322
1
2
BrW 545
BrR 547
6 NB LgR 540
M10 M10 M10 M10
3
1.25 GR 312
OW 303
0.65 GR 231
B23. BREAKER / CRUSHER PILOT PRESSURE SWITCH
1.25 W 325
MB
B 703
GW 303
0.85 OR 375
0.85 YR 260
- + - +
8
2
R 222
WR 541 B24. SECOND OPTION PILOT CIRCUIT 2 PRESSURE SWITCH
0.85 LR 381
BrR 544
BrR 547
7
R 223
1
M4 B25. BREAKER PILOT PRESSURE SWITCH
60 B 799
BP 690
12V 12V B26. UPPER PILOT PRESSURE SWITCH (YELLOW BAND)
1.25 R 206 1 1.25 R 206
B27. TRAVEL PILOT PRESSURE SWITCH
G1 G1
LgR 540 2 LgR 540
WR 541 3 WR 541 B28. SECOND OPTION PILOT CIRCUIT 1 PRESSURE SWITCH
CN 13 1
1
GrR 010 4 GrR 010 M8 B41. ENGINE RPM SENSOR
5 6 BrR 543 5 BrR 543 CN C0 B42. PUMP PRESSURE SENSOR (P1)
B 779
1 2 3 4 7 8 9
2 BrR 547 P1 10 11 12 13 14 15 16 17 18 19 20
YR 630
VW 800
6
7
YR 630
VW 800
B43. PRESSURE SENSOR (NEGA-CONT)
B44. PUMP PRESSURE SENSOR (P2) (YELLOW BAND)
1 WR 548
VR 900 8 VR 900 BG 650
0.85 BG 660
B45. OVERLOAD INDICATOR PRESSURE SWITCH
9
BG 651 B61. SUNLOAD SENSOR
BG 641
BG 652
BG 640
OR 505 10 OR 505
B 779 B81. HORN
CN 5 CN 6 0.85 L 910 11 0.85 L 910
CN 32
2
2 BG 800 E1. WORKING LIGHT (UPPERSTRUCTURE)
IGN 0.85 LW 911 12 0.85 LW 911
IGN 1.25 W 1.25 W 1.25 W 322
1
1 1
P2 B+ 2 R B+ R 2 R 221
0.85 LY 912 13 0.85 LY 912 2 B 700
BP 690
E2. WORKING LIGHT (ATTACHMENT)
0.85 LR 380 14 0.85 LR 380 M8 E3. WORKING LIGHT (CAB)
1 2 3 4 5 6 7 8 17 18 19 20 21 22 23 24 25 26 S2 3 BrG BrG 3 BrG 441 GND
A1
B 779
2 BG 800
(GI)
2 B 700
9 10 11 12 13 14 15 16 27 28 29 30 31 32 33 34 35 36 S3 4 VY VY 4 VY 440 E4. CAB LIGHT
CN B4
S4 5 WG (OG) WG (OG) 5 WG 446
B 719 M5
24V 40A E51. CIGARETTE LIGHTER
E
1
2
VG VG 6 VG 534
M4
6 E52. AIR CONDITIONER
CN 5
S5 7 7
WV 930 1 F1. FUSE 20A; ENGINE CONTROLLER
S6 OG (GY) OG (GY) 8 OG 442 M
4
8
7 8
BW 630 2 F10. FUSE 10A; OPTION LINE AND LUBRICATOR CONNECTOR
CN 21
9 YG YG 9 YG 443
3
FILTER GND F11. FUSE 10A; BACK-UP
POWER 24V 10 1.25 LgR 351 RXD 10 PW RXD PW 10 PW 583
5 6
2
5V F12. FUSE 10A; KEY SWITCH
2 1.25 LgR 350 TXD 11 PL TXD PL 11 PL 584 24V
1
1.25 W 320
F13. FUSE 20A; HEATER / AIR CONDITIONER
CONTROL 24V 4 12 LY LY 12 LY 444
12 1.25 W 321 WR WR 13 WR 531 1.25 WR 209 1 1.25 WR 209 F14. FUSE 5A; AIR CONDITIONER COMPRESSOR
13 8 R 100 8 R 100 M5 B
GND 1 1.25 BG 600 14 BrR (BrY) BrR (BrY) 14 BrR 501 1.25 YR 208 2 1.25 YR 208 F15. FUSE 15A; WORKING LIGHT
WR 541
LgR 540
GND 9 1.25 BG 501
P3 15 GrR GrR 15 GrR 520 2 LR 060 3 2 LR 060 2 LR 050 SG F16. FUSE 15A; WORKING LIGHT (NOT USED)
BrR 530
GND 3 16 LR 16 LR 521 1.25 GrR 330 4 1.25 GrR 330 BP 690 BrR 030 2 L F17. FUSE 10A; DC-DC (24V-12V) CONVERTER
11
S7 YR 17 YR 522 1.25 GR 312 1.25 GR 312 010, 540, 541, 543 LgR 020 1 R
GND 17 5 F18. FUSE 15A; WIPER AND WASHER
S8
CPU GND 5 18 LR VR 18 VR 523 BP 690 6 BP 690
140 F19. FUSE 10A; HORN
CN E0
S9
010, 543
GND 13 19 YR BrW (BrR) 19 BrW 545 1.25 B 700 7 2 B 700
CN C9
F2. FUSE 20A; COMPUTER CONTROL INSTRUMENT PANEL AND DIAGNOSTIC TEST SOCKET
1
PWM 1 OUT 14 YR 940 S10 20 VR GND 1.25 BG 20 1.25 BG 602 602, 603, 604 1.25 BG 600 8 2 BG 600
S11 YR 830
Y2
2
PWM BrW (BrR) B 703 B 703 1 F20. FUSE 15A; CIGARETTE LIGHTER AND CAB SEAT COMPRESSOR ADJUSTMENT
PWM 1 RET 6 BY 941 21
B 755
1.25 B 730
1.25 B 731
S12 B 760 2 F21. FUSE BOX
BG (B)
NOT USED 16 22 1.25 BG
603, 604
VR 524
B 760
PWM 2 OUT 15 GND F22. FUSE 20A; MAIN FUSE FOR F11 AND F12 CIRCUITS
CN P4
CN E2
D/A PWM
G2
PWM 2 RET 7 F23. FUSE 65A; MAIN FUSE FOR F3 TO F10 AND F13 TO F20 CIRCUITS
2
1
E4
8 BIT
8 1.25 BG 602
2 STAGE RELIEF YW 802
CN P0
F24. FUSE 20A; MAIN FUSE FOR F2 CIRCUIT
BG 603 VW 800 1
Y3
3
6
60 R 001 M10 B
CN 9
1 0.85 BrR 6 0.85 BrR 360 F25. FUSE 20A; MAIN FUSE FOR F1 CIRCUITS
PROTECT BG 604 B 762 B 762 2 M
2
5
2 WR GrR 14 GrR 520 F3. FUSE 20A; COMPUTER POWER
1
4
24VB LR 12 LR 521
CN E1
11 12 13 14 15 16 17 18 19 20 21 22
F4. FUSE 10A; HYDRAULIC FUNCTION CANCELLATION LEVER SWITCH
9 10
P4 5V
4.7K 24V - 10W
YR 13 YR 522 F5. FUSE 15A; LUBRICATOR (NOT USED)
VR 3 VR 523 1 1.25 B 700
Y4
LW 801 1 F6. FUSE 10A; ROTARY LIGHT
8
17 FPC
FPC
SPARE 1 (PNP) B 710 0.85 GrR 010 S
S53 0.85 OR 11 0.85 OR 892 2
CN P8
B 702
1.25 B 701
B 761 B 761 2 F7. FUSE 20A; FUEL FILLER PUMP
7
18
H1
2
ROTARY LIGHT PW 819 VW 2 VW 525 3 B 711
19 F8. FUSE 15A; ENGINE STOP MOTOR
1
AUDIBLE ALARM WR 1 WR 390 4 B 713
CN E3
21 0.85 BrR 543 R F9. FUSE 30A; GLOW PLUG
SPARE 2 (PNP) LW 7 LW 972 5 B 715
2
M1
1 VW VW
3
8
6
SPARE 3 (PNP) 22 BL 8 BL 973 6 B 728 G1. BATTERY
Y5
2 BG (B) 1 BG (B) YW 802 1
2
7
CN P3
5
SWING BRAKE 27 VW 800 YW 9 YW 970 G2. ALTERNATOR
3 B 763 2
6
28
4
2 STAGE TRAVEL LW 801 BY BY 971 2 LR 060
P5 10
E51
M4 H1. AUDIBLE WARNING DEVICE
B 763
29 LgW 803
3
CUSHION CONTROL WV 4 WV 730
CN E4
K1. RELAY-ENGINE EMERGENCY STOP
CN P9
719, 715, 728

4
NOT USED 30
2
BW 5 BW 720
R1
1.25 B 701
K2. RELAY-GLOW PLUG
2
SWING SHUT OFF 31 BrW 804 0.85 BrW 230 B 715
710, 711
S54 Y6
WV 931
LgW 803 1
1
K3. RELAY-HORN
BW 721
B 702
NOT USED 32 WR 1 WR
B 764 B 764 2 K4. RELAY-WORKING LIGHT
BATT. RELAY 20 WR 541 VW 2 VW
CN 14
9 10 11 12 13 14
6
NOT USED 23 WR 548 1 VR VR 3 VR K5. RELAY-ROTARY LIGHT
CN E5
CN D7
5
NOT USED 36 BG (B) 4 BG (B) K7. RELAY BATTERY
1
2 BG (B)
1.25 BG 800
4
CCW 24 3 BL (SPK: L-) 5 BL
2
M1. STARTER MOTOR
BrW 804 1
26
U1 Y1
CN 30
CW LW (SPK: L+) 6 LW
33 B 765 B 765 2 BG 640 1 B21 M2. ENGINE EMERGENCY STOP MOTOR
2
NOT USED BY (SPK: R-) 7 BY
CN P7
LgY 438 2
M3. WIPER MOTOR
34
3
3
NOT USED YW (SPK: R+) 8 YW
2
X5
M4. WASHER MOTOR
1
CN 27
GY 566
E3
25
3
1.25 W 325
X4
1
8
A/C CONT.
8
B 763
1
B 760
3
PROTECT
2 BG 600
CN A5
2
5V 35 M5. MOTOR (AIR CHANGING)
2 B 700
2
CN 25
7
NOT USED WR 571
2
1
7
1
24 V 1 OR OR VW 280 1 VW 280 VW 280 6
B 779
24V
3
3
M6. AIR VENT DIRECTION CONTROL MOTOR
LG 570
6
2
2 BG (B) R 223 R 223 R 223
CN D6
70W 2 2
1
M7. MOTOR ACT (AIR-MIX)
9 10 11 12 13
P 585 4
5
6
B 702 3 B 702 B 702 5 t C
0.85 BP 494 1
B1
OW 301
2
PG 586 5 M8. BLOWER MOTOR
1
CN 6
CN P10
4
5
BP 633 1 0.85 YR 281 1
0.85 PL 484 2
BP 587 6 P1. INSTRUMENT PANEL
4
2
2
1
1
CN P1
P 588 0.85 RW 282 3 0.85 L 913
VG 576 7 3 LW 801 1 LW 801 P2. SWITCH PANEL (LEFT-HAND)
BP 632 0.85 BY 729 4 0.85 B 751 2
YW 802 YW 802
M2
BG 620 8 2
2 3
7 P3. SWITCH PANEL (RIGHT-HAND)
LgW 803 3 LgW 803
A4
8
1 BY P4. MONITOR DISPLAY
R BrW 804 4 BrW 804
1
7
0.85 BrY 575 2 YW P5. HOURMETER
5 0.85 L 910 1 L
CN 1
P6. AIR CONDITIONER CONTROL PANEL

BrR 840 6 BrR 840 0.85 LW 911 2 LW
1K 100K 1K R1. GLOW PLUG
VR 841
CN P5
11 7
3
LR
7
5 LY
W1
0.85 LY 912
CN 70
4
2 3 M
CN A7
0.85 VG 469 0.85 BG 621 1
2
1
VW 842 8 R2. FUEL FLOW ADJUSTMENT RESISTOR
1
YR
2
12
X9
6
6 0.85 OL 415 0.85 LR 380 4 LR
THERMO SENSOR (0) 5 6 7 8 9 CN 11 WV 930 9 WV 930
2
13 GrR 0.85 B 750 R3. THROTTLE VOLUME
5
A GND 13 0.85 BO 425 6 B
2 WV BW 720 10 BW 720
R2
R4. THERMISTOR
1
4
FUEL SENSOR 14 0.85 GL 413 0.85 B 751 3 YL 488 1
0.85 GR 890 11 0.85 GR 890
CN 31
3 BW B 763 R5. FUEL SENSOR
1
2
SPARE 11 (A/D) 15 BL BY 498 2
1 1 1 0.85 BrR 0.85 LgR 891 12 0.85 LgR 891
WR 391
YW 970
LW 972
L S1. KEY SWITCH

BY 971
3 0.85 WY 400 2
BL 973
1
S14
1
LW
4
S13
A VCC
CN D6
R 222
LR 901 LR 901
B 710
2 3 2 3 10 1.25 B 13
CN 63 CN 62
CN A8
1 0.85 WL 410 S10. WORKING LIGHT SWITCH
2
5
P1 SIG
WR 980 14 WR 980
1
9
9 0.85 YL 411
3
6
P2 SIG S11. WIPER SWITCH
GND
(G2)
OW 300 15 OW 300 B 760
2
7 VW WV 931 1
0.85 L 412
CN P6
10
X8
N1 SIG WG 448 BrR 840 GrR 893 GrR 893 S12. WASHER SWITCH
8
3
9
4
6
2
1
7
5
8 VR 16
BW 721 2 O 487 1
B41
2
1
A GND 2 0.85 BW 420 M6
B G 604 BP 690 YR 940 17 YR 940 S13. OVERLOAD SWITCH
4 W 497
A VCC 11 2
BrG 460 5 GW BY 941 18 BY 941 S14. BREAKER / CRUSHER SWITCH
4
X2
SPARE 9 (A/D) GrR 893
6 GR S15. HORN SWITCH
PRESSURE SWITCH 5 B 755
S16. ONE TOUCH IDLE
9 10 11 12 13 14 15 16 17 18
8
A/O PRESSURE SENSOR (HBCV) 12 0.85 WG 417
LR 901
10 BIT LgR 542 24V. 370 HZ. 111dB S2. TRAVEL MODE SWITCH
7
KEY SW. 7 CN 53
1
CN 60
5 6
SPARE 12 (CMP) 16 1 2 3 4 S3. WORK MODE SWITCH
6
2
B81 B81
CN A2
6
M3
CN P2
2
8 BrR 543 LR 900 LR 901
5
S4. AUTO MODE SWITCH
1
5V BATT. CHARGE
S51 S15
5
2
CN 23
7 8
3
5V 1 LW 532 B 753 B 754 S5. CUSHION CONTROL SWITCH
4
1
4
10V 2 B 713 3 GR S51. HYDRAULIC FUNCTION CANCELLATION LEVER SWITCH
1 VR 240
M A3
1.25 BG 800
5V 3 VW 842
4
2 YR 830 1 GW 24V. 370 HZ. 111dB 1.25 RG 950 1 VB S52. AIR CONDITIONING COMPRESSOR CLUTCH SWITCH
CN 2
4
R
B 714
2 BG 600
5 1.25 B 1.25 BrB 951 2 POWER GND S53. DOOR LIMIT SWITCH
2 B 700
VR
B 779
2
6 0.85 GR 954 3 PWM S54. FRONT WINDOW LIMIT SWITCH
E
CN B5
4
1
VW 0.85 WL 482 4 RACK 1ST
TXD 23 S55. RESERVE TANK LSW
1
2
SPARE 13 (CMP)
SCI RXD RS 232 C
TX 27 P 585 R3 2
0.85 LgR 891 1
0.85 WY 472 5 VCC
D
S6. ROTARY LIGHT SWITCH
E1
0.85 YG 508
X6
6 PULL DOWN
B 710
RX 21 PG 586 24V S7. AUDIBLE ALARM CUT OUT SWITCH
0.85 B 741 2 Y 486
S1
BP 587 CONNECTION 24V 7 TACHO SENSOR (SIG)
SG 20 OFF ACC 70W S8. SWING BRAKE SWITCH
1 2 B G1 G2 Acc M ST L 496 8 TACHO SENSOR (GND)
SW. TO ACCESS 28 LG 570 HEAT ON 222, 391, 710, 970, 971, 972, 973 S9. ENGINE EMERGENCY STOP SWITCH
PROTECT 22 WR 571 ST HEAT
4
3
2
1
1
2
CN 54 240, 448 U1. DC-DC (24V-12V) CONVERTER
CN B2
TXD 25 PW 583 OFF
1
SERIAL OUTPUT 830, 840, 842
SCI
WR 391
ACC W1. ANTENNA
B 717
0.85 GR 291
0.85 L
0.85 B
0.85 Y
RXD 19 PL 584 BrG 460
2
SERIAL INPUT
S16
1
4
CN A3
5
1
26 ON 1 2 3 4 X1. FUEL FILLER PUMP CONNECTOR
GROUND BrG 461
2
5
START 0.85 GR 890 1 0.85 GR 890 1
6
VR 240 1 VR 240 2 X2. ROTARY LIGHT CONNECTOR
E2
TA INPUT 24 24V
CN 19
CN 53
3
COUNTER 1/4
6
1.25 B 740 2 0.85 B 740 2
17 1 2 YR 830 2 YR 830 7 70W X3. OPTINAL POWER CONNECTOR
GROUND 3 2 1 CN 55 8
2 B 700
18 BrG 460 3 BrG 460 1.25 LG 952 1 X4. ENGINE TEST POINT CONNECTOR
B 753
B 754
TA GND VB
1 G 450
3
10 9
1 2 3
3
2
1
BrR 840 4 BrR 840 1.25 GrB 953

CN 50 4 5 6 2 BG 603 1.25 B 740 1.25 B 740 4 POWER GND X5. CONTROLLER TEST POINT CONNECTOR
4
GR 231 1
6
2
5
1
VW 642 VW 642
4
3 VR 841 2 X6. CAB SEATCOMPRESSOR MOTOR CONNECTOR

B 779
0.85 L 480
0.85 BL 490
0.85 LY 470
B 716 2 WG 448 6 WG 448

CN 52 0.85 BG 465 3 PWM
WR 390
LgR 540
GrR 010
RW 220
4 B 711 1 X8. RADIO CONNETOR

YR 940 YR 940
CN 3
LW 532 7 LW 532
603, 604
0.85 BW 492 5 SIG GND
BY 941 BY 941 2 X9. ANTI-THEFT SYSTEM CONNETOR
B 713 8 B 713
BP 690 9 BP 690 BP 690 Y7 0.85 WG 473 6 VCC
Y1. SWING PILOT SHUT-OFF SOLENOID VALVE (GREEN BAND)
CN D4
X1
IMMOBILIZER 31 0.85 VG 469 BG 604 10 BG 604 BG 604 Y2. PILOT PRESSURE SOLENOID VALVE (BLUE BAND)
2 B 700
32
2 BG 600
NOT USED Y3. SWING BRAKE SOLENOID VALVE (PINK BAND)
1.25 GrR 330
2
NOT USED 33 2 B 700 Y4. 2 STAGE TRAVEL SOLENOID VALVE (RED BAND)
NOT USED 34 E52 2 BG 600 1 Y5. POWER-UP SOLENOID VALVE (YELLOW BAND)
WR 391
PRESSURE SWITCH 35 G 464

2 Y6. CUSHION CONTROL SOLENOID VALVE (LIGHT GREEN BAND)
AUDIBLE ALARM CUT OUT 36 YG 443
WR 390
0.85 LG 507 3 LIMP HOME Y7. MAIN PUMP PROPORTIONAL SOLENOID

37 2
R4
NOT USED
1 G 465
RW 220 RW 220
LgR 542
LgR 540
BrG 460
Y8. AIR CONDITIONER MAGNET CLUTCH
BREAKER MODE 38
WR 390 2 WR 390 BG 667 1
B28
GrR 010
Y9. CRUSHER/BREAKER OPTION TWO FLOW SOLENOID VALVE
1
TEST 41
CN A4
LgR 540 3 LgR 540
2
NOT USED 42
CN M1
GrR 010 4 GrR 010
3
NOT USED 43
1.25 BG 800
G 450 5 G 450
LgR 502
LgR 503
GrR 504
2
CUSHION CONTROL 44 WG 446 M10
VR 841 16 VR 841
P6 LEGEND
SWING BRAKE 45 LY 444
0.85 LY 470 6 0.85 LY 470 G 464 2
NOT USED 46
0.85 L 480 7 0.85 L 480 t C
BG 656 1
B24 0.85 BO 425
B2
NOT USED 47 1 2
0.85 BL 490 8 0.85 BL 490
NOT USED 48 0.85 OL 415
I/O 0.85 GR 231 15 0.85 GR 231 NOT CONNECTED
CN G2 CONNECTED
CN M0
NOT USED 40
1
4 B 711 17 B 711
1
2
CN D3
CAN H 29
1
7 BG 603 18 BG 603
2
CAN CAN L 39 P 580
G 464
BG 656
2
8 YR 560 9 YR 560
CAN GROUND 30 PG 581
1 BY 561 10 BY 561 OW 300 1 OW 300 OW 300 1 BOOT GROUND CABLE GROUND
2 PL 562 11 PL 562 BrR 840 2 BrR 840 BrR 840 2 Y9
3
6
PW 563
WL 564
12
13
PW 563
WL 564
K1 K2 G 464 3 G 464 0.85 BG 660
R5
CN 4
CN G0
BrG 461 4 0.85 GL 413
1
5 BW 565 14 BW 565 LY 435 LY 435 SINGLE WIRE CONNECTOR HARNESS
5
2
BG 655 6 BG 655
CN B3
1
49 LgY 436
3
ENGINE OIL PRESSURE

8
11 12 13 14 15 16 17 18 19 20 21 22
9 10
18 17 16 15 14 13 12 11 10 9
2 1
2
50
2
7
SPARE 21
CN 51
1 2 LY 435 2 CONNECTOR (MALE) CONNECTOR (FEMALE)

B23
1
4
YG 431
CN B1
TRAVEL PILOT 51 1 2
6
1 2
3
8
BG 655 1
2
5
ROTARY LIGHT 52 VG 534 3 5 3 5
5
CN G2 0.85 WY 400 1
7
B61
3
2
2
4
4
3
5
1
5
1
3
6
L/M MODE 53
CN 10
1
4
2
0.85 WL 410
B42
CN G1
AUTO MODE 54 OG 442
1
CN 24
3
0.85 L 910
0.85 LR 381
BrR 530
0.85 LY 812
0.85 LW 811
2 WR 050
2 WR 051
OR 506
2 LR 060
CN 18 CN 15 0.85 BW 420
1
2
BREAKER PILOT 55 LY 435 OW 300 1
2
1 WL 564
5
56 VY 440 BrR 840 2 INSULATION AGAINST MAGNETISM
BG 656
WORK MODE
2 BW 565
6
CN D0
G 464 G 464
5
COOLANT 57 GrG 437 3
1
7
3
BrG 461 BrG 461
4
SPARE 22 58 4 INDICATES CONSTANT POWER
2
CN 12
LY 435 LY 435 LY 435
3
2
59 5
WG 448
B25
WARNING CHG.
060, 506, 910, 911, 912
1
1
2
SPARE 23 60 BG 655 6 BG 655 BG 655
050, 361, 530 INDICATES POWER WHEN KEY SWITCH IS ON
B44
1
SWING PILOT 61 BrY 432 0.85 Y 401 1
PW 563
CN C0
4
UPPER PILOT 62 LG 430 0.85 YL 411 2
1
ONE-TOUCH IDLE 63 G 450
5 PL 562
LG 430 1 LG 430 S52 0.85 BY 421 3 CN12 (R)
2
6 BY 561
TRAVEL MODE 64 BrG 441 YG 431 2 YG 431
I/O 7 YR 560
K5 Y8
3
K4
BrY 432 BrY 432
CN C8
K3
CN D1
16 VW 525 WR 980 2
1
CONNECTOR NUMBER COLOR OF CONNECTOR
4
3
15 VR 524 W 981 1 (IN CAB)
2
LY 435 LY 435
(IF NOT INDICATED COLOR IS WHITE)
5
14 GY 566
0.85 WY 400 6 0.85 WY 400
CONNECTOR
17 WR 590 W 981 1 LETTER LOCATED
0.85 WL 410 7 0.85 WL 410 BrY 432
3 0.85 GR 567 0.85 LY 402 1 (OUTSIDE CAB)
RAM - 2 K BYTE 9 1.25 LW 340
0.85 YL 411 8 0.85 YL 411
0.85 L 412 2
B43 60 B 001
0.85 L 412 9 0.85 L 412
8 0.85 YW 270 0.85 BL 422 3
0.85 W 420 10 0.85 W 420 LG 430 AREA CIRCUIT NUMBER
1 1.25 B 701 1 2 1 2 1 2 2
LgY 436 LgY 436
430, 431, 432, 433, 435
436, 437, 440, 580, 581
11
641, 650, 651, 652

FLASH 3 5 3 5 3 5 COLOR
EPROM 2 BG 650 1
MEMORY
3
GrG 437 12 GrG 437

2
2
4
CN D2
2
5
1
5
1
4
3
4 4
5
1
8 K BYTE TABLE OF COLOR SYMBOLS
1
2 M BYTE 10
BrG 461 13 BrG 461
3
LR 250
PW 819
B 728
GrR 893
GW 290
GW 291
LW 532
LR 900
0.85 VR 370
0.85 VR 371
WR 531
0.85 GR 890
11
2
CN 16 CN 17 CN 35 G 464 14 G 464
SYMBOL COLOR
0.85 OR892
12
CN C5
0.85 GL 413 15 0.85 GL 413 BrY 432 2
1
B26
0.85 GR 667
13
0.85 OL 415 16 0.85 OL 415 B
250, 290, 370, 534
B22
BG 652 1 BLACK
2
0.85 LgR 891
18
CN 3
LR 901 0.85 BO 425 17 0.85 BO 425 BG 641 1
S55 W
10 11 12 13 14 15 16 17 18
CN 1 CN 2 CN 4 WHITE
8 9
18 GrG 437 2
M PWM 0.85 PL 484 19 0.85 PL 484 Br BROWN
CN B0
7
0.85 WG 417 20 0.85 WG 417
CN B8
1 2 3 4 5 6 7 8 17 18 19 20 21 22 29 30 31 32 33 34 35 36 37 38 49 50 51 52 53 54 55 56 YG 431 P
1
2 PINK
6
P 580 21 P 580
1.25 BG 600
1.25 BG 630
2
CN 2B
9 10 11 12 13 14 15 16 23 24 25 26 27 28 39 40 41 42 43 44 45 46 47 48 57 58 59 60 61 62 63 64
M8
2
M M M BG 651
5
PG 581 22 PG 581 1
V VIOLET
4
531, 532, 567, 890
650, 651, 652

G
CN C6
891, 892, 893, 900, 901 GREEN
3
1.25 BG 800
1
M5 M6 M7
BG 652
2
BP 509
461, 470
480, 490
501, 502
503, 504
2
B27
ORANGE
BW 505
1
0.85 PL 484 650, 651 650, 651, 652 0.85 LY 407 1 0.85 LY 407 1 B45 R RED
0.85 WG 417 2 0.85 WG 417 2
0.85 BG 427 3 0.85 BG 427 3 Y YELLOW
BY 500 Lg LIGHT GREEN
CN A0 CN A1 CN 7 CN 8 Sb SKY BLUE
1
CN R0
CN R1
1
L BLUE
3
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
2
1.25 GrB 953
0.85 WG 473
0.85 BrY 575

1.25 BrB 951
0.85 WY 472
0.85 BW 492
1.25 GR 313
1.25 GR 312
1.25 RG 950
0.85 GR 954
0.85 GR 311
1.25 GR 310
0.85 YG 506
0.85 BG 955
0.85 BG 631
1.25 BG 630
1.25 LG 952
0.85 LG 507
0.85 BP 494
0.85 WL482
0.85 YL 465
0.85 LY 470
0.85 BL 490
0.85 PL 484
3
Gr GRAY
1.25 B 730
1.25 B 731
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
0.85 L 481
0.85 L 480
680
681
GrR 504
LgR 503
LgR 502
BrR 501
BW 505
OR 506
VG 576
PG 581
BP 509
BY 498
BY 500
BL 782
YL 488
25 26 27 28 29 30 31 30 51 52 53 54 55 56 57 80 81 82 83 84 85 86 87 88 101 102 103 104

W 497
O 487
Y 486
P 580
P 588
L 496
NOTE :
CN A0 CN A1 CN 7 CN 8 1. "BR" INDICATES BLACK CABLE WITH RED STRIPE.
89
94
90
91
92
93
95
96
97
98
99
100
101
102
103
104
2
3
6
7
8
12
13
14
16
18
19
21
23
24
25
26
28
29
1
4
15
30
5
17
31
9
10
11
20
22
27
32
39
42
33
51
54
52
34
36
45
43
53
35
44
38
48
55
37
46
40
41
47
49
50
55
57
88
63
64
66
69
71
72
75
77
78
79
84
85
87
59
67
82
80
60
61
65
62
73
74
83
86
70
81
68
75
58
2. WATERPROOF CONNECTORS USED OUTSIDE OF CAB.
A2
HEAT RELAY
TACHO SENSOR (SIG)
TACHO SENSOR (GND)
RPM SENSOR (SIG)
PULL DOWN (RED 4)

NV VB
TF SENSOR (SIG)
LIMP HOME (RED 4)
GND (TW & TF SENSOR)
PS (GE) PWR GND
GND (MV)
VBB (RED 4)
GND (RED 4)
SHLD (RED 4)
GND (RED 4)
VBB (RED 4)
5V (RED 4)
5V (RED 4)
SIG GND (RED 4)

PWM SOLL (RED 4)
PWM SOLL (RED 4)
CAN-H
CAN-L
CAN GND
Q ADJUST RES.
Q ADJUST RES.
RPM SENSOR (GND)
PS (GE) PWR VB
V 1ST (RED 4)
THROTTLE (GND)
ENGINE STOP MOTOR

ANTI-REVERSE SW
LIMP HOME SW.
MEMORY CLEAR
ENGINE STOP SIG IN
KEY SWITCH
KEY SWITCH
START SWITCH
ACCEL VOLUME (5V)
THROTTLE (SIG)
THROTTLE (SIG)
NAP SELECT-0
NAP SELECT-1
NAP SELECT-3
TW SENSOR (SIG)
CAN USE SELECTING SWITCH
TECH 2 (TXD)
TECH 2 (RXD)
MAIN POWER (VB)

MAIN POWER (VB)
CHECKER SELECT
GND
GND
NAP SELECT-2
5 B 796 CX210 - CX230 - CX240 - CX290 EXCAVATOR

M6 M8 ELECTRICAL SCHEMATIC
Part Number 7-27623
22 27 26 25
Pm1 Ps Ps Pm2
P *B45 ITEM DESCRIPTION PRESSURE SETTING
30 * * 29 29 * 28 * 83 A=
A=
MAIN RELIEF (STANDARD)
MAIN RELIEF (BOOST)

34.3 MPa / 343 bar / 4980 psi
37.3 MPa / 373 bar / 5412 psi
T2 T1 B= BOOM RAISING PORT SECONDARY RELIEF 39.2 MPa / 392 bar / 5688 psi
Dr B1/B2 = RELIEF ON BOOM HBCV 39.2 MPa / 392 bar / 5688 psi
P2 P3 P3 P2
C= BOOM LOWERING PORT SECONDARY RELIEF 39.2 MPa / 392 bar / 5688 psi
B1 B2 D= DIPPER OUT PORT SECONDARY RELIEF 392 MPa / 392 bar / 5688 psi
D1 = RELIEF ON DIPPER HBCV 39.2 MPa / 392 bar / 5688 psi

P1 P2
Pi K1 P2 P1
K2 E= DIPPER IN PORT SECONDARY RELIEF 39.2 MPa / 392 bar / 5688 psi
RED
RED
F= BUCKET OPEN PORT SECONDARY RELIEF 39.2 MPa / 392 bar / 5688 psi
L1 L2 Pi Pi G= BUCKET CLOSE PORT SECONDARY RELIEF 39.2 MPa / 392 bar / 5688 psi
H= PILOT PRESSURE RELIEF 3.92 MPa / 39.2 bar / 568 psi

A B C I= RIGHT-HAND SWING PORT SECONDARY RELIEF (CX 290) 27.9 MPa / 279 bar / 4048 psi
T2 T1 P1
J= LEFT-HAND SWING PORT SECONDARY RELIEF (CX 290) 29.4 MPa / 294 bar / 4264 psi
D1 15 P1 T T P1 K1/K2 = TRAVEL REVERSE PORT SECONDARY RELIEF 27.9 MPa / 279 bar / 4048 psi
J I GB
Pb5 L1/L2 = TRAVEL FORWARD PORT SECONDARY RELIEF 29.4 MPa / 294 bar / 4264 psi
GA 77 77 N1/N2 = NEGATIVE CONTROL RELIEF 35.3 MPa / 353 bar / 5119 psi
B C 51 = ACCUMULATOR 35.3 MPa / 353 bar / 5119 psi
Pm2 Pm1 O/P = SECONDARY RELIEF (2eme OPTION) 2.55 MPa / 25.5 bar / 370 psi
15 77 R= MAIN RELIEF (2eme OPTION) 1.5 MPa / 15 bar / 212 psi

MU 23 Pb8 A
23 21 16 21 23.5 MPa / 235 bar / 3410 psi
A 20.6 MPa / 206 bar / 2988 psi
C E B
A B F D
RIGHT
LEFT RH FRONT LH FRONT
RH REAR LH REAR
* 73 R ITEM DESCRIPTION
1.2 44 84 * B1 A1
1. HYDRAULIC RESERVOIR
71 Pa1 2. BREATHER
2
0.29 MPa
42 B A Y9 4. BY-PASS VALVE
A 5. SCREEN FILTER
42.08 psi
2.9 bar C 6. RETURN FILTER
3
10. MAIN HYDRAULIC PUMP
10 P
Ps1 Dr T2 T1 T3 T5 T4 Ps2 A4 15. MAIN CONTROL VALVE
76 T 16. HYDRAULIC SWIVEL

41 0.1MPa
14.5 psi
T 21. TRAVEL MOTOR
1 bar 22. SWING MOTOR
CX210 - CX230 - CX240 - CX290 EXCAVATOR

78 N1 N2 23. TRAVEL MOTOR BRAKE
T 25. RIGHT BOOM CYLINDER
2 45 31µ 71 Pb1
10µ 55 26. LEFT BOOM CYLINDER
Pc1 31 RETRACTED
1 O 27. DIPPER CYLINDER
DIPPER (2) 28. BUCKET CYLINDER
Pb9
29. BOOM SAFETY VALVE
A5 75
59 30. DIPPER SAFETY VALVE
0.03 MPa
B5
DIPPER (1) EXTENDED Pa9 D P 31. DIPPER LOAD HOLDING VALVE
4.35 psi 0.004 MPa RETRACTED 32. BOOM LOAD HOLDING VALVE
0.3 bar 0.58 psi 30 Pb5'
0,04 bar 41. FILTER (ULTRA-CLEAN)
Pi
Pb5 42. OIL COOLER
43 Pa5
B Pc2 43. RETURN MANIFOLD
HYDRAULIC / ELECTRIC
Pa5 EXTENDED 44. OIL COOLER BY-PASS VALVE
A8
D1 C 32 43
15 45. NON-RETURN CHECK VALVE
52 B8 T 51. ACCUMULATOR
0.103 MPa T D2
T
Pc3'
D E LOWER 52. 6 SOLENOID VALVE BANK
14.9 psi
BOOM (1) Pb8' 53. BOOM & BUCKET CONTROL LEVER
10µ
1.03 bar
D3 Pc3 Pb8 29 54. SWING & DIPPER CONTROL LEVER
150 MESH 83 Pi
RAISE Pa8' 55. TRAVEL CONTROL PEDAL
C T1 Pbu
SCHEMATIC
BOOM (2) Pa8 15 43 57. BOOM & DIPPER CONTROL SHOCK ABSORBER
Pb4 B7 Pb4' D1 58. PILOT AND RETURN SYSTEM MANIFOLD
52 51 59. FILTER
C 30 15 Pb4'
OPEN A7 60. PILOT SYSTEM MANIFOLD
T1 Pa8 B3 BUCKET
Pb7 SECOND B T 72. CONTROL PEDAL (OPTIONAL)
5 1 4 6 A B
77
* 2.5
A3 RIGHT SWING
CLOSED Pa7
OPTION
* 71 C1
1.5 MPa
212 psi 60 82
75.
76.
FLOW RE-INJECTION BLOCK (OPTIONAL)
3-WAY SELECTOR (OPTIONAL)
29 30
Pb3 F 15 bar 77. SAFETY VALVE RETURN SYSTEM MANIFOLD (OPTIONAL)
Pa3
T T2
LEFT
B6
Y4 Y2 P3
78. RETURN FILTER (OPTIONAL)
76 2.5 TRAVEL 79. CONTROL SHUTTLE BLOCK (OPTIONAL)
D B2 A6 10 µ
P P0 P 81. SWING SHUTTLE BLOCK
Pb6 55
15
T 76 A2 HAMMER (H) G 1
82. PILOT CIRCUIT FILTER
A REAR C3 C2
0.02 MPa 83. SHUT-OFF VALVE (OPTIONAL)
Pb2 2.9 psi
Pa9 D FRONT Pa6 55 1 T 2 0.2 bar 0.103 MPa 84 T-SHUTTLE BLOCK (OPTIONAL)
79 Pa2
79 ON 2 14.5 psi 85. HAND/FOOT CONTROL PILOT FILTER
E
B2
B1 Y5 Y3 1 bar
86. PILOT FILTER BY-PASS VALVE
C
P4 P 85 *B24 P1 P2
B22. SWING PILOT PRESSURE SWITCH
B23. BREAKER / CRUSHER PILOT PRESSURE SWITCH

P B1
TRAVEL B25. BREAKER PILOT PRESSURE SWITCH
A A1 REAR *B28 C5 C4 86 B26. UPPER PILOT PRESSURE SWITCH (YELLOW BAND)

55 B27. TRAVEL PILOT PRESSURE SWITCH
*75 3
Pb1 Y1 Y6 B42. PUMP PRESSURE SENSOR (P1)
55 Pa1 FRONT B43. PRESSURE SENSOR (NEGA-CONT)

B 4 ON 1.2 MPa ON 1.2 MPa B44. PUMP PRESSURE SENSOR (P2) (YELLOW BAND)
194 psi
A 12 bar
194 psi
12 bar B45. OVERLOAD INDICATOR PRESSURE SWITCH
OFF 0.9 MPa OFF 0.9 MPa Y1. SWING PILOT SHUT-OFF SOLENOID VALVE (GREEN BAND)
130.5 psi 130.5 psi Y2. PILOT PRESSURE SOLENOID VALVE (BLUE BAND)
9 bar 9 bar
D B A 15 P1 PT ON PP PA ON P2 P3 PH Y3. SWING BRAKE SOLENOID VALVE (PINK BAND)
2.0 MPa 1.2 MPa
A2
174 psi
83
* B27
290 psi
20 bar
OFF 1.5 MPa B26 12 bar
OFF 0.9 MPa 15 73 73
Y4.
Y5.
2 STAGE TRAVEL SOLENOID VALVE (RED BAND)
POWER-UP SOLENOID VALVE (YELLOW BAND)
130 psi Pb1 Pa1 Y6. CUSHION CONTROL SOLENOID VALVE (LIGHT GREEN BAND)
217 psi
15 15 bar 9 bar Y7. MAIN PUMP PROPORTIONAL SOLENOID
E C D B2 Y9. CRUSHER/BREAKER OPTION TWO FLOW SOLENOID VALVE
73
T
* 78
Y7
B42 B44
B43 A1 Psv a4 A2
* 76 T
10µ
T 42
A LEGEND
a1 a2 PUMP 1
(FRONT) (REAR) PUMP 2
P4 P5 T4 T5
72 * 55 PILOT SYSTEM PUMP
OPTIONAL
58 RETURN TO RESERVOIR
P3 P2 P1 T3 T2 T1 E LEAK-OFF RETURN
TRAVEL (LEFT) TRAVEL (RIGHT)
81
PILOT SYSTEM CIRCUIT
85
P P 2S 3S 1S REAR FRONT FRONT REAR COMPONENT BOUNDARY
RAISE Pi1
54 85 53 Pi2
HOSE
G
T T ISUZU
1 T 2 6BG1T PIPING CONNECTION
121,4 Kw CX240
H à 2150 tr/mn PIPING CROSS-OVER
S2 S3 S1
LOWER
P ISUZU
41 COMPONENT ITEM NO.
6BG1T
F B25 85
* 103 Kw
à 1950 tr/mn
CX210
COMPONENT NUMBER
BOOM BUCKET
DIPPER
RETRACT EXTEND LEFT
SWING
RIGHT LOWER RAISE OPEN CLOSED T
R
* 79
* 15
3 1 3 1
B B22 B23
A1 S1 A2 M Pb1
ON 0.5 MPa 1 2 4 T 3 ISUZU

ON 0.5 MPa CX290 CONNECTION ITEM NO.
72.6 psi 6BG1T
2 4 2 4 72.5 psi B1 S2 B2
5 bar 5 bar 132,4 Kw
OFF 0.3 MPa
85 85 D EXTENDED
43.5 psi
3 bar
OFF 0.3 MPa
43.5 psi
3 bar
15
Pa2
5a4
15
Pb2 85
P à 2000 tr/mn H
M3 * OPTION ITEM NO.
C RETRACTED T 10 a3
73 A4
15 15 15 15 P
Pb6 Pa6 Pa1 Pb1 A3
A Y9 *
57 79
A A
S B4 Dr B1 B3
CX210 - CX230 - CX240 - CX290 EXCAVATOR
HYDRAULIC SCHEMATIC
Number 7-27623

CX210 230 240 WSM

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CX210 230 240 WSM

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Available Formats

CX210 - CX230 - CX240 Crawler Excavators

* Consult the Engine Service Manual

Cre 9-93540GB Issued 05-05

SAFETY, GENERAL INFORMATION

Copyright  2000 Case France

Cre 7-27690GB Issued 09-00

Cre 7-27690GB Issued 09-00

To prevent injury always follow the Warning, Caution

WARNING: If you wear clothing that is too

WARNING: When working in the area of the

WARNING: When doing checks and tests

WARNING: When putting the hydraulic

Cre 7-27690GB Issued 09-00

WARNING: When the battery electrolyte is

WARNING: Use suitable floor (service)

Cre 7-27690GB Issued 09-00

STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS

Cre 7-27690GB Issued 09-00

Cre 7-27690GB Issued 09-00

Cre 7-27690GB Issued 09-00

Copyright  2005 CNH France S.A.

Cre 7-29361GB Issued 05-05

TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE

Component serial numbers

Cre 7-29361GB Issued 05-05

FLUIDS AND LUBRICANTS

Transmission component oil

Cre 7-29361GB Issued 05-05

Oil viscosity/Oil range

Cre 7-29361GB Issued 05-05

Cre 7-29361GB Issued 05-05

Lower roller capacity....................................................................210 cm3 .................................................... 250 cm3

Cre 7-29361GB Issued 05-05

Cre 7-29361GB Issued 05-05

Incline that can be overcome........................................................................................ 70% (35°)

Displacement...........................................................................162.2/95 cm3 ................................... 168.9/100.3 cm3

Turnable bearing .......................................................................... 263 kg ........................................................ 389 kg

Cre 7-29361GB Issued 05-05

DIMENSIONS AND LIMIT OF WEAR AND TEAR OF THE TRACKS SET

Marking Dimension (mm)

Cre 7-29361GB Issued 05-05

Cre 7-29361GB Issued 05-05

Cre 7-29361GB Issued 05-05

Dimension (mm) Dimension (mm)

Cre 7-29361GB Issued 05-05

Dimension (mm) Dimension (mm)

Cre 7-29361GB Issued 05-05

DIMENSIONS AND LIMIT OF WEAR AND TEAR OF

Cre 7-29361GB Issued 05-05

2. Boom cylinder foot/Undercarriage

3. Boom cylinder head/Boom

4. Dipper cylinder foot/Boom

6. Dipper cylinder head/Dipper

Cre 7-29361GB Issued 05-05

7. Bucket cylinder foot/Dipper

Cre 7-29361GB Issued 05-05

10. Connecting rod/Compensator/Bucket cylinder head

Cre 7-29361GB Issued 05-05

SPECIAL TORQUE SETTINGS

Cre 7-29361GB Issued 05-05

Cre 7-29361GB Issued 05-05

CS00E522 CS00E523 CS00E525

Cre 7-29361GB Issued 05-05