Case Crawler Excavator Cx75sr Cx80 Tier 3 Service Manual

Copyright
CRAWLER EXCAVATOR CX75SR/CX80 TIER 3

SERVICE MANUAL
TABLE OF CONTENTS
DIVISION/SECTION
1
SECTION N
GENERAL INFORMATION
Safety, general information and standard torque data..................................... 1001
General specifications and special torque setting ........................................... 1002
ENGINE
Removal and installation of the engine............................................................ 2000
Engine specifications..............................................................................................*
Disassembly and assembly of the engine ..............................................................*
FUEL SYSTEM
Removal and installation of the fuel tank......................................................... 3001
Fuel engine system ................................................................................................*
REFERENCE N
7-27691EN
SC75SRCX80-1002-2EN
SM75SR2000-0EN
SM75SR3001-0EN
ELECTRICAL SYSTEM
Electrical and engine functions and service support ....................................... 4001
Electrical equipment and electrical circuit diagrams........................................ 4020
SC75SRCX80-4001-0EN
SC75SRCX80-4020-0EN
UNDERCARRIAGE
Removal and installation of tracks ................................................................... 5001
Rollers ............................................................................................................. 5003
Take-up roller................................................................................................... 5005
SM75SR5001-0EN
SM75SR5003-0EN
SM75SR5005-0EN
DRIVE TRAIN
Removal and installation of the drive motor and
final drive transmission................................................................................ 6001
Disassembly and assembly of the drive motor and
final drive transmission................................................................................ 6002
Removal and installation of the swing motor and
swing reduction gear ................................................................................... 6003
Disassembly and assembly of the swing reduction gear ................................. 6004
SM75SR6001-0EN
SM75SR6002-0EN
SM75SR6003-0EN
See 8019
UNDERCARRIAGE HYDRAULICS
* Consult the Engine Service Manual
CNH
Lep SM75SRTOC-0EN
Copyright 2008 CNH France S.A.

Printed in France
March 2008
Copyright
DIVISION/SECTION
8
SECTION N
REFERENCE N
UPPERSTRUCTURE HYDRAULICS
Specifications, troubleshooting, checks and
hydraulic pressure settings..........................................................................8001
Removal and installation of the hydraulic reservoir .........................................8002
Removal and installation of the main hydraulic pump......................................8003
Removal and installation of the main hydraulic control valve - CX75SR .........8004
Removal and installation of the main hydraulic control valve - CX80 ..............8004
Removal and installation of the attachment cylinders......................................8005
Removal and installation of the hydraulic swivel ..............................................8006
Removal and installation of the pilot blocs.......................................................8007
Disassembly and assembly of the main hydraulic pump .................................8010
Disassembly and assembly of the main hydraulic control valve - CX75SR .....8011
Disassembly and assembly of the main hydraulic control valve - CX80 ..........8011
Disassembly and assembly of the attachment cylinders .................................8012
Disassembly and assembly of the hand control levers ....................................8013
Disassembly and assembly of the foot control levers ......................................8014
Disassembly and assembly of the solenoid valve block ..................................8015
Disassembly and assembly of the cushion valve.............................................8016
Disassembly and assembly of the hydraulic swivel .........................................8018
Disassembly and assembly of the swing motor ...............................................8019
Hydraulic functions ..........................................................................................8020
Hydraulic component functions........................................................................8030
SC75SRCX80-8001-1EN
SM75SR8002-0EN
SM75SR8003-0EN
SM75SR8004-0EN
SM80-8004-0EN
SM75SR8005-0EN
SM75SR8006-0EN
SM75SR8007-0EN
SM75SR8010-0EN
SM75SR8011-0EN
SM80-8011-0EN
SM75SR8012-0EN
SM75SR8013-0EN
SM75SR8014-0EN
SM75SR8015-0EN
SM75SR8016-0EN
SM75SR8018-0EN
SM75SR8019-0EN
SC75SRCX80-8020-0EN
SC75SRCX80-8030-0EN
UPPERSTRUCTURE
Air conditioning unit .........................................................................................9007
Large size hydraulic schematics - CX75SR.................................................. Pocket
Large size electrical schematics - CX75SR.................................................. Pocket
Large size hydraulic schematics - CX80....................................................... Pocket
Large size electrical schematics - CX80....................................................... Pocket
SM75SR9007-0EN
87725706A
87732675A
KAJ11600-E00
KAJ11060-E00
NOTE: CNH Company reserves the right to make changes in the specification
and design of the machine without prior notice and without incurring any 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.
Lep SM75SRTOC-0EN
Issued 03-08
1001
Copyright
Section
1001
SAFETY, GENERAL INFORMATION
AND TORQUE SPECIFICATIONS
CNH
Lep 7-27691EN

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

cleaning solvent or by steam cleaning. Do not use
caustic soda for steam cleaning. After cleaning, dry
and put oil on all parts. Clean oil passages with
compressed air. Clean bearings in a suitable cleaning
solvent, dry the bearings completely and put oil on
the bearings.
Check all gears for wear and damage. Replace gears

that have wear or damage.
Inspection
Check all parts when the parts are disassembled.
Replace all parts that have wear or damage. Small
scoring or grooves can be removed with a hone or
crocus cloth. Complete a visual inspection for
indications of wear, pitting and the replacement of
parts necessary to prevent early failures.
Bearings
Check bearings for easy action. If bearings have a
loose fit or rough action replace the bearing. Wash
bearings with a suitable cleaning solvent and permit
to air dry. DO NOT DRY BEARINGS WITH
COMPRESSED AIR.
Needle bearings
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.
Lep 7-27691EN
Oil seals, O-rings and gaskets

Always install new oil seals, O-rings and gaskets. Put
petroleum jelly on seals and O-rings.
Shafts
Check all shafts that have wear or damage. Check
the bearing and oil seal surfaces of the shafts for
damage.
Service parts
Always install genuine Case service parts. When
ordering refer to the Parts Catalog for the correct part
number of the genuine Case replacement items.
Failures due to the use of other than genuine Case
replacement parts are not covered by warranty.
Lubrication
Only use the oils and lubricants specified in the
Operators or Service Manuals. Failures due to the
use of non-specified oils and lubricants are not
covered by warranty.
Issued 02-06
Copyright
1001-4
SAFETY
This symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED. The message that follows the
symbol contains important information about safety. Carefully
read the message. Make sure you fully understand the
causes of possible injury or death.
To prevent injury always follow the Warning, Caution

and Danger notes in this section and throughout the
manual.
Put the warning tag shown below on the key for the
keyswitch when servicing or repairing the machine.
One warning tag is supplied with each machine.
Additional tags Part Number 331-4614 are available
from your service parts supplier
WARNING: Before starting engine, study

Operators Manual safety messages. Read
all safety signs on machine. Clear the area of
other persons. Learn and practice safe use
of controls before operating.
It is your responsibility to understand and
f o l l o w m a n u f a c tu r e r s i n s tr u c t i o n s o n
machine operation, service and to observe
pertinent laws and regulations. Operators
and Service Manuals may be obtained from
your Case dealer.
WARNING: If you wear clothing that is too

loose or do not use the correct safety
equipment for your job, you can be injured.
Always wear clothing that will not catch on
objects. Extra safety equipment that can be
required includes hard hat, safety shoes, ear
protection, eye or face protection, heavy
gloves and reflector clothing.
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.
WARNING: Read the operators manual to

familiarize yourself with the correct control
functions.
WARNING: Operate the machine and

equipment controls from the seat position
only. Any other method could result in
serious injury.
WARNING: This is a one man machine, no

riders allowed.
Lep 7-27691EN
Issued 02-06
Copyright
1001-5
WARNING: When servicing or repairing the

machine, keep the shop floor and operators
compartment and steps free of oil, water,
grease, tools, etc. Use an oil absorbing
material and/or shop cloths as required. Use
safe practices at all times.
WARNING: Some components of this

machine are very heavy. Use suitable lifting
equipment or additional help as instructed in
this Service Manual.
WARNING: Engine exhaust fumes can

cause death. If it is necessary to start the
engine in a closed place, remove the exhaust
fumes from the area with an exhaust pipe
extension. Open the doors and get outside
air into the area.
WARNING: When the battery electrolyte is

frozen, the battery can explode if (1), you try
to charge the battery, or (2), you try to jump
start and run the engine. To prevent the
battery electrolyte from freezing, try to keep
the battery at full charge. If you do not follow
these instructions, you or others in the area
can be injured.
WARNING: Use insulated gloves or mittens

when working with hot parts.
WARNING: Lower all attachments to the

ground or use stands to safely support the
attachments before you do any maintenance
or service.
WARNING: Pin sized and smaller streams

of hydraulic oil under pressure can penetrate
the skin and result in serious infection. If
hydraulic oil under pressure does penetrate
the skin, seek medical treatment
immediately. Maintain all hoses and tubes in
good condition. Make sure all connections
are tight. Make a replacement of any tube or
hose that is damaged or thought to be
damaged. DO NOT use your hand to check
for leaks, use a piece of cardboard or wood.
WARNING: When removing hardened pins

such as a pivot pin, or a hardened shaft, use
a soft head (brass or bronze) hammer or use
a driver made from brass or bronze and a
steel head hammer.
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.
Lep 7-27691EN
Issued 02-06
Copyright
1001-6
STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS

Tightening of cap screws, nuts
Tighten alternately so that tightening torque can be applied evenly. The numbers in the figure below indicate the
order of tightening.
JS00481A
Cap screws which have had Loctite used (white residue remains after removal) should be cleaned with loght oil or
suitable cleaning solvent and dried. Apply 2-3 drops of Loctite to the thread portion of the cap screw and then
tighten.
Torque table
Tighten cap screws and nuts according to the table below if there are no other special instructions.
Cap Screw Name Size (Size)

Spanner
Cap Screw
Tightening
torque
Spanner
Socket
Head Cap
Screw
Lep 7-27691EN
Tightening
torque
M6
[mm]
M8
M10
M12
M14
M16
M18
M20
10
13
17
19
22
24
27
30
[in.]
0.39
0.51
0.67
0.75
0.87
0.95
1.06
1.18
[Nm]
6.9
19.6
39.2
58.8
98.1
156.9
196.1
294.2
[lb-ft]
5.1
14.5
28.9
43.4
72.3
115.7
144.6
217
[mm]
10
12
14
14
17
[in.]
0.20
0.24
0.32
0.39
0.47
0.55
0.55
0.67
[Nm]
8.8
21.6
42.1
78.5
117.7
176.5
245.2
343.2
[lb-ft]
6.5
15.9
31.1
57.9
86.9
130.2
181
253.2
Issued 02-06
1002
Copyright
Section
1002
SPECIFICATIONS
AND SPECIAL TORQUE SETTINGS
CNH
Lep SC75SRCX80-1002-0EN
Copyright @ 2008 CNH France SA

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

AND YEAR OF MANUFACTURE OF THE MACHINE..................................................................................................... 5
Machine ....................................................................................................................................................................... 5
Engine .......................................................................................................................................................................... 5
Serial numbers of the components .............................................................................................................................. 5
FLUIDS AND LUBRICANTS ............................................................................................................................................ 6
Hydraulic fluid .............................................................................................................................................................. 6
Transmission component oil ........................................................................................................................................ 6
Grease ......................................................................................................................................................................... 6
Engine Oil .................................................................................................................................................................... 7
Engine fuel, maintenance of fuel filters and fuel storage ............................................................................................. 8
Anti-freeze/Anti-corrosion........................................................................................................................................... 10
Environment ............................................................................................................................................................... 10
Plastic and resin parts................................................................................................................................................ 10
SPECIFICATIONS ......................................................................................................................................................... 11
Main data ................................................................................................................................................................... 11
Performance .............................................................................................................................................................. 11
Main body dimensions ............................................................................................................................................... 11
Engine ........................................................................................................................................................................ 11
Cooling system .......................................................................................................................................................... 12
Capacity of coolant and lubricants ............................................................................................................................. 12
Air conditioning .......................................................................................................................................................... 12
Hydraulic oil filter........................................................................................................................................................ 12
Fuel filter .................................................................................................................................................................... 12
Operating devices ...................................................................................................................................................... 12
Hydraulic system........................................................................................................................................................ 13
Hydraulic Cylinders .................................................................................................................................................... 15
Rotating Joint ............................................................................................................................................................. 16
Swing unit .................................................................................................................................................................. 21
Travel lower body....................................................................................................................................................... 21
Work Unit ................................................................................................................................................................... 22
COMPONENT WEIGHT................................................................................................................................................. 24
Major component weight (CX75SR)........................................................................................................................... 24
Major component weight (CX80)................................................................................................................................ 25
Other component weight ............................................................................................................................................ 26
DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY .................................................................................. 27
Sprocket ..................................................................................................................................................................... 27
Idler wheel.................................................................................................................................................................. 28
Upper roller ................................................................................................................................................................ 29
Issued 03-08
Copyright
1002-3
Lower roller .................................................................................................................................................................30
Track...........................................................................................................................................................................31
DIMENSIONS AND WEAR LIMITS OF ATTACHMENT LINKAGES (MONO BOOM) ...................................................32
1. Boom foot/Frame ....................................................................................................................................................32
2. Boom cylinder foot/Frame.......................................................................................................................................33
3. Boom cylinder head/Boom......................................................................................................................................33
4. Dipper cylinder foot/Boom ......................................................................................................................................34
5. Boom/Dipper...........................................................................................................................................................34
6. Dipper cylinder head/Dipper ...................................................................................................................................34
7. Bucket cylinder foot/Dipper.....................................................................................................................................35
8. Connecting rod/Dipper............................................................................................................................................35
9. Compensator/Bucket ..............................................................................................................................................35
10. Connecting rod/Compensator/Bucket cylinder head ............................................................................................36
11. Dipper/Bucket .......................................................................................................................................................36
DIMENSIONS AND WEAR LIMITS OF ATTACHMENT LINKAGES (CX75SR OFFSET BOOM) .................................37
1. Base Boom/Offset boom.........................................................................................................................................37
2.Base Boom/Offset cylinder/Rod...............................................................................................................................38
3. Offset Boom/ Offset cylinder...................................................................................................................................38
4. Offset Dipper/Rod ...................................................................................................................................................39
5. Offset arm/Offset Boom ..........................................................................................................................................39
6. Offset Dipper/ Dipper cylinder.................................................................................................................................39
7. Offset dipper/Dipper................................................................................................................................................40
8. Dipper/Dipper cylinder ............................................................................................................................................40
9. Dipper/Bucket cylinder............................................................................................................................................40
DIMENSIONS AND WEAR LIMITS OF BLADE AND BLADE CYLINDER .....................................................................41
10. Blade/Blade cylinder .............................................................................................................................................41
11. Lower frame/Blade cylinder ..................................................................................................................................41
12. Lower frame/Blade................................................................................................................................................42
LIST OF SHIMS ..............................................................................................................................................................43
For Adjusting Attachment Gaps..................................................................................................................................43
For Adjusting Attachment Gaps (for Boom Foot)........................................................................................................47
SPECIAL TORQUE SETTINGS CX75SR.......................................................................................................................49
SPECIAL TORQUE SETTINGS CX80............................................................................................................................52
MACHINE OVERALL DIMENSIONS ..............................................................................................................................55
Issued 03-08
Copyright
1002-4
Issued 03-08
Copyright
1002-5
TYPE, SERIAL NUMBER

AND YEAR OF MANUFACTURE OF THE MACHINE
For all part orders, request for information or assistance, always specify the type and the serial number of the machine
to your Case dealer.
Fill in the following lines with the required information: Type, serial number, year of manufacture of the machine and the
serial numbers of the hydraulic and mechanical components.
Machine
1
2
CT04A171A
(1) Type .......................................................................................................................................................................

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

Hydraulic pump ...........................................................................................................................................................
Swing reduction gear...................................................................................................................................................
Travel reduction gears .................................................................................................................................................
Control valve................................................................................................................................................................
Issued 03-08
Copyright
1002-6
FLUIDS AND LUBRICANTS

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

Extreme pressure oil used for enclosed transmission components.
CASE/AKCELA: GEAR 135H EP (SAE 80W-90. API GL 5. MIL-L-2105 D. MS 1316. ZF TE-ML 05A)
Grease
CASE/AKCELA: MOLY GREASE 251H EP-M (251H EP-M. NLGI 2)
"Extreme Pressure" multipurpose grease with lithium soap and molybdenum disulphide.
CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (251H EP. NLGI 2)
"Extreme Pressure" multipurpose grease with lithium soap and calcium.
CASE/AKCELA: PREMIUM GREASE EP2 (NLGI 2)
"Extreme Pressure" multipurpose grease with lithium soap.
Hydraulic breakers
CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (NLGI 2).
Issued 03-08
Copyright
1002-7
Engine Oil
THE CASE/AKCELA No. 1 engine oil is recommended
for your engine. This oil ensures proper lubrication of
your engine for all operating conditions.
If the CASE/AKCELA Multigrade "No. 1 ENGINE OIL"
cannot be obtained, use the oil corresponding to one of
the following categories: ACEA E7. API CI-4.
CP02N001
Oil viscosity / Oil range
1
2
2
3
3
CT02M001
1) With mineral base

(2) With semi-synthetic base
(3) With synthetic base
Issued 03-08
Copyright
1002-8
Engine fuel, maintenance of fuel filters and fuel storage

In order to meet the emission control regulation of 3rd-stage, the engine components have been made precisely and
they are to be used under high-pressure conditions.
Therefore, the specified fuel must be used for the engine.
As a matter of course, not only the guarantee will not be given for the use of a fuel other than the specified but also it
may invite a serious breakdown.
In addition, since suitable specifications for the fuel filter elements have been established for this engine, use of the genuine filter is essential.
The following describes the specifications and the requirements of the fuel to be applied, and maintenance of the fuel
and the fuel elements.
Fuel to be applied
Selection of fuel
Following conditions must be met for the diesel engines, that is the one;
1 In which no dust even fine one is mixed,
2 With proper viscosity,
3 With high cetane rating,
4 With good flow properties in lower temperature,
5 With not much sulfur content, and
6 With less content of carbon residue
Applicable standards for diesel fuel
Applicable Standard
Recommendation
JIS (Japanese Industrial Standard)
NO.2
DIN (Deutsche Industrie Normen)
DIN 51601
SAE (Society of Automotive Engineers)

Based on SAE-J-313C
NO. 2-D
BS (British Standard)
Based on BS/2869-197
Class A-1
EN590
If a standard applied to the fuel for the diesel engine is stipulated in your country, check the standard for details.
Requirements for diesel fuel
Although conditions required for the diesel fuel are illustrated above, there are other requirements exerting a big
influence on its service durability and service life.
Be sure to observe the following requirements for selecting fuel.
Sulfur content............................................................................... 2500 ppm or less
HFRR*.......................................................................................... 460 mm or less
Water content............................................................................... 0.05 wt% or less
* HFRR (High-Frequency Reciprocating Rig.): An index showing lubricating properties of the fuel.
Sulfur content reacts to moisture to change into sulfuric acid after combustion.
Use of a fuel containing much sulfur content allows it to accelerate internal corrosion and wear.
In addition, much sulfur content quickens deterioration of engine oil allowing its cleaning dispersive property to be
worse which results in acceleration of wear of sliding portions.
HFRR is an index that indicates lubricating property of a fuel.
Large value of the index means poor lubrication so that seizure of the machine components may result if such a
fuel is used.
Since a fuel with high HFRR value also has lower viscosity, it can easily be leaked out.
Issued 03-08
Copyright
1002-9
If the fuel is mixed with the engine oil, the oil is diluted to deteriorate its lubricating property resulting in acceleration of wear.
Water content allows inside of the fuel tank to rust which in turn blocking the fuel line and the fuel filter.
IMPORTANT : In cold weather, fill the fuel tank at the end of the day's work, in order to prevent the formation of condensation.
This may also cause wear and seizure of the machine components.
If atmospheric temperature goes below the freezing point, moisture content in the fuel forms fine particle of ice
allowing the fuel line to be clogged.
IMPORTANT : Obtain table of analysis for the fuel you are using from the fuel supplier to confirm that it meets the criteria described above.
IMPORTANT : If a fuel which does not meet the specifications and the requirements for the diesel engine, function and
performance of the engine will not be delivered. In addition, never use such a fuel because a breakdown of the engine
or an accident may be invited.
Guarantee will not be given to a breakdown caused by the use of a improper fuel.
Some fuels are used with engine oil or additives mixed together with diesel engine fuel.
In this case, do not use these fuels because damage to the engine may result as the fuel has been contaminated.
It is natural that the emission control regulation of 3rd-stage will not be cleared in case where a fuel that does not
meet the specifications and the requirements is used.
Use the specified fuel for compliance of the exhaust gas control.
IMPORTANT : It you use diesel fuel which contains much sulfur content more than 2500 ppm, be sure to follow the
items below for the engine oil selection and maintenance of engine parts. Guarantee will not be given to breakdowns
caused by not to follow these items.
1 Selection of engine oil
Use API grade CF-4 or JASO grade DH-1.
2 Exchange the engine oil and engine oil filter element by the periodical interval reported on the Operators
Manual.
3 Inspect and exchange the EGR (*)parts and fuel injector parts of engine every 3000 hour of use.
* EGR: Exhaust Gas Recircultion
Maintenance of fuel filters

Be sure to use the genuine fuel filters.
The fuel injection system is precisely constructed and the genuine filter employs finer mesh than conventional filters to improve protection of machine equipment.
If a filter with coarse mesh is used, foreign object passing through the filter enters into the engine so that machine
equipment can wear out in a short period of time.
IMPORTANT : If a fuel filter other than the genuine filter is used, guaranty will not be applied to a fault caused by the
use of a wrong filter.
Two kinds of fuel filter, the pre-filter and the main filter, are mounted on the machine.
Be sure to use the genuine fuel filters and replace them at the periodic intervals reported on the operators Manual.
IMPORTANT : Since the pre-filter also has a function of water separation, discharge water and sediment when the float
reaches lower part of the filter elements. CHECK EVERY DAY before to start the engine.
Time to replace filters may be advanced according to properties of the fuel being supplied.
Therefore, take measures to prevent dust or water from being entered in the fuel tank when supplying fuel.
When supplying fuel directly from a fuel drum can, leave the drum as it stands for a long period of time to supply
clean fuel standing above a precipitate.
If it is hard to leave the drum for a long period of time, install a fuel strainer and a water separator before the fuel
tank of the machine to supply clean fuel.
Water drain cock is provided on the bottom side of the fuel tank.
Drain water before starting the engine every morning.
In addition, remove the cover under the tank once a year to clean up inside of the tank.
Issued 03-08
Copyright
1002-10
Fuel storage
Long storage can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can often be
traced to the presence of water in the fuel.
The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off
water and impurities regularly.
Anti-freeze/Anti-corrosion
Use anti-freeze in all seasons to protect the cooling system from corrosion and all risk of freezing.
CASE/AKCELA: PREMIUM ANTI-FREEZE (MS 1710)
For areas where the temperature goes down to -38C (-36.4F), mix 50/50 with water.
IMPORTANT : Do not mix products of a different origin or brand. The same product must be used when topping up the
system.
Environment
Before carrying out any maintenance operation on this machine and before disposing of used fluids or lubricants,
always think of the environment. Never throw oil or fluid on the ground and never place it in leaking receptacles.
Contact your local ecological recycling centre or your CASE Dealer to obtain information on the correct method of disposing of these lubricants.
Plastic and resin parts

When cleaning plastic parts, the console, the instrument panel, the indicators etc... avoid using petrol, kerosene, paint
solvents etc... Use only water, soap and a soft cloth.
The use of petrol, kerosene, paint solvents etc... causes discoloration, cracks or deformation of these parts.
Issued 03-08
Copyright
1002-11
SPECIFICATIONS
Main data
Model name ...............................................CX75SR, CX80 (Mono Boom), CX75SR (Offset Boom) Hydraulic Excavator
Operating weight:
Mono Boom ...............................................................................................................................7950 kg (17526.73 lbs)
Mono Boom (CX80) ........................................................................................................................ 8470 kg (18673 lbs)
Offset Boom (CX75SR) .............................................................................................................. 8290 Kg (18276.3 lbs)
Engine output ......................................................................................................................................... 40 kW / 1800 rpm
Performance
Swing speed....................................................................................................................................................... 9.5 Tr/min.
Travel speed:
Low Speed.................................................................................................................................... 3.3 km/h (2.05 mph)
High Speed .................................................................................................................................... 5.1 km/h (3.16 mph)
Maximum drawbar pull .................................................................................................................... 59.5 kN (13376.13 lbf)
Maximum drawbar pull (CX80)....................................................................................................................... 59.2 kN ( lbf)
Grade ability ........................................................................................................................................................70% (35)
Ground pressure:
Mono Boom .................................................................................................. 36 kPa (450 mm (17.72 in) grouser shoe)
Offset Boom.................................................................................................. 37 kPa (450 mm (17.72 in) grouser shoe)
Main body dimensions

Main body length............................................................................................................................... 3280 mm (129.13 in)
Main body length (CX80) .................................................................................................................. 3510 mm (138.18 in)
Main body width .................................................................................................................................. 2320 mm (91.34 in)
Upper swing body width ...................................................................................................................... 2225 mm (87.60 in)
Cab width ............................................................................................................................................ 1065 mm (41.93 in)
Main body height............................................................................................................................... 2700 mm (106.30 in)
Main body height (CX80)
1.71 m (Arm)................................................................................................................................. 2700 mm (106.29 in)
2.12 m (Arm)................................................................................................................................. 2950 mm (116.14 in)
Swing radius (rear end)....................................................................................................................... 1235 mm (48.62 in)
Swing radius (rear end), (CX80) ......................................................................................................... 1655 mm (65.15 in)
Swing body rear end distance............................................................................................................. 1235 mm (48.62 in)
Swing body rear section bottom height ................................................................................................. 745 mm (29.33 in)
Distance between tumblers...................................................................................................................... 2210 mm (87 in)
Overall track length ................................................................................................................................ 2845 mm (112 in)
Overall track width............................................................................................................................... 2320 mm (91.33 in)
Distance between tracks ..................................................................................................................... 1870 mm (73.62 in)
Width of track shoe .............................................................................. 450 mm (17.72 in), (Optional: 600 mm (23.62 in))
Minimum ground clearance (To bottom of lower frame) ........................................................................ 360 mm (14.17 in)
Engine
Name..................................................................................................................................................... ISUZU, AU-4LE2X
Type: ........................................................................ water-cooled, 4-cycle diesel, 4-cylinder in-line, direct injection type
............................................................................................. (electronic control), turbocharger with air cooled intercooler.
No. of cylinders - bore x stroke................................................................................. 4 - 85 mm x 96 mm (3.35 x 3.78 in)
Displacement .................................................................................................................................. 2179 cc (132.98 cu-in)
Compression ratio ........................................................................................................................................................18.3
Rated output ........................................................................................................................................ 40 kW / 2000 min-1
Maximum torque ................................................................................................... 200 N.m (147.51 lb-ft) / 2000rpm min-1
Fuel consumption ratio.............................................................................................................................. 240g/KW.h max
Engine dimensions (LxWxH)........................................................................ 757.1x650.7x753.7 mm (29.8 x25.6x29.7 in)
Oil pan............................................................................................................................... All direction 0.61 rad, inclinable
Oil pan capacity........................................................ Maximum: 10.4 L (2.7 gal) Minimum: 7 L (2 gal) (excluding oil filter)
Direction of rotation ...................................................................................................................... Right (as seen from fan)
Starter, reduction type.....................................................................................................................................24 V, 3.2 kW
Alternator, AC type ............................................................................................................................................. 24 V, 50 A
Battery..................................................................................................................................................2 x 12V, 64 Ah/5 Hr
Issued 03-08
Copyright
1002-12
Cooling system
Fan type............................................................................................ 650 mm (25.59 in), suction type - 7 blades, intake
Radiator
Capacity .................................................................................................................................................... 5.1L (1.3 gal)
Fin type .................................................................................................................................................................. wavy
Fin pitch ................................................................................................................................................ 2 mm (0.079 in)
Oil cooler
Capacity ................................................................................................................................................... 4.4 L (1.2 gal)
Fin type .................................................................................................................................................................. wavy
Fin pitch ........................................................................................................................................... 1.75 mm (0.069 in)
Inter-cooler
Capacity ................................................................................................................................................... 4.1 L (1.1 gal)
Fin type .................................................................................................................................................................. wavy
Fin pitch ........................................................................................................................................... 1.75 mm (0.069 in)
Capacity of coolant and lubricants

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

Suction filter (inside tank) ....................................................................................................................................150 mesh
Return filter (inside tank) ............................................................................................................................................ 6 m
Pilot line filter (inside housing).................................................................................................................................... 8 m
Fuel filter
Main filter.................................................................................................................................................................... 4 m
Pre-filter.................................................................................................................................................................... 10 m
Operating devices
Operator's seat
Location: left side
Structure: Adjustable forward and back and up and down, reclining mechanism, with seat suspension.
Cab
Sealed steel type, all reinforced glass.
Levers and pedals
For travel use: Lever and pedal type (hydraulic pilot type) (x2)
For operating machine use: Lever type (hydraulic pilot type) (x2)
For blade use: Lever type (hydraulic pilot type) (x1)
For offset-boom operating use (CX75SR)............................................................. Pedal type (hydraulic pilot type) (x1)
Instruments and switches
Work mode select switch: 2 modes (N/Standard operating mode, E/Economy operating mode)
Travel mode select switch: Low-speed/high-speed switch type
One-touch idle: Knob switch type
Engine emergency stop: Switch type
Monitor device
Machine status display (full-dot liquid crystal)
Work mode selection status: N/E
Instruments (full-dot liquid crystal, except for hour meter)
Fuel gauge: Analog
Engine coolant temperature gauge: Analog
Hour meter: digital type
Machine Status and Warning Alarms *Items have a warning alarm
Over heat*
Battery charge*
Check engine*
Refill fuel*
Engine oil pressure*
Engine preheat
Issued 03-08
Copyright
1002-13
Lighting
Working light
Cab top:
24V, 55W (x1)
Boom up:
24V, 70W (x1)
Interior light
Horn
24V, 6W (x1)
Electric horn
x2
Other
Wiper with intermittent function, window washer, air conditioner, rear view mirrors, clock
Hydraulic system
Hydraulic pump drive system, direct engine link (no transmission)
Main pump
Manufacturer ...................................................................................................................................... Bosch Rexroth
Pump type ........................................................................................double variable displacement piston pump x 1
Gear pump ........................................................................................................................................................... x 2
Gear pump (for blade use) ........................................................................................................................24.2 L/min
Displacement volume ..................................................................................................34.0 cm3 (2.07 cu in) x 2 /rev
Operating pressure Rated .................................................................................................... 29.4 MPa (4264.11 psi)
Input revolution speed Rated................................................................................................. 2000 min-1 (2000 rpm)
Maximum input revolution speed ........................................................................................... 2250 min-1 (2250 rpm)
Maximum discharge flow ........................................................68 x 2 L/min at 2000 min-1 (18 x 2 gpm at 2000 rpm)
Pilot pump
Pump type ................................................................................................................Fixed displacement gear pump
Displacement volume ......................................................................................................... 10.7 cm3 (0.65 cu in)/rev
Operating pressure........................................................................................................................ 4.2 MPa (610 psi)
Maximum flow.................................................................................................... 21.4 L/min (5.6 gpm) at 2000 min-1
Gear pump (for blade)
Pump type ................................................................................................................Fixed displacement gear pump
Displacement volume .......................................................................................................................... 12.1 cm3 / rev
Operating pressure.................................................................................................................... 22.6 MPa (3280 psi)
Maximum flow.................................................................................................... 24.2 L/min (6.4 gpm) at 2000 min-1
Control method
Full hosepower angle control in concurrence.
Horsepower control by blade pump operation pressure.
Set pressure of main relief valve
Boom/Arm/ Bucket/Travel .................................................................................................... 29.4 MPa (4264.11 psi)
Swing.................................................................................................................................... 22.6 MPa (3277.85 psi)
Blade .................................................................................................................................... 22.6 MPa (3277.85 psi)
Set pressure of overload relief valve
Boom/Arm/ Bucket............................................................................................................... 31.9 MPa (4626.70 psi)
Blade .................................................................................................................................... 25.5 MPa (3698.46 psi)
Control Valve
Model; Double spool x 1 Quintuple spool x 2
Operation method: hydraulic pilot method: travel, swing, blade and operating machine
Maximum flow
Mono Boom with blade ................................................................................... 75.8 L / min (20 gpm) (at 2230 min-1)
Offset Boom with blade (CX75SR) .............................................................. 75.2 L / min (19.8 gpm) (at 2320 min-1)
Overload set pressure
Other:
Mono Boom with blade .......................................................................... 31.9 0.3 MPa (4630 44 psi) at 20 L/min
Offset Boom with blade (CX75SR) ........................................................ 31.9 0.3 MPa (4630 44 psi) at 20 L/min
Boom (CX80):
Swing right ........................................................................................ 33.3 0.3 MPa (4830 44 psi) at 20 L/min
Swing left .......................................................................................... 31.9 0.3 MPa (4630 44 psi) at 20 L/min
Boom up/down (CX75SR)
Mono Boom with blade ..................................................................... 25.5 0.3 MPa (3700 44 psi) at 20 L/min
Offset Boom with blade..................................................................... 25.5 0.3 MPa (3700 44 psi) at 20 L/min
Offset right (CX75SR)
Offset Boom with blade..................................................................... 31.9 0.3 MPa (4630 44 psi) at 20 L/min
Issued 03-08
Copyright
1002-14
Offset left (CX75SR)
Offset Boom with blade ..................................................................... 33.3 0.3 MPa (4830 44 psi) at 20 L/min
Main relief set pressure ................................................................................. 29.4 0.3 MPa (4260 0.4 psi) at 44 L/min
Functions
Travel priority
Boom up / arm 2 pumps internal flow
Boom load holding circuit
Arm-in forced regenerative circuit
Swing priority
2 pumps flow is joined at reserve section
Issued 03-08
Copyright
1002-15
Hydraulic Cylinders
Mono boom spec.
with dozer blade
Offset boom spec.

with dozer blade
Boom cylinder
Cylinder bore ................................................................................. 110 mm (4.33 in)
Rod diametre ................................................................................... 70 mm (2.75 in)
Maximum retracted length ...............................................................1408 mm (55.43 in)
Stroke ................................................................................................911 mm (35.87 in)
Arm (dipper) cylinder
Cylinder bore ................................................................................... 95 mm (3.74 in) ............95 mm (3.74 in)
Rod diametre ................................................................................... 60 mm (2.36 in) ............60 mm (2.36 in)
Maximum retracted length ....................................................................1270 mm (50 in) ............... 240 mm (9.45 in)
Stroke ................................................................................................797 mm (31.38 in) ............. 685 mm (26.97 in)
Bucket cylinder
Cylinder bore ................................................................................... 85 mm (3.35 in)
Maximum retracted length ...............................................................1035 mm (40.75 in)
Stroke ................................................................................................665 mm (26.18 in)
Blade cylinder
Cylinder bore ................................................................................. 100 mm (3.94 in)
Maximum retracted length .................................................................530 mm (20.87 in)
Stroke ..................................................................................................180 mm (7.09 in)
Offset cylinder (CX75SR)
Maximum retracted length ..............................................................710 mm (27.95 in)
Stroke .............................................................................................315 mm (12.40 in)
Boom swing cylinder (CX80)
Maximum retracted length ..................................1085 30 mm (42.71 in 1.18 mm)
Stroke ................................................................640 2.0 mm (25.19 in 0.078 mm)
Issued 03-08
Copyright
1002-16
Rotating Joint
Operating pressure
High pressure passage (ABCDEF)............................................................................................ 29.4 MPa (4260 psi)
Drain port (T) .............................................................................................................................. 0.5 MPa (72.52 psi)
Pilot port (P)................................................................................................................................... 3.9 MPa (566 psi)
Flow
High pressure passage (ABCDEF)............................................................................................... 68 L/min (18 gpm)
Drain port (T) .................................................................................................................................. 15 L/min (4 gpm)
Pilot port (P).................................................................................................................................... 23 L/min (6 gpm)
Port A; forward right ................................................................................................................................................G1/2
Port B; forward left ..................................................................................................................................................G1/2
Port C; backward right.............................................................................................................................................G1/2
Port D; backward left ...............................................................................................................................................G1/2
Port E; blade up ..................................................................................................................................................... G3/8
Port F; blade down ..................................................................................................................................................G3/8
Port T; drain port .....................................................................................................................................................G3/8
Port P; pilot port ......................................................................................................................................................G1/4
Number of revolutions....................................................................................................................15 min-1 (15 rpm)
Torque:
No load ...................................................................................................................................... 160 Nm (1420 lbf.in)
When pressurizing 2 ports......................................................................................................... 190 Nm (1480 lbf.in)
Solenoid Valve (4 stack)
Manufacturer ................................................................................................................................ Yuken kogyo co., LTD
Maximum flow ............................................................................P -> B: 20 L/min (5.3 gpm) Other: 5 L/min (1.32 gpm)
Rated pressure ............................................................................................................................. 4.5 MPa (652.67 psi)
Port size
P, T, B port...........................................................................................................................................................G3/8
C1, C2, C3 port...................................................................................................................................................G1/4
Solenoid specifications
Operating voltage ................................................................................................................................DC 20 to 32 V
Power consumption .................................................................................................................................. 17 W max.
Issued 03-08
Copyright
1002-17
Hand control valve
Manufacturer................................................................................................................................................... Kawasaki
Operating pressure .......................................................................................................................... 3.92 MPa (569 psi)
Secondary pressure, primary short type .......................................................... 0.64 to 2.45 MPa (92.82 to 355.34 psi)
Operating angle
Ports 1, 3 .............................................................................................................................................................. 19
Ports 2, 4 .............................................................................................................................................................. 25
Operating torque
Ports 1 ................................................................................................................... 0.58 - 2.03 Nm (0.42 - 1.49 (lb-ft)
Ports 3 ................................................................................................................... 0.47 - 1.92 Nm (0.34 - 1.41 (lb-ft)
Ports 2, 4 ............................................................................................................... 0.71 - 2.30 Nm (0.52 - 1.69 (lb-ft)
Port 1, 3
Port 2, 4
4.0
Secondary
pressure
Secondary pressure (MPa)
4.0
3.0
2.0
1.0
3.0
2.0
1.0
Secondary
pressure
2
4
6
Push rod stroke (mm)
5
10
15
Operating angle (deg.)
19
4
6
10
15
20
9.4
25
RST-03-01-001B
Foot control valve (for travel)

Manufacturer....................................................................................................................................... Nishina industrial
Operating angle ..................................................................................................................................................... 12.4
Operating torque
Valve....................................................................................................................... 2.62 - 8.58 Nm (1.93 - 6.33 lb-ft)
Damper................................................................................................................... 6.87 Nm at 0.018 m/s (60.8 lb-ft)
3.9
3.0
2.0
1.0
Secondary
pressure
2
4
5.5
0
5
10 12.4
RST-03-01-001D
Issued 03-08
Copyright
1002-18
Operating torque (Nm) (lbf-ft)
Foot control valve (for Dozer Blade)

Manufacturer ....................................................................................................................................... Nishina industrial
Secondary pressure, primary short type........................................................... 0.64 to 2.45 MPa (92.82 to 355.34 psi)
Operating angle......................................................................................................................................................... 10
Operating torque ............................................................................................................................See the figure below
Secondary
pressure
Push rod stroke (mm) (in)
Issued 03-08
Copyright
1002-19
Operating torque (Nm) (lbf-ft)
Foot control valve (for Offset Boom) (CX75SR)

Manufacturer....................................................................................................................................... Nishina industrial
Operating angle ..................................................................................................................................................... 12.4
Operating torque............................................................................................................................ See the figure below
Secondary
pressure
Push rod stroke (mm) (in)
Issued 03-08
Copyright
1002-20
Foot control valve (for Boom Swing) (CX80)
Manufacturer ....................................................................................................................................... Nishina industrial
Secondary pressure, primary short type................................................. 0.59 0.1 to 3.14 0.3MPa (85.6 to 455 psi)
Operating angle.............................................................................................................................................10.0 0.3
Operating torque .......................................................................................................2.80 to 5.70 Nm (2.06 to 4.20 psi)
Issued 03-08
Copyright
1002-21
Swing unit
Swing circle ........................................................................................................... Swing bearing type (with internal gear)
Swing hydraulic motor ..................................................................................................... Fixed displacement piston motor
Reduction gear....................................................................................................... Planetary gear 2-stage reduction gear
Swing parking brake................................................................................ Mechanical lock (operational lever linkage type)
Displacement .............................................................................................................................................44.1 cm3 /rev
Operating pressure ........................................................................................................................ 22.6 MPa (3280 psi)
Operating flow................................................................................................................................... 68 L/min (18 gpm)
Mechanical brake torque ................................................................................................... 174.1 Nm (1540.7 lb-ft) min.
Brake off pressure .................................................................................................................4.9 MPa (710.68 psi) max
Relief valve set pressure ....................................................... 22.6 0.3 MPa at 57.5 L/min (3280 44 psi at 15 gpm)
Reduction ratio.....................................................................................................................................................20.615
Travel lower body

Travel hydraulic motor (x2) ......... Variable displacement piston motor, automatic 2-speed switch-over with parking brake
Displacement ..................................................................................................................................... 48.0/30.5 cm3/rev
Operating pressure ........................................................................................................................ 29.4 MPa (4260 psi)
Operating flow................................................................................................................................ 68.0 L/min (18 gpm)
Brake torque ..............................................................................5.54 KNm (40.86 Ib-ft) min. (including reduction gear)
Relief valve set pressure...................................................................... 38.25 1.45 MPa at 15 L/min (5550 210 psi)
Automatic 2-speed switch-over pressure .......................................................... 23.8 MPa at 3.9 MPa (3450 at 570 psi)
Reduction ratio.......................................................................................................................................................45.97
Travel brake.................................................................................................................................................. Hydraulic lock
Parking brake ................................................................................................... Mechanical lock (travel lever linkage type)
Track shoe
Model ........................................................................................................................Assembly type triple grouser shoe
Number of shoes (per side) ........................................................................................................................................39
Shoe width
Standard ....................................................................................................................................... 450 mm (17.72 in)
Optional ....................................................................................................................................... 600 mm (23.62 in)
Grouser height ...................................................................................................................................... 20 mm (0.79 in)
Link pitch............................................................................................................................................. 154 mm (6.06 in)
Roller
Number of upper rollers (per side)................................................................................................................................1
Number of lower rollers (per side) ................................................................................................................................5
Track belt tension adjuster ...............................................................................Grease cylinder type (with cushion spring)
Mounting length of spring ................................................................................................................. 402 mm (15.83 in)
Issued 03-08
Copyright
1002-22
Work Unit
Model..................................................................................................................................................Backhoe attachment
Components / dimensions / working dimensions
CX75SR
Model
MONO BOOM
Boom length
Arm type
OFFSET BOOM
3870 mm (152.36 in)

Standard
1.710 mm
(67.32 in)
Long
2.120 mm
(83.46 in)
Standard
1.750 mm
(68.90 in)
1710 mm
(67.32 in)
2120 mm
(83.46 in)
1740 mm
(68.50 in)
Bucket capacity
Heaped 0.28 m3
(Leveled 0.20 m3)
Heaped 0.22 m3
(Leveled 0.16 m3)
Heaped 0.28 m3
(Leveled 0.20 m3)
Bucket width
730 mm (28.74 in)
600 mm (23.62 in)
730 mm (28.74 in)
Bucket width with side cutter
804 mm (31.65 in)
673 mm (26.50 in)
804 mm (31.65 in)
Bucket weight with side cutter
204 kg (449.74 lb)
178 kg (392.42 lb)
204 kg (449.74 lb)
1450 mm (57.08 in)
1050 mm (41.34 in)
1450 mm (57.08 in)
Arm (dipper) length
Bucket radius
Bucket wrist action
177
Maximum digging radius
6520 mm
(256.69 in)
6900 mm
(271.65 in)
6080 mm
(239.40 in)
Maximum digging radius at ground line
6390 mm
(251.57 in)
6770 mm
(266.53 in)
6360 mm
(250.39 in)
Maximum digging depth
4140 mm
(162.99 in)
4540 mm
(178.74 in)
4190 mm
(164.96 in)
Maximum vertical straight wall digging radius
3640 mm
(143.31 in)
4100 mm
(161.42 in)
4580 mm
(180.31 in)
Maximum digging height
7330 mm
(288.58 in)
7620 mm
(300 in)
7195 mm
(283.27 in)
Maximum dump height
5250 mm
(206.69 in)
5540 mm
(218.10 in)
5150 mm
(202.75 in)
Minimum swing radius at front
1785 mm
(70.27 in)
2085 mm
(82.08 in)
2230 mm
(87.79 in)
Height for minimum swing radius at front
5620 mm
(221.26 in)
5650 mm
(222.44 in)
5700 mm
(224.41 in)
Issued 03-08
Copyright
1002-23
CX80
Model
MONO BOOM
Boom length
Arm type
3500 mm (137.79 in)

Standard
1.710 mm
(67.32 in)
Long
2.120 mm
(83.46 in)
1710 mm
(67.32 in)
2120 mm
(83.46 in)
Bucket capacity
Heaped 0.28 m3
(Leveled 0.20 m3)
Heaped 0.22 m3
(Leveled 0.16 m3)
Bucket width
730 mm (28.74 in)
600 mm (23.62 in)
Bucket width with side cutter
804 mm (31.65 in)
673 mm (26.50 in)
Bucket weight with side cutter
204 kg (449.74 lb)
178 kg (392.42 lb)
1050 mm (41.34 in)
1050 mm (41.34 in)
Arm (dipper) length
Bucket radius
Bucket wrist angle
177
Maximum digging radius
7030 mm
( 276.77 in)
7400 mm
(291.33 in)
Maximum digging radius at ground line
6390 mm
(275.19 in)
7270 mm
(286.21 in)
Maximum digging depth
4180 mm
(164.56 in)
4590 mm
(180.70 in)
Maximum vertical straight wall digging radius
3080 mm
(121.25 in)
3550 mm
(139.76 in)
Maximum digging height
6390 mm
(251.57 in)
6600 mm
(259.84 in)
Maximum dump height
4390 mm
(172.83 in)
4600 mm
(181.10 in)
Minimum swing radius at front
2750 mm
(108.26 in)
2910 mm
(114.56 in)
Height for minimum swing radius at front
5060 mm
(199.21 in)
5080 mm
(199.99 in)
Issued 03-08
Copyright
1002-24
COMPONENT WEIGHT
Major component weight (CX75SR)
(MONO BOOM)
(OFFSET BOOM)
AQ29001-001_EU
Weight (kg) information is approximate

Symbol
Component Name
MONO BOOM SPEC.
OFFSET BOOM SPEC.
Operating weight
7952 (17531 lbs)
8292 (18280 lbs)
Upper mechanism (including counterweight and turntable bearing
3892 (8580 lbs)
3892 (8580 lbs)
Counterweight
1357 (2991 lbs)
1357 (2991 lbs)
Lower mechanism (with standard

grouser shoe)
2801 (6175l bs)
2801 (6175 lbs)
Main Unit Weight
6693 (14755 lbs)
6691 (14751 lbs)
Attachments
1176 (2592 lbs)
1518 (3346 lbs)
Boom (including cylinders)
703 (1549 lbs)
1043 (2299 lbs)
Arm (dipper) (including cylinders

and linkage)
263 (579 lbs)
266 (586 lbs)
Blade
332 (732 lbs)
332 (732 lbs)
Issued 03-08
Copyright
1002-25
Major component weight (CX80)
B
A
AS09001-001
Weight (kg) information is approximate

Symbol
Component Name
Operating weight
8470 (18673 lbs)
Upper mechanism (including counterweight and turntable bearing
4527 (9980 lbs)
Counterweight
1237 (2727 lbs)
Lower mechanism (with standard grouser shoe)
2801 (7175 lbs)
Main Unit Weight
7328 (16155 lbs)
Attachments
1063 (2343 lbs)
Boom (including cylinders)
595 (1311 lbs)
Arm (dipper) (including cylinders and linkage)
262 (577 lbs)
Blade
332 (732 lbs)
Issued 03-08
Copyright
1002-26
Other component weight

Engine ....................................................................................................................................................194 kg (427.6 lbs)
Air cleaner ...................................................................................................................................................1.7 kg (3.7 lbs)
Hydraulic pump ........................................................................................................................................51.4 kg (113 lbs)
Attachment control valve
Mono Boom with blade............................................................................................................................82 kg (181 lbs)
Mono Boom with blade (CX80) ..........................................................................................................85 kg (187.39 lbs)
Offset boom with blade (CX75SR) ..........................................................................................................88 kg (194 lbs)
Swing unit..............................................................................................................................................80.0 kg (176.3 lbs)
Travel unit ....................................................................................................................................................83 kg (183 lbs)
Rotary joint ....................................................................................................................................................40 kg (88 lbs)
Solenoid valve (4 stack) (CX80) ..............................................................................................................4.7 kg (10.36 lbs)
Solenoid valve (4 stack) (CX75SR) .................................................................................................................5 kg (11 lbs)
Hand control valve.....................................................................................................................................1.6 kg (3.52 lbs)
Blade control valve ......................................................................................................................................0.7 kg (1.5 lbs)
Offset control valve (CX75SR) ....................................................................................................................0.7 kg (1.5 lbs)
Foot control valve ......................................................................................................................................4.7 kg (10.4 lbs)
Foot control valve (for boom swing) (CX80) ................................................................................................0.7 kg (1.5 lbs)
Boom cylinder ...........................................................................................................................................103 kg (227 lbs)
Boom swing cylinder (CX80) ..................................................................................................................56 kg (123.45 lbs)
Arm (dipper) cylinder (Mono Boom With Dozer Blade) ............................................................................78 kg (3172 lbs)
Arm (dipper) cylinder (Offset Boom With Dozer Blade) (CX75SR) .............................................................81 kg (179 lbs)
Bucket cylinder ............................................................................................................................................51 kg (112 lbs)
Blade cylinder............................................................................................................................................... 34 Kg (75 lbs)
Offset cylinder (CX75SR) ............................................................................................................................. 41 Kg (90 lbs)
Turntable bearing......................................................................................................................................91.6 kg (202 lbs)
Counterweight ................................................................................................................................... 1356.4 kg (2990 Ibs)
Counterweight (CX80).......................................................................................................................... 1235 kg (2723 Ibs)
Muffler .....................................................................................................................................................13.0 kg (28.7 lbs)
Radiator total weight....................................................................................................................................50 kg (110 lbs)
Oil cooler ................................................................................................................................................12 kg (26.4 lbs)
Radiator ...................................................................................................................................................5.4 kg (12 lbs)
Air cooler ..................................................................................................................................................4.5 kg (10 lbs)
Idler wheel ...............................................................................................................................................45.1 kg (99.4 lbs)
Upper roller..................................................................................................................................................4.3 kg (9.5 lbs)
Lower roller..............................................................................................................................................13.5 kg (47.1 lbs)
Recoil spring assembly ...........................................................................................................................37.3 kg (82.3 lbs)
Recoil spring .......................................................................................................................................14.1 kg (31.1 lbs)
Grease cylinder assembly.....................................................................................................................8.8 kg (19.4 lbs)
Threaded rod ........................................................................................................................................6.3 kg (13.9 lbs)
Yoke .........................................................................................................................................................7.7 kg (17 lbs)
Track chains (per side)
450 mm (17.72 in) ...........................................................................................................................425.4 kg (937.6 lbs)
600 mm (23.62 in) .........................................................................................................................479.8 kg (1057.5 lbs)
450 mm (17.72 in) Rubber Track.................................................................................................... 424.4 kg (935.4 Ibs)
450 mm (17.72 in) Rubber Track (with special core metal) ............................................................ 421.0 Kg (927.9 lbs)
Issued 03-08
Copyright
1002-27
DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY

Sprocket
Dimensions
a
b c
CS01B512
Mark
Dimension (mm)
Standard
Limit
Standard
Limit
Standard
Limit
Standard
Limit
Standard
Limit
a
b
c
d
P
35
30
480.81
474.91
533.61
527.61
522.47
--154
---
Gauge
185
153 - 155
48.89
12
3.9
.7
7
40.
3.9
25
R3
.8
53
R2
0.8
to 6
21.6
15.1
70
82.8
90
.7
28
17.1
17.1
AQ19002-031A
Issued 03-08
Copyright
1002-28
Idler wheel
Dimensions
Mark
Dimension (mm)
Standard
a
Limit
Standard
b
Limit
Standard
c
Limit
Standard
d (shaft)
Limit
Standard
d (bushing)
Limit
Standard
e
Limit
Standard
f
Limit
c
b
400
369
28
25
44
40
42
41
42
42.8
42
41.6
20
19.5
AQ19002-001A
Gauge
110
94 - 98
39 - 44
38.4
10
28
R
6-
40
10
5
2-
R3
AQ19002-032A
Issued 03-08
Copyright
1002-29
Upper roller
Dimensions
Mark
a
80
70
30
---
a
b
b (shaft)
Dimension (mm)
Standard
Limit
Standard
Limit
AQ19002-002A
Gauge
Measure with a slide caliper.
Issued 03-08
Copyright
1002-30
Lower roller
Dimensions
d
AQ19002-003A
Mark
a
b
d
e (shaft)
Dimension (mm)
Standard
Limit
Standard
Limit
Standard
Limit
Standard
Limit
Mark
118
112
13
11
44
40
40
39
e (ring)
f
g
Dimension (mm)
Standard
Limit
Standard
Limit
Standard
Limit
40
40.8
38
37.6
30.2
29.7
Gauge
170
150.5 - 151.5
105.7 - 106.3
44
2-
15
13
R4
R5
6.5
2-
50
R3
4-
1 .5
R6
AQ19002-033A
Issued 03-08
Copyright
1002-31
Track
f'
d
e'
g'
g
h
AQ19002-004A
Mark
a
b
c
d
Dimension (mm)
Standard
Limit
Standard
Limit
Standard
Limit
Standard
Limit
26
20
74
71.5
45
50
105
100
Mark
Standard
e (ring)
Limit
Standard
f (ring)
Limit
Standard
g (shaft)
Limit
Standard
h
Limit
Standard
e' (bushing)
Limit
Standard
f' (bushing)
Limit
Standard
g' (shaft)
Limit
Dimension (mm)
41.3
40.3
24.5
23.8
23.8
23.2
154
150
41.26
40.26
24.5
25.2
24
23
Issued 03-08
Copyright
1002-32
DIMENSIONS AND WEAR LIMITS OF ATTACHMENT LINKAGES (MONO

BOOM)
4
1
5
6
3
7
8
10
11
9
AQ19002-005A
1. Boom foot/Frame
a
b
c
AQ19002-006A
Mark
Standard
Limit
Standard
b (boom)
Limit
Standard
c (a - b)
Limit
Standard
d (shaft)
Limit
Standard
d (bushing)
Limit
a (frame)
Dimension (mm)
400
410
399
397
1.0 to 3.5
Shims
60
59
60
61.5
Issued 03-08
Copyright
1002-33
2. Boom cylinder foot/Frame

a
b
AQ19002-007A
Mark
Standard
a (frame)
Limit
Standard
b (cylinder)
Limit
Standard
c (play)
Limit
Standard
d (shaft)
Limit
Standard
e (bushing)
Limit
Dimension (mm)
91
92
90
88
1.0 to 3.5
Shims
65
64
65
66.5
3. Boom cylinder head/Boom
a
AQ19002-008A
Mark
Standard
a (boom)
Limit
Standard
b (cylinder)
Limit
Standard
c (play)
Limit
Standard
d (shaft)
Limit
Standard
d (bushing)
Limit
Dimension (mm)
91
87
90
88
0.5 to 3.5
Shims
65
64
65
66.5
Issued 03-08
Copyright
1002-34
4. Dipper cylinder foot/Boom

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

Mark
a
b
Standard
Limit
Standard
b (cylinder)
Limit
Standard
c (a - b)
Limit
Standard
d (shaft)
Limit
Standard
e (bushing)
Limit
a (dipper)
Dimension (mm)
81
87
80
78
0.5 to 3.0
Shims
60
59
60
61.5
AQ19002-011A
Issued 03-08
Copyright
1002-35
7. Bucket cylinder foot/Dipper

Mark
a
AQ19002-012A
Dimension (mm)
Standard
a (dipper)
Limit
Standard
b (cylinder)
Limit
Standard
c (a - b)
Limit
Standard
d (shaft)
Limit
Standard
e (bushing)
Limit
76
82
75
73
0.5 to 3.0
Shims
50
49
50
51.5
Mark
a (connecting Standard
Limit
rod)
Dimension (mm)
Standard
Limit
Standard
c (play)
Limit
Standard
d (shaft)
Limit
Standard
e (bushing)
Limit
190
188
1.0 to 1.5
Shims
50
49
50
51.5
8. Connecting rod/Dipper
c
a
b (dipper)
b
e
a
d
25
22
AQ19002-013A
9. Compensator/Bucket
d
Mark
e
b
191
197
190
188
Standard
Limit
Standard
d (shaft)
Limit
Standard
e (bushing)
Limit
0.5 to 3.5
Shims
50
49
50
51.5
c (play)
Dimension (mm)
Standard
a (bucket)
Limit
Standard
b
(compensator) Limit
AQ19002-014A
Issued 03-08
Copyright
1002-36
10. Connecting rod/Compensator/Bucket cylinder head

Mark
a (connecting
rod)
b
(compensator)
c
a
f
b
e d
h
a
Dimension (mm)
Standard
Limit
25
22
Standard
Limit
190
188
Standard
Limit
d (connecting Standard
Limit
rod)
1.0 to 1.5
Shims
71
73
Standard
Limit
Standard
f (d - e)
Limit
Standard
g (shaft)
Limit
Standard
h
(compensator) Limit
70
68
1.0 to 2.0
Shims
55
54
55
56.5
c (play)
e (cylinder)
g
g
AQ19002-015A
i (cylinder)
Standard
Limit
55
56.5
11. Dipper/Bucket
Mark
a (bucket)
g
d
b (dipper)
f
a
c (a - b)
d (bucket)
e (shaft)
f (dipper)
e
AQ19002-016A
g (bucket)
Dimension (mm)
Standard
Limit
Standard
Limit
Standard
Limit
Standard
Limit
Standard
Limit
Standard
Limit
Standard
Limit
210
216
190
188
1.0 to 3.5
Shims
19
11
50
49
50
51.5
50
51.5
Issued 03-08
Copyright
1002-37
DIMENSIONS AND WEAR LIMITS OF ATTACHMENT LINKAGES (CX75SR

OFFSET BOOM)
4
AQ19002-017A
1. Base Boom/Offset boom

c
d
e
AQ19002-018A
Mark
a (boom)
b (offset
boom)
Dimension (mm)
Standard
Limit
Standard
Limit
Standard
Limit
Standard
d (shaft)
Limit
Standard
d (bushing)
Limit
c (a - b)
361
367
360
358
0.5 to 1.5
Shims
100
99
100
101.5
Issued 03-08
Copyright
1002-38
2.Base Boom/Offset cylinder/Rod

h
c
f
g
i
AQ19002-019A
Mark
Dimension (mm)
Standard
a (frame)
Limit
b (offset cylin- Standard
Limit
der)
c (play)
d (boom)
e (rod)
71
77
70
68
Standard
Limit
0.5 to 3.0
Shims
Standard
Limit
Standard
158
164
157
Limit
152
Mark
Dimension (mm)
Standard
Limit
Standard
Limit
f (play)
g (shaft)
0.5 to 3.0
Shims
55
54
h (bushing off- Standard

set cylinder) Limit
55
56.5
Standard
Limit
55
56.5
i (bushing rod)
3. Offset Boom/ Offset cylinder
e
d
AQ19002-020A
Mark
a (offset
boom)
b (offset cylinder)
Dimension (mm)
Standard
Limit
71
77
Standard
Limit
70
68
Standard
Limit
Standard
d (shaft)
Limit
e (bushing off- Standard
set cylinder Limit
c (play)
0.5 to 3.0
Shims
55
54
55
56.5
Issued 03-08
Copyright
1002-39
4. Offset Dipper/Rod
Mark
a (offset
dipper)
b (rod)
b
a
c (a - b)
d (shaft)
d
e
e (bushing
rod)
Dimension (mm)
Standard
Limit
158
164
Standard
Limit
Standard
Limit
Standard
Limit
Standard
Limit
157
155
0.5 to 3.0
Shims
55
54
55
56.5
AQ19002-021A
5. Offset arm/Offset Boom

Mark
a (offset
dipper)
b (offset
boom)
b a
c (play)
c
d (shaft)
d
e
AQ19002-022A
e (bushing
offset boom)
Dimension (mm)
Standard
Limit
281
287
Standard
Limit
280
278
Standard
Limit
Standard
Limit
Standard
Limit
0.5 to 1.5
Shims
100
99
100
101.5
6. Offset Dipper/ Dipper cylinder

Mark
a (offset
dipper)
b dipper
cylinder)
a
b
c
c (a - b)
d (shaft)
AQ19002-023A
e (bushing
dipper
cylinder)
Dimension (mm)
Standard
Limit
251
257
Standard
Limit
250
248
Standard
Limit
Standard
Limit
Standard
Limit
0.5 to 3.0
Shims
60
59
60
61.5
Issued 03-08
Copyright
1002-40
7. Offset dipper/Dipper
Mark
a (offset
dipper)
a
b
Dimension (mm)
Standard
Limit
Standard
Limit
Standard
c (a - b)
Limit
Standard
d (shaft)
Limit
e (bushing Standard
Limit
dipper)
b (dipper)
c
AQ19002-024A
184.5
190.5
184
182
0.5 to 1.1
Shims
60
59
60
61.5
8. Dipper/Dipper cylinder
Mark
a
b
a (dipper)
c
b (dipper
cylinder)
Dimension (mm)
Standard
Limit
Standard
Limit
Standard
Limit
Standard
d (shaft)
Limit
e (bushing Standard
arm cylinder) Limit
c (play)
81
87
80
78
0.5 to 3.0
Shims
50
49
50
51.5
AQ19002-025A
9. Dipper/Bucket cylinder
Mark
a
b
a (dipper)
b (bucket
cylinder)
Standard
Limit
Standard
d (shaft)
Limit
Standard
e (bushing)
Limit
c (play)
Dimension (mm)
Standard
Limit
Standard
Limit
76
82
75
73
0.5 to 3.0
Shims
50
49
50
51.5
AQ19002-026A
Issued 03-08
Copyright
1002-41
DIMENSIONS AND WEAR LIMITS OF BLADE AND BLADE CYLINDER
10
11
12
AQ19002-027A
10. Blade/Blade cylinder

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

Mark
a (frame)
b (cylinder
blade)
d
b
a
Dimension (mm)
Standard
Limit
Standard
Limit
Standard
Limit
Standard
d (shaft)
Limit
Standard
e (bushing)
Limit
c (play)
76
82
75
73
3.0 to 4.5
Shims
55
54
55
56.5
AQ19002-029A
Issued 03-08
Copyright
1002-42
12. Lower frame/Blade

Mark
a (frame)
b (blade)
c (play)
d
e
d (shaft)
b
a
e (bushing)
Dimension (mm)
Standard
Limit
Standard
Limit
Standard
Limit
Standard
Limit
Standard
Limit
69
75
65
63
3.0 to 5.0
Shims
45
44
45
46.5
AQ19002-030A
Issued 03-08
Copyright
1002-43
LIST OF SHIMS
For Adjusting Attachment Gaps
(Units: mm)
Part No.
I.D.
O.D.
Shim Thickness
Material
KMV0650
30.2
50
0.4
SPCC
KMV0651
30.2
50
0.8
SPCC
KMV0652
30.2
50
1.6
SPHC
KMV0653
30.2
50
3.2
SPHC
KMV0654
30.2
50
4.5
SS00
KMV0655
30.2
50
6.0
SS00
KMV0912
32
45
0.4
SPCC
KMV0913
32
45
0.8
SPCC
KMV0914
32
45
1.2
SPCC
KHV0327
36
65
1.2
SPHC
KHV0316
36
70
1.2
SPHC
KHV0315
41
75
1.2
SPHC
KHV0324
41
80
1.2
SPHC
KHV0317
41
90
1.2
SPHC
KAV0058
43
90
1.6
SPHC
KHV0347
46
80
1.2
SPHC
KAV0180
46
80
1.6
SPHC
KAV0682
46
90
1.2
SPHC
KHV0299
46
100
1.2
SPHC
KHV0328
51
85
1.2
SPHC
KAV0160
51
85
1.6
SPHC
BHV1030
51
90
1.2
SPHC
BHV1031
51
90
2.6
SPHC
KHV0330
51
95
1.2
SPHC
KAV0813
51
100
1.2
SPHC
KAV1951
51
100
2.6
SPHC
KAV0061
51
101.6
1.6
SPHC
KHV0348
51
105
1.2
SPHC
KAV0805
51
120
1.2
SPHC
KAV0812
56
90
1.2
SPHC
KAV0558
56
100
1.2
SPHC
BHV1033
56
100
2.6
SPHC
KHV0298
56
105
1.2
SPHC
KAV0395
56
110
0.8
SPHC
KAV0060
56
110
1.6
SPHC
KAV0396
56
115
1.2
SPHC
KAV0427
56
120
1.2
SPHC
KMV0771
60.5
76
1.2
SPHC
KAV0161
61
90
1.6
SPHC
Issued 03-08
Copyright
1002-44
(Units: mm)
Part No.
I.D.
O.D.
Shim Thickness
Material
KAV0811
61
110
1.2
SPHC
KNV0230
61
110
1.2
SPHC
KAV0059
61
110
1.6
SPHC
KHV0286
61
120
1.2
SPHC
KAV0801
61
130
1.2
SPHC
KMV0942
61
140
3.2
SPHC
KMV1246
61
160
1.2
SPHC
KMV0693
65.5
90
1.2
SPHC
KNV0538
66
100
1.2
SPHC
KLV0034
66
110
1.2
SPHC
KNV0535
66
120
1.2
SPHC
KMV0122
66
130
1.2
SPHC
KHV0273
66
150
1.2
SPHC
KHV0458
66
170
1.2
SPHC
KNV0696
71
110
1.2
SPHC
KNV0539
71
130
1.2
SPHC
KRV0823
71
130
1.2
SPHC
KMV0144
71
135
1.2
SPHC
KMV0145
71
135
2.6
SPHC
KMV0774
71
150
1.2
SPHC
KMV0775
71
150
2.6
SPHC
KMV0941
71
150
3.2
SPHC
KNV0189
71
150
1.2
SPHC
KRV1176
76
130
1.2
SPHC
KRV1177
76
140
1.2
SPHC
KRV1584
76
140
1.2
SPHC
KHV0169
76
140
1.2
SPHC
KNV0534
76
160
1.2
SPHC
KRV2264
76
180
1.2
SPHC
KAV0776
77
120
1.2
SPHC
KSV0141
78
170
1.2
SPHC
KSV0142
78
170
2.6
SPHC
KSV0143
78
170
3.2
SS00
KAV0095
81
105
1.6
SPHC
KLV0170
81
110
1.2
SPHC
KRV1197
81
140
1.2
SPHC
KRV0822
81
150
1.2
SPHC
KRP1350
81
150
2.6
SPHC
KLV0035
81
170
1.2
SPHC
Issued 03-08
Copyright
1002-45
(Units: mm)
Part No.
I.D.
O.D.
Shim Thickness
Material
KSP0408
81
200
1.2
SPHC
KSP0409
81
200
2.6
SPHC
KBV0122
82
120
3.2
SS00
KBV0123
82
120
4.5
SS00
KBV0124
82
120
6.0
SS400
KBV0373
82
180
1.0
SPCC
KRV1178
86
130
1.2
SPHC
KRV1585
86
150
1.2
SPHC
KHV0170
86
150
1.2
SPHC
KBV0389
87
210
1.0
SPCC
KBV0390
87
210
1.6
SPCC
BHV1030
90
51
1.2
SPHC
KBV0837
91
135
1.2
SPHC
KSV0477
91
145
1.2
SPHC
KSP0411
91
145
2.6
SPHC
KMV0121
91
159
1.2
SPHC
KBV0769
91
160
1.2
SPHC
KSP0269
91
160
2.6
SPHC
KBV0764
91
165
1.2
SPHC
KRV0559
91
180
1.2
SPHC
KRV1180
91
190
1.2
SPHC
KSP0412
91
200
1.2
SPHC
KSP0413
91
200
2.6
SPHC
KBV0381
92
180
1.0
SPCC
KBV0382
92
180
1.6
SPCC
KBV0383
92
180
2.0
SPCC
KBV0384
92
180
3.2
SS00
KBV0377
92
220
1.0
SPCC
KBV1749
96
140
1.2
SPHC
KNV0468
96
150
1.2
SPHC
KSP0828
96
150
1.2
SPHC
KBV1629
96
170
1.2
SPHC
KBV0361
97
250
1.0
SPCC
KBV0362
97
250
1.6
SPCC
BHV1032
100
56
1.2
SPHC
KSV0478
101
160
1.2
SPHC
KSP0415
101
160
2.6
SPHC
KSP0416
101
180
1.2
SPHC
KSP0417
101
180
2.6
SPHC
KBV0474
101
219
1.2
SPHC
Issued 03-08
Copyright
1002-46
(Units: mm)
Part No.
I.D.
O.D.
Shim Thickness
Material
KBV0369
102
210
1.0
SPCC
KSV0138
103
190
1.2
SPHC
KSV0139
103
190
2.6
SPHC
KSV0140
103
190
3.2
SS00
KSV0135
103
213
1.2
SPHC
KSV0136
103
213
2.6
SPHC
KSV0137
103
213
3.2
SS00
KSP0827
106
170
1.2
SPHC
KHV0190
111
150
1.2
SPHC
KSP0418
111
180
1.2
SPHC
KSP0419
111
180
2.6
SPHC
KTV0533
111
190
1.2
SPHC
KSV0476
111
230
1.2
SPHC
KBV0214
112
150
6.0
SS400
KBV0215
112
150
9.0
SS400
KBV0357
112
270
1.0
SPCC
KHV0193
121
155
1.2
SPHC
KMV1517
121
220
0.4
SPHC
KMV1518
121
220
0.6
SPHC
KMV1519
121
220
0.8
SPHC
KHV0296
121
230
1.2
SPHC
KTV0534
121
250
1.2
SPHC
KWV0101
131
170
1.2
SPHC
KSV0839
131
200
1.2
SPHC
KHV0287
131
240
1.2
SPHC
KTV0850
141
225
1.2
SPHC
KHV0297
141
240
1.2
SPHC
KHV0288
151
300
1.2
SPHC
KUV0080
171
280
1.2
SPHC
Issued 03-08
Copyright
1002-47
For Adjusting Attachment Gaps (for Boom Foot)
R
O.D I.D
000-6-10-02-02a1
Part No.
I.D.
O.D.
Shim
Thickness
Material
KNV1132
76
160
100
30
1.2
SPHC
KRV2390
91
190
115
30
1.2
SPHC
KBV1441
101
220
130
30
1.2
SPHC
KBV1748
101
230
135
30
1.2
SPHC
KSV1805
111
240
140
30
1.2
SPHC
Issued 03-08
Copyright
1002-48
R
O.D I.D
000-6-10-02-02b1
Part No.
I.D.
O.D.
Shim
Thickness
Material
KSV1930
111
240
140
30
1.0
Urethone
KSV11380
111
240
140
30
2.0
Urethone
KSV1931
116
240
140
30
1.0
Urethone
KSV11390
116
240
140
30
2.0
Urethone
KTV10730
121
245
150
50
2.0
Urethone
KTV10740
121
245
150
50
1.0
Urethone
KTV10750
121
260
150
50
2.0
Urethone
KTV10760
121
260
150
50
1.0
Urethone
KWV0097
141
280
160
50
1.0
Urethone
KWV10510
141
280
160
50
2.0
Urethone
KWV0096
141
300
180
50
1.0
Urethone
KWV10500
141
300
180
50
2.0
Urethone
KUV10150
141
300
170
30
1.0
Urethone
KUV10160
141
300
170
30
2.0
Urethone
KUV10130
151
300
170
30
1.0
Urethone
KUV10140
151
300
170
30
2.0
Urethone
Issued 03-08
Copyright
1002-49
SPECIAL TORQUE SETTINGS CX75SR

No.
Component
Screw
Wrench (mm)
Torque setting
1*
Travel motor and reduction gear assembly
M16
24
267-312 Nm (197-230 lb-ft)
2*
Drive sprocket
M14
22
173-202 Nm (127-149 lb-ft)
3*
Idler wheel
M10
17
63-73 Nm (46-54 lb-ft)
4*
Upper roller
M16
24
267-312 Nm (197-230 lb-ft)
5*
Lower roller
M20
30
521-608 Nm (384-448 lb-ft)
Shoe bolt
M14
22
267-312 Nm (197-230 lb-ft)
Counterweight
M24
36
850-992 Nm (627-658 lb-ft)
Turntable bearing (lower frame)
M16
24
280-322 Nm (206-237 lb-ft)
Turntable (swing frame)
M16
24
280-322 Nm (206-237 lb-ft)
10 *
Swing unit
M16
24
273-318 Nm (201- 234 lb-ft)
11 *
Engine (engine mount)
M16
24
265-314 Nm (196-231 lb-ft)
12 *
Engine bracket
M10
17
64-74 Nm (47-54 lb-ft)
Radiator
M12
19
64-74 Nm (47-54 lb-ft)
M10
17
63-73 Nm (47-54 lb-ft)
M12
10
Hexagon
socket head
13
14 *
15 *
16 *
Hydraulic pump
109-127 Nm (80-94 lb-ft)
Hydraulic reservoir
M12
19
69-79 Nm (51-58 lb-ft)
17
Fuel reservoir
M10
17
36-44 Nm (26-32 lb-ft)
18 *
Control valve
M16
24
267-312 Nm (197-230 lb-ft)
M12
19
88-107 Nm (65-79 lb-ft)
19 *
Hydraulic swivel
M12
19
88-107 Nm (65-79 lb-ft)
20
Cab
M16
24
71-86 Nm (52-63 lb-ft)
21
Battery
M10
17
64-74 Nm (47-54 lb-ft)
NOTE: Use Loctite 262 or an equivalent on retaining screws of those components marked with an asterisk (*).
Issued 03-08
Copyright
1002-50
16
21
17
13
18
20
11 12
7
14 15
10
19
10
6
1 7
2
5
4
8,9
1 , 2
2
FRONT
3 , 4 , 5 ,
3
4
7
AQ09002-001
Issued 03-08
Copyright
1002-51
8 , 9 , 10
11 , 12 ,13
10
8
11 12
16
14 , 15
11 12
17
13
17
15
14
17
16
17
18
19
19
18
20
21
21
20
AQ09002-002
Issued 03-08
Copyright
1002-52
SPECIAL TORQUE SETTINGS CX80

No.
Component
Screw
Wrench (mm)
Torque setting
1*
Travel motor and reduction gear assembly
M16
24
267-312 Nm (197-230 lb-ft)
2*
Drive sprocket
M14
22
173-202 Nm (127-149 lb-ft)
3*
Idler wheel
M10
17
63-73 Nm (46-54 lb-ft)
4*
Upper roller
M16
24
267-312 Nm (197-230 lb-ft)
5*
Lower roller
M20
30
521-608 Nm (384-448 lb-ft)
6*
Front guard
M16
24
267-312 Nm (197-230 lb-ft)
Shoe bolt
M14
22
220-270 Nm (162-199 lb-ft)
Counterweight
M24
36
850-992 Nm (627-658 lb-ft)
Turntable (swing frame)
M16
24
252-283 Nm (186-209 lb-ft)
10 *
Swing unit
M16
24
273-317 Nm (201-234 lb-ft)
11 *
Engine (engine mount)
M16
24
265-313 Nm (196-231 lb-ft)
12 *
Engine bracket
M10
17
64-74 Nm (47-54 lb-ft)
Radiator
M10
17
36-44 Nm (26-32 lb-ft)
M10
63-73 Nm (47-54 lb-ft)
M12
17
Hexagon
socket head
Hydraulic reservoir
M12
19
69-78 Nm (51-57 lb-ft)
17 *
Fuel reservoir
M12
19
98-108 Nm (72-80 lb-ft)
18 *
Control valve
M12
19
53-64 Nm (39-47 lb-ft)
19 *
Hydraulic swivel
M10
17
63-73 Nm (46-54 lb-ft)
13
14 *
15 *
16 *
Hydraulic pump
109-126 Nm (80-93 lb-ft)
NOTE: Use Loctite 262 or an equivalent on retaining screws of those components marked with an asterisk (*).
Issued 03-08
Copyright
1002-53
FRONT
FRONT
Issued 03-08
Copyright
1002-54
FRONT
Issued 03-08
Copyright
1002-55
MACHINE OVERALL DIMENSIONS

MONO BOOM SPEC (CX75SR)
1. Standard Arm (1.71 m)
NOTE: Numbers are subject to change without notice due to design change or other reasons.
The figures give values that include the shoe lug height (20 mm (0.79 in)
2. Long Arm (2.12 m)
Issued 03-08
Copyright
1002-56
MONO BOOM SPEC (CX80)

NOTE: Numbers are subject to change without notice due to design change or other reasons.
The figures give values that include the shoe lug height (20 mm (0.79 in)
2. Long Arm (2.12 m)
Issued 03-08
Copyright
1002-57
OFFSET BOOM SPEC (CX75SR)

Issued 03-08
Copyright
1002-58
NOTES
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
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....................................................................................................................................................................................
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....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
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....................................................................................................................................................................................
....................................................................................................................................................................................
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....................................................................................................................................................................................
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....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
Issued 03-08
Copyright
Section
2000
CNH
Lep SM75SR2000-0EN

Printed in France
August 2008
2000
REMOVAL AND INSTALLATION OF THE ENGINE
Copyright
2000-2
TABLE OF CONTENTS
ENGINE.................................................................................................................................................................... 3
Lep SM75SR2000-0EN
Issued 08-2008
Copyright
2000-3
ENGINE
100 11
6
8 744
4.9 to 5.9 Nm
8.8 to 9.8 Nm
8.8 to 9.8 Nm
133 2
155
144
200 21 222
X3 X3
166 177
68.7 to 98.1 Nm
199
18
5
200
X2
4
3
8.8 to 9.8 Nm
X2
655 666
100 11
122
4
X4
288 322
399
31
63.8 to 73.6 Nm
244 255 266

X4
264.9 to 313.9 Nm
288
63.8 to 73.6 Nm
299
244 255 266 277
233
264.9 to 313.9 Nm
A
4.9 to 5.9 Nm
4.9 to 5.9 Nm
522
4.9 to 5.9 Nm
X2
2
X2
555
533
500 51
4.9 to 5.9 Nm
599
61
599 4.9 to 5.9 Nm
622
30
63
64
655
66
244 255 266 277 288
233
288 300
63.8 to 73.6 Nm
X4
677
688
264.9 to 313.9 Nm
1. Coat the thread of sym (24) (30) (32) (45) with loctite 262 or equivalent after removing any oil film and
fasten by tightening torque.
2. apply packing liquid (50) to the connection of radiator hose after removing any oil film and fasten by
tightening torque.
Lep ASM-17-11-002EN
X4
X4
699 700 233 244 255 266 277 288
288 322
722
71
733
63.8 to 73.6 Nm
63.8 to 73.6 Nm
KAH11280-E02
3. Tighten up the clip; jubilee from the direction

shown on the drawing.
4. Arrow mark ( ) in the labels (69) represent the top.
Issued 08-2008
Copyright
2000-4
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
Air inlet pipe (1)

Hose clamp (2)
Radiator stay (1)
Bolt (6)
Air hose (1)
Vacuum indicateur (1)
Cushion seal (1)
Radiator (standard) assy (1)
Label (1)
Rubber hose (L = 800) (1)
Corrugated tube 13 x 8 00 (1)
Hose band (3)
Jubilee clip 50 - 65 (1)
Hose clamp (1)
Air hose (1)
High strength nut M8 (3)
Spring washer 8 (3)
Exhaust pipe (1)
Clamp (1)
Diesel engine dom (1)
Elastic rubber (8)
High strength bolt M16 x 130 (4)
High strength washer 16 (4)
Plate (4)
Nut (4)
Bond 262 (-)
Engine supt (1)
Bolt M10 x 25 (10)
Engine supt (1)
Bolt M10 x 30 (8)
Bracket (1)
Cushion seal (1)
Hose clamp (1)
Cushion seal (1)
Reserve tank (1)
Harness band L = 250 (1)
Rubber hose (L = 900) (1)
Muffler (1)
U bolt M8 (2)
Franged nut M8 (8)
Hose band (1)
Muffler bracket (1)
Tube L = 700
Bolt M8 x 25 (1)
Clamp M8 (1)
Liquid packing (-)
Hose clamp 38 - 50 (2)
Plain washer 8 (2)
Seal retainer (2)
Cushion seal (1)
Bolt M10 x 20 (2)
Bracket (1)
Air hose (1)
Air hose (1)
Bracket (1)
Bolt M8 x 20 (2)
Air cleaner (1)
Bolt M6 x 16 (2)
Holder (1)
Engine supt (1)
Hose band (1)
Rubber hose L = 600
Engine supt rf (1)
Cushion seal (1)
Acoustic insulation (1)
Blot M12 x 30 (4)
Radiator (standard) assy (1)
Lep ASM-17-11-002EN
X2
2
4 333
344
366
355
8.8 to 9.8 Nm
400
41
X8
422
433
444
288 455 46
63.8 to 73.6 Nm
477
366
344
722
D
KAH11280-E02b
Issued 08-2008
3001
Copyright
Section
3001
REMOVAL AND INSTALLATION
OF THE FUEL TANK
CNH
Lep SM75SR3001-0EN

Printed in France
August 2008
Copyright
3001-2
TABLE OF CONTENTS
FUEL TANK ............................................................................................................................................................. 3
Lep SM75SR3001-0EN
Issued 08-2008
Copyright
3001-3
FUEL TANK
See detail A
1
x2
7
x2
7
2
12
8
11
3
x2x2
4 5
x2
8
7
x2
10
13
See detail B
21
x2
7
22
23
25
14
22
See detail C
20
14
24
x2x2
15 16 17
18
19
KAH10760-D00
NOTE:
1. The specifications of fuel tank refer to the bollows.
Tank capacity: 100L
Limited inclined angle: 35
2. Do not cover the drill hole.
Lep AST-15-11-003
Issued 08-2008
Copyright
3001-4
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
Fuel tank
Bracket
Tank belt
Hige strength washer
High strength nut
Bracket
Sems bolt M10x25
Hose band
Rubber hose
Sems bolt M10x16
Drain cock
Plate
Filter
Bracket
High strength bolt M10x40
Hige strength washer
Bond 262
Sponge cushion
Sponge cushion
Sensor cover
Bracket
Rubber plate
Rubber plate
Rubber plate
Rubber plate
High strength bolt
Tank frange
Rubber packing
Fuel sensor
Non-asbestos packing
Liquid packing
Pan screw hd M5x12
High strength bolt
High strength washer
Spacer
Rubber cushion
High strength bolt M10x65
12
33 34 35 36
21
36
35 34 37
x8
26
5.9 to 6.9 Nm
27 28
29 30 31
x5
32
Lep AST-15-11-003
KAH10760-D00
Issued 08-2008
4001
Copyright
Section
4001
ELECTRICAL AND ENGINE FUNCTIONS,
&
SERVICE SUPPORT
CNH

Printed in France
March 2008
Copyright
4001-2
TABLE OF CONTENTS
CNH-EST DIAGNOSTIC TOOL ..................................................................................................................................... 3
Monitor Display ...................................................................................................................................................... 4
Engine Control ....................................................................................................................................................... 6
Issued 03-08
Copyright
4001-3
CNH-EST DIAGNOSTIC TOOL
The EST (Electronic Service Tool) system allows diagnoses on machines and engines by detecting the operating
parameters of electronic control components (control units, sensors etc). It is also capable of reading fault codes.
To use this tool, please refer to the book provided during the training sessions.
Issued 03-08
Copyright
4001-4
Monitor Display
1. Monitor Switch Panel
1.Fuel gauge
4.Overheat
10.Wiper switch
2.Coolant temperature gauge
5.Abnormal engine oil pressure
11.Washer switch
3.Hour meter
6.Low fuel
12.Working light switch
7.Battery charge error
13.High speed travel switch
8.
9.Glow (Preheat) Indicator
Issued 03-08
Copyright
4001-5
2. List of Functions
Functions
1
Remarks
Engine Start-up Control

Engine Start-up Circuit
Monitor Output Control
Monitor Display Control
See page 6
2.1
Throttle control
See page 8
2.2
One-touch idling
See page 10
2.3
EGR cut control
See page 11
3.1
2-speed travel
See page 13
3.2
Swing brake
See page 14
3.3
Travel alarm
See page 15
3.4
Working light
See page 16
3.5
Windshield wiper/washer
See page 17
3.6
Power cut delay
See page 19
4.1
Overheat warning
See page 20
4.2
Engine oil pressure warning
See page 22
4.3
Low fuel warning
See page 23
4.4
Battery charging warning
See page 24
4.5
Glow timer (auto)
See page 25
4.6
Hour meter
Gate lock
Horn
Radio
AM/FM
Interior light
4
Heater
Air Conditioner (optional)
See Air Conditioner
Combined Line for Breaker and Crusher (optional)
See Hydraulic Circuit
Interference Prevention System
See Interference
Prevention System
Issued 03-08
Copyright
4001-6
Engine Control
1. Engine start-up control
[1] Power supply (key switch at ON position)
1) Battery relay is energized.
2) Power is supplied to the initial excitation port (IG) in the alternator. (The alternator does not generate electricity until the input signal is recognized).
3) Power is supplied to the monitor to initiate operation.
[2]
Cranking (key switch at Start)

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

1) The heat relay is also energized during cranking (key switch at ST) to supply power to the air heater.
This is to maintain the temperature achieved through manual preheating.
Issued 03-08
Copyright
4001-7
2. Engine Start-up Circuit

BATTERY
G1 G2 ACC
C M
1.25G 505
0.85BrW 270
OR 851
VW 170
1.25LW 180
LIMIT
(GATE)
SWITCH
1.25GR 185
VW 170
SAFTY RL.
1.25B 750
0.85BrR 51
0.85GrR 01
FUSE BOX
0.85W 160
0.85GrR 010
YR 852
ST
0.85GrR 009
KEY SW.
HEAT
A
OFF
ACC
ON
ST
60R 001
B 707
5WR 009
8R 030
101
0.85LgR
g 500
FUSE
KEY SW.
5R 102
LOCK
0.85VR 195
SOLENOID
GW 225
0.85PW 230
STARTER MOTOR
0.85LgR
g 500
LEVER
LgW
g 175
60R 001
FUEL PUMP
5L 021
GLOW TIMER RL.
0.85LgR
g 501
0.85LgR 501
GLOW PLUG
OPTION
OPTIONAL
POWER
AUX.
1.25B 700
GR 255
GR 252
GW 225
GR 250
1.25WR 200
LgW
g 175
0.85BrR 190
1.25GR 185
1.25LW 180
VW 170
0.85BrW 270
0.85W 160
R 150
VR 196
R 151
G 022
0.85WR 290
0.85LgR
g 504
0.85GrR 011
0.25WR 520
0.858Br 510
ENG.
WATER TEMP. SENSOR
FUEL FEED PUMP
OPTION LINE (KNOB SW.)
TRAVEL MODE
TRAVEL ALARM
SWING BRAKE
AIR-CON.
HORN
WIPER/WASHER
LAMP (SWING)
LAMP (CAB.BOOM)
LEVER LOCK
THROTTLE MOTOR
MONITOR
BACK UP
AIR-CON BACK LIGHT
BACK UP AIR-CON
GLOW LAMP
KEY. ACC
KEY. ST
KEY. M
BATTERY RL
BATTERY CHARGE
0.85PW 230
0.85Y 310
2B 700
2B 600
600
700
255
151
011
520
510
Issued 03-08
0.85LgR
g 500
ALTERNATOR
0.85B 753
0.85RW 120
BATTERY
RL.
1.25GrR 330
3Y 331
G 022
1.25WR 200
3Y 330
0.85BG G04
8R 105
60R
0.85Br 510
1
0.85BrR 190
5WR 003
R 150
1.85G 505
0.85WR 290
0.85WR 520
0.85B 779
RELAY R11
STARTER
CUT
8R 030
8B 797
1.25SR 102
60R 100
60B 799
8R 106
3B 767
GR 255
5WR 020
AO28002-001a
Copyright
4001-8
[1] Throttle control
1) Configuration
IDLING
POWER SUPPLY 24V
MONITOR
THROTTLE
VOLUME
ONE-TOUCH IDLING SWITCH
CONTROL DEVICE
IDLING SPRING
GEAR
DC
MOTOR
POTENTIOMETER
GOVERNOR
LEVER
PULL CABLE
SPRING CHAMBER
IDLING ADJUSTMENT
SCREW
RACK
PULL SIDE L/S
THROTTLE MOTOR
RETURN SIDE L/S
STROKE = 28mm (1.10 in)

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

RETURN SIDE L/S: ON
PULL SIDE STOP

HIGH-IDLING
PULL SIDE L/S: OFF
POWER SUPPLY 24V

THROTTLE
VOLUME
RETURN SIDE L/S: ON
OPERATION THROUGH
THROTTLE VOLUME
MONITOR
CONTROL DEVICE
DC
MOTOR
THROTTLE MOTOR
HIGH-IDLING
ADJUSTMENT SCREW
AO28002-002A
Note:The idling and the high-idling positions for the engine governor are pre-adjusted by the engine supplier before delivery.
Issued 03-08
Copyright
4001-9
1) Operational Description
1) When the power is supplied to the throttle motor, the control device compares the throttle volume signal and the potentiometer signal. It then outputs a signal to the DC motor to move the rack to the target
position set by the throttle volume.
2) The DC motor then makes a normal or reverse rotation according to the signal received from the control device.
3) The output from the DC motor will be transferred to the reduction gears via the rack. The rack rotates
the governor lever by allowing the PULL cable to stroke to increase/decrease the engine revolutions.
4) The potentiometer signals interlock with the rack. When the signal coincides with the throttle volume
signal, the control device will stop the output of the command signal for motor rotation.
5) The rack strokes are controlled by the Pull side L/S and the Return side L/S.
PULL SIDE L/S: ON, RETURN SIDE L/S: ON
STROKE
28 mm
(1.10in)
ENGINE RPM
HIGH-IDLING
2150 RPM
SPRING BEND AREA
POTENTIOMETER
VOLTAGE
PULL SIDE L/S: OFF,

RETURN SIDE L/S: ON
CABLE SLACK AREA
PULL SIDE L/S: OFF, RETURN SIDE L/S: ON
IDLING
1100 RPM
6) When the working tension on the throttle motor reaches 15 kgf or above, the overload protection circuit
will be initiated to prevent the DC motor seizure.
Note: When the limit switch becomes damaged by an open circuit or a short circuit, the conditions will be
as follows:
Damage by open circuit: The DC motor alters the engine rpm in response to the throttle volume. The
current continues to flow to the DC motor at the time of maximum engine rpm and during idling. The
overload is thus detected and the output to the DC motor will be stopped.
Damage by short circuit: The rack does not move to the side where a short circuit has taken place in
the limit switch. If the limit switch has a short circuit on the Pull side, the rack can only move toward the
Return side from the location it was in when the short circuit took place (to the limit switch on the
Return side).
If the limit switch had a short circuit on the Return side, the rack can move to the Pull side only (to the
limit switch on the Pull side).
Issued 03-08
Copyright
4001-10
[2]
One-touch idling
POWER SUPPLY 24V
MONITOR
THROTTLE
VOLUME
GND
GND
CONTROL DEVICE
DC
MOTOR
PULL CABLE
GOVERNOR
LEVER
SPRING CHAMBER
IDLING ADJUSTMENT
SCREW
THROTTLE
VOLUME
POWER SUPPLY
MONITOR
CONTROL DEVICE
5V
GND
GND
DC
COMMAND SIGNAL FOR

MOTOR ROTATION
MOTOR
GND
MONITOR POWER
SUPPLY
OFF=0 V
ON=24 V
OFF=24 V
ONE-TOUCH IDLING
SWITCH
ON=0 V
OFF=5 V
MONITOR OUTPUT
ON=0 V
RESET
PROGRAMMED POSITION FOR THROTTLE VOLUME

THROTTLE POSITION
IDLING POSITION
AO28002-004A
Note:When the motor output is ON, the control device moves the rack to the idling position regardless of
the throttle volume location.
Issued 03-08
Copyright
4001-11
[3]
EGR cut control

The purpose of EGR cut control is to reduce nitrogen oxide (NOx), which occurs easily at high combustion
temperatures, by opening EGR and partially mixing the exhaust gas with the suction air to reduce the combustion temperature.
1) Operation explanation
1) When the coolant temperature reaches 60C or higher, the EGR cut relay is turned ON. (When the
coolant temperature is less than 60C EGR is closed. However, note that there is a hysteresis setting
for the opening side at 60C and the closing side at 55C and EGR will not close immediately even if
the coolant temperature drops below 60C)
2) When the EGR cut relay is ON, the sensor reads the boost pressure and engine speed and the following graph operations are performed.
15
EGR OPEN
Boost Pressure (KPa)
EGR OPEN
EGR OPEN
EGR OPEN
EGR CLOSE
EGR CLOSE
EGR CLOSE
EGR CLOSE
4
0
1250
1400
Engine Speed (min
1820 1850
-1)
AQ28002-024A
When the boost pressure is less than 4 kPa, EGR opens when the engine speed is 1850 min-1 or higher,
and EGR closes when the engine speed is less than 1820 min-1.
15
EGR OPEN
EGR OPEN
EGR OPEN
EGR OPEN
EGR CLOSE
EGR CLOSE
EGR CLOSE
EGR CLOSE
4
0
1250
1400
Engine Speed (min -1)
1820 1850
AQ28002-025A
Issued 03-08
Copyright
4001-12
When the boost pressure is 15 kPa, EGR opens when the engine speed is 1400 min-1 or higher, and EGR
closes when the engine speed is less than 1250 min-1.
*:Once EGR is open, it does not close until the engine speed reaches a level where it is set to close.Conversely, once EGR is closed, it does not open until the engine speed reaches a level where it is set to
open.
15
EGR OPEN
EGR OPEN
EGR OPEN
EGR OPEN
EGR CLOSE
EGR CLOSE
EGR CLOSE
EGR CLOSE
4
0
1250
1400
1820 1850
AQ28002-026A
When the boost pressure is 4 kPa or higher but less than 15 kPa, EGR opens when the engine speed is
1850 min-1 or higher, and EGR closes when the engine speed is less than 1250 min-1.
*:Once EGR is open, it does not close until the engine speed reaches a level where it is set to close.Conversely, once EGR is closed, it does not open until the engine speed reaches a level where it is set to
open.
15
EGR OPEN
EGR OPEN
EGR OPEN
EGR OPEN
EGR CLOSE
EGR CLOSE
EGR CLOSE
EGR CLOSE
4
0
1250
1400
1820 1850
AQ28002-027A
Issued 03-08
Copyright
4001-13
3. Monitor Output Control

[1] 2-Speed travel
1) Configuration
MONITOR
RELAY
SOLENOID
TRAVEL
CHANGEOVER SWITCH
2) Operation
TRAVEL CHANGEOVER SWITCH

MONITOR
OUTPUT
RESET
LIGHTS ON
LIGHTS
OUT
LED DISPLAY
LAMP CHECK
LAMP CHECK
If the key switch is turned ON again after it was turned OFF, the low travel speed is always selected.
Issued 03-08
Copyright
4001-14
[2]
Swing brake
1) Configuration
MONITOR
KEY.M
KEY SWITCH
RELAY
SWING RIGHT PRESSURE SWITCH

SWING LEFT PRESSURE SWITCH
ATTACHMENT PRESSURE SWITCH

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

The brake will go ON 3 s after the power cut delay.
Issued 03-08
Copyright
4001-15
[3]
Travel alarm
1) Configuration
MONITOR
TRAVEL ALARM
TRAVEL PRESSURE SWITCH
2) Operation
TRAVEL PRESSURE SWITCH
MONITOR OUTPUT
The travel pressure switch will also be turned ON through steering/pivot turn operations, thus activating
the alarm.
Issued 03-08
Copyright
4001-16
[4]
Working light
1) Configuration
RELAY
SWING WORKING LIGHT
MONITOR
REAR LIGHT
LAMP
RELAY
WORKING
LIGHT SWITCH
BOOM WORKING LIGHT

CAB WORKING LIGHT
REAR LIGHT LAMP
REAR LIGHT LAMP
CRANE MONITOR
AIR CONDITIONER PANEL

AO28002-010A
2) Operation
WORKING LIGHT
SWITCH
MONITOR OUTPUT
RESET
LIGHTS ON
WORKING LIGHT
REAR LIGHT
LIGHTS ON
LIGHTS
OUT
RESET
If the key switch is turned ON again after it was turned OFF, the working lights and the rear lights will
be reset.
Issued 03-08
Copyright
4001-17
[5]
Windshield wiper / washer

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

(INTERMITTENT)
CNT LED DISPLAY
(CONTINUOUS)
LIGHTS OUT
LIGHTS ON
LAMP CHECK
LIGHTS OUT
LIGHTS ON
LIGHTS OUT
Issued 03-08
Copyright
4001-18
2) Windshield wiper / washer
WIPER SWITCH
WIPER OUTPUT
OUT 2
WIPER OUTPUT
OUT 1
The LED for intermittent/continuous movements will not be turned ON when the windshield washer
switch is turned ON.
Issued 03-08
Copyright
4001-19
[6]
Power cut delay

1) Configuration
MONITOR
KEY SWITCH
BATTERY
BATTERY RELAY
KEY. M
2) Operation
KEY. M
KEY SWITCH ON
MONITOR OUTPUT
Due to the overcurrent protection circuit provided in the monitor output, the monitor will not be damaged in the event that a short circuit occurs in the harness or in the battery relay coil.
Issued 03-08
Copyright
4001-20
4. Monitor Display Control

[1] Overheat warning
1) Configuration
MONITOR
COOLANT TEMPERATURE GAUGE
THERMO-SENSOR
(COOLANT)
THERMO-SWITCH
(COOLANT)
OVERHEAT
SIGNAL
THERMO-SWITCH
(OIL)
Thermo-sensor specifications for analog meter

Temperature (C {F})
50
{122}
80
{176}
100
{212}
120
{248}
Resistance (ohm)
153.9
32.3
18.4
16.1
Thermostat switch (coolant) specifications

Switch ON (C {F})
105
{221}
Thermostat switch (oil) specifications
Switch ON (C {F})
98
{208.4}
Switch OFF (C {F})
91
{195.8}
Issued 03-08
Copyright
4001-21
2) Operation
OVERHEAT SIGNAL
LAMP CHECK
OVERHEAT
WARNING LED
BUZZER CHECK
BUZZER
When the overheat signal falls 1V or below, the monitor recognizes this as the switch being ON and
turns the LED on. Therefore, even when the signal line is removed, the LED will still be turned ON.
Issued 03-08
Copyright
4001-22
[2]
Engine oil pressure warning

1) Configuration
MONITOR
ENGINE OIL
PRESSURE SWITCH
CRANKING SIGNAL
KEY. ST
Pressure switch
0.029 MPa {4.2 psi} or less
2) Operation
IGN
KEY ST (CRANKING)
ENGINE OIL
PRESSURE SWITCH
LAMP CHECK
ENGINE OIL PRESSURE

WARNING LED
BUZZER CHECK
BUZZER
Even if a warning is requested, the buzzer will not be activated until the key switch signal (cranking signal) is received.
Issued 03-08
Copyright
4001-23
[3]
Low fuel warning

1) Configuration
FUEL GAUGE
MONITOR
FUEL SENSOR UNIT

FUEL SENSOR
FUEL THERMISTOR
Fuel sensor specifications

Fuel remaining
Sensor resistance
(ohm)
Empty
1/2
Full
90
38
10
FUEL
EMPTY
2) Operation
IGN
LOW FUEL
WARNING SIGNAL
(TERMISTOT)
LAMP CHECK
FUEL REMAINING
WARNING LED
BUZZER CHECK
BUZZER
When the thermistor resistance falls to 37 ohm or below, the monitor recognizes this as the signal
being ON and turns on the LED.
Issued 03-08
Copyright
4001-24
[4]
Battery charge warning

1) Configuration
MONITOR
ALTERNATOR
BELOW 6V
CRANKING SIGNAL
KEY. ST
2) Operation
IGN
KEY. ST
(CRANKING)
ALTERNATOR
SIGNAL
LAMP CHECK
BATTERY CHARGE
WARNING LED
BUZZER CHECK
BUZZER
Even if a warning is requested, the buzzer will not be activated until the key switch signal (cranking signal) is received.
When the alternator signal falls below 6V, the monitor turns the warning ON.
Issued 03-08
Copyright
4001-25
[5]
Glow timer (auto)

1) Configuration
KEY SWITCH
OFF
ON
ST
PREHEAT LAMP
A
BATTERY
DC24V
GLOW PLUG
TIMER
5
GLOW
PLUG
6
TEMPERATURE
SENSOR
AO28002-022A
2) Operation
ST
ST
KEY SWITCH
ON
ON
ON
OFF
LAMP
ON
OFF
ON
GLOW PLUG
OFF
AO28002-023A
Issued 03-08
Copyright
4001-26
NOTES
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Issued 03-08
Copyright
Section
4020
CNH

Printed in France
March 2008
4020
ELECTRICAL EQUIPEMENT
&
ELECTRIC CIRCUIT DIAGRAMS
Copyright
4020-2
TABLE OF CONTENTS
ELECTRIC CIRCUIT DIAGRAMS .................................................................................................................................. 4
List of components ................................................................................................................................................... 4
Electric Circuit Diagram 1 ......................................................................................................................................... 5
Electric Circuit Diagram 2 (CX75SR) ....................................................................................................................... 6
Electric Circuit Diagram 2 (CX80) ............................................................................................................................ 7
Electric Circuit Diagram: Air Conditioner 1 ............................................................................................................... 8
Electric Circuit Diagram: Air Conditioner 2 ............................................................................................................... 9
WIRING DIAGRAM ..................................................................................................................................................... 11
Electrical Components and Wiring For Upper (frame) ........................................................................................... 11
Electrical Components and Wiring for Cab ............................................................................................................ 12
Electrical Components and Wiring for Upper Frame (engine) ................................................................................ 13
Electrical Components and Wiring for Upper Frame (battery) ............................................................................... 14
Heater .................................................................................................................................................................... 15
Air Conditioner (inside Frame) ............................................................................................................................... 16
Air conditioner (inside cab) ..................................................................................................................................... 17
ELECTRICAL CONNECTOR WIRING DIAGRAM ....................................................................................................... 18
Main Frame Harness (CX75SR) ............................................................................................................................ 18
Main Frame Harness (CX80) ................................................................................................................................. 19
Cab Main Harness (inside cab) .............................................................................................................................. 20
Issued 03-08
Copyright
4020-3
Issued 03-08
Copyright
4020-4
ELECTRIC CIRCUIT DIAGRAMS

List of components
A7.
A9.
A11.
B1.
B2.
B21.
B22.
B26.
B27.
B41.
B45.
B47.
B51.
B81.
E2.
E3.
E4.
E8.
E51.
E52.
F1.
F3.
F7.
F8.
F9.
F10.
F11.
F12.
F13.
F14.
F15.
F16.
F17.
F18.
F19.
F20.
F21.
F22.
F23.
F24.
F25.
F26.
F27.
F33.
F34.
G1.
G2.
H3.
H4.
H5.
K3.
K4.
K5.
K7.
K8.
K18.
K19.
K20.
K21.
K22.
K23.
K24.
K25.
K34.
K47.
K48.
K49.
M1.
M3.
M4.
M5.
M6.
M7.
M8.
M10.
M14.
M20.
P2.
P3.
OVER LOAD WARNING CONTROLLER

AIR CONDITIONER CONTROLLER
CONTROLLER EGR CUT
COOLANT TEMPERATURE SENSOR
HYDRAULIC OIL TEMPERATURE SENSOR
ENGINE OIL PRESSURE SWITCH
SWING PILOT PRESSURE SWITCH
UPPER PILOT PRESSURE SENSOR
TRAVEL PILOT PRESSURE SENSOR
ENGINE RPM SENSOR
OVERLOAD INDICATOR PRESSURE SWITCH
BOOST PRESSURE SENSOR
BOOST TEMPERATURE SENSOR
HORN
WORKING LIGHT (ATTACHMENT)
WORKING LIGHT (CAB)
CAB LIGHT
SWING LAMP
CIGARETTE LIGHTER
AIR CONDITIONER
FUSE 65A ; MAIN FUSE FOR F8 TO F26
FUSE 15A ; KEY SWITCH AND MAIN FUSE
FUSE 10A ; MEMORY, CAB LIGHT, RADIO
FUSE 30A ; ENGINE PRE-HEATING
FUSE 10A ; SOLENOID EGR CUT
FUSE 5A ; AIR CONDITIONER HEATER UNIT
FUSE 15A ; AIR CONDITIONER BLOWER
FUSE 5A ; AIR CONDITIONER COMPRESSOR
FUSE 10A ; SOLENOID
FUSE 15A ; WINDSHIELD WIPER / WASHER
FUSE 10A ; HORN
FUSE 15A ; LAMP (BOOM, HOUSE)
FUSE 20A ; FUEL FILLER PUMP
FUSE 15A ; CIGAR. LIGHTER
FUSE 10A ; OVER-LOAD WARNING
FUSE 10A ; DC /DC CONVERTER
FUSE 10A ; BEACON
FUSE 10A ; MONITOR
FUSE 10A ; FUEL SUPPLY PUMP
FUSE 15A ; LAMP (SWING) OPTION POWER
FUSE 10A ; LEVER LOCK (GATE)
FUSE 15A ; THROTTLE MOTOR
FUSE 50A; SAFETY RELAY
FUSE 20A; ENGINE STOP SOLENOID
FUSE BOX
BATTERY
ALTERNATOR
OVER LOAD WARNING AUDIBLE ALARM
SPEAKER RIGHT
SPEAKER LEFT
RELAY-HORN
RELAY-WORKING LIGHT
RELAY-ROTARY LIGHT
RELAY BATTERY
RELAY SAFETY
RELAY-TRAVEL MODE
RELAY-SWING BRAKE
RELAY-WIPER MOTOR
RELAY-WASHER PUMP MOTOR
RELAY-AIR CONDITIONER MAGNET CLUTCH
RELAY-LOW BLOWER
RELAY-MEDIUM BLOWER
RELAY-HIGH BLOWER
RELAY STARTER CUT
RELAY EGR CUT
RELAY GLOW TIMER
RELAY LAMP SWING
STARTER MOTOR
WIPER MOTOR
WASHER MOTOR
MOTOR (AIR CHANGING)
AIR VENT DIRECTION CONTROL MOTOR
MOTOR ACT (AIR-MIX)
BLOWER MOTOR
THROTTLE MOTOR
FUEL FEED PUMP MOTOR
ELECTRIC FUEL PUMP
SWITCH PANEL (LEFT-HAND)
SWITCH PANEL (RIGHT-HAND)
P4.
P5.
P6.
P10.
R1.
R3.
R4.
R5.
R7.
S1.
S2.
S6.
S10.
S11.
S12.
S13.
S15.
S16.
S28.
S33.
S34.
S35.
S51.
S52.
U1.
W1.
X2.
X8.
X15.
Y2.
Y3.
Y4.
Y8.
Y9.
Y22.
Y45.
MONITOR DISPLAY
HOURMETER
AIR CONDITIONER CONTROL PANEL
SWITCH PANEL
GLOW PLUG
THROTTLE VOLUME
THERMISTOR INNER TEMPERATURE
FUEL SENSOR
RESISTOR
KEY SWITCH
TRAVEL MODE SWITCH
ROTARY LIGHT SWITCH
WORKING LIGHT SWITCH
WIPER SWITCH
WASHER SWITCH
OVERLOAD SWITCH
HORN SWITCH
IDLE SWITCH
TRAVEL ALARM
OPTION 2 SOLENOID VALVE SWITCH
OPTION 2 SOLENOID VALVE SWITCH
CRUSHER OPTION TWO FLOW SOLENOID
HYDRAULIC FUNCTION CANCELLATION LEVER
AIR CONDITIONING COMPRESSOR CLUTCH
DC-DC (24V-12V) CONVERTER
ANTENNA
ROTARY LIGHT CONNECTOR
RADIO CONNECTOR
ACCESSORY SOCKET
PILOT PRESSURE SOLENOID VALVE (BLUE
SWING BRAKE SOLENOID VALVE (WHITE
2 STAGE TRAVEL SOLENOID VALVE (RED
AIR CONDITIONER MAGNET CLUTCH
CRUSHER OPTION TWO FLOW SOLENOID
ENGINE STOP SOLENOID
SOLENOID EGR CUT
Issued 03-08
Copyright
4020-5
Electric Circuit Diagram 1
E4
H4
H5
M3
E3
X8
K20
M4
K21
E2
K4
E8
K49
P4
K18
K19
S51
Issued 03-08
Copyright
4020-6
Electric Circuit Diagram 2 (CX75SR)
R3
0.85W 160
0.85W 161
2
0.85GrR 011
0.85WR 520
WL 821
0.85Br 510
0.85Br
513
HOUR
METER
0.85BrW 514
0.85YB 412
0.85YB 412
0.85WB 318
YR 460
GR 462
GR 463
YL 860
ONE TOUCH IDLE
LR 461
UPPER
E
P.SW
YR 460
B26
P4
14 13
0.85BG 605
SWING
G
P.SW
P.SW
B27
LR 461
1
9
MONITOR SW.PANEL
L 465
SWING
G
P.SW
BG 646
0.85Br 344
OIL
TEMP
P
SW
B22
BG 645
0.85Br 344
B21
ENG..
OIL
P-SW
W
BG 648
0.85VG 413
0.85WB 467
1.25R 347
B2
B22
0.85B 706
B51
OVER
R
HEAT
T
SW
ENGINE
BG 647
0.85B 705
B1
1.25R 318
WATER
TEMP
SENSOR
(FOR METER)
R)
BG 643
P4
10
0
20
0
0.85VG 413
0.25BG 640
11 12
FUEL
SENSOR
R5
1 2
12
2
MONITOR SW.PANEL
0.75BW 650
0.85LgR
g 504
1 17 15
0.85B 745
0.85R
0.85B
4 13
0.75W 430
RELAY BATTERY
0.75R 410
0.85W 160
LGR 500
Y 810
160
1 4
6POLE
0.85P
0.85G
THROTTLE MOTOR
0.85W
BATTERY RELAY
W-LAMP
ALTERNATOR
0.85L
0.85Y
0.85Y
500
THROTTLE VOLUME
2B 700
M10
0.85BG 605
0.85BG 720
S16
BG 610
0
YL 860
KNOB(R)
R
B 747
L 865
175
S15
KNOB(L)
B81
B 712
AO30001-002
Issued 03-08
Copyright
4020-7
Electric Circuit Diagram 2 (CX80)
R3
M10
P4
R5
B1
B51
B21
B2
P4
B22
B22
B27
B26
B22
B22
S34
S16
S33
B81
S15
Issued 03-08
Copyright
4020-8
Electric Circuit Diagram: Air Conditioner 1
AIR CONDITIONER UNIT
BLOWER MOTOR
RESISTOR
3
2
1
4POLE
4
5
4
6
3
2
MODE BOX
1.25WR 200
0.85LB 540
0.85LY 541
0.85LW 542
O 549
YR 556
BG 557
WR 554
RY 555
LgB
g 553
O 551
O 549
10
LY 563
13
12
WG 547
14
GR 548
27
0.
RY 555
CONTROLLER AMP.
AIR CON.BACK UP
AIR CON.POWER
16
0.85B 720
5
0.85VR 195
17
0.
AIR CON. CONTROL AMP.

CN-AC1 30POLE
3
9
11
CN-WATER VALVE
RECIRCULATE/FRESH
LW 543
24
M5
19
GY 581
WL 559
A9
YW 558
15
WR 554
BG 557
BG 562
CN-WATER VALVE
GY 581
WATER VALVE
R 151
K24
1.25W 981
150
200
195
205
OR
R
R 150
K22
WB 564
WB 564
LR 546
K25
COMPRESSOR
0.8
YR 556
Issued 03-08
K23
S52
0.
LgB
g 553
G 560
OL 545
Y8
0 550
M6
M8
R7
R4
AO30001-003
Copyright
4020-9
Electric Circuit Diagram: Air Conditioner 2
13
CONTROL AMP
14
18
16
17
LW 576
GW 570
RY 567
RW 569
OR 572
LgR
g 571
BrR 575
LR 566
GR 577
BW 573
WR 568
WG 574
P6
15
16
18
CONTROL PANEL
13
14
WL 822
W-LAMP
820
195
Issued 03-08
2B 700
2B 600
2B 700
2B 600
VR 196
A9
AO30001-004
Copyright
4020-10
NOTES
....................................................................................................................................................................................
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....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
Issued 03-08
Copyright
4020-11
WIRING DIAGRAM
Electrical Components and Wiring For Upper (frame)
CN181
(PRESS. SW;TRAVEL:2PINS)
WITHOUT COLOR TAPE
DESCRIPTION
CN146
(BOOM LAMP HARNESS;2PINS)
CND12
(RECIEVER DRIER;2PINS)
MARKING POSITION ; FIT

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

THE HARNESS'S WHITE TAPE
I~
H~
KHR20160
CABLE;BATTERY
K~
KAR10930-D00
Issued 03-08
Copyright
4020-12
Electrical Components and Wiring for Cab
CONNECTOR:OVER LORD WARNING(8PIN)
LANP SWING
X10
DESCRIPTION
STARTER CUT(WHITE TAPE)
HORN(WHITE TAPE) SWING BRAKE
CONNECTOR:DC-DC COMVERTER
(7PIN)
6
B
EGR CUT
BEACON(WHITE TAPE)
PIN TERMINAL:PRESSURE CHECK
BLOWER L
BLOWER M
CONNECTOR:GROW TIMER 2
BLOWER H
CONNECTOR:GROW TIMER 1
BOX;FUSE
(ATTACHMENT FOR CAB MAIN HARNESS)
COMPRESSOR
FRAME MAIN HARNESS
LAMP(WHITE TAPE)
TRAVEL MODE(WHITE TAPE)
WASHER(WHITE TAPE)
WIPER(WHITE TAPE)
DETAIL OF ASSEMBLING RELAY
SYM
QTY
LOUD SPEAKER
RADIO SET AM/FM ST(12/24V) NA
ANTENNA CODE
DC-DC CONVERTER
WIRE HARNESS
BUZZER (24V)
SOCKET (DC12V)
CONTROLLER
CHANGE OVER RELAY
10
ROCKER SWITCH
10
WORKING LIGHT
11
MONITOR@24V
12
STARTER SWITCH ASSY
13
ROCKER SWITCH
14
ROCKER SWITCH
15
CONNECTOR:CONT EGR CUT(13PIN)
CONNECTOR;THERMISTOR
MARKING POSITION
CONNECTOR:OPTION POWER
(FIT HARNESS WHITE TAPE)
(4PIN)
(FIX WITH RED TAPE)
CONNECTOR:SUB HARNESS
CONNECTOR;BLOWER MOTOR
CONNECTOR;AIRCON CONTROLER
CONNECTOR;RESISTOR
(2PIN)
(FIX WITH RED TAPE)
CONNECTOR;MODE BOX
DETAIL OF ELEC. BRACKET
12
13
12V OUTPUT
(FIX WITH RED TAPE)
DETAIL OF ASSEMBLING RADIO

11
14
BACKSIDE OF COVER;TOP (RIGHT)
PANEL;CONTROL
CONNECTOR;WATER VALVE
CONNECTOR;FRESH AIR
DETAIL OF AIRCON HARNESS

13
12
8
BACKSIDE OF COVER;TOP (LEFT)
10
15
HARNESS;BEACON SW(WHITE TAPE)

HARNESS;OVER LOAD WARNING SW(BLUE TAPE)
CONNECT TO CAB HARNESS
CONSOLE RIGHT
DETAIL OF ASSEMBLING SWITCH
FRAME MAIN HARNESS

SWITCH;LIMIT
3
CONNECT TO ANTENNA CORD OF CAB
CONSOLE LEFT
KAR10750-E00
Issued 03-08
Copyright
4020-13
Electrical Components and Wiring for Upper Frame (engine)

DESCRIPTION
CN193
TERMINAL(FEMALE)
CN192
(EGR CUT;2PINS) (WATER TEMP. SENSOR 1)
CN189
RING TERMINAL M4
(GLOW)
CN196
RING TERMINAL M4
(OIL PRESS SWITCH)
THERMO SENSOR
SYM
QTY
HEATER HOSE
DETAIL-A
CN194
PIN TERMINAL(FEMALE)
(TACHO SENSOR)
SEE DETAIL-A
CN195
PIN TERMINAL(MALE)
(TACHO SENSOR)
CN.D13
(AIR COMPRESSOR)1PIN
CODE COLOR:WHITE
AIR COMPRESSOR
B~
BE CAREFUL OF THE DIRECTION OF
BATTERY CABLE
STARTER MOTOR
(ATTACHMENT FOR ENGINE)
CN190
(ENGINE STOP;3PINS)
CN109
TERMINAL(FEMALE)
(STARTER MOTOR S)
DETAIL OF STARTER MOTOR

KAR10690
(HARNESS;WIRE)
CN.179
RING TERMINAL M4
(WATER TEMP. SENSOR 2)
CODE COLOR:RED
CN187
(BOOST PRESS SENSOR;3PINS)
CN186
RING TERMINAL M4
(OVER HEAT SWITCH)
CODE COLOR:RED
SAFTY RELAY(ATTACHMENT
FOR ENGINE)
CN.111
RING TERMINAL M6
(ALTERNATOR:B)
CODE COLOR:RED
CN110
(ALTERNATOR L,R;2PINS)
1
ENGINE EARTH
(ATTACHMENT FOR ENGINE)
CN.112
RING TERMINAL M6
(ALTERNATOR:E)
CODE COLOR:BLACK
CN106
(SAFTY RELAY:S.R.E)3PIN
DETAIL-D
CN108
(SAFTY RELAY:C)1PIN
C~
E~
KHR20160
CABLE;BATTRY
CN107
(SAFTY RELAY:C)1PIN
KHR20160
CABLE;BATTRY
SEE DETAIL-D
KAR10940-D00
Issued 03-08
Copyright
4020-14
Electrical Components and Wiring for Upper Frame (battery)
CN104
RING TERMINAL M4(BATTERY RELAY COIL)
CODE COLOR:WHITE BASE,RED STRIPE
CN103
RING TERMINAL M4(BATTERY RELAY COIL)
CODE COLOR:LIGHT GREEN BASE,RED STRIPE
1
TANK;SUMP
DESCRIPTION
SYM
QTY
BATTERY CABLE
BATTERY HOLDER
BATTERY 95D31R
BATTERY CABLE
BATTERY CABLE
BATTERY CABLE
BATTERY RELAY
FUSE
FUSE 50A
M8(ATTACHMENT FOR BATTERY)

TIGHTENING TORQUE 6.0 + or - 0.5 Nm(4 POINTS)
3
CNG1
(GROUND)
CODE COLOR:BLACK
CN105
(BATTERY RELAY GND)1PIN
DETAIL OF BATTERY (DETACH PLATE;RUBBER)

6
M10(ATTACHMENT FOR BATTERY)
TIGHTENING TORQUE 11.8 + or - 1.2 Nm(4 POINTS)
CN101
(BATTERY RELAY 1GN)
CODE COLOR:RED
CN100
(BATTERY RELAY B+)
WITH WHITE TAPE
DETAIL OF BATTERY RELAY
HOUSE;FRAME
CNF3
(FUSE:KEY 15A)2PINS
WITHOUT TAPE
CNF4
(FUSE:ENGINE STOP 20A)2PINS
WITH RED TAPE
CNF7
(FUSIBLE LINK 65A)2PINS
CODE COLOR:RED
CNF2
(FUSIBLE LINK 50A)2PINS
CODE COLOR:RED WHITE BASE,RED STRIP
KAR10690
(HARNESS;WIRE)
A~
DETAIL OF BATTERY (INSIDE)
DETAIL OF FUSE
KAR10860-D00
Issued 03-08
Copyright
4020-15
Heater
HEATER(ENG.OUT)
THE HOSE LENGTH FROM THIS CLAMP
TO THE HEATER UNIT.
HEATER INLET:780 mm
HEATER OUTLET:660 mm
WHITE MARKING
HEATER(ENG.RETURN)
DETAIL-A
IN
CONNECT HEATER UNIT
OUT
CONNECT HEATER UNIT
HEATER(ENG.RETURN)
HEATER(ENG.OUT)
TO THE NIPPLE.
HEATER INLET:550 mm
DETAIL-A
KAR10850-D00
Issued 03-08
Copyright
4020-16
Air Conditioner (inside Frame)

TO THE COMPRESSOR.
DISCHARGE:290 mm
OUT
IN
HEATER(ENG.OUT)
HEATER(ENG.RETURN)
WHITE MARING.
TO THE UNIT;AIR CONDITIONER.
LIQUID 2:800 mm
SUCTION:700 mm
HEATER INLET:780 mm
SEE DETAIL-B
DETAIL-A
DETAIL RECEIVER;DRIER ASSEMBLING
BE CAREFUL OF DIRECTION.
HEATER(ENG.RETURN)
IN
CONNECT AIR CON UNIT
OUT
LIQUID
DETAIL-B
HEATER(ENG.OUT)
SUCTION
SUCTION
SEE DETAIL-A
DETAIL PULLY ASSEMBLING

TO THE NIPPLE AND COMPRESSOR.
HEATER INLET:550 mm
SUCTION:520 mm

TO THE RECEIVER;DRIER AND CONDENSER
LIQUID 2:930 mm
DISCHARGE:830 mm
DISCHARGE
KAR10830-E00
Issued 03-08
Copyright
4020-17
Air conditioner (inside cab)
SYM
QTY
CHANGE OVER RELAY
DESCRIPTION
CONTROL PANEL
WHITE MARKING
CONNECT TO DCCT;SPL
COOLER INLET
COOLER OUTLET
HEATER OUT
HARNESS;WIRE
CONTROLLER
MODE BOX
BLOWER MOTOR
THERMISTOR
X3
BLOWER H
BLOWER M
BLOWER L
COMPRESSOR
RESISTOR
ONLY AIR CONDITIONER
10
DETAIL OF RELAY ASSEMBLING

10
COVER;FRONT
BOX;CONSOLE(L)
KHR3949Z-D07
Issued 03-08
Copyright
4020-18
ELECTRICAL CONNECTOR WIRING DIAGRAM

Main Frame Harness (CX75SR)
CMF7M
KAR10690-E00
Issued 03-08
Copyright
4020-19
Main Frame Harness (CX80)
CMF7M
(FUSIBLE LIMK
(FUSE BOX))
Issued 03-08
Copyright
4020-20
Cab Main Harness (inside cab)
CN28F
(AIRCON CONTROLER AMP 2)
CN29F
KAR10710-E00
Issued 03-08
5001
Copyright
Section
5001
OF THE TRACKS
CNH
Lep SM75SR5001-0EN

Printed in France
August 2008
Copyright
5001-2
TABLE OF CONTENTS
TRACK SHOE.......................................................................................................................................................... 3
Removal ............................................................................................................................................................ 4
Installation ......................................................................................................................................................... 5
TRACK LINK CHANGING PROCEDURE ...................................................................................................................... 6
Lep SM75SR5001-0EN
Issued 08-2008
Copyright
5001-3
TRACK SHOE
1
10
5
11
9
11
6
13
7
12
13
4
16
14
15
AQ10002-001
1.
2.
3.
4.
5.
6.
7.
8.
Grouser shoe
Track link assembly
Track link (right)
Track link (left)
Master link (right)
Master link (left)
Track bushing
Track pin
Lep ASM-17-10-002EN
9.
10.
11.
12.
13.
14.
15.
16.
Master bushing
Master pin
Collar
Locking pin
Seal
Shoe plate
Shoe bolt
Shoe nut
Issued 08-2008
Copyright
5001-4
1 Removal
[1] Position the master pin (1) of the track shoe as shown in
the drawing on the left.
Place track shoe support blocks as shown in the drawing.
AQ10002-002
[2] Loosen the track shoe.

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

1) Remove the locking pin (2).
2) Pull out the master pin using a jig.
3) Remove the track shoe supporting blocks.
AQ10002-004
[4] Lift one side of the lower frame about 20 cm and hold it
there.
WARNING: Place protection blocks under the lower frame and
secure them.
Move the travel unit as shown in the drawing to the left to remove
the track shoe.
AQ10002-006
Lep ASM-17-10-002EN
Issued 08-2008
Copyright
5001-5
2 Installation
[1] Lift the track shoe and align it to the drive sprocket.
AQ10002-007
[2] Feed the track shoe toward the take-up roller by moving
the travel unit slowly as shown in the drawing to the left.
NOTE: Be careful. Sudden and quick movements may cause
the track shoe to jump and run off.
(During work, lift the roller shoe using the steel bar when
crossing over the upper roller).
[3] Remove protection blocks and lower the lower frame.
AQ10002-008
[4] Wind the end of the track shoe onto the take-up roller of
the track shoe.
[5] Connect the track shoe.
1) Place the track shoe supporting blocks.
2) Insert the master pin using a jig.
3) Insert a locking pin.
AQ10002-009
[6] Adjust the track shoe to the specified tension.

1) Fasten the check valve to the original position.
2) Fill the grease cylinder with grease, while observing the track shoe tension.
NOTE: For the track shoe tension adjustment, refer to Inspection and Maintenance in the Instruction Manual.
AQ10002-010
Lep ASM-17-10-002EN
Issued 08-2008
Copyright
5001-6
1 Track link changing procedure

1) Remove the track shoe.
2) Remove bolts, nuts and shoe plates for three sections, including the sections on both sides of the
damaged link section.
3) Pull the track pin using a jig.
4) Remove the damaged link.
5) Align a new track link.
6) Press fit the track pin using a jig.
7) Align the shoe plate and tighten the bolts to the
specified torque.
8) Install the track shoe.
AQ10002-011
Lep ASM-17-10-002EN
Issued 08-2008
Copyright
5003
Section
5003
UPPER AND LOWER ROLLERS
CNH
Lep SM75SR5003-0EN

Printed in France
August 2008
Copyright
5003-2
TABLE OF CONTENTS
TRACK SHOE.......................................................................................................................................................... 3
UPPER ROLLER ..................................................................................................................................................... 3
Removal ............................................................................................................................................................ 4
Installation ......................................................................................................................................................... 4
Tools and jigs .................................................................................................................................................... 5
Disassembly instructions................................................................................................................................... 7
Assembly instructions ....................................................................................................................................... 9
Assembly drawings ......................................................................................................................................... 13
LOWER ROLLER .................................................................................................................................................. 14
Removal .......................................................................................................................................................... 15
Installation ....................................................................................................................................................... 15
Component diagram........................................................................................................................................ 16
Tools and jigs .................................................................................................................................................. 16
Disassembly instructions................................................................................................................................. 18
Assembly instructions ..................................................................................................................................... 21
Lep SM75SR5003-0EN
Issued 08-2008
Copyright
5003-3
TRACK SHOE
1 Upper roller
AQ10002-023
1.
2.
3.
4.
Upper roller
Bolt
Loctite 262
Shim
Lep ASM-17-10-002EN
Issued 08-2008
Copyright
5003-4
1 Removal
[1] Loosen track shoe. See Track shoe, removal.
[2] Place the hydraulic jack (A) as shown in the drawing to
the left.
AQ10002-024
[3] Using the hydraulic jack (A), lift the track shoe high
enough that the upper roller can be removed.
[4] Place blocks between the track shoe and side frame
and secure them.
[5] Loosen the upper roller mounting bolt (2) slightly (so
that the bolt head comes off 2 to 4 mm).
[6] Hit the upper roller gently with a copper hammer and
detach it from the side frame.
[7] Attach lifting tools on the upper roller.
[8] Remove the upper roller by removing mounting bolts (2)
completely while lifting the upper roller using the lifting
tools.
AQ10002-025
NOTE: Be careful to keep fingers and hands clear.

2 Installation
[1] Apply Loctite No. 262 to the upper roller mounting bolts
(2).
[2] Finger tighten all upper roller mounting bolts (2) while
lifting the upper roller.
NOTE: Adjust the position of the upper roller if necessary, using
shims (4) so that the track links are evenly supported.
[3] Tighten the upper roller mounting bolts (2) to the specified torque.
[4] Remove the blocks and jack.
[5] Fill grease into the grease cylinder and give the track
shoe the specified tension.
(See Track shoe, installation).
Lep ASM-17-10-002EN
Issued 08-2008
Copyright
5003-5
3 Component diagram
1.
Cover
2.
O-ring
3.
Plug
4.
Snap ring
5.
Ball bearing
6.
Roller
7.
Shaft
8.
Oil seal
9.
Cover
10. Bracket
AQ14002-001
4 Tools and jigs

1.
Tools
Hammer
AQ13002-002
Hexagon bar wrench
AQ13002-003
Lep ASM-17-14-002EN
Issued 08-2008
Copyright
5003-6
2.
Jigs
Install jig.
AQ13002-004
Pulling jig
AQ13002-005
Lep ASM-17-14-002EN
Issued 08-2008
Copyright
5003-7
5 Disassembly instructions
[1] Preparation
Prior to disassembly, take full preparatory measures.
1) Workbench with vises
Prepare a suitable workbench large enough to arrange and keep parts and perform the work.
2) Tools and Jigs
For tools and jigs, refer to the previous section.
[2] General cautions
1) Handle precision parts carefully during the operation; do not drop or hit them on other parts during the operation.
2) Do not attempt to finish the operation quickly; do not forcedly pry or hit the parts.
Perform the operation carefully and patiently in order to prevent parts deformation, oil leakage and lower efficiency.
3) As disassembled parts tend to get rusted or collect dust and dirt, dust proof and rust prevention treatment should
be applied immediately after disassembling the parts.
[3] Disassembling procedure
1)
1) Clean the upper roller with kerosene.
2) Remove the plug (3) from the cover to drain the
oil.
AQ14002-006
2)
1) Remove the cover (1) from the upper roller (6) using
a press and a pulling jig.
2) Remove O-ring (2) from the cover (1).
AQ14002-003
Lep ASM-17-14-002EN
Issued 08-2008
Copyright
5003-8
3) Remove snapring (4) from shaft (7).
AQ14002-004
4) Pull out the roller (6) from the shaft (7).
AQ14002-005
5) Remove the cover (9) and oil seal (8) from roller using
a press and a pulling jig.
AQ14002-006
Lep ASM-17-14-002EN
Issued 08-2008
Copyright
5003-9
6) Remove ball bearings (5) from roller (6) using a press
and a pulling jig.
Do not disassemble ball bearings (5) unless they are
unusable due to wear.
AQ14002-007
7) Cleaning parts
1) Place parts in the preparatory cleaning container containing cleaning oil.
NOTE: Wash off deposited substances which may cause scratches.
NOTE: Leave the parts submerged in the kerosene until the dirt and grease come off and float up
2) Put the parts in the finish cleaning container containing cleaning oil and wash them by slowly moving them.
3) Wipe off remaining cleaning oil with clean cloth.
NOTE: Place the parts somewhere free of dust and moisture, and dry them using compressed air. After drying, apply
engine oil to the parts.
6 Assembly instructions
[1] Prior to assembly
Clean all the parts.
Polish scratches, flashes or burrs using oil stons.
Change sealing parts such as O-rings with new ones.
[2] Assembling procedure
1) Press fit the shaft (7) into the bracket (10). Press fitting
should be securely conducted through the side of the
plug hole.
NOTE: In an ordinary case, do not disassembly the bracket from
the shaft. Reassembly will be a very difficult task.
AQ14002-008
Lep ASM-17-14-002EN
Issued 08-2008
Copyright
5003-10
2) Install the ball bearings (5) on roller (6) using a jig and a
hammer.
NOTE: Use new ball bearings (5).
AQ14002-009
3)
1) Install the oil seal (8) and cover (9) to the roller (6).
2) Apply oil to the surface (lip section) of the floating
seal.
NOTE: Do not reuse oil seal (8).
AQ14002-010
4)
1) Apply grease to the shaft (7) surface.
2) Install roller (6) into shaft (7).
AQ14002-011
Lep ASM-17-14-002EN
Issued 08-2008
Copyright
5003-11
5) Install snap ring (4) on shaft (7).
NOTE: Do not reuse O-ring (4).
AQ14002-012
6)
1) Apply grease to O-ring (2) and install on cover (1).
2) Press fit the cover (1) with the O-ring attached on
roller (6), using a press and a jig.
NOTE: Use a new O-ring.
AQ14002-013
7) Check for leakage in the assembly using compressed

air. Compressed air pressure: 0.2 MPa.
AQ14002-014
Lep ASM-17-14-002EN
Issued 08-2008
Copyright
5003-12
8) Fill oil through the plug hole.
AQ14002-015
9) Install the plug (3).

NOTE: Clean the assembly and dry it using compressed air.
AQ14002-016
Now the assembly has been completed.
Lep ASM-17-14-002EN
Issued 08-2008
Copyright
5003-13
7 Assembly drawings
-##<$
1.
2.
3.
4.
5.
Cover (1)
O-ring 1B-G65 (1)
Plug 1/8 (1)
Snap ring (1)
Ball bearing (2)
Lep ASM-17-14-002EN
6.
7.
8.
9.
10.
Roller (1)
Shaft (1)
Oil seal (1)
Cover (1)
Bracket (1)
Issued 08-2008
Copyright
5003-14
2 Lower roller
AQ10002-026
1. Lower roller
2. Bolt
3. Loctite 262
ASM-17-10-002
Issued 08-2008
Copyright
5003-15
1 Removal
[1] Loosen track shoe. See Track shoe, removal.
[2] Remove the lower roller mounting bolts (2).
[3] Lift one side of the lower frame about 200 mm and hold
it there. (Lift it high enough that the lower roller can be
removed from the track shoe).
[4] Place protection blocks under the lower frame and
secure them.
AQ10002-027
[5] Remove the lower roller (1) from the track shoe.
AQ10002-028
2 Installation
[1] Place the lower roller on the track links with its fitting
surface up.
[2] Remove the protection blocks.
[3] Lower the frame slowly and gradually to where the bolts
can be installed.
NOTE: Be careful to keep fingers and hands clear. (Keep the
frame raised about 5 to 10 mm, instead of lowering it
completely.)
[4] Align the lower roller to the frame fitting position.
[5] Apply Loctite No. 262 to the lower roller mounting bolts
(2).
[6] Tighten the lower roller mounting bolts (2) to the specified torque.
[7] Fill the grease cylinder with grease to give the track
motor cover shoe the specified tension.
(See Track shoe, installation).
ASM-17-10-002
Issued 08-2008
Copyright
5003-16
3 Component diagram
1.
Collar (without plug)
2.
Roller
3.
Shaft
4.
Bushing
5.
Floating seal
6.
O-ring
7.
Wire clip
8.
Collar (with plug)
9.
Plug
AQ15002-001
4 Tools and jigs

1.
Tools
Hammer
AQ13002-002
Hexagon bar wrench
AQ13002-003
ASM-17-15-002
Issued 08-2008
Copyright
5003-17
2.
Jigs
Install jig
AQ13002-004
Pulling jig
AQ13002-005
ASM-17-15-002
Issued 08-2008
Copyright
5003-18
[1] Preparation
2) Tools and Jigs
Do not attempt to finish the operation quickly; do not forcedly pry or hit the parts.
2) Perform the operation carefully and patiently in order to prevent parts deformation, oil leakage and lower efficiency.
1)
1) Clean the lower roller with kerosene.
2) Remove the plug (9) from the collar (8) to drain the
oil.
AQ15002-002
2)
1) Remove the wire clips (7) from the shaft (3).
2) Remove the collars (1), (8) from the shaft (3).
AQ15002-003
ASM-17-15-002
Issued 08-2008
Copyright
5003-19
3) Remove the floating seals (5) from the collars (1), (8)
using pulling jig.
AQ15002-004
4)
1) Remove the O-rings (6) from the shaft (3).
2) Draw out the shaft (3) from the roller (2).
AQ1002-005
5) Remove the floating seals (5) from the roller (2).
AQ15002-006
ASM-17-15-002
Issued 08-2008
Copyright
5003-20
6) Remove the bushings (4) from the roller (2) using pulling jig and press.
AQ15002-007
7) Cleaning parts
1) Place parts in the preparatory cleaning container containing kerosene.
2) Put the parts in the finish cleaning container containing kerosene and clean them by slowly moving them.
3) Wipe off kerosenel with clean cloth.
ASM-17-15-002
Issued 08-2008
Copyright
5003-21
Polish scratches, flashes or burrs using oil stone.
1) Install the bushings (4) to the roller (2) using jig and
hammer.
NOTE: Pay full attention when inserting the bushings by
hammering. Do not reuse bushings (4).
AQ15002-008
AQ15002-009
2) Install the floating seals (5) to the roller (2).

NOTE: Do not reuse floating seals (5).
AQ15002-006
ASM-17-15-002
Issued 08-2008
Copyright
5003-22
3)
1) Apply grease to the surface of the shaft (3).
2) Install the shaft (3) to the roller (2).
3) Install the greased O-rings (6) to the shaft (3).
AQ15002-005
4) Install the floating seals (5) to the collars (1), (8).

AQ15002-004
5) Apply oil to the surface (lip section) of the floating seal.
AQ15002-010
ASM-17-15-002
Issued 08-2008
Copyright
5003-23
6) Press fit the collars (1), (8) to the shaft (3) and install
the wire clips (7). (Temporary fastening)
NOTE: Do not reuse wire clips (7).
AQ15002-003

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

NOTE: Do not reuse wire clip (7).
AQ15002-012
9)
1) Fill oil through the plug hole.
AQ15002-002
ASM-17-15-002
Issued 08-2008
Copyright
5003-24
7 Assembly drawings
-##<%
1.
2.
3.
4.
5.
Collar (without plug) (1)

Track roller (1)
Roller shaft (1)
Bushing (2)
Floating seal (2)
ASM-17-15-002
6.
7.
8.
9.
O-ring 1B-G35 (2)

Wire clip (2)
Collar (with plug) (1)
Plug 1/8 (1)
Issued 08-2008
Copyright
Section
5005
5005
TAKE-UP ROLLER
AND
TENSION SHOCK ABSORBER
CNH
Lep SM75SR5005-0EN

Printed in France
August 2008
Copyright
5005-2
TABLE OF CONTENTS
TAKE-UP ROLLER AND TENSION SHOCK ABSORBER .................................................................................... 3
Removal ............................................................................................................................................................ 4
Installation ......................................................................................................................................................... 5
GREASE CYLINDER ................................................................................................................................................ 6
Component diagram.......................................................................................................................................... 6
Tools and jigs .................................................................................................................................................... 6
Assembly instructions ....................................................................................................................................... 8
TAKE-UP ROLLER ................................................................................................................................................ 11
Component diagram........................................................................................................................................ 11
Tools and jigs .................................................................................................................................................. 11
Disassembling instructions.............................................................................................................................. 13
Assembling instructions .................................................................................................................................. 16
Lep SM75SR5005-0EN
Issued 08-2008
Copyright
5005-3
TAKE-UP ROLLER AND TENSION SHOCK ABSORBER

#3
1.
2.
3.
4.
5.
6.
7.
8.
9.
Yoke
Bolt
Threaded rod
Castle nut
Spring pin
Spring
Grease cylinder assembly
O-ring
Backup ring
ASM-17-10-002
10.
11.
12.
13.
14.
15.
16.
17.
Check valve
Dust seal
Piston rod
Grease cylinder
Bracket
High strength bolt
Spring washer
Take-up roller
Issued 08-2008
Copyright
5005-4
1 Removal
[1] Remove track shoe. See Track shoe, removal.
[2] Pull out the recoil spring assembly from the side frame
using a steel bar.
[3] Attach a lifting tool to the recoil spring assembly..
AQ10002-019
[4] Lift the recoil spring assembly out from the side frame
using the lifting tool.
[5] Place the recoil spring assembly on blocks.
[6] Remove the take-up roller mounting bolts (2) to separate the take-up roller and coil spring.
[7] Prepare hydraulic jack and jigs for recoil spring disassembling and reassembling.
[8] Set recoil spring in jig as shown in the drawing to the
left.
[9] Raise the hydraulic jack to compress the spring.
[10]Pull out the spring pin (5) and remove the castle nut (4).
AQ10002-020
[11]Lower the hydraulic jack to restore the spring to its original position.
[12]Take the recoil spring components out from the jig in
the following order: yoke (1), spring (6) and grease cylinder (7).
ASM-17-10-002
Issued 08-2008
Copyright
5005-5
2 Installation
[1] Set the recoil spring components in the recoil spring jig
in the following order: grease cylinder (7) spring (6) and
yoke (1).
[2] Raise the hydraulic jack to compress the spring.
Mounting length of spring: 402 mm
[3] Attach the castle nut (4) and lock it with spring pin (5).
AQ10002-021
[4] Lower the hydraulic jack to restore the spring to the original position.
[5] Remove the recoil spring from the jig.
[6] Apply Loctite No. 262 to the take-up roller mounting
bolts (2).
[7] Tighten the take-up roller mounting bolts (2) to the specified torque to reassemble the take-up roller and recoil
spring.
[8] Attach lifting tool to recoil spring assembly.
[9] Place recoil spring assembly on side frame using a lifting tool.
AQ10002-022
[10]Set the recoil spring assembly in the side frame using a

steel bar.
[11]Install the track shoe. (See Track shoe, installation.)
WARNING: A jig should be used for disassembly and
reassembly because the coil spring is compressed.
ASM-17-10-002
Issued 08-2008
Copyright
5005-6
1 Grease cylinder
1 Component diagram
KAA1160Z-C01
1.
2.
3.
4.
5.
Dust seal
Backup ring
O-ring
Piston rod
Grease cylinder
6.
7.
8.
9.
High strength bolt

Spring washer
Bracket
Check valve
2 Tools and jigs

1.
Tools
Hammer
AQ16002-002
Spanner
AQ16002-003
Socket
AQ16002-004
Ratchet handle
AQ16002-005
2.
Jigs
Install jig
AQ16002-006
Pulling jig
AQ16002-007
ASM-17-16-002
Issued 08-2008
Copyright
5005-7
[12]Preparation
2) Tools and Jigs
[13]General cautions
2) Do not attempt to finish the operation quickly; do not forcedly pry or hit the parts. Perform the operation carefully
and patiently in order to prevent parts deformation, oil leakage and lower efficiency.
[14]Disassembling procedure
1)
1) Clean grease cylinder with kerosene.
2) Remove bolts (6), washers (7) and then remove
the bracket (8).
3) Remove check valve (9) from grease cylinder (5).
AQ16002-008
2) Draw out piston rod (4) from grease cylinder (5).
AQ16002-009
ASM-17-16-002
Issued 08-2008
Copyright
5005-8
3) Remove dust seal (1) from grease cylinder (5) using
pulling jig.
AQ16002-010
4) Remove back-up ring (2) and O-ring (3) from grease

cylinder (5).
AQ16002-011
[2] Assembling instructions
1)
1) Install grease-applied O-ring (3) to grease cylinder
(5).
2) Install back-up ring (2).
NOTE: Do not reuse back-up ring (2) and O-ring (3).
AQ16002-011
ASM-17-16-002
Issued 08-2008
Copyright
5005-9
2)
1) Install dust seal (1) to grease cylinder (5) using a
jig and hammer.
2) Apply grease on lip section of dust seal.
NOTE: Do not reuse dust seal (1).
AQ16002-010
AQ16002-013
3)
1) Apply grease to the surface of piston rod (4).
2) Insert piston rod (4) into grease cylinder (5).
AQ16002-012
4)
1) Install check valve (9) to grease cylinder (5) by
applying specified tightening torque.
2) Install bracket (8), and then fasten it with bolts (6)
and washers (7).
AQ16002-008
ASM-17-16-002
Issued 08-2008
Copyright
5005-10
5 Assembly drawings
KAA1219Z-B01
1.
2.
3.
4.
5.
Dust seal (1)

Back-up ring T-P60 (1)
O-ring 1B-P60 (1)
Piston rod (1)
Grease cylinder (1)
ASM-17-16-002
6.
7.
8.
9.

Spring washer 8 (2)
Bracket (1)
Check valve (1)
Issued 08-2008
Copyright
5005-11
2 Take-up roller
1 Component diagram
1.
Take-up roller
2.
Bushing
3.
Floating seal
4.
O-ring
5.
Shaft
6.
Spring pin
7.
Hub (with plug)
8.
Plug
9.
Hub (without plug)
AQ13002-001
2 Tools and jigs

1.
Tools
Hammer
AQ13002-002
Hexagon bar wrench
AQ13002-003
ASM-17-13-002
Issued 08-2008
Copyright
5005-12
2.
Jigs
Install jig
AQ13002-004
Pulling jig
AQ13002-005
ASM-17-13-002
Issued 08-2008
Copyright
5005-13
3 Disassembling instructions
[1] Preparation
2) Tools and Jigs
Do not attempt to finish the operation quickly; do not forcedly pry or hit the parts.
2) Perform the operation carefully and patiently in order to prevent parts deformation, oil leakage and lower efficiency.
1)
1) Clean the take-up roller with kerosene.
2) Remove the plug (8) from the hub (7) to drain the
oil.
AQ13002-006
2)
1) Remove the spring pin (6) from the shaft (5) (or hub
(7). The removal is to be performed on one side only.
2) Remove the hub (7) from the shaft (5). The removal
is to be performed on one side only.
AQ13002-020
ASM-17-13-002
Issued 08-2008
Copyright
5005-14
3)
1) Take-up roller (1) is reversed.
2) Remove the O-ring (4) from the shaft (5).
3) Pull out the shaft (5) from the take-up roller (1).
AQ13002-008
4)
1) Remove the spring pin (6) from the shaft (5) (or
hub (9).
2) Remove the hub (9) from the shaft (5).
3) Remove the O-ring (4) from the shaft (5).
AQ13002-009
5) Remove the floating seals (3) from the hubs (7),(9).
AQ13002-010
6) Remove the floating seals (3) from the take-up roller

(1).
AQ13002-011
ASM-17-13-002
Issued 08-2008
Copyright
5005-15
7) Remove the bushings (2) from the take-up roller (1)
using pulling jigs, press and other instruments.
NOTE: Do not attempt to disassemble bushings (2) unless
they are unusable due to wear.
AQ13002-012
8) Cleaning parts
1) Place parts in the preparatory cleaning container containing cleaning oil.
2) Put the parts in the finish cleaning container containing cleaning oil and wash them by slowly moving them.
3) Wipe off remaining cleaning oil with clean cloth.
ASM-17-13-002
Issued 08-2008
Copyright
5005-16
4 Assembling instructions
Polish scratches, flashes or burrs using oil stones.
1) Install bushings (2) to the take-up roller (1) using a jig
and hammer.
NOTE: Pay full attention when inserting the bushings (2) by
hammering. Do not reuse bushings (2).
AQ30002-013
AQ30002-014
2) Install the floating seals (3) to take-up roller (1). apply

grease to the floating seals.
AQ13002-011
ASM-17-13-002
Issued 08-2008
Copyright
5005-17
AQ30002-015
3) Install the floating seals (3) to the hubs (7), (9).

AQ13002-010
AQ30002-016
4)
1) Install the greased O-ring (4) to the shaft (5). The
installation is to be performed on one side only.
2) Install the shaft (5) to the hub (9) and secure them
with a spring pin (6).
NOTE: Do not reuse spring pin (6) and O-ring (4).
AQ13002-022
ASM-17-13-002
Issued 08-2008
Copyright
5005-18
5)
1) Apply grease on the surface of the shaft.
2) Install the shaft (5) to the take-up roller (1).
3) Install the greased O-ring (4) to the shaft (5).
AQ13002-021
6) Install the hub (7) to the shaft (5) and secure them with
a spring pin (6).
NOTE: Do not reuse spring pin (6).
AQ13002-020

air. Compressed air pressure: 0.2 MPa
AQ13002-017
8) Fill oil through the plug.
AQ13002-018
ASM-17-13-002
Issued 08-2008
Copyright
5005-19
AQ13002-019
ASM-17-13-002
Issued 08-2008
Copyright
5005-20
5 Assembly drawings
-##<%
1.
2.
3.
4.
5.
Track-up roller (1)

Bushing (2)
Floating seal (2)
O-ring 1B P36 (2)
Roller shaft (1)
ASM-17-13-002
6.
7.
8.
9.
Spring pin (2)

Hub (with plug) (1)
Plug 1/8 (1)
Hub (without plug) (1)
Issued 08-2008
6001
Copyright
Section
6001
REMOVAL AND INSTALLATION OF THE
DRIVE MOTOR AND
FINAL DRIVE TRANSMISSION
CNH
Lep SM75SR6001-0EN

Printed in France
August 2008
Copyright
6001-2
TABLE OF CONTENTS
TRAVEL UNIT.......................................................................................................................................................... 3
Precautions when installing............................................................................................................................... 3
Removal ............................................................................................................................................................ 4
Installation ......................................................................................................................................................... 5
Lep SM75SR6001-0EN
Issued 08-2008
Copyright
6001-3
TRAVEL UNIT
8
7
6
AQ10002-012
1.
2.
3.
4.
Travel motor
Bolt
Loctite 262
Drive sprocket
5.
6.
7.
8.
Bolt
Drain port
Oil level check port
Oil fill port
1 Precautions when installing

[1] Be careful of direction when attaching sprockets to the machine.
The side having the C2 chamfer of the sprocket must face the traction motor.
[2] Coat the threads with loctite 262 or equivalence, and fasten them by tightening torque.
[3] When starting the machine after assembling, bleed the air from the upper drain port (6).
[4] Set the reduction gear as shown in the follewing fig when checking and filling the oil.
(The lowest point of oil level port (7) is the standard oil level.)
[5] When changing the reduction gear oil, remove drain plugs from the reduction gear side, and let the oil drain out.
Next, screw the plugs back in and fill the oil the normal oil level.
ASM-17-10-002
Issued 08-2008
Copyright
6001-4
2 Removal
[1] Remove track shoe. See Track shoe, removal.
[2] Lift one side of lower frame about 200 mm and hold it
there.
(Lift it high enough for the drive sprocket to be removed
from the track shoe).
[3] Place protection blocks under lower frame and secure
them.
[4] Stop engine and release pressure in the hydraulic circuits. (See the procedures for bleeding the hydraulic
pressure in Operators Manual).
[5] Remove motor cover.
AQ10002-013
[6] Remove drive sprocket mounting bolts (2).

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

[14]Remove travel unit using a steel bar.
AQ10002-016
ASM-17-10-002
Issued 08-2008
Copyright
6001-5
3 Installation
[1] Lift travel unit and align it so that it fits on the frame. (Be
careful of the fitting angles.).
[2] Apply Loctite No. 262 to threads of travel unit mounting
bolts (5) and finger tighten all mounting bolts.
Bolt tightening order:

Tighten the four numbered bolts evenly in the
sequence shown below and then fasten the remaining bolts.
[3] Tighten travel unit mounting bolts (5) to the specified

torque alternatively, up/down and left/right, so that the
tightening force acts on them equally. (Refer to Tightening torque in the Maintenance Instructions.)
[4] Lift drive sprocket and confirm that it is oriented correctly.
[5] Align drive sprocket to mounting flange on the travel unit
using a steel bar.
[6] Apply Loctite No. 262 to threads of drive sprocket
mounting bolts (2), and finger tighten all mounting bolts.
AQ10002-017
[7] Tighten drive sprocket mounting bolts (2) to the specified torque alternatively, up/down and left/right, so that the tightening force acts on them equally. (Refer to Tightening torque in the Maintenance Instructions.)
[8] Connect hoses to travel motor.
[9] Check reduction gear oil level. Fill if necessary.
[10]Bleed air from travel motor. (Fill motor with hydraulic oil)
[11]Remove protection blocks.
[12]Lower the lower frame on the track shoe.
[13]Install track shoe. See Track shoe, installation.
[14]Check to ensure that there is no oil leakage. If leakage is found, take appropriate measures.
[15]Install motor cover.
ASM-17-10-002
Issued 08-2008
Copyright
6001-6
NOTES
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
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....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
ASM-17-10-002
Issued 08-2008
6002
Copyright
Section
6002
DISASSEMBLY AND ASSEMBLY OF THE
DRIVE MOTOR AND
FINAL DRIVE TRANSMISSION
CNH
Lep SM75SR6002-0EN

Printed in France
August 2008
Copyright
6002-2
TABLE OF CONTENTS
TRAVEL UNIT.......................................................................................................................................................... 3
SERVICE OUTLINE.................................................................................................................................................. 3
Tools ................................................................................................................................................................. 3
Tightening torque table ..................................................................................................................................... 7
Weight table ...................................................................................................................................................... 7
DISASSEMBLY ....................................................................................................................................................... 8
Preparations. ..................................................................................................................................................... 8
General suggestion when working .................................................................................................................... 8
Disassembly procedure..................................................................................................................................... 9
SERVICE PREPARATION ....................................................................................................................................... 26
ASSEMBLY .......................................................................................................................................................... 28
PERFORMANCE CONFIRMATION TEST.................................................................................................................... 44
Required measuring devices........................................................................................................................... 44
Test procedure ................................................................................................................................................ 44
EXPLODED DIAGRAM OF REDUCTION GEAR ........................................................................................................... 45
EXPLODED DIAGRAM OF HYDRAULIC MOTOR......................................................................................................... 46
INTERNAL STRUCTURE DIAGRAM .......................................................................................................................... 47
TRAVEL UNIT PART TABLE ................................................................................................................................... 48
Lep SM75SR6002-0EN
Issued 08-2008
Copyright
6002-3
TRAVEL UNIT
1 Service outline
1 Tools
1) Standard tools
No
Name
Description and remarks
Qty
Hexagon wrench
3, 6, 10, 12 mm
One of each
Socket wrench (ratchet handle) (JIS B 4641)
Barrel type
Torque wrench (JIS B 4650)
Dial type, approx. 12 N

1
1
1
1
Torque wrench adapter
Nominal socket 13, 30

Nominal rod size 3, 6, 8
One of each
Hexagon socket
Opposite side
13, 17, 24, 36 mm
One of each
Extension bar (JIS B 4637)
150 mm
Hand hammer
Nominal 12 mm
Plastic hammer
About L = 300 mm
Flat-blade screwdriver (JIS B 4609)
50 mm
150 mm
1
1
10
Snap ring pliers
For shafts
For holes
1
1
11
Cutting pliers (JIS B 4623)
200 mm
12
Lifting tool (crane)
Lifting load 2940 N or more

Eyebolt (For PF3/8)
Wire with hook
1
2
1
13
Receptacles
Volume:
W450 x D300 x H120
14
Leather gloves
1 pair
2) Bolts
No
1
Name
Hexagon socket head bolt (JIS B 1176)
ASM-17-21-002
Description
Approx. M6 (P1.0) x 50
Approx. M16 (P2.0) x 40
Approx. M16 (P2.0) x 150
Qty
1
2
3
Issued 08-2008
Copyright
6002-4
3) Equipment and materials
Applicable parts
(Usage method or parts No.)
For disassembling and reassembling
works
Name
Qty
General work bench
For washing motor and parts
Washing tank
104, 149
Press machine
Press capacity: 1960 N or more
Heating tank
Heating capacity: over 100C

Volume: 500 x 500 x 500 mm
Compressed air supply
Pressure: 0.29 - 0.49 MPa
149
For drying washed parts
4) Manufacturing tools
Name: Travel motor workbenchp
Workbench for easily and safely disassembling and

assembling the travel motor.
AQ21002-001
Name: Fixture
For connecting spindle (2) and hub (1).
AQ21002-002
Name: Holder ( I )
For inserting spring (114), washer (110) and snap ring
(145) into cylinder block (104).
For removing spring (114) from cylinder block (104).
AQ21002-003
Name: Holder ( II )
For removing ball bearing (149) from or insertingit
onto shaft (102).
AQ21002-004
ASM-17-21-002
Issued 08-2008
Copyright
6002-5
Name: Holder ( III )
For press fitting oil seal (132) into the oil seal holethe
spindle (2).
AQ21002-005
Name: Press tool

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

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

For fitting ring nut (22) to spindle (2).
AQ21002-008
Name: Eyebolt
For lifting the GM motor, spindle (2) and hub (1).
A:
Hub, M14
Spindle, M16
GM motor, M16
AQ21002-009
Name: Slice
For removing timing plate (109) from rear flange
(301).
AQ21002-010
ASM-17-21-002
Issued 08-2008
Copyright
6002-6
Name: Aluminium rod
For removing the outer race of ball bearing (24).
AQ21002-011
Name: Cover removable jig

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

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

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

For installing floating seal (31) to spindle (2).
AQ21002-015
ASM-17-21-002
Issued 08-2008
Copyright
6002-7
Name: Thrust washer installation tool (carrier(3))
For installing three thrust washers 3 (12) to the carrier
(3) with hexagon head bolt.
AQ21002-016
Name: Thrust washer installation tool (spindle(2))

For installing four thrust washers 1 (10) to the spindle
(2) with hexagon head bolt.
AQ21002-017
2 Tightening torque table

Bolt/Nut used
Part No.
(structure
drawing)
Part name
Nominal
designation
Width across flats

(mm)
Qty
Tightening torque
(Nm)
33
Plug
PF3/8
58.8 9.81
39
Socket plug
PF3/8
58.8 9.81
40
Hexagon head bolt
M8 (P1.25)
13
33.3 4.9
47
Hexagon socket set screw
M6 (P1.0)
4.9 0.98
51
Hexagon socket set screw
M6 (P1.0)
4.9 0.98
221
Plug
PF1/4
29.4 4.9
224
Plug
M25 (P1.5)
30
196 44.7
226
Plug
M20 (P1.5)
78.5 9.81
243
Hexagon socket head cap

screw
M8 (P1.25)
29.4 4.9
3 Weight table
Applicable parts
(structure drawing)
Name
Weight (kg)
Travel motor assembly
Approx. 53
Hub
Approx. 15
Spindle
Approx. 15
Rear flange assembly
Approx. 6.2
201
ASM-17-21-002
Issued 08-2008
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2 Disassembly
1 Preparations.
1) Perform the following preparations before disassembling.
1) Workbench preparations
Provide a travel motor workbench.
Provide a sturdy workbench with which the internal parts of the travel motor can be disassembled or assembled, is wide enough to place parts so they do not move or fall off the bench while working.
Spread a rubber or vinyl sheet on the workbench.
2) Preparation of tools and materials.
Provide the tools and materials listed in 1.Tools.
2 General suggestion when working
WARNING: Internal parts are coated with hydraulic fluid and gear oil during disassembly and are slippery. If a
part slips out of your hand and falls, it could result in bodily injury or could damage the part. Be very careful when
handling.
WARNING: Combustibles such as white kerosene are used for washing parts. These combustibles are easily
ignited, and could result in fire or injury. Be careful when handling.
[1] Before disassembling, perform inspections and clearly determine the nature of any abnormalities which might be
occurring, and work according to the disassembly procedure.
[2] Each part is manufactured to extreme precision. Handle with care and be sure not to hit the parts together or drop
them.
[3] When working, do not attempt to forcefully beat or wrench tightly fitting parts.
Doing so could produce burrs or damage the parts so they cant be mounted or may reduce their performance.
You should exercise patience when working.
[4] If you leave parts disassembled or partially disassembled, rust could develop on the parts due to moisture or dirt.
If you have to interrupt work before completion, be careful to take measures to protect against rust or dust.
[5] Place a counter mark on mating faces of parts when disassembling.
[6] Arrange removed parts neatly when disassembling so as not to damage or lose the parts while working.
[7] As a rule, once any type of seal is disassembled it should be replaced with a new one even if it shows no signs of
damage. You should have a new ready when disassembling.
[8] The photographs and drawings contained in the manual are of representative models.
Disassembly procedure is however not affected even if the product you are using differs in part.
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3 Disassembly procedure
[1] Washing the GM motor
1) Fasten the eyebolts to spindle (2).
NOTE: Fasten the two eyebolts in the screw holes for
mounting the spindle so they are positioned symmetrically.
AQ21002-018
2) Hook the wire in the eyebolts, hoist the GM motor

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

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

two hexagon socket head cap screws are positioned symmetrically.
WARNING: Tighten the hexagon socket head cap

screws securely. Failure to do so could result in injury
cased by the GM motor falling when it is inverted.
AQ21002-021
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[3] Lubricating oil extraction
NOTE: If disassembling the rear flange only, proceed to the
item [8] Rear flange removal of page 12.
1) Invert the GM motor. (Turn up the side of reduction gear)
2) Loosen and remove plug (33) and socket plug
(39).
NOTE: When extracting the lubricating oil, place a container
under the workbench.
AQ21002-022
3) Invert slowly the GM motor and extract the lubricating oil. (Turn up the side of motor)
4) Remove O-ring (37) from plug (33) and socket
plug (39).
NOTE: Do not reuse O-rings (37) which have been removed.
AQ21002-023
[4] Cover removal

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

could cause the piston (112) to pop out.
To ensure your safety hold a protective cover over
the piston (112).
1) Remove piston (112) from spindle (2) by injecting
compressed air into the access hole in the spindle
(2).
2) Remove O-ring (135), (139) from piston (112).
NOTE: Do not reuse O-ring (135), (139) which have been

removed.
AQ21002-054
3) Remove spool (363) and spring (366) from rear

flange (301).
AQ21002-055
[14] Disassembly of the Hydraulic motor

NOTE: Place an oil receptacle just below the motor to catch
the oil.
1) Turn the GM motor 90 degrees.
2) Drain the hydraulic oil from the motor.
3) Take out mating plate (116) (3 pcs) and friction
plate (115) (2 pcs).
AQ21002-056
4) Hold the cylinder block (104) by hand, turn alternately 2 - 3 times, and cut off shoe (106) adhered
on the swash plate (103).
NOTE: If remove the cylinder block (104) as-is, shoe (106)
remains adhered on swash plate (103), and the parts (piston,
shoe and etc.) mounted on the cylinder block will come off the
cylinder block and fall into the spindle (2).
AQ21002-057
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5) Draw out cylinder block (104) from shaft (102).
6) Remove the piston ASSY ( piston (105), shoe
(106) ) and retainer plate (107) ) from cylinder
block (104).
NOTE: When removing the piston ASSY, grip retainer plate
(107) with both hands and remove together with the retainer
plate.
The piston ASSY is a minimum unit.
If replacement is necessary, replace the piston ASSY as one
unit.
AQ21002-058
7) Remove piston ASSY (9 pcs) ( piston (105), shoe

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

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

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

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

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

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

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

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

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

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

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

1) Remove floating seal (31) from hub (1).
NOTE: Do not reuse floating seal (31) which has been
removed.
AQ21002-075
2) Tapping the end face of ball bearing (24) with aluminum rod (pin punch) and hammer, remove the
ball bearing from hub (1).
NOTE: When the fit section of the outer race of ball bearing
(24) comes out of hub (1), the ball bearing (24) drop from the
hub (1).
Therefore place a receptacle under the workbench and
spread a rubber mat on the receptacle so as not to damage
the parts.
3) Turn over the travel motor.
4) Tapping the end face of outer race of ball bearing
(24) with aluminum rod (pin punch) and hammer,
remove the ball bearing from hub (1).
AQ21002-076
NOTE: Remove ball bearing (24) little by little, tapping evenly

the end face of outer race of the ball bearing at 3 or 4 points
so that the ball bearing is not suck.
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[21] Removal of the spindle fittings
1) Remove floating seal (31) from spindle (2).
AQ21002-077
2) Remove oil seal (132) from spindle (2).

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

Take notice of a possibility of due to combustibility.
To prevent the built-in parts from being marred by dirt
during washing, immerse the parts in kerosene long
enough for any dirt or oil to become loose and
surface before washing them,
3) Full a primary washing vessel with kerosene. Put
the built-in parts in it and wash them.
AQ21002-080
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[23] Finish washing
1) Rinse the washed parts in the rinsing sink filled
with clean kerosene by gently shaking each parts
in the kerosene.
2) Using clean, list-free cloth, wipe each rinsed part
to remove dripping kerosene.
NOTE: Dry the inside of hub (1) and spindle (2) by spraying
with compressed air until they are dray and clean.
Let other parts dry naturally until they are dry and clean.
After drying, coat every part with oil.
AQ21002-081
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3 Service preparation
Follow these standards when disassembling and inspecting the GM motor. Handle the various parts carefully.
Be especially careful not to damage the moving and sliding parts.
1) Seals
Once disassembled, all seals (O-rings, oil seals, floating seals) should be replaced with new ones even if no damage is observed.
2) Service standards for parts subject to wear
1) Replace all parts which show striking damage.
2) Replace if various parts have the following problems (phenomenon).
No
Part name
Phenomenon
Standard
Service limit
(1)
Hub
Serious damage in appearance.

Occur pitting phenomenon on tooth flank of ring gear.
Abnormal wear such as scuffing.
(2)
Spindle
Serious damage in appearance.

(3)
Carrier assembly
(4)
(6)
(5)
(7)
Sun gear 1
Sun gear 2
Planetary gear 1
Planetary gear 2
Pitting on tooth surface.

Flaking phenomenon on rolling surface of bearing.
(9)
(11)
(12)
Thrust washer 1
Thrust collar 4
Thrust washer 3
Sliding surface is tarnished.
(24)
Ball bearing
Has indentation.
Exhibits flaking phenomenon.
Worn unequally.
(27)
(28)
Needle roller bearing
Pitting phenomenon on roller.

Cage end face has abnormally worn.
(29)
(30)
Inner ring
Exhibit flaking phenomenon on rolling face of bearing.
(301)
Rear flange
Flaw on sliding part with spool (323).
(102)
Shaft
Working face with oil seal (132) is worn.

Spline is worn.
(103)
Swash plate
Has burning phenomenon.
(104)
Cylinder block
Spline section is worn.

Inner surface of bore is worn too much.
Flaw and wear on sliding surface with timing plate
(109).
(105)
(106)
Piston assembly
Piston
Shoe
Clearance is found in the axial direction between

piston (105) and shoe (106).
Shoe is abnormally worn and nequally worn.
Clearance
0.05 mm
Clearance
0.15 mm
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No
Part name
Phenomenon
Standard
Service limit
(107)
Retainer plate
Sliding part with shoe (106) is worn unequally.

Flaw and unequal wear on sliding surface with
thrust ball (108).
(108)
Thrust ball
Ball surface sliding part with retainer plate (107) is

worn unequally.
(109)
Timing plate
Sliding surface has burning phenomenon and unequal wear.
(115)
(116)
Friction plate
Mating plate
Both end faces are unequally worn.

Torque is not specified torque.
Has burning phenomenon.
Braking
torque
120 Nm
or more
Braking
torque
120 Nm
or more
(105)
Piston
Flaw on circumference
(149)
(150)
Deep groove ball

bearing
Has indentation.
Exhibits flaking phenomenon.
Worn unequally.
(161)
(162)
Dual speed piston kit

Piston
Shoe
Circumference is abnormally worn.

Shoe is abnormally worn and unequally worn.
(323)
(363)
Spool
Circumference worn unequally.

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

ofthe O-ring of floating seal (31), and fit the floating seal in the floating seal groove of hub (1).
NOTE: When applying grease to the O-ring of the floating
seal, remove the O-ring from the floating seal and apply lightly
grease to the entire surface of it .
NOTE: To mount floating seal, place the floating seal installation tool ( II ) (D), floating seal and floating seal installation tool
( III ) (E) in that order, and press in until floating seal installation tool ( II )) reaches floating seal installation tool ( III ).
Remove the installation tools, and make certain that the end
face of the hub and the face of the floating seal are parallel
with each other within a tolerance of 1 mm.
AQ21002-083
6) Fasten two eyebolts in the screw holes of hub (1)

so they are symmetrically positioned.
7) Hook the hook and wire in the eyebolts, hoist the
hub (1) with a crane, and set the hub (1) on the
workbench.
NOTE: While matching the screw holes of hub (1) and mounting holes of the workbench, place the hub gently in the mounting holes of the workbench.
AQ21002-084
8) Fasten hub (1) to the workbench so that the hexagon socket bolts are symmetrically positioned.
WARNING: Tighten the hexagon socket bolts

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

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

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

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

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

of the spindle (2).
3) Apply lithium grease to the hemispherical surface
of pivot (167) (2 pcs), and fit it into parallel pin
(177) of spindle (2).
4) Apply lithium grease to spring (190), and install
the spring into the piston kit (piston (161), shoe
(162)).
5) Apply hydraulic fluid to the sliding surface of the
piston ASSY, install it into the piston hole of spindle (2).
AQ21002-093
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Issued 08-2008
Copyright
6002-32
[4] Installing shaft
WARNING: Wear thick leather grooves in handling

the heated deep groove ball bearing.
1) Put deep groove ball bearing (149) in a heating
tank to heat it at 100 10C for ten minutes, it
puts on the holder ( II ) (D), it does shaft (102) at
the press fitting by the press.
AQ21002-094
2) Fit motor shaft (102) slowly into the spindle (2).

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

NOTE: Apply lithium grease to the swash plate (103) where mating surface of the spindle (2).
Make sure that the locating the pivot (167) of the spindle (2)
enters the pivots hole of the swash plate (103).
AQ21002-096
ASM-17-21-002
Issued 08-2008
Copyright
6002-33
[5] Assembly of cylinder block interior
NOTE: Introduce the sharp side of the angled section of the THS
snap ring (145) and washer (110) as shown in the figure on the
left.
1) Insert washer (110), spring (114), washer (110)
and snap ring (145) in that order into cylinder
block (104).
2) Place cylinder block (104) on the press bench.
AQ21002-097
WARNING: Press force of spring (114) is 1180 N or

more.
Protect by covering cylinder block (104) with a vinyl
sheet so the contact surface with timing plate (109) of
cylinder block (104) does not become damaged.
3) Place holder ( I ) on washer (110), and while
clamping with press, fit snap ring (145) in the snap
ring groove of cylinder block (104) with a snap ring
pliers.
AQ21002-098
[6] Assembly of the hydraulic motor parts

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

plate (107).
NOTE: After assembling, dip the whole thing in hydraulic fluid.
3) Fit retainer plate (107) and the piston assembly (9
pcs) into cylinder block (104).
NOTE: Match the round surface sections of retainer plate
(107) and thrust ball (108).
AQ21002-100
ASM-17-21-002
Issued 08-2008
Copyright
6002-34
4) Install cylinder block (104) to shaft (102).
NOTE: Install cylinder block (104) into the spline of shaft (102)
by aligning the spline hole with the spline of the shaft.
AQ21002-101
5) After installing the cylinder block (102), turn it by

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

NOTE: Install the friction plate to the cylinder block after
immerse the friction plate (115) in hydraulic fluid.
1) Turn the workbench 90 degrees.
2) Install mating plate (116).
AQ21002-103
3) Friction plate (115) into the groove outside of cylinder block (104) alternately.
Then install mating plate (116), friction plate (115)
and mating plate (116).
4) Fit O-ring (135), (139) to the O-ring groove of piston (112).
At this time, apply a thin coat of grease to the Orings.
5) Install piston (112) into spindle (2).
NOTE: If the piston (112) doesnt fit into the spindle (2)
because of the resistance of the O-rings, tap the edge of the
piston (112) lightly and equally with a plastic hammer.
Be careful not to damage the O-rings at this time
ASM-17-21-002
AQ21002-104
Issued 08-2008
Copyright
6002-35
[8] Assembly of the brake valve parts in the rear flange
1) Fit O-ring (338) (2 pcs) to the plug (382) (2 pcs).
NOTE: Apply grease to O-ring (338) (2 pcs).
2) Install valve (327) (2 pcs), and spring (330) (2 pcs)
on rear flange (301).
At this time, apply grease and on it to connect the
valve (327), spring (330) and plug (382) by cohesion of the grease.
AQ21002-106
3) Insert the plug (382) (2 pcs) assembled in one

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

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

NOTE: Apply hydraulic fluid to the spool and insert the spool
into the rear flange.
To install the spool, align the hole of the rear flange with the
spool shaft center so as to prevent the inner surface of the
rear flange and the outer surface of the spool from being damaged due to interference.
Otherwise internal leaks will occur after reassembly, resulting
in performance deterioration of the travel motor.
AQ21002-109
ASM-17-21-002
Issued 08-2008
Copyright
6002-36
6) Insert O-ring (336) into plug (324).
NOTE: Apply grease to O-ring (336).
AQ21002-110
7) Install stopper (325) and spring (328) to the plug

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

1) Attaches O-ring (207) and backup ring (208) onto
valve sheet (201).
2) Attaches O-ring (212) onto sleeve (203).
NOTE: Apply grease to O-ring (207), (212).
AQ21002-112
AQ21002-113
ASM-17-21-002
Issued 08-2008
Copyright
6002-37
3) Insert sleeve (203) onto rear flange (301).
AQ21002-114
4) Temporarily tighten sleeve (203) (2 pcs) by spanner.

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

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

4) Tighten plug (382) into rear flange (301).
5) Temporarily tighten plug (382) into the rear flange
(301).
2) Apply hydraulic fluid to deep groove ball bearing (150),
and fit the deep groove ball bearing into rear flange
(301).
3) Insert parallel pin (342) (2 pcs) in the pin holes of rear
flange (301).
4) Apply grease to the mating face of timing plate (109) in
contact with rear flange (301) of timing plate (109).
ASM-17-21-002
AQ21002-117
Issued 08-2008
Copyright
6002-38
5) Fit timing plate (109) on rear flange (301) using parallel
pin (342) and deep groove ball bearing (150) as a
guide.
NOTE: Fitting of timing plate (109) is carried out until the timing plate adheres to the rear flange (301).
Adhesion prevents the timing plate (109) from falling from the
rear flange (301) when mounting the rear flange (301) on
spindle (2).
6) Install spring (113) (10 pcs) into rear flange (301).
NOTE: Apply grease to the spring enough prevents the spring
(113) (10 pcs) falling from the rear flange (301).
AQ21002-118
[11] Connection of the rear flange with the spindle

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

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

two parallel pins (42) on the spindle enter the pinholes in the rear flange.
AQ21002-121
ASM-17-21-002
Issued 08-2008
Copyright
6002-39
5) Tighten hexagon socket head cap screw (345) (8
pcs) equally and evenly with the specified torque.
NOTE: When it installs rear flange (301) onto spindle, mount
spring (113) (10 pcs) to rear flange side.
Apply grease to the spring enough prevents the springs falling
from the rear flange (301).
AQ21002-122
6) Tighten plug (382) with the specified torque.

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

AQ21002-124

AQ21002-125
ASM-17-21-002
Issued 08-2008
Copyright
6002-40
AQ21002-126
[12] Carrier assembly

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

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

carrier (3) with installation tool (carrier (3)).
4) Install thrust washer 3 (12) (3 pcs) to the carrier
(3) with hexagon head bolt (40) (3 pcs).
Tightening Torque: 33.3 4.9 Nm
NOTE: When it do not use jig, be careful circumference of a
companion of tighten thrust washer 3 (12). After tightening,
check to rotate planetary gear smooth.
AQ21002-129
ASM-17-21-002
Issued 08-2008
Copyright
6002-41
[13] Planetary gear 2 assembly
1) Turn the workbench upside down. (Turn up the
side of reduction gear).
2) Install thrust collar 1 (9) to spindle (2).
AQ21002-130
3) Install thrust washer 2 (11) (4 pcs), finner ring (30)

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

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

carrier (3) with installation tool (carrier (3)).
8) Install thrust washer 3 (12) (3 pcs) to the carrier
(3) with hexagon head bolt (40) (3 pcs).
Tightening Torque: 57.9 9.81 Nm
NOTE: When it do not use jig, be careful circumference of a
companion of tighten thrust washer 3 (12). After tightening,
check to rotate planetary gear smooth.
AQ21002-133
ASM-17-21-002
Issued 08-2008
Copyright
6002-42
[14] Carrier assembly
1) Install the carrier ASSY, meshing with internal
teeth of hub (1) and planetary gear 2 (7).
AQ21002-134
[15] Sun gear 1 assembly

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

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

NOTE: The free gap of ring (45) does not install onto the
notch of hub (1).
AQ21002-137
ASM-17-21-002
Issued 08-2008
Copyright
6002-43
4) Introduce 1.1 liters of lubricating oil into hub (1).
AQ21002-138
5) Fit O-ring (37) to plug (33) and socket plug (39).

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

1) Turn the workbench upside down.
2) Remove the bolts securing the GM motor to the
workbench.
3) Fasten two eyebolts to spindle (2).
NOTE: Be sure that the two eyebolts are opposite to each
other.
4) Hook the hook and wire on the eyebolts and
remove the GM motor from the workbench with a
crane.
ASM-17-21-002
AQ21002-140
Issued 08-2008
Copyright
6002-44
5 Performance confirmation test

After servicing the GM motor, perform the following tests by the following procedure.
1 Required measuring devices
Pressure gauge for 3.43 MPa
2 pieces
Measuring cylinder (for 5 liters)
1 piece
Stop watch
1 piece
2 Test procedure
Installation and
connection of
travel motor
Install and connect the travel motor to the machine body (frame section).
However, do not attach the track shoe.
This is to perform the travel motor performance test (no-load operation)
Note :
Travel motor
breaking-in
operation
When connecting, connect the travel motor so that the pressure gauge
(main circuit) can be installed and the drain amount of the hydraulic motor
can be measured.
Whem installing GM motors, do not strike them with a hammer or other
instrument. Use the bolt holes to gently install the motor.
Switching
Travel motor
speed
Low speed rotation
10 min-1
High speed rotation
Pressure
Rotation
direction
Operation
time
No load
Left or right
Each 1 min.
or longer
20 min-1
Travel motor performance confirmation test
Pre-test preparation operation

Perform preparation operation until the temperatures indicated below are reached.
Hydraulic oil temperature: 45~55C
Reduction gear hub external temperature: 40~80C
Confirmation test
Measure the items below at low speed to determine whether travel motor is acceptable.
Criteria for acceptability
Travel motor drive pressure difference: 1.57 MPa or less at 10 min-1
Hydraulic motor drain amount: 0.6 L/min at 10 min-1
Acceptable
Attach the track shoe
ASM-17-21-002
Not acceptable
Disassemble and adjust again
Issued 08-2008
Copyright
6002-45
6 Exploded diagram of reduction gear
AQ21002-0142
ASM-17-21-002
Issued 08-2008
Copyright
6002-46
7 Exploded diagram of hydraulic motor
AQ21002-0143
ASM-17-21-002
Issued 08-2008
Copyright
6002-47
8 Internal structure diagram
KAA10310-A01
ASM-17-21-002
Issued 08-2008
Copyright
6002-48
9 Travel unit part table

Sym
Part name
Qty
Sym
Part name
Qty
Sym
Part name
Qty
Hub
103
Swash plate
208
Backup ring
Spindle
104
Cylinder block
211
O-ring
Carrier
105
Piston
212
O-ring
Sun gear 1
106
Shoe
213
Shim
Planetary gear 1
107
Retainning plate
214
Piston
Sun gear 2
108
Thrust ball
215
O-ring
Planetary gear 2
109
Timing plate
216
Backup ring
Thrust coller 1
110
Washer
301
Rear flange
10
Thrust washer 1
111
Washer
321
Plug
11
Thrust washer 2
112
Piston
323
Spool
12
Thrust washer 3
113
Spring
10
324
Plug
13
Cover
114
Spring
325
Spring retainer
22
Ring nut
115
Spring
327
Valve
24
Ball bearing
116
Mating plate
328
Spring
27
132
Oil seal
330
Spring
28
135
O-ring
336
O-ring
29
Inner ring
139
O-ring
338
O-ring
30
Inner ring
145
Snap ring
342
Parallel pin
31
Floating seal
149
Ball bearing
345
Hex. socket bolt
33
Plug
150
Ball bearing
352
Hex. socket plug
35
O-ring
151
Roller
363
Spool
37
O-ring
161
Piston
366
Spring
39
Socket plug
162
Shoe
368
Steel ball
40
Hex. head bolt
167
Pivot
375
Hex. socket plug
41
Steel ball
171
Parallel pin
377
Orifice
42
Parallel pin
190
Spring
379
Filter
43
O-ring
201
Valve seat
380
Orifice
44
O-ring
202
Valve
382
Plug
45
Ring
203
Sleeve
383
Plug
47
Hex. socket set screw
204
Coller
392
O-ring
50
Retainning ring
205
Plug
399
Name plate
51
Hex. head bolt
206
Spring
102
Shaft
207
O-ring
ASM-17-21-002
Issued 08-2008
Copyright
6003
Section
6003
SWING MOTOR AND SWING REDUCTION GEAR
CNH
Lep SM75SR6003-0EN

Printed in France
August 2008
Copyright
6003-2
SWING UNIT
Air bleeder
10
X7
8 11
272.6 to 317.7 Nm
X22
1.
2.
3.
4.
5.
6.
Turn table bearing assembly (1)

High strength bolt M16x80 (22)
Cover plate (1)
Cork packing (1)
Bolt M10x20 (2)
ASM-17-11-002
7.
8.
9.
10.
11.
12.
252.0 to 283.4 Nm
KAC0178Z-C05
Liquid packing
Loctite
Swing motor (1)
Knock pin (1)
Spl bolt M16x80 (2)
Issued 08-2008
Copyright
6003-3
Notes
Coat the thread with loctite 262 after removing any oil
film.
(S mark position)
Liquid gasket should be applied between the turn table

bearing and the revolving frame, lower frame.
The air in the swing motor should be bled off, in starting
engine after assembly or after long term storage of this
machine. And the air in the swing motor should be bled
off in accordance with the following procedure.
1) Set the engine rev. at low idle speed. loosen the
air bleeding plug of swing motor. then select lever
of swing gentlY. And should be confirm hyd. oil
coming out from air bleeding port.
2) Completely tighten the air bleeding plug.
Tightening torque : 44.1 ~ 53.9 Nm
X24
Inner race soft zone
12
252.0 to 283.4 Nm
252.0 to 283.4 Nm
Outer race soft zone

(Slot position)
grease nipple
12
252.0 to 283.4 Nm
X2
5
KACO178Z-C05
ASM-17-11-002
Issued 08-2008
Copyright
6003-4
Notes
Use hydraulic of motor drain for lubrication of the gear
box. Feelthe hydrauric motor case with working fluid
before strating. (The hydraulic motor and the reduction
gear are not filled with the hydraulic oil. when it is delivered.) Suitable piping is recommended, such as the
motor and reduction gear are filled with the hydraulic oil
always.
Air bleeder
Install a filter in drain line:

Recommended filtration rate:
0.074 mm (200 mesh).
1.
Swing motor
2.
Reduction gear assembly
-#%:#
ASM-17-11-002
Issued 08-2008
8001
Copyright
Section
8001
SPECIFICATIONS, TROUBLESHOOTING,
INSPECTIONS AND HYDRAULIC PRESSURE SETTING
CNH

Printed in France
March 2008
Copyright
8001-2
TABLE OF CONTENTS
WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see
this symbol, carefully read the message which follows. Your safety depends on it.
SPECIFICATIONS .................................................................................................................................................... 3
SPECIAL TOOLS ...................................................................................................................................................... 3
Tester .................................................................................................................................................................... 3
IDENTIFICATION OF HYDRAULIC COMPONENTS ............................................................................................... 5
Pump..................................................................................................................................................................... 5
Control valve (CX75SR MONO BOOM)................................................................................................................ 6
Control valve (CX80)............................................................................................................................................. 8
Control valve (CX75SR OFFSET BOOM)........................................................................................................... 10
MEASURING PRESSURE...................................................................................................................................... 12
PRESSURE ADJUSTMENT ................................................................................................................................... 18
BLEEDING AIR ....................................................................................................................................................... 21
FLOW CURVE ........................................................................................................................................................ 22
Issued 03-08
Copyright
8001-3
SPECIFICATIONS
See section 1002.
SPECIAL TOOLS
Tester
1
CD01B005
CP96E001
1. TEST KIT E5444449 FOR MULTI-HANDY 2051
2. FEMALE COUPLING JOINT E47894 (1)

PRESSURE TEST POINT 14X1.5 A3237549 (2)
MALE COUPLING JOINT WITH UNION (3) AND
PLUGS (4) CONTAINED IN THE SUITCASE CAS
30038
The Multi-Handy tester can be used every day in the

workshop for normal operations.
The Multi-Handy can be used for:
Checking pressure (two pressure scales), maximum
pressure, differential pressure (P delta), temperature,
engine rpm and flow.
1 Multi-Handy 2051 tester .......................... D5444448
2 pressure detectors (0-600 bar)................ V5344460
2 straight unions for detector..................... W5344461
1 elbow union for detector .......................... X5344462
1 engine rpm detector ................................ Z5344463
3 cables (5 m long)..................................... E3144472
1 electrical outlet 220V 50Hz ..................... D5344467
1 cigarette lighter cable .............................. E5344468
1 instruction manual .................................... ------------1 carrying case........................................... N5344476
CD98M009
3. 600 LITRE FLOWMETER, ORDER THE

FOLLOWING:
ONE FLOWMETER RE3 Z5344486
TWO PLATES (M45X2) D4323359
TWO FLANGES ( 24) B8230183
FOUR HALF FLANGES D4024267
EIGHT SCREWS (12 X 75) Z1232983
Issued 03-08
Copyright
8001-4
CS99B532
4. SET OF UNIONS FOR PRESSURE TEST AND

HYDRAULIC FLOW CAS 30038.
CD99C002
5. SET OF HIGH PRESSURE HYDRAULIC HOSES

CAS XXXXX (INCLUDING TWO HIGH
PRESSURE HOSES).
Issued 03-08
Copyright
8001-5
IDENTIFICATION OF HYDRAULIC COMPONENTS

Pump
MUFFLER BRACKET
R2
R1
A2
G2
A1
G1
PPG
A3
P3G
PP
AO14001-001
Port
Description
Location
Inlet port
SAE 2
A1, A2
Delivery port
G3/4
A3
Delivery port
G1/2
PP
Pilot port
G3/8
PPG
Gauge port (pilot)
G1/4 (plug)
P3G
Gauge port (3rd pump)
G1/4 (plug)
R1
Drain port
G1/2 (plug)
R2
Air bleeding port
M10 x 1.0 (plug)
G1, G2
Gauge port
G1/4 (plug)
Issued 03-08
Copyright
8001-6
Control valve (CX75SR MONO BOOM)

PR5
B8
T2
B6
B7
P3
P2
BR2
A6
AR2
A7
pcc
T4
pa7
dr2
TRAVEL
STRAIGHT
TRAVEL
BUCKET
BOOM 1
pc2
ARM 2
BLADE
A8
DR1
pa6
T3
pa8
pa2
pa9
pa1
T1
PP
TRAVEL
BACKUP
SWING
A5
BOOM 2
pa4 pa3
ARM 1
pa5
A1
PT
A2
A3
P1
B1
T5
B2
B5
pb5
B3
pb9
pb4 pb3
pb8 pb7
pb2
pb1
pb6
Issued 03-08
Copyright
8001-7
Port
Description
Port
Description
A1
Travel line (backward left)
pb1
Travel (forward left) Pilot Line
A2
Backup Line
pb2
Backup Pilot Line
A3
Swing-right Line
pb3
Swing-left Pilot Line
A5
Arm-out Line
pb4
Boom-down 2-speed Pilot Line
A6
Travel Line (backward right)
pb5
Arm-in Pilot Line
A7
Bucket-close Line
pb6
Travel (forward right) Pilot Line
A8
Boom-up Line
pb7
Bucket-open Pilot Line
B1
Travel-line (forward left)
pb8
Boom-down Pilot Line
B2
Backup Line
pb9
Arm-in 2-speed Pilot Line
B3
Swing-left Line
pc2
Load Holding at Boom
B5
Arm-in Line
T1, T2, T3, T4 Return Line
B6
Travel Line (forward right)
T5
Bypass Filter
B7
Bucket-open Line
dr2
Pilot drain
B8
Boom-down Line
pcc
Backup Confluence Pilot Line
DR1
Drain
AR2
Blade-up line
P1, P2, PR5, PP
Pressure Line
BR2
Blade-down line
P3, P4
Backup Confluence Line
pra2
Blade-up pilot line
PA
Attachment Signal Pressure

Measurement
prb2
Blade-down pilot line
PT
Travel Signal Pressure

Measurement
pa1
Travel (backward left) Pilot Line
pa2
Backup Pilot Line
pa3
Swing-right Pilot Line
pa4
Boom-up 2-speed Pilot Line
pa5
Arm-out Pilot Line
pa6
Travel (backward right) Pilot Line
pa7
Bucket-close Pilot Line
pa8
Boom-up Pilot Line
pa9
Arm-out 2-speed Pilot Line
Issued 03-08
Copyright
8001-8
Control valve (CX80)

B8
T2
BR1
BR2 PR5
B6
B7
P3
P2
BR3
A6
AR3
A7
pcc
T6
AR2
TRAVEL
TRAVEL
dr2
pa8
STRAIGHT
pa7
BUCKET
BOOM 1
pc2
ARM 2
A8
pra1
AR1
BOOM SWING
pra2
BLADE
pra3
BACKUP 2
T4
DR1
T3
pa9
pa6
pa5
pa1
A5
TRAVEL
BACKUP 1
SWING
ARM 1
pa3
BOOM 2
UP
pa4
MOUNTING DIRECTION
pa2
PP
A3
PT
PA
A1
T1
A2
P1
B5
P4
T5
B4
B3
B2
B1
pb5 pb4 pb3 pb2 pb1

prb3
prb2 prb1
pb9 pb8 pb7 pb6
Issued 03-08
Copyright
8001-9
Port
Description
Port
Description
A1
pb1
A2
Backup Line
pb2
Backup Pilot Line
A3
Swing-right Line
pb3
A5
Arm-out Line
pb4
A6
pb5
Arm-in Pilot Line
A7
Bucket-close Line
pb6
Travel (forward right) Pilot Line
A8
Boom-up Line
pb7
B1
Travel-line (forward left)
pb8
B2
Backup (1) Line
pb9
B3
Swing-left Line
pc2
B5
Arm-in Line
B6
T5
Bypass Filter
B7
Bucket-open Line
dr2
Pilot drain
B8
Boom-down Line
pcc
DR1
Drain
AR2
Blade-up line
P1, P2, PP
Pressure Line
BR2
Blade-down line
P3, P4
pra2
Blade-up pilot line
PA

Measurement
prb2
PT

Measurement
pra1
Swing-right pilot line
pa1
prb1
Swing-left pilot line
pa2
Backup Pilot Line
AR1
Swing-right line
pa3
BR1
Swing-left line
pa4
pra3, prb3
Buckup (2) pilot line
pa5
Arm-out Pilot Line
AR3, BR3
Buckup (2) line
pa6
PR5
Blade pressure line
pa7
B4
Plug
pa8
Boom-up Pilot Line
pa9
Issued 03-08
Copyright
8001-10
Control valve (CX75SR OFFSET BOOM)

PR5
B8
T2
P3
B6
B7
P2
BR2
A6
AR2
A7
pcc
T4
pa7
STRAIGHT
TRAVEL
TRAVEL
BUCKET
BOOM 1
BLADE
pc2
ARM 2
A8
dr2
DR1
pa6
T3
pa8
pa2
pa9
pa1
T1
PP
TRAVEL
BACKUP
SWING
A5
ARM 1
pa4 pa3
BOOM 2
pa5
A1
PT
A2
A3
P1
B1
T5
B2
B5
pb5
B3
pb4
pb3
pb2
pb1
pb9
pb8 pb7
pb6
Issued 03-08
Copyright
8001-11
Port
Description
Port
Description
A1
pb1
A2
Backup left Line
pb2
Offset right Pilot Line
A3
Swing-right Line
pb3
A5
Arm-out Line
pb4
A6
pb5
Arm-in Pilot Line
A7
Bucket-close Line
pb6
Travel (forward line) Pilot Line
A8
Boom-up Line
pb7
B1
Travel line (forward left)
pb8
B2
Offset right Line
pb9
B3
Swing-left Line
pc2
B5
Arm-in Line
B6
T5
Bypass Filter
B7
Bucket-open Line
dr2
Pilot drain
B8
Boom-down Line
pcc
DR1
Drain
AR2
Blade-up line
P1, P2, PR5, PP
Pressure Line
BR2
Blade-down line
P3
pra2
Blade-up pilot line
PA

Measurement
prb2
PT

Measurement
pa1
pa2
Offset left Pilot Line
pa3
pa4
pa5
Arm-out Pilot Line
pa6
pa7
pa8
Boom-up Pilot Line
pa9
Issued 03-08
Copyright
8001-12
MEASURING PRESSURE
1) Basic Conditions
Oil temperature
45 - 55 C {113 - 131F}
Engine revolutions at no load
2200 rpm {2200 min-1}
2) Pressure Settings
Relief valve
Individual pressure
settings
Actual readings
measured on machines
(reference)
Method of
measurement
29.4 MPa at 44 L/min

{4264 psi at 11.6 gpm}
29.7 MPa
{4307 psi}
Arm relief
Up

{4626 psi at 5.3 gpm}
33.5 MPa
{4858 psi}
Fasten main relief 180

+
Boom-up relief
Down

{4626 psi at 5.3 gpm}
33.2 MPa
{4815 psi}

+
Boom-down relief
Out

{4626 psi at 5.3 gpm}
32.7 MPa
{4742 psi}

+
Arm-out relief
In

{4626 psi at 5.3 gpm}
33.0 MPa
{4786 psi}

+
Arm-in relief
Open

{4626 psi at 5.3 gpm}
33.1 MPa
{4800 psi}

+
Bucket-open relief
Close

{4626 psi at 5.3 gpm}
33.1 MPa
{4800 psi}

+
Bucket-closed relief
Right
22.6 MPa at 57.5 L/min

{3277 psi at 15.2 gpm}
25.0 MPa
{3625 psi}
Swing relief
Left
22.6 MPa at 57.5 L/min

{3277 psi at 15.2 gpm}
25.0 MPa
{3625 psi}
Swing relief
Right

{4830 psi at 5.3 gpm}
33.7 MPa
{4888 psi}

+ Boom swing-right relief
Left

{4626 psi at 5.3 gpm}
32.9 MPa
{4772 psi}

+ Boom swing-left relief

{3277 psi at 6.3 gpm}
23.3 MPa
{3379 psi}
Blade-up relief
Up

{3698 psi at 5.3 gpm}
26.5 MPa
{3843 psi}
Fasten blade main relief 180

+
Blade-up relief
Down

{3698 psi at 5.3 gpm}
26.5 MPa
{3843 psi}
Fasten blade main relief 180

+ Blade-down relief
4.2 MPa
{609 psi}
3.8 MPa
{551 psi}
Lever neutral
Main relief pressure
Boom overload
relief
Arm overload
relief
Bucket overload
relief
Swing relief
Boom Swing port

relief (CX80)
Main
Blade
Overload
relief
Pilot relief
Issued 03-08
Copyright
8001-13
3) Ports for Measuring Pressure

1] Main pump
MAIN PUMP
ENGINE
BLADE PUMP
PILOT PUMP
G2
PRESSURE DETECTION PORT G1/4
A2 RIGHT TRAVEL SIDE DELIVERY
PORT
FRONT SIDE OF BODY
G1 PRESSURE DETECTION PORT G1/4

A1 LEFT TRAVEL SIDE DELIVERY PORT
PG3 BLADE PUMP PRESSURE DETECTION PORT G1/4
2] Pilot line
PRG
Issued 03-08
Copyright
8001-14
4) Preparation for Measuring Pressure

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

Position the machine on solid level ground.
Lower the boom so the arm end touches the ground with the bucket cylinder out at stroke end and
the arm cylinder out at stroke end.
The blade should also be lowered to touch the ground.
Issued 03-08
Copyright
8001-15
3] Relieving pressure in circuit

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

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

See section 3 on the previous page for the port positions for measuring.
Measuring actuator
Port
Pressure gauge
Port size
Tool
Main, Left travel, Offsett,Swing, Arm
G1
49.1 MPa
{7221 psi}
G1/4
Hexagonal bar wrench

6 mm
Main, Right travel,

Bucket, Boom
G2
49.1 MPa
{7221 psi}
G1/4

6 mm
Pilot
P2
9.8 MPa
{1421 psi}
G1/4
Spanner 17 mm
P3G
49.1 MPa
{7221 psi}
G1/4

6 mm
Blade
6] Checking oil temperature

Check hydraulic oil temperatures using a temperature gauge.
Oil temperature
45 - 55 C (113 - 131 F)
If the oil temperature is low, follow the instructions for warm-up in the Operators Manual to
increase the temperature.
The preparation is now complete.
Issued 03-08
Copyright
8001-16
5) Measuring Pressure
1] Main relief pressure
Lever operation
Arm-in relief
Pressure gauge to be used
50 MPa {7250 psi}
Pressure setting
29.4 1.0 MPa {4264 145 psi}
2] Swing relief pressure

Lever operation
Swing relief
50 MPa {7250 psi}
Pressure setting
24.6 1.0 MPa {3567 145 psi}
Attach the pressure gauge to the G1 side of the pressure detection port on the main pump.
When measuring the pressure for swing, first activate the mechanical brake by disconnecting the
connector on the swing pressure switch located on the lower left of the cab.
The swing pressure switch will be revealed after removing the side cover located on the lower left
of the cab. See the figure below.
CAUTION
Before positioning the swing lever in place for the first time, the engine revolutions should
be reduced to approximately 1100 min-1{1100 rpm}.
When the swing is confirmed to be no longer moving, increase the engine revolutions to
the maximum.
Disconnecting the hose to the swing motors parking release port PB or inserting the
connector of the solenoid valve for switching for high speed into swing brake solenoid to
change the speed to high mode would also work for measuring pressure along with disconnecting the connector.
(At this point, leave the connector for the swing brake solenoid disconnected.)
HIGH
SPEED TRAVEL
GATE LOCK
FRONT SIDE
OF BODY
SWING BRAKE
BOTTOM OF CAB
SWING PRESSURE SWITCH
Issued 03-08
Copyright
8001-17
3] Pilot relief pressure

Lever operation
Neutral
10 MPa {1450 psi}
Pressure setting
3.9 0.2 MPa {540 29 psi}
4] Blade relief pressure

Main relief pressure for blade
Lever operation
Blade up
50 MPa {7250 psi}
Pressure setting
23.0 1.0 MPa {3335 145 psi}
Overload relief pressure for blade

Lever operation
Blade up/down
50 MPa {7250 psi}
Pressure setting
26.4 1.0 MPa {3829 145 psi}
Overload relief pressure for boom swing (CX80)

Lever operation
Boom swing-right/left
49.1 MPa {7121 psi}
Actual pressure setting (Right)
33.7 1.0 MPa {4888 145 psi}
Actual pressure setting (Left)
32.9 1.0 MPa {4772 145 psi}
When measuring the overload relief pressure, fasten the main relief valve of the blade 180 to
temporarily adjust it.
5] Other overload relief pressures
Lever operation
Boom
up
Boom
down
Actual pressure
reading
33.5 1.0 MPa

{4860 145 psi}
Port for detection
G2
Arm out
Arm in
33.4 1.0 MPa

{4844 145 psi}
G1
Bucket
open
Bucket
closed
32.8 1.0 MPa

{4760 145 psi}
G2
Offset right
(CX75SR)
32.9 1.0 MPa
{4770 145 psi}
Offset left
(CX75SR)
33.7 1.0 MPa
{4890 145 psi}
G1
Temporary adjustments are required because the overload relief pressures of the attachments
are set higher than those for the main relief.
Issued 03-08
Copyright
8001-18
PRESSURE ADJUSTMENT
1) Pressure Adjusting Points
1] Control valve (CX75SR)
OFFSET LEFT
OFFSET RIGHT
BLADE UP
BLADE DOWN
ARM 1 OUT
ARM 2
ARM 1 IN
B00M 2 UP
BOOM 2 DOWN
SWING RIGHT
SWING LEFT
OPTION OUT
OPTION IN
TRAVEL
BACKWARD
LEFT
TRAVEL
FOWARD
LEFT
FRONT SIDE OF BODY

VIEWED FROM THE EXTERNAL SIDE OF BODY
BOOM 1
DOWN
BUCKET
OPEN
TRAVEL
FORWARD
RIGHT
BOOM 1 UP
BUCKET
CLOSED
TRAVEL
BACKWARD
RIGHT
FRONT SIDE OF BODY

VIEWED FROM THE INTERNAL SIDE BODY
Tool needed
Location
Lock nut
1
Main
Boom up
Boom down
Arm out
Arm in
Bucket open
Bucket closed
Option in
Adjustment
screw
Pressure setting
29.4 MPa {4260 psi}
Pressure per one turn of

adjustment screw
17.8 MPa {2580 psi}
33.5 MPa {4860 psi}
33.4 MPa {4844 psi}
17 mm
Hexagonal
wrench
6 mm
32.8 MPa {4760 psi}

21.2 MPa {3070 psi}
31.9 MPa {4630 psi}
Option out
10
Blade, offset main
11
Blade up
12
Blade down
13
Offset right
32.9 MPa {4770 psi}
14
Offset left
33.7 MPa {4890 psi}
23.0 MPa {3335 psi}

26.4 MPa {3830 psi}
Issued 03-08
Copyright
8001-19
2] Control valve (CX80)
OPTION (2) IN
BLADE UP
BOOM SWING RIGHT
ARM 1 IN
ARM 1 OUT
BOOM 2 DOWN
B00M 2 UP
SWING LEFT
SWING RIGHT
OPTION IN
OPTION (1) OUT
TRAVEL
FOWARD
LEFT
TRAVEL
BACKWARD
LEFT
FRONT SIDE OF BODY

VIEWED FROM THE EXTERNAL SIDE OF BODY
OPTION (2) OUT

BLADE DOWN
BOOM SWING LEFT
ARM 2
BOOM 1 UP
BUCKET
CLOSED
TRAVEL
BACKWARD
RIGHT
BOOM 1 DOWN
BUCKET OPEN
TRAVEL
FORWARD
RIGHT
FRONT SIDE OF BODY

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

adjustment screw
17.8 MPa {2582 psi}
21.2 MPa {3070 psi}
Issued 03-08
Copyright
8001-20
3] Hydraulic pump
4] Swing motor
Tool needed
Name
Lock nut
Adjustment
screw
13
Pilot
24 mm
14 mm
14
Swing Motor
17 mm
Hexagonal
wrench
6 mm
Pressure setting

adjustment screw
3.9 MPa {570 psi}
0.6 MPa {87 psi}
24.6 MPa {3570 psi}
9.7 MPa {1410 psi}
Issued 03-08
Copyright
8001-21
BLEEDING AIR
MAIN PUMP
AIR BLEEDING VALVE
BLADE PUMP
PILOT PUMP
DIA 6.3 mm
(0.24 in)
HEX. WAF
10 mm
(0.39 in)
RUBBER CAP
SEAT FACE
FRONT SIDE OF BODY
Start the engine and keep it at idle. Remove the rubber cap on the air bleeder. Loosen the air bleeding valve gradually to bleed air.
Issued 03-08
Copyright
8001-22
FLOW CURVE
Torque: Nm
P = P1 + P2
Shift pressure P3 MPa
Leakage flow
line
Flow: Q1, Q2 L/min
AQ08002-001
Issued 03-08
8002
Copyright
Section
8002
OF THE HYDRAULIC RESERVOIR
CNH
Lep SM75SR8002-0EN

Printed in France
August 2008
Copyright
8002-2
TABLE OF CONTENTS
HYDRAULIC RESERVOIR ...................................................................................................................................... 3
Lep SM75SR8002-0EN
Issued 08-2008
Copyright
8002-3
HYDRAULIC RESERVOIR
x4x4
2 3
2.94 to 4.90 Nm
x4
6
1
4
9
5
9
See detail A
10
7 8
15
16
17
14
X4
Lep AST-15-11-003
X4
11 12 13
68.6 to 78.5Nm
KAJ11230-D00
Issued 08-2008
Copyright
8002-4
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Air breather
Hex bolt soc HD M6 x 16
Spring washer
Sems bolt M10 x 30
Hydraulic reservoir
Sems bolt M10 x 20
Plate shim (T=2)
Plate shim (T=0.8)
Plug G3/4
Cushion seal
High strength bolt M12 x 45
High strength washer
Bond #262
Strainer
Compression spring
Relief valve
Return filter
Oil gauge level
18 12.75Nm
KAJ11230-D00
Lep AST-15-11-003
Issued 08-2008
Copyright
8003
Section
8003
MAIN HYDRAULIC PUMP
CNH
Lep SM75SR8003-0EN

Printed in France
August 2008
Copyright
8003-2
HYDRAULIC PUMP
X4 X4
1 2 3
108.9 to 126.5 Nm
R2
R1
A2
G2
10
A1
X9
G1
1 5
62.8 to 72.6 Nm
8 9
6 7
A
PPG S
130 to 150 Nm
8 9
100 to 120 Nm
A3
P3G
PP
130 to 150 Nm
A
1.
2.
3.
4.
5.
KAJ11370-C00
6.
7.
8.
9.
10.
Bond 262 (-)

Spring washer 12 (4)
Hex bolt soc hd M12 x 30 (4)
Mount flange (1)
Bolt M10 x 30 (9)
Mark
Name
Bushing (3)
Cplg plug (3)
Hydraulic pump (1)
Hydraulic pump (for blade) (1)
Pump coupling (1)
Bore
Mark
Suction port
SAE2 1/2
P3G
A1, A2
Delivery port
G3/4
A3
Delivery port
PP
Pilot port
PPG
Gauge port (pilot)
Name
Bore
Gauge port (gear)
G1/4 Plug
R1
Drain port
G1/2 Plug
G1/2
Air-bleeding port
M10 x 1.0
G3/8
G1, G2
Gauge port
G1/4 Plug
G1/4 Plug
1. Loctite 262 or equivalent should be applied on the

thread of the bolts after removing the oil film.
All hexagon socket head cap screws for the drive plate
coupling have been already done by vender.
3. The pump shaft and flange surfaces should be

cleaned. (for removing anti-rust material)
2. After assembled the machine or long term storage

of the machine. At first loose the air-bleeding plug
R2 and fill inside of the pump with the hydraulic oil
before starting the engine.
ASM-17-11-002
Issued 08-2008
Copyright
Section

MAIN HYDRAULIC CONTROL VALVE
CX80 TIER 3
CNH
Lep SM80-8004-0EN

Printed in France
August 2008
8004
8004
Copyright
8004-2
CONTROL VALVE
pp
T3
DR1
1
p
pa6
p
pa1
pa2
p
pa
p
dr
p
pa
p
pa
p
pa3
p
pa4
p
pra1
p
pa5
pra2
p
p
pra3
X4
1 4
A8
A7
A6
T4
pc2
pcc
AR1
T6
AR2
AR3
T5
X4
2 3 4
7
A5 A3 A2 A1 PT PA
R3
2
P2
2
P1
B5
5
B4
4
B3
3
B2
2
P3 B6 B7 B8 T2
prb3
p
prb2
B1
pb5
rb1 p
p
pb4
p
pb3
p
pb2
p
pb1
KAJ11680-D00
1.
2.
3.
4.
Sems bolt M12 x 30 (4)

High strength M12 x 40 (4)
Bond 262 (-)
Main line
P1, P2
T1, T2
A1
B1
A2
B2
A3
B3
B4
A5
B5
A6
B6
A7
Pilot port
pa1
pb1
pa2
pb2
pa3
pb3
pa5, pa9
pb5, pb9
pa6
pb6
pa7
B7
pb7
ASM-19-04-001
5.
6.
7.
8.
Line name
Pressure line
Low pressure line
Traction line left backward
Traction line left forward
Option 1
Option 1
Swing line right
Swing line left
Plug (boom 2)
Arm line out
Arm line in
Traction line right backward
Traction line right forward
Bucket line close
Bucket line open
Plug (1)
Protection cap (1)
Plate (1)
Control valve (1)
Main line
A8
B8
T3
AR1
BR1
AR2
BR2
AR3
BR3
PR5
T5
P3, T4
-
Pilot port
pa8, pa4
pb8, pc2
pra1
prb1
pra2
prb2
pra3
prb3
PP
PT, PA
DR1, pcc,
dr2, pb4
Line name
Boom line up
Boom line down
Swing line
Swing right
Swing left
Blade line up
Blade line down
Option 2
Option 2
Blade line pressure
Plug
Plug
Pilot pressure line
Pressure detection
Drain line
Issued 08-2008
Copyright
Section

ATTACHMENT CYLINDERS
CNH
Lep SM75SR8005-0EN

Printed in France
August 2008
8005
8005
Copyright
8005-2
TABLE OF CONTENTS
ATTACHMENT CYLINDERS................................................................................................................................... 3
BUCKET CYLINDER ................................................................................................................................................ 3
Removal ............................................................................................................................................................ 3
Installation ......................................................................................................................................................... 5
DIPPER CYLINDER ................................................................................................................................................. 7
Removal ............................................................................................................................................................ 7
Installation ......................................................................................................................................................... 9
BOOM CYLINDER ................................................................................................................................................. 11
Removal .......................................................................................................................................................... 11
Installation ....................................................................................................................................................... 13
BOOM SWING CYLINDER (CX80 ONLY) ................................................................................................................. 16
Removal .......................................................................................................................................................... 16
Installation ....................................................................................................................................................... 17
Lep SM75SR8005-0EN
Issued 08-2008
Copyright
8005-3
1 Bucket cylinder
1 Removal
1) Lower the attachment to the ground.
800-5-03-00-21A
2) Put a block between the bucket cylinder and the dipper.
MQ12001-001-003
3) Stop the engine and release pressure in the hydraulic

circuit.
NOTE: Refer to the procedures for bleeding the hydraulic
pressure in Operators manual. When releasing pressure from
the tank, stop the engine and press the button to completely
release the internal pressure. The hydraulic oil may be hot, so
be careful not to get burned.
800-5-03-00-20C
4) Remove the nuts and bolt.
800-5-03-00-20D
MSM-17-12-001
Issued 08-2008
Copyright
8005-4
5) Drive out the pin, using a steel bar and hammer.
800-5-03-00-20E
6) Fasten a wire to prevent the cylinder rod from extending.
800-5-03-00-20F
7) Remove the hoses. Install bull plugs or caps.
MQ12001-002
8) Lift the bucket cylinder, using a sling.
MQ12001-003
MSM-17-12-001
Issued 08-2008
Copyright
8005-5
9) Remove the nuts and bolt. Drive out the pin, using a
steel bar and hammer.
10)Remove the bucket cylinder.
MQ12001-004
2 Installation
1) Lift the bucket cylinder and position it so that it is
aligned for installation in the dipper.
MQ12001-005
2) Install the pin and fasten it with a bolt and nuts.
MQ12001-006
3) Connect the hoses to the bucket cylinder.
MQ12001-007
MSM-17-12-001
Issued 08-2008
Copyright
8005-6
4) Position the cylinder head so that it is aligned for installation in the link.
MQ12001-008

NOTE: Cycle the cylinder to bleed air from the cylinder. After
leading air, check for oil leakage.
MQ12001-009
MSM-17-12-001
Issued 08-2008
Copyright
8005-7
2 Dipper cylinder
1 Removal
800-5-03-00-21A
2) Put a block between the dipper cylinder and the boom.
700-5-03-00-22R

circuit.
pressure in Operators Manual. When releasing pressure from
800-5-03-00-20C
4) Remove the nuts and bolt.
MQ12001-010
MSM-17-12-001
Issued 08-2008
Copyright
8005-8
5) Drive out the pin, using a steel bar and hammer.
MQ12001-011
6) Fasten a wire to prevent the cylinder rod from extending.
800-5-03-00-20F
MQ12001-012
8) Remove the grease hose.
MQ12001-013
MSM-17-12-001
Issued 08-2008
Copyright
8005-9
9) Lift the dipper cylinder, using a sling.
700-5-03-00-22Y
10)Remove the nuts and bolt. Drive out the pin, using a
11)Remove the dipper cylinder.
MQ12001-014
2 Installation
1) Lift the dipper cylinder and position it so that it is
aligned for installation in the boom.
700-5-03-00-22AA
MQ12001-015
MSM-17-12-001
Issued 08-2008
Copyright
8005-10
3) Install the grease hose to the dipper cylinder.
MQ12001-016
4) Connect the hoses to the dipper cylinder.
MQ12001-017
5) Position the cylinder head so that it is aligned for installation in the arm.
MQ12001-018
6) Install the pin and fasten it with a bolt and spacer.

When putting in a pin, it unites with the circle boss of a
dipper.
bleeding air, check for oil leakage.
MQ12001-019
MSM-17-12-001
Issued 08-2008
Copyright
8005-11
3 Boom cylinder
1 Removal
800-5-03-00-21A
2) Remove the grease hose.
700-5-03-00-22AH
3) Attach a sling to the boom cylinder.
700-5-03-00-22AI
4) Remove the nuts and bolt to remove the collar.

5) Pull out the pin, using a steel bar and hammer.
000-5-03-00-20AC
MSM-17-12-001
Issued 08-2008
Copyright
8005-12
6) Lower the cylinder and place on a stand.
700-5-03-00-22AK
7) Attach a wire to prevent the cylinder rod from extending.
MQ12001-020

circuit.
pressure in Operators Manual. When releasing pressure from
800-5-03-00-20C
MQ12001-021
MSM-17-12-001
Issued 08-2008
Copyright
8005-13
10)Remove the nuts and bolt and drive out the pin, with a
MQ12001-022
11)Remove the boom cylinder.
MQ12001-023
2 Installation
1) Lift the boom cylinder and position it so that it is aligned
for installation in the frame.
MQ12001-024
MQ12001-025
MSM-17-12-001
Issued 08-2008
Copyright
8005-14
3) Connect the hoses to the boom cylinder.
MQ12001-026
4) Position the cylinder so that the head is aligned for

installation in the boom.
700-5-03-00-22AS
5) Install the pin with a steel bar and hammer.
700-5-03-00-22AM
6) Attach the collar and install the bolt and nuts.
MQ12001-027
MSM-17-12-001
Issued 08-2008
Copyright
8005-15
7) Install the grease hose.
bleeding air, check for oil leakage.
700-5-03-00-22AU
MSM-17-12-001
Issued 08-2008
Copyright
8005-16
4 Boom swing cylinder (CX80 only)

1 Removal
4
6
1
5
2
3
7
9
8
AS05001-043
[1] Use wire to lift the boom swing cylinder (1).

[2] Use a wrench to remove the bolt (5) on the cylinder head (piston rod side) (2).
[3] Use a steel rod and hammer to remove the pin (3).
WARNING: When removing the pin, be careful not to let it fall or get caught.
[4]
[5]
[6]
[7]
[8]
[9]
Secure the piston rod (2) with wire so that it will not fall out.
Remove the hose (4) and cover the hose with either a plug or cap.
Use a wrench to remove the bolt (8) on cylinder bottom (cylinder tube side) (6) and washer (9).
Use a steel rod and hammer to remove the pin (7).
Lift the boom swing cylinder (1) and remove it.
Place the boom swing cylinder (1) on crossties.
MSM-17-12-001
Issued 08-2008
Copyright
8005-17
2 Installation
To install, perform the reverse of the removal procedure.
[1] Use wire to lift the boom swing cylinder (1), and align the cylinder bottom (cylinder tube side) (6) with the installation position.
[2] Insert the pin (7) and secure it with the bolt (8) and washer (9).
[3] Connect the boom swing cylinder (1) to the hose (4).
Do not pull out the piston rod (2) before connecting the hose. This can cause hydraulic oil to fly out from the line.
[4]
[5]
[6]
[7]
Align the cylinder head (piston rod side) with the installation position.
Use a steel rod and hammer to insert the pin (3).
Secure the bolt (5) with the pin (3).
Remove wire, etc.
Bleed off air and check that there is no oil leaking.
As the final step, always grease up each pin.
MSM-17-12-001
Issued 08-2008
Copyright
8005-18
NOTES
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MSM-17-12-001
Issued 08-2008
Copyright
Section
8006
8006

HYDRAULIC SWIVEL
CNH
Lep SM75SR8006-0EN

Printed in France
August 2008
Copyright
8006-2
TABLE OF CONTENTS
ROTATING JOINT ................................................................................................................................................... 3
Removal ............................................................................................................................................................ 4
Installation ......................................................................................................................................................... 5
Lep SM75SR8006-0EN
Issued 08-2008
Copyright
8006-3
ROTATING JOINT
AQ10002-029
1. Bolt
2. Lock bar
3. Rotating joint assembly
ASM-17-10-002
Issued 08-2008
Copyright
8006-4
1 Removal
1) Jack up the body.
2) Stop engine and release pressure in the hydraulic
circuits.
3) Place protection blocks under the lower frame and
secure them.
AQ10002-030A
4) Remove the under cover.
AQ10002-030B
5) Attach marking tags to the rotating joint hoses to

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

8) Remove the lock bar (2).
9) Remove the rotating joint mounting bolts (3).
10) Lift out the rotating joint.
AQ10002-030
ASM-17-10-002
Issued 08-2008
Copyright
8006-5
2 Installation
1) Align it so that it fits on the lower frame.
2) Apply Loctite No. 262 to the rotating joint mounting bolts (3).
3) Tighten the rotating joint mounting bolts (3) to the specified torque.
4) Apply Loctite No. 262 to the lock bar mounting bolts (1).
5) Tighten the lock bar mounting bolts (1) to the specified torque to install the lock bar (2).
6) Connect the hoses.
7) Check to ensure that there is no oil leakage. If leakage is found, take appropriate measures.
8) Install the under cover.
9) Remove the blocks.
10) Lower the body.
ASM-17-10-002
Issued 08-2008
Copyright
8006-6
NOTES
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ASM-17-10-002
Issued 08-2008
Copyright
Section
8007
8007

PILOT FUNCTION BLOCKS
CNH
Lep SM75SR8007-0EN

Printed in France
August 2008
Copyright
8007-2
TABLE OF CONTENTS
REMOTE CONTROL VALVE .................................................................................................................................. 3
Lep SM75SR8007-0EN
Issued 08-2008
Copyright
8007-3
REMOTE CONTROL VALVE

41.1 2.9 Nm
17 18
54 59 63 67
41.1 2.9 Nm
19 61
X4
X4 X4 X4
20
23 60 64 68
17 18
22
24
19 61
X4
4 X4
4 X4
20 21 22
6 70.6 ~ 86.2 Nm
25
46
26
12
13 14
X44
33
31 32
X44
X4
28 29 30
6 70.6 ~ 86.2 Nm
27
X4
66
3
X4
2
1
4
56
70.6 ~ 86.2 Nm 5
7
8
10 9
51
X10
11
X2
2 X2
13 14
2
70.6 ~ 86.2 Nm 5
15
46
KHJ2287Z-E26A
7
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
17.
18.
19.
Frame console (1)

Bolt M10 x 25 (28)
Vinyl cap (1)
Hand lever(1)
Washer (4)
U-nut (4)
Mount rubber (4)
Rubber grommet (2)
Floor (1)
Floor (1)
Bolt M12 x 30 (10)
Pedal (2)
Bracket right (1)
Jam nut M14 (2)
Vinyl cap (2)
Remote control valve
ASM-17-11-002
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
Hex soc hd bolt M6 x 30 (8)

Spring washer 6 (8)
Plain washer 6 (8)
Knob left 2 switch (1)
Frame console unit (1)
Rubber grommet (1)
Rubber grommet (1)
Bracket left (1)
Plain washer 8 (4)
Bolt M8 x 25 (4)
Remote control valve (1)
Bolt M10 x 20 (4)
Floor mat (SB)
Floor mat (BH)
Bolt M10 x 16 (3)
Issued 08-2008
Copyright
8007-4
36
37
X2
36
X2
39
X2
40
38
X2
41
X2
42 17.7 ~ 20.6 Nm
34 35 69 70
C
B
46
46
P - Port
4 - Arm open
3 - Swing left
2 - Arm closed
T - Port
1 - Swing right
57
T - Port
58
1 - Bucket closed
4 - Boom up
50
14 45
2 - Boom down
P - Port
3 - Bucket open
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
Cover (1)
Foot rest left (1)
Cover (1)
Foot rest right (1)
Knob L type (2)
High strength nut M12 x 1.25 (2)
Hand lever left (1)
Hand lever right (1)
High strength bolt (2)
Cushion seal (2)
Cushion seal (2)
Cushion seal (1)
Cushion seal (1)
Safety trim (1)
Cover (1)
Bolt M10 x 30 (8)
ASM-17-11-002
46
KHJ2287Z-E26
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
Knob right (1)

Rubber grommet (1)
Cushion seal (1)
Side cover (1)
Knob right 4 switch (1)
Harness band L= 250 (-)
Boot (2)
Boot (for short lever) (2)
Floor mat (1)
Issued 08-2008
Copyright
Section
8010
CNH
Lep SM75SR8010-0EN

Printed in France
August 2008
8010

MAIN HYDRAULIC PUMP
Copyright
8010-2
TABLE OF CONTENTS
HYDRAULIC PUMP................................................................................................................................................. 3
DISASSEMBLING AND ASSEMBLING INSTRUCTIONS .................................................................................................. 3
Tools and jigs needed ....................................................................................................................................... 3
Precautions ....................................................................................................................................................... 3
Disassembling main pump .............................................................................................................................. 4
Disassembling the cover section..................................................................................................................... 7
Removing the power adjuster (only if required) .............................................................................................. 8
Removing the pilot relief valve (only if required) ............................................................................................. 9
Assembling instructions .................................................................................................................................... 9
Assembling the cover section ......................................................................................................................... 9
Installing the cylinder..................................................................................................................................... 10
Installing the main pump ............................................................................................................................... 11
Disassembling the gear pump......................................................................................................................... 16
Removing the gear pump (G1)...................................................................................................................... 16
Disassembling the gear pump (G1) .............................................................................................................. 16
Disassembling the gear pump (GSP2).......................................................................................................... 17
Reassembling gear pump ............................................................................................................................... 19
Reassembling the gear pump (GSP2) .......................................................................................................... 19
Assembling the gear pump (G1) ................................................................................................................... 21
STRUCTURE DRAWING ......................................................................................................................................... 25
No. 1 Shaft assembly ...................................................................................................................................... 26
No. 2 Swash plate assembly ........................................................................................................................... 26
No. 3 Rotary group .......................................................................................................................................... 27
No. 4 Cover assembly ..................................................................................................................................... 27
No. 5 Control spring assembly ........................................................................................................................ 28
No. 6 Control piston assembly ........................................................................................................................ 28
No. 7 Gear pump............................................................................................................................................. 29
No. 30 Relief valve assembly .......................................................................................................................... 29
Lep SM75SR8010-0EN
Issued 08-2008
Copyright
8010-3
HYDRAULIC PUMP
1 Disassembling and assembling instructions
1 Tools and jigs needed
Name
Size (nominal)
Quantity
Hexagon wrenches (torque wrench)
4, 5, 6, 8, 12 mm
One of each
Wrenches (torque wrench)
14, 17, 24, 27 mm
One of each
Screwdriver (flathead)
Medium-sized
Snap ring pliers
Internal (for snap ring 80)
Plastic hammer
Medium-sized
Magnet
Bar-shaped: approximate diameter 5 mm
Grease
Industrial grease
Cleaning solution
As needed
As needed
Adhesive agent
Three bond No. 1305
As needed
Support
To be used for standing the pump vertically

2 Precautions
[1] Precautions for disassembling
1) Adjusting screws are pre-adjusted according to the specifications. Do not disassemble unless necessary. If
disassembled, settings will be altered, adversely affecting the machine.
2) After draining oil from the pump, clean the outside of the pump. Conduct work in a clean area.
3) Use a clean cloth and take sufficient measures to keep foreign substances from entering the pump.
4) Each pump is composed of pre-adjusted parts. Mark each part with a pen or the like so that they can be
aligned correctly during reassembly.
[2] Precautions for assembling
1) Replace old seals with new ones.
2) Conduct work in a clean area and take sufficient measures to keep foreign substances from entering the
pump.
3) Fasten screws with proper tightening torque.
4) Apply grease to all sliding sections.
ASM-17-20-002
Issued 08-2008
Copyright
8010-4
1 Disassembling main pump
1) Remove gear pump.
Remove hexagon socket head bolts: (M10 x 25 x2)
Hexagon wrench (width across flats: 8)
Remove coupling and collar.
AQ20002-002
2) Remove cover section.

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

straight up.
Take care to keep the shift piston and control plate
from falling off. Place the cover section in a level
position immediately after removal.
If it is difficult to remove, hammer it out by hitting it
lightly with a plastic hammer.
AQ20002-004
AQ15002-002
ASM-17-20-002
Issued 08-2008
Copyright
8010-5
4) Remove parts from inside the housing:
Packing on the mating surface of cover
Spring (external)
Spring (internal)
Guide
Take out spring seat.
AQ20002-005
5) Take out rotary group.

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

removed from the housing when removing the
rotary group.
AQ20002-007
ASM-17-20-002
Issued 08-2008
Copyright
8010-6
7) Removing the shaft section.
Remove C-shaped snap ring (internal 80).
Snap ring pliers (internal snap ring 80).
AQ20002-008
8) Remove the oil seal case.

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

If it is difficult to pull out, hit the back end of the
shaft lightly with a plastic hammer.
AQ20002-010
ASM-17-20-002
Issued 08-2008
Copyright
8010-7
10) Take out the swash plate.
AQ20002-011
11) Remove the guides.

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

1) Remove the control plate
AQ20002-013
ASM-17-20-002
Issued 08-2008
Copyright
8010-8
2) Remove the piston.
Remove the cylinder.
Wrench (width across flats: 27)
AQ20002-014
3) Remove the piston.

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

1) Loosening the Hexagon nut will change the power
setting.
Remove hexagon socket head bolts (M10 x 30
x2) and remove cover.
AQ20002-016
ASM-17-20-002
Issued 08-2008
Copyright
8010-9
2) Take out spring seat.
Handle carefully. Shim[s] may come out with the
spring seat.
AQ20002-017
4 Removing the pilot relief valve (only if required)

1) Disassembling the valve will change the pilot pressure setting. Prior to disassembly, record the
screw height and make counter marks.
Loosen and remove the locknut and adjusting
screw.
Remove the spring.
Remove the spool.
NOTE: Using a magnet or M5 bolt will aid removal of the
spool.
AQ20002-018
1 Assembling the cover section
1) Installing the pilot relief valve
Install the spool.
Install the spring.
Fasten the locknut and adjusting screw according
to the screw height and counter marks recorded
before disassembly.
Tightening torque: 9.8 Nm.
AQ20002-019
ASM-17-20-002
Issued 08-2008
Copyright
8010-10
2) Install the spring seat.
If the spring seat has a shim, install the shim.
AQ20002-020
3) Install the power adjuster section.

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

1) Assemble the piston, Belleville spring and shim
into the cylinder and install the assembly on the
cover.
To keep these parts from falling off when screwing
in the cylinder, apply grease to each part.
Cylinder
Piston
NOTE: Apply a small amount of Three Bond No. 1305 to the

threaded section of cylinder.
Belleville spring
AQ20002-022
ASM-17-20-002
Shim
Issued 08-2008
Copyright
8010-11
2) Fasten the cylinder.
Install the piston.
AQ20002-023
3) Install the control plate.

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

1) Install the guide (delivery side).
Install the guide (suction side).
To keep guides from falling off, apply grease to the
mating surfaces with the housing.
AQ20002-025
ASM-17-20-002
Issued 08-2008
Copyright
8010-12
2) Install the swash plate.
To keep the swash plate from falling off, apply
grease to the area (spherical) in contact with the
guide.
AQ20002-026
3) Install the shaft.

Do this with the housing on its side.
NOTE: Be careful that the swash plate does not fall off.
AQ20002-027
4) Apply grease to the O-ring and install.
AQ20002-028
ASM-17-20-002
Issued 08-2008
Copyright
8010-13
5) Install the oil seal case with the oil seal installed.
Apply grease to lip section of the oil seal.
AQ20002-029
6) Install C-shaped snap ring (internal 80).

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

Apply grease to pins (dia. 3 x 30 x3) and install
them in the spline grooves in the cylinder block.
AQ20002-031
ASM-17-20-002
Issued 08-2008
Copyright
8010-14
8) Assemble pistons (x10) into retainer, and apply
grease to the spherical part of the guide and
install it inside retainer.
At the same time the pistons are installed into the
holes, carefully place the guide on the three pins.
AQ200020-032
9) Install the rotary group.

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

Place the pump in an upright position, and install
the following parts:
Spring seat
Guide
Spring (internal)
Spring (external)
Packing on the mating surface with the cover.
AQ20002-034
ASM-17-20-002
Issued 08-2008
Copyright
8010-15
11) Installing the cover section:
Install by lowering the cover perpendicularly onto
the pump.
Verify that packing is straight.
AQ200020-035
12) Fasten the following hexagon socket head bolts:

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

Install the coupling.
Attach the collar.
AQ20002-037
ASM-17-20-002
Issued 08-2008
Copyright
8010-16
14) Installing the gear pump.
Hexagon socket head bolts (M10 x 25 x2)
AQ200020-038
5 Disassembling the gear pump

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

1) Position as if for pulling out the drive gears and
remove the side plate, backup ring, square ring
and gears.
AQ20002-040
ASM-17-20-002
Issued 08-2008
Copyright
8010-17
2) Remove the idle gear.
AQ20002-041
3 Disassembling the gear pump (GSP2)

1) Remove Hexagon bolts (M10 x 95 x4).
(AP2D36-904 only)
Wrench (nominal: 17)
AQ20002-042
2) Remove the front frame.
AQ20002-043
3) Remove the intermediate frame.
AQ20002-044
ASM-17-20-002
Issued 08-2008
Copyright
8010-18
4) Remove the square ring.
AQ20002-045
5) Remove the plate, guide and O-ring.
AQ20002-046
6) Remove the plate.
AQ20002-047
7) Remove the drive gear, idle gear and side plate.
AQ20002-048
ASM-17-20-002
Issued 08-2008
Copyright
8010-19
6 Reassembling gear pump
1 Reassembling the gear pump (GSP2)
1) Install the square ring onto the side plate.
NOTE: At this time, pay attention to suction and delivery orientation.
Suction side
Delivery side
Square ring insertion orientation
AQ20002-082
AQ20002-049
2) Install the drive gear and idle gear on the side

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

them into the plate.
Side with larger R
Guide
AQ20002-052
AQ20002-053
ASM-17-20-002
Issued 08-2008
Copyright
8010-20
5) Install the plate, guide and O-ring as an assembly.
AQ20002-054
6) Assemble the 2 plates.

NOTE: At this time, pay attention to suction and delivery orientation.
Suction side
Delevery side
AQ20002-056
AQ20002-055
7) Install the drive square ring.
AQ20002-057
8) Assemble the 2 parallel pins into the front frame.
AQ20002-058
ASM-17-20-002
Issued 08-2008
Copyright
8010-21
9) Install the front frame.
AQ20002-059
2 Assembling the gear pump (G1)

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

keep them from falling off, and install them into the
side plate in that order.
AQ20002-062
ASM-17-20-002
Issued 08-2008
Copyright
8010-22
4) Install side plate assembled in (3. ) on the housing.
AQ20002-063
5) Assemble the 2 parallel pins into the intermediate

frame.
AQ20002-064
6) Install the O-ring on the intermediate frame.
AQ20002-065
7) Install the intermediate frame.
AQ20002-066
ASM-17-20-002
Issued 08-2008
Copyright
8010-23
8) Using hexagon socket head bolts (M8 x 50, four),
fasten the intermediate frame.
Hexagon bar wrench (width across flats: 6)
Tightening torque: 29 Nm.
AQ20002-067
9) Assemble the 2 parallel pins into the intermediate

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

GSP2 side.
AQ20002-069
11) Connect GSP2 and G1.
AQ20002-070
ASM-17-20-002
Issued 08-2008
Copyright
8010-24
12) Fasten GSP2 and G1 firmly with hexagon bolts
(M10 x 95 x4)
Wrench (nominal: 17)
Tightening torque: 59 Nm.
AQ20002-071
13) Install the O-ring on the front frame.
AQ20002-072
ASM-17-20-002
Issued 08-2008
Copyright
8010-25
2 Structure drawing
AQ20002-073
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Shaft assembly (1)

Swash plate assembly (1)
Rotary groupt (1)
Cover assembly (1)
Control spring assembly (1)
Control piston assembly (1)
Gear pump (1)
Housing (1)
Air vent valve (1)
Bushing (1)
Steel ball (1)
Plug (1)
ASM-17-20-002
13.
14.
15.
16.
17.
18.
19.
22.
23.
25.
30.
Plug (1)
Packing (1)
Shim (1)
Plug (1)
Name plate assembly (1)
Plug assembly (1)
Plug (1)
Plug (1)
Orifice (1)
Square ring (1)
Relief valve assembly (1)
Issued 08-2008
Copyright
8010-26
1 No. 1 Shaft assembly

#3
AQ20002-074
1.
2.
3.
4.
Shaft (1)
Seal case (1)
Bearing (1)
Retaining ring (C type) (2)
5. Oil seal (1)

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

Guide (1)
Guide (1)
O-ring (1)
ASM-17-20-002
7.
8.
9.
10.
Backup-ring (1)
Plug (1)
Parallel pin (1)
Bushing (1)
Issued 08-2008
Copyright
8010-27
3 No. 3 Rotary group
AQ20002-076
1.
2.
3.
5.
Piston assembly (10)

Cylinder block (1)
Retainer (1)
Guide (1)
6.
7.
8.
9.
Spring (1)
Parallel pin (3)
Spring seat (2)
4 No. 4 Cover assembly
AQ20002-077
1.
2.
3.
4.
5.
6.
7.
Cover (1)
Control plate (1)
Parallel pin (2)
Hexagon socket head bolt M14 x 40 (2)
Bearing (1)
ASM-17-20-002
8.
9.
10.
11.
12.
15.
O-ring (1)
Square ring (2)
Plug assembly (4)
Plug (2)
Plug (1)
Packing (1)
Issued 08-2008
Copyright
8010-28
5 No. 5 Control spring assembly
AQ20002-078
1.
2.
3.
4.
5.
6.
7.
Spring seat (1)

Spring seat (1)
Cover (1)
Adjust screw (1)
Spring (1)
Spring (1)
O-ring (1)
8.
9.
10.
34.
44.
54.

Hexagon nut M20 (1)
Guide (1)
Shim (0.3 mm) (2)
Shim (0.5 mm) (2)
Shim (1.0 mm) (2)
6 No. 6 Control piston assembly
AQ20002-079
1.
2.
3.
4.
Cylinder (1)
Piston (1)
Piston (1)
Coned disc spring (4)
ASM-17-20-002
5.
6.
7.
8.
Distance piece (3.3) (1)

Issued 08-2008
Copyright
8010-29
7 No. 7 Gear pump
AQ20002-080
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Frame (1)
Housing (1)
Gear (1)
Gear (1)
Thrust plate (1)
Metal (4)
Backup-ring (1)
Parallel pin (4)
Square ring (1)
Coupling (1)
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.

O-ring (1)
Frame (1)
Hexagon head bolt M10 x 25 (4)
O-ring (1)
O-ring (1)
O-ring (1)
O-ring (2)
O-ring (1)
Bushing (1)
8 No. 30 Relief valve assembly
AQ20002-081
1. Spool (1)
2. Adjusting screw (1)
3. O-ring (1)
ASM-17-20-002
4. Spring (1)
5. Hexagon nut (1)
6. Shim (1)
Issued 08-2008
Copyright
8010-30
NOTES
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ASM-17-20-002
Issued 08-2008
8011
Section
8011
MAIN HYDRAULIC CONTROL VALVE
CX80 TIER 3
CNH
Lep SM80-8011-0EN

Printed in France
August 2008
8011-2
TABLE OF CONTENTS
CONTROL VALVE................................................................................................................................................... 3
MAINTENANCE INSTRUCTIONS ................................................................................................................................ 3
Disassembling ................................................................................................................................................... 3
Disassembling Procedures ............................................................................................................................... 3
CLEANING ............................................................................................................................................................. 7
INSPECTION........................................................................................................................................................... 7
ASSEMBLING......................................................................................................................................................... 7
Subassemblies .................................................................................................................................................. 7
Assembling the Control Valve Main Body ......................................................................................................... 9
RELIEF VALVES ................................................................................................................................................... 13
Instructions for Disassembling and Assembling the Main body Relief Valves ................................................ 13
Instructions for Disassembling and Assembling the Add-on Relief Valves ..................................................... 14
Instructions for Disassembling and Assembling the Overload Relief Valves .................................................. 15
Instructions for Disassembling and Assembling the Negative Control Relief Valves ...................................... 15
Adjusting the Relief Valves ............................................................................................................................. 16
INSTALLATION ..................................................................................................................................................... 16
OPERATION ......................................................................................................................................................... 16
LIST OF CONTROL VALVE SPECIFICATIONS ............................................................................................................ 17
TROUBLESHOOTING............................................................................................................................................. 17
Control valves in general................................................................................................................................. 17
Relief valves .................................................................................................................................................... 18
Hydraulic system in general ............................................................................................................................ 18
REFERENCE DRAWING ........................................................................................................................................ 19
Parts list .......................................................................................................................................................... 19
Overall View 1/3 .............................................................................................................................................. 20
Overall View 2/3 .............................................................................................................................................. 22
Overall Drawing 3/3......................................................................................................................................... 25
Reference number (2): Spool section assembly ............................................................................................. 28
Reference number (3): Inlet section assembly................................................................................................ 29
Reference number (40): Anti-drift valve assembly .......................................................................................... 30
Reference number (29): Shut-off valve assembly ........................................................................................... 31
Lep SM80-8011-0EN
Issued 08-2008
8011-3
CONTROL VALVE
1 Maintenance instructions
1 Disassembling
[1] Disassembling Precautions
1) Stop the engine after the pressure in the actuator has been completely released.
WARNING: Do not replace valve assemblies or disassemble valves when unreleased pressure remains.
Pressurized hydraulic oil may spray out, or parts may fly out under pressure.
When disassembling, place the bucket firmly on the ground, and then completely release the pressure from the
circuits.
2) Release the air pressure from the tank.
3) Thoroughly clean around the area to be disassembled to prevent any foreign substances from getting into
the valves during disassembly.
4) Put tags on the disassembled parts so that their location can be easily identified for reassembly.
5) Replace all disassembled seals with new ones (O-rings and backup rings).
6) Do not replace spools, because they are selectively fit with their valve housings and sleeves.
2 Disassembling Procedures
* Numbers for parts contained in an assembly are expressed as (assembly no. - part no.).
1 Disassembling the main spools (2 through 10) (80-2)
1) Loosen socket head bolts (65) (80-12) (WAF: 6), and disassemble long caps (11 and 15) (80-3). Remove Orings (12) (80-4) from the grooves in the valve housing.
2) Loosen socket head bolt (66) (WAF: 5), and disassemble caps (46 and 47). Remove O-ring (42) from the
cap.
3) Pull each spool out of the valve housing as a subassembly.
WARNING: Pull the spools straight up so they will not be dented or scratched. If the spools are dented or
scratched, they may damage the holes in the body as they come out and may not fit back in at reassembly. Even
if they go in, they may not operate correctly.
Place tags on each spool so that their location can be easily identified for reassembly.
If a wrong spool is installed, the actuator will not function properly, and this is extremely dangerous.
4) Loosen socket head bolts (65) (80-12) (WAF: 6) and disassemble short caps (13 and 14) (80-5). Remove Orings (12) (80-4) from the grooves of the valve housing.
5) Loosen spool ends (2-4, 3-4, 4-4, 5-4, 7-4, 9-4, 10-4 and 80-2-4; WAF: 6) of spools (2 to 5, 7, 9, 10 and 8-2),
and remove spring seats (2-2, 3-2, 4-2, 5-2, 7-2, 9-2, 10-2 and 80-2-2) and springs (2-3, 3-3, 4-3, 5-3, 7-3,
9-3, 10-3 and 80-2-3).
6) Loosen spool end (6-4) (WAF: 6) of spool (6), then remove spring seat (6-2) and spring (6-3). Loosen plug
(6-5; groove width 3) and remove poppet (6-6), spring (6-7), O-ring (6-8) and backup ring (6-9).
7) Loosen spool end (8-4) (WAF: 6) of spool (8), then remove spring seat (8-2) and spring (8-3). Loosen plug
(8-5; groove width 3), then remove poppet (8-6), spring (8-7), O-ring (8-8) and backup ring (8-9).
ASM-19-07-001
Issued 08-2008
8011-4
WARNING: Secure the spool between blocks in a vise in order to avoid damaging the spool during disassembly.
At this time, secure the spool as close to the spool end as possible to avoid bending the spool.
Adhesive is applied to the threaded part of the spool end. Use an industrial dryer to heat the threaded part of the
outside of the spool until the spool end can be easily tightened (heating temperature should be 200 to 250C).
Replace with a new one if overheated. Overheating may cause thermal deformation of the spring, resulting in
poor performance and durability. Note that the spring will be extremely hot after it is heated. Handle with care to
avoid burns from direct contact with bare hands.
Blocks for spool disassembly/reassembly

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

1) Loosen spool ends (43) (WAF: 5) of spools (41 and 48), then remove spring seats (43) and spring (44).
2) Adhesive is applied to the threaded parts of the spool and to the joint section of the spool end. Disassemble
following the note above.
3 Disassembling the sub-spool section (52)
1) Loosen plug (49) (WAF: 32) and remove O-ring (50).
2) Remove spring (51) and pull out spool (52-1).
3) Draw it out by hooking a wire inside the hole on the near side of the sleeve (52-2). Piston (52-3) is pulled out
at the same time.
4) Remove backup ring (53) and O-ring (54).
4 Disassembling the boom and arm anti-drift valves
1) Loosen socket head bolt (67) (WAF: 6), remove body assembly (30), and then remove O-ring (31) from the
groove on the housing.
WARNING: If the control valve is attached to the machine during disassembly, unreleased pressure can cause
parts to fly out.
Loosen socket head bolt (67) slowly, and verify that there is no more resistance from unreleased pressure.
2) Remove spacer assembly (29) using a M6 x 1.0 screw, and then remove O-rings (29-2 and 29-4) and
backup ring (29-3).
3) Remove spring (28) and poppet (27).
4) Secure body assembly (30) in a vise, taking care not to damage the mating face on the mounting side of Oring (31).
5) Loosen plug assembly (30-14) (WAF: 38) and remove O-ring.
6) Pull out piston (30-4), spool (30-5) and spring (30-7).
7) Loosen plug (30-3) (WAF 38) and remove O-ring (30-13).
ASM-19-07-001
Issued 08-2008
8011-5
WARNING: If the control valve is attached to the machine during disassembly, unreleased pressure can cause
parts to fly out. Loosen plug (30-3) slowly, and verify that there is no more resistance from unreleased pressure.
8) Pull out sleeve (30-6) and poppet (30-2). Remove O-rings (30-9 and 30-10) and backup rings (30-11 and
30-12) from around the sleeve.
9) Pull out spring seat (30-15) and spring (30-8) from the back of the hole.
5 Disassembling Travel Right, Swing, Bucket, Booms 1 and 2, Arm1 and Blade load check sections
1) Loosen plug (19) (80-9) (WAF: 27) on the load check and remove O-ring (18) (80-8) from the plug.
2) Remove spring (17) (80-7) and poppet (16) (80-6).
6 Disassembling the check on the Travel Straight restrictor section (Travel Left section)
1) Loosen plug (19) (WAF: 27) on the Travel Straight restrictor section and remove O-ring (18) from the plug.
2) Pull out poppet (26) and spring (17).
7 Disassembling the Arm 2 load check section
1) Loosen socket head bolt (68) (WAF: 8) and remove flange (39) from the main body. Remove O-ring (38)
from the groove of the valve housing.
2) Remove sleeve (33), springs (35 and 37) and poppets (34 and 36).
WARNING: Use caution to keep the springs from falling into the passage. If a spring falls into the passage, it
may get caught on the main spool sliding section, and the spool will stick, which may cause the actuator to
overrun unstoppably.
8 Disassembling the backup external confluence check section

1) Loosen plug (23) (WAF: 32) and remove O-ring (18) from the plug.
2) Take out spring (25) and poppet (24).
3) Loosen plug assembly (81) (WAF: 27) and remove the O-ring.
9 Disassembling the common check section
1) Loosen plug (19) (WAF: 27) on the check, then remove O-ring (18) from the plug.
10 Disassembling the Arm 1 semi-parallel check section
1) Loosen plug assembly (32) (WAF: 8) and remove the O-ring.
11 Disassembling the relief valves
1) Remove overload relief valve (63) (WAF: 32) from the main body valve and the add-on spool section.
2) Remove main relief valve (62) (WAF: 32) from the main body valve and main relief valve (79) (WAF: 24) from
the add-on inlet section.
3) Remove negative control relief valve (55) (WAF: 32) from the main body valve.
* For disassembly and reassembly of relief valves, refer to appropriate chapter in Section.
ASM-19-07-001
Issued 08-2008
8011-6
12 Disassembling the shut-off valves
4) Loosen plug assembly (64) (WAF: 32), then remove O-rings and backup rings.
13 Disassembling the other plugs
1) Loosen plug assembly (20) (WAF: 19) on the Port PP section and remove the O-ring.
2) Loosen plug (89) (WAF:19) on the backup cap section and remove the O-ring (88).
3) Disassemble G1/8 size plugs (21) (WAF: 5; 3 locations in all), then remove the O-rings.
4) Disassemble G3/8 size plugs (32) (61-2) (WAF: 8; 4 locations in all), then remove the O-rings.
5) Disassemble G1/2 size plugs (69) (78-2) (WAF: 10; 2 locations in all), then remove the O-rings.
6) Disassemble G3/4 size plugs (90) (WAF: 36; 2 locations in all), then remove the O-rings.
7) Disassemble 7/8-14 UN size plug (22) (WAF: 27) and remove O-ring (18).
14 Disassembling the add-on section
1) Loosen and remove hexagonal nuts (72) (WAF: 19) and (74) (WAF: 22).
2) Pull out outlet housing (61-1).
3) Pull out the valve housing for the spool section (80-1) and remove O-rings (80-10 and 80-11) for the mating
surface.
4) Pull out inlet housing (78-1) and remove the O-rings (78-3 and 78-4) from the mating surfaces.
5) Remove O-rings (59 and 60) from the mating surfaces on the main body.
6) Loosen tie rods (71 and 73) and remove from main body valve housing (1). (Use a pipe wrench or the like).
WARNING: When pulling out the add-on section, be careful not to dent or scratch the mating surfaces.
If they are dented or scratched, malfunctioning may occur due to oil leakage from the mating surfaces.
Also, use caution to prevent foreign substances from getting into the oil passages.
Foreign substances may lodge in the spool sliding section causing the spool to stick, and faulty seating of the
load check may cause the actuator to overrun unstoppably.
ASM-19-07-001
Issued 08-2008
8011-7
2 Cleaning
Thoroughly clean all disassembled parts with clean mineral oil.
Dry with compressed air and place each part on a clean paper or vinyl surface for inspection.
3 Inspection
Inspect all surfaces of each part for burrs, scratches or other damage.
1) Check for scratches and nicks, dents, dirt, and rust on the load check seat surfaces in the valve housing,
and remove small scratches an oilstone.
2) Check for scratches, dents and other damage on the outside of the spool, and remove small scratches with
an oilstone.
3) All sliding parts should move smoothly, and there should be no foreign substances in any grooves or passages.
4) Broken, severely deformed, or worn springs must be replaced.
5) If the relief valve is not working properly, inspect according to 5. Adjusting the Relief Valves.
6) All O-rings and backup rings on the disassembled parts must be replaced with new ones.
7) After removing caps and plugs, check to see that there is no paint around the holes in the body or on the
plug seats. (If paint chips get into the valve, binding or blockage may occur, leading to malfunctioning or oil
leakage).
4 Assembling
WARNING: Prior to assembly, verify the number of parts, locations for installation and tools required.
1 Subassemblies
* Before installing parts onto the valve housing body, assemble the required parts into subassemblies.
1 Main spools (2 to 10) (80-2)
Apply adhesive to the threaded parts of spools (2 to 5, 7, 9, 10 and 80-2).
1) Install spring seats (2-2, 3-2, 4-2, 5-2, 7-2, 9-2, 10-2 and 80-2-2), springs (2-3, 3-3, 4-3, 5-3, 7-3, 9-3, 10-3
and 80-2-3) and spool ends (2-4, 3-4, 4-4, 5-4, 7-4, 9-4, 10-4 and 80-2-4). Secure the spool between blocks
in a vise and tighten the spool end.
Tightening torque: 9.8 to 11.8 Nm
WARNING: Do not apply too much adhesive. Excess adhesive will overflow when the spool is tightened.
Grasp the spool as close as possible to the end so that the spool is not bent by the tightening torque.
If the spool end is overtorqued, swelling of the spool may cause it to stick, and this may cause the actuator to
everrun unstoppably.
* Observe this precaution when adhesive is used in the instructions below.
WARNING: Springs (5-3 and 10-3) on Boom 2 spool (5) and Travel Straight spool (10) are different from the
springs for other parts.
Installing incorrect parts may lead to malfunctioning of the actuator.
ASM-19-07-001
Issued 08-2008
8011-8
2) Install poppet (6-6) and spring (6-7) into the hole in spool (6).
Next, apply adhesive to the threaded part of the spool.
Secure the spool between blocks in a vise.
Apply adhesive to the threaded part of plug (6-5).
Install O-ring (6-8) and backup ring (6-9) onto plug (6-5), then fasten the plug.
Install the spring seat (6-2), springs (6-3) and spool end (6-4), then fasten the spool end.
Install poppet (8-6) and spring (8-7) into the hole in spool (8).
Next, apply adhesive to the threaded part of the spool to which plug (8-5) is to be installed.
Install O-ring (8-8) and backup ring (8-9) onto plug (8-5), then fasten the plug.
Apply adhesive to the threaded part of spool to which spool end (8-4) is to be installed.
Install spring seat (8-2), spring (8-3) and spool end (8-4). Secure the spool between blocks with a vise and
tighten the spool end.
Tightening torque: 9.8 to 11.8 Nm.
WARNING: Be careful to assemble O-rings and backup rings in the correct locations. If installed backwards, Orings may break and this may lead to malfunctioning.
2 Sub-spool section (41 and 48)

1) Apply adhesive to the threaded parts of spools (41 and 48).
2) Install spring seat (43), spring (44) and spool end (45). Secure the spool between blocks in a vise and
tighten spool end (45).
Tightening torque: 19 to 22 Nm.
3 Sub-spool section (52)
1) Install backup ring (53) and O-ring (54) on sleeve (52-2).
2) Install a seal onto sleeve (52-2), then install piston (52-3) into the sleeve.
3) Insert spool (52-1) into sleeve (52-2).
4 Boom and arm anti-drift valves
1) Install O-rings (30-9 and 30-10) and backup rings (30-11 and 30-12) in the groove around sleeve (30-6).
WARNING: Be careful to assemble O-rings and backup rings in the correct locations. If installed backwards, Orings may break and increase the natural drop of the actuator.
2) Insert poppet (30-2) and spool (30-5) into the sleeve holes, taking care to orient them correctly.
3) Attach spring seat (30-15) onto the smaller poppet end, place spring (30-8) on spring seat, and then insert
together with sleeve into the hole in body (30-1).
4) Secure body (30-1) in a vise so that the mating faces of the body and the fitting side of the O-ring (31) are
not damaged.
WARNING: Apply grease to seats so that the springs and the spring seats are seated firmly on the poppet.
If the spring is not seated on the spring seat, the spring may be broken by the spring seat, and the broken
pieces may travel through the flow passage and cause malfunctioning of moving parts.
5) Install spring (30-7) and piston (30-4) onto plug (30-3).
6) Install an O-ring on plug assembly (30-14), then tighten the assembly onto plug (30-3).
Tightening torque: 147 to 157 Nm
7) Install O-ring (30-13) on plug (30-3), then tighten the plug onto body (30-1).
ASM-19-07-001
Issued 08-2008
8011-9
5 Shut-off Valve
1) Install spring (30-7) and piston (30-4) onto plug (30-3).
WARNING: Be careful to assemble O-rings and backup rings in the correct locations. If installed backwards, Orings may break and lead to malfunctioning.
2 Assembling the Control Valve Main Body

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

Be careful not to dent or scratch the mating surfaces when installing add-on sections. At the same time, be
careful to keep foreign substances from lodging between mating surfaces and to keep O-rings from falling off or
protruding.
WARNING: When installing add-on sections, always install the tie rod first and use it as a guide in positioning
the installation.
If positioned without using the tie rod, the incorrectly aligned O-ring on the mating surface may cause oil
leakage, which may cause malfunctioning.
6) Fasten hexagonal nut (74) onto tie rod (73).
Tightening torque: 152 7 Nm
Fasten hexagonal nut (72) onto tie rod (71).
Tightening torque: 93 4 Nm
WARNING: Always fasten hexagonal nuts to within the specified torque range. Undertorquing may cause oil
leakage from the mating surfaces due to lack of fastening force. Overtorquing may cause the spool to stick due
to distortion of the valve housing for the spool section, causing the actuator to overrun unstoppably.
Tighten the two nuts alternately so that they will be tightened equally.
WARNING: This control valve is designed so that add-on sections supplied as kits can be added on afterwards.
When adding add-on sections, always follow the same precautions as for disassembly and reassembly.
ASM-19-07-001
Issued 08-2008
8011-10
2 Assembling Travel Right, Swing, Bucket, Booms 1 and 2, Arm 1 and Blade load check sections
1) Insert poppets (16) (80-6) and springs (17) (80-7) into the valve housing.
2) Install O-rings (18) (80-8) on plugs (19) (80-9), then screw in and tighten the plugs.
3 Assembling the Arm 2 load check section
1) Assemble spring (35) and poppet (34) around the perimeter inside sleeve (33), then insert the sleeve into
the valve housing with poppet (36) and spring (37) inside.
2) Install O-ring (38) onto the groove of the valve housing. Install flange (39) and fasten with socket head bolts
(68).
WARNING: When installing flange (39), ensure that spring (37) is firmly seated in the flange seat. If the spring is
not seated when assembled, it may break.
When tightening socket head bolts (68), tighten the 2 bolts alternately so that they will be tightened equally.
Observe this precaution when fastening flanges in the instructions below.
4 Assembling the check on the Travel restrictor section (Travel Left section)
1) Insert poppet (26) and spring (17) into the valve housing.
2) Install O-ring (18) on plug (19), then fasten the plug.
WARNING: When installing the flange (19), ensure that the spring (17) is firmly seated in the plug seat. If the
spring is not seated firmly when assembled, it may break.
Observe this precaution when fastening plugs in the instructions below.
5 Assembling the backup external confluence check section

2) Install O-ring (18) on plug (23) and fasten the plug.
3) Install O-ring on plug assembly (81) and fasten the assembly.
6 Assembling the common check section
7 Assembling the Arm 1 semi-parallel check section
1) Insert poppet (57) and spring (58).
2) Install O-ring on plug (32) and fasten the plug.
ASM-19-07-001
Issued 08-2008
8011-11
8 Assembling the boom and the anti-drift valve
1) Install O-ring (31) on the mating surface.
2) Insert poppet (27) into the valve housing.
3) Install O-rings (29-2 and 29-4) and backup ring (29-3) on spacer (29-1). Press the spacer into the valve
housing together with spring (28).
WARNING: Be careful to assemble so that the spring is seated correctly on the spacer seat.
If the spring is not seated on the spacer, it may be broken by the poppet, and broken pieces may travel through
the flow passage and cause malfunctioning of moving parts.
4) Pass socket head bolt (67) through body assembly (30) and fasten.
9 Assembling the relief valves

1) Screw in overload relief valves (63) and tighten: total 8 locations.
2) Screw in main body main relief valve (62) and tighten.
3) Screw in add-on main relief valve (79) and tighten.
4) Screw in negative control relief valve (55) and tighten.
10 Assembling the subassembly spools (41 and 48)
1) Assemble spool assemblies (41 and 48) in the same locations as before disassembly.
2) Install O-rings (42) on caps (46 and 47) and install the caps. Pass socket head bolt (66) through the caps
and fasten.
Tightening torque: 8.8 to 10.5 Nm.
WARNING: Hold the spool perpendicular to the hole and insert slowly.
After insertion, slide the spool back and forth by hand to make sure it does not move unevenly or roughly. If the
spool is inserted so that it moves unevenly or roughly, it may malfunction.
Observe this precaution when inserting spools in the instructions below.
11 Assembling the sub-spool (52)

1) Assemble spool assembly (52) in the same location as before disassembly.
2) Install spring (51).
ASM-19-07-001
Issued 08-2008
8011-12
12 Assembling the main spools (2 through 10) (80-2)
1) Install O-ring (12) (80-4) on the valve housing (1) (80-1).
2) Install short cap (14) on Travel Straight spool (10). Install short caps (13) (80-5) on all the other spools. Pass
socket head bolts (65) (80-12) through the caps and fasten.
3) Install spools (2 through 10) (80-2), assembled as a subassemblies, into spool holes in the same locations
as before disassembly.
4) Install long cap (15) on Travel Straight spool (10). Install long caps (11) (80-3) on all the other spools. Pass
socket head bolt (65) through the long caps and fasten.
WARNING: Be careful that the mating surface O-rings do not fall off when installing the caps.
13 Assembling the other plugs

1) Install an O-ring on plug assembly (90) and fasten the assembly.
2) Install O-rings on plug assemblies (32) (61-2) and fasten the assemblies.
5) Install O-rings on plug assemblies (69) (78-2) and fasten the assemblies.
WARNING: After completing the assembly, check for parts that may have been forgotten or not tightened.
Forgetting to tighten parts will cause oil leakage from loose parts.
All tightening torque values are for under wet conditions (with hydraulic oil applied).
ASM-19-07-001
Issued 08-2008
8011-13
5 Relief valves
1 Instructions for Disassembling and Assembling the Main body Relief Valves
AQ23002-001
[1] Disassembling
This component must be replaced as an assembly.
When disassembling, loosen plug (1) (WAF: 32) with a wrench or the like and remove O-ring (2).
If oil is leaking from the adjuster kit section (3), loosen the kit and replace the O-rings (4).
WARNING: When disassembling the adjuster kit, be careful that parts do not fly out due to the spring, and be
careful not to lose the poppet.
[2] Assembling
Make sure there is no dirt or paint chips around the threaded section of plug (1) and install a new O-ring (2).
Thoroughly clean the area where the relief valve is to be installed on the valve housing as well. Install the relief
valve and fasten plug (1).
If the adjuster kit has been disassembled, thoroughly clean around the threaded part, then adjust the pressure
according to 5. Adjusting the Relief Valves.
WARNING: All the above tightening torque values are for under wet conditions (with hydraulic oil applied).
ASM-19-07-001
Issued 08-2008
8011-14
2 Instructions for Disassembling and Assembling the Add-on Relief Valves
[1] Disassembling
When replacing, loosen plug (1) (WAF: 32) with a wrench or the like and remove O-ring (2).
If there is leakage from the adjuster kit section (3), loosen the adjuster kit and replace the O-rings (4).
[2] Assembling
Thoroughly clean the area where the relief valve is to be installed on the valve housing as well. Install the relief
valve and fasten plug (1).
If the adjuster kit has been disassembled, thoroughly clean around the threaded part, then adjust the pressure
ASM-19-07-001
Issued 08-2008
8011-15
3 Instructions for Disassembling and Assembling the Overload Relief Valves
AQ23002-002
[1] Disassembling
When replacing it, loosen cap (1) (WAF: 32) with a wrench, etc. and remove O-ring (2).
If there is a leak from the adjuster kit section (3), loosen the adjuster kit and replace the O-rings (4).
[2] Assembling
Make sure there is no dirt or paint chips around the threaded section of cap (1) and install a new O-ring (2). Thoroughly clean the area where the relief valve is to be installed on the valve housing as well. Install the relief valve
and fasten cap (1).
If the adjuster kit has been disassembled, thoroughly clean around the threaded part, and adjust the pressure
4 Instructions for Disassembling and Assembling the Negative Control Relief Valves
1 Disassembling
This component cannot be disassembled because Section D is press fit. It must be replaced as an assembly.
2 Assembling
Install a new O-ring (4) on sleeve (2).
Thoroughly clean the area where the relief valve is to be installed on the valve housing as well. Install and fasten
the relief assembly plug (1).
ASM-19-07-001
Issued 08-2008
8011-16
5 Adjusting the Relief Valves
1 Main relief valves
(procedure is the same for the main body and add-on relief valves)
1) Attach an accurate pressure gauge at the entry circuit.
2) Run the pump at its rated rpm.
3) Switch spools on the control valve. Read the pressure gauge with the cylinder at stroke end.
WARNING: Switch spools on the actuator, in which the set pressure of the overload relief valve is higher than
that of the relief valve.
4) Turn the adjuster clockwise until the required pressure is obtained. One turn of the adjuster increases the
pressure by 17.8 MPa.
5) When the pressure reaches the specified value, press down on the adjuster to stop the rotation, then fasten
the lock nut.
2 Overload Relief Valve
WARNING: If the set pressure of the overload relief valve is higher than that of the main relief valve, do not
adjust the overload relief valve. Replace it with a pre-set relief valve as an assembly.
1) Switch spools on the control valve. Read the pressure gauge with the cylinder at stroke end.
2) Turn the adjuster clockwise until the required pressure is obtained.
One turn of the adjuster increases the pressure by 21.2 MPa.
3) When the pressure reaches the specified value, press down on the adjuster to stop the rotation, then fasten
the lock nut.
4) Increase the pressure again to verify that the specified pressure has been obtained.
6 Installation
1) Piping should be done with caution to avoid excessive outside pressure on the valves.
2) Fasten all mounting bolts equally.
3) Use caution when welding closely to the valves. Seals may be damaged by excessive heat and sputter.
4) To keep foreign substances from getting into ports, do not remove coverings until starting piping work.
7 Operation
1) Verify that hydraulic circuits and hydraulic oil are clean before starting operation.
2) Use hydraulic oil with an aniline point between 82 and 113 C.
3) Do not exceed the specified set pressure of the relief valve.
4) There must be a difference of 2.0 MPa or more between the set pressures of the main valve and the overload
valve.
5) Bleed air and warm up the machine completely before actual operation.
In particular, if the hydraulic oil temperature and the valve temperature are low, follow the precautions below at
start-up in order to prevent the spool from sticking due to heat shock:
Do not attempt sudden continuous operation of the main relief valve or the overload valve. Let the hydraulic oil
in all the actuators circulate so the temperature rises uniformly in all the sections.
Sudden fine adjustments or combined operations at low temperatures generate heat locally due to throttling of
all sections and must be avoided.
ASM-19-07-001
Issued 08-2008
8011-17
8 List of control valve specifications

Rated flow (main body): 160 L/min (Note: 30 L/min in neutral)
Maximum pressure (main body): 35 MPa
Rated flow (add-on Pr): 70 L/min
Maximum pressure (add-on Pr): 28 MPa
Allowable back pressure
Peak pressure: < or = 1.5 MPa
Pressure for normal operation: > or = 0.5 MPa
Allowable oil operating temperature range
For normal operations: -25 to 80C
Instantaneous maximum: 100C
(Nitrile rubber is used for seals)
9 Troubleshooting
1 Control valves in general
Problem
Spool does not cycle.
Cause
Remedy
1. Abnormal increase in oil temperature.
Remove cause of resistance in oil flow from pipe.
2. Dirty hydraulic oil.
Replace hydraulic oil and clean circuit.
3. Over-tightened port joints in piping.
Check torque.
4. Valve housing deformed at time of

installation.
Loosen mounting bolts and check.
5. Pressure is too high.
Attach pressure gauges to pump port and cylinder

port to check pressure.
6. Spool is bent.
Replace as a valve assembly.
7. Damaged return spring.
Replace damaged parts.
8. Spring or cap is crooked.
Loosen cap; center and retighten.
9. Uneven temperature distribution in

valve.
Warm up entire circuit.
10. Valve is blocked by dirt.
Flush to remove dirt.
11. Insufficient pilot pressure.
Check pilot valve and pilot relief pressure.
1. Oil leakage from cylinder.
Check cylinder seals.
2. Oil bypassing from spool.
Check spool for damage.
3. Oil leakage from overload relief valve.
Clean valve housing seat and relief valve seat.
4. Oil leakage from anti-drift valve.
Disassemble anti-drift valve and clean seats in all

parts.
If seats are damaged, replace poppet, or lap poppet and seats.
If a problem is found in the anti-drift valve, replace
spools and sleeves at the same time because
they are fit together.
1. Dirt in load check valve.
Disassemble and clean check valve.
2. Damaged poppet or seat in check

valve.
Replace poppet, or lap poppet and seat.
Cannot hold load.
Load drops when spool

is switched from neutral
to upward position.
ASM-19-07-001
Issued 08-2008
8011-18
2 Relief valves
Problem
Cause
Pressure does not rise

at all.
1. Main poppet, sleeve or pilot poppet is

stuck open, or there is dirt in the seat
section.
Unstable relief pressure.

Incorrect relief pressure.
1. Pilot poppet seat is damaged.
Replace relief valves.
2. Piston or main poppet is stuck.

1. Seat is worn by dirt.
2. Loose lock nut or adjuster.
1. Damaged seat in relief valve.
Oil leakage.
Remedy
2. Parts are stuck because of dirt.

3. Worn O-ring.
Reset pressure, then fasten lock nut to specified

torque.
Replace relief valves.
Replace adjusters or O-rings in mounting section.
3 Hydraulic system in general

Problem
Hydraulic system does

not function properly or
does not operate at all.
ASM-19-07-001
Cause
Remedy
1. Faulty pump.
Check pressure or replace pumps.
2. Faulty relief valve.
Replace relief valves
3. Faulty cylinder.
Repair or replace.
4. Pump load pressure is too high.
Check pressure in circuit.
5. Cracks on valves.
Replace as a valve assembly.
6. Incomplete spool stroke.
Check spool movement.
7. Oil level in tank is too low.
Refill with hydraulic oil.
8. Blocked filter in circuit.
Clean or replace filter.
9. Restricted piping in circuit.
Check piping.
Issued 08-2008
8011-19
10Reference Drawing
1 Parts list
Sym
Part name
Qty
Sym
Part name
Qty
Sym
Part name
Qty
Valve housing
29
Spring
57
Plug
Spool section assembly
30
Spool
58
Shut-off valve assembly
Inlet section assembly
31
Plug
59
Plug
Spool
32
Spring
60
Relief valve kit
Spool
33
Outlet housing
61
Relief valve kit
Spool
34
Spacer
62
Plug assembly
Spool
35
O-ring
63
Plug assembly
Spool
36
Backup ring
64
Plug assembly
Spool
37
Sleeve
65
Plug
10
Spool
38
Plate
66
O-ring
11
Spool
39
Socket head bolt
44
67
Plug
12
Spool
40
Anti-drift valve assembly
68
Spacer
13
Spool
41
Poppet
69
Poppet
14
Cap
10
42
Spring
70
Spring
15
Cap
10
43
Socket head bolt
71
Tie rod
16
Spring
44
Sleeve
72
Nut
17
Spool end
10
45
Poppet
73
O-ring
18
Spring seat
20
46
Spring
74
O-ring
19
O-ring
20
47
Poppet
75
O-ring
20
Spring
48
Plug
76
O-ring
21
Plug assembly
49
Spring
77
Name plate
22
Sleeve
50
O-ring
78
Drive screw
23
O-ring
51
Sleeve
79
O-ring
24
Backup ring
52
Poppet
80
Spool section assembly
25
Plug assembly
14
53
Spring
81
Relief valve kit
26
Poppet
54
Plug
82
Relief valve kit
27
Spring
55
O-ring
28
Plug assembly
56
Poppet
ASM-19-07-001
Issued 08-2008
8011-20
2 Overall View 1/3
Arm 1
Boom 2
Swing
Backup
Travel
(right)
KAJ5076S1D01
ASM-19-07-001
Issued 08-2008
8011-21
Blade
W-W
Boom swing
Arm 2
Boom 1
Bucket
Travel
(left)
Travel
(Straight)
KAJ5076S1D01
ASM-19-07-001
Issued 08-2008
8011-22
3 Overall View 2/3
Arm 1
Boom 2
Swing
Option
Travel
(right)
5 spool side
A-A
KAJ5076S2D01
ASM-19-07-001
Issued 08-2008
8011-23
Blade
Boom swing
Arm 2
Boom 1
Bucket
Travel
(left)
Travel
(straight)
KAJ5076S2D01
B-B
(4-Speed side)
ASM-19-07-001
Issued 08-2008
8011-24
D-D
Arm 1
Arm 2
KAJ5076S2D01
E-E
ASM-19-07-001
Issued 08-2008
8011-25
4 Overall Drawing 3/3
Boom 2
Boom 1
F-F
Travel
(right)
Travel
(straight)
KAJ5076S3D01
I-I
ASM-19-07-001
Issued 08-2008
8011-26
Swing
Bucket
G-G
KAJ5076S3D01
J-J
ASM-19-07-001
Issued 08-2008
8011-27
Option
Travel
(left)
KAJ5076S3D01
H-H
ASM-19-07-001
Issued 08-2008
8011-28
5 Reference number (2): Spool section assembly
KAJ5076S6B00
W-W
1.
2.
3.
4.
5.
6.
7.
8.
9.
Valve housing (1)

Spool (1)
Cap (1)
Cap (1)
Spool end (1)
Spring (1)
Spring seat (2)
Poppet (1)
Plug (1)
ASM-19-07-001
10.
11.
12.
13.
14.
15.
16.
17.
Spring (1)
O-ring (2)
O-ring (2)
O-ring (1)
O-ring (2)
O-ring (1)
Socket head bolt (4)
Issued 08-2008
8011-29
6 Reference number (3): Inlet section assembly
B-B
AS07001-004
1.
2.
3.
4.
Inlet housing (1)

Relief valve kit (1)
Plug assembly (1)
Plug assembly (1)
ASM-19-07-001
5.
6.
7.
8.
O-ring (1)
O-ring (1)
O-ring (2)
O-ring (1)
Issued 08-2008
8011-30
7 Reference number (40): Anti-drift valve assembly
AS07001-005
1.
2.
3.
4.
5.
6.
7.
8.
Body (1)
Poppet (1)
Plug (1)
Piston (1)
Spool (1)
Sleeve (1)
Spring (1)
Spring (1)
ASM-19-07-001
9.
10.
11.
12.
13.
14.
15.
16.
O-ring (1)
O-ring (1)
Backup ring (1)
Backup ring (1)
O-ring (1)
Plug assembly (1)
O-ring (2)
Spring seat (1)
Issued 08-2008
8011-31
8 Reference number (29): Shut-off valve assembly
AS07001-006
1. Poppet (1)
2. O-ring (1)
3. O-ring (1)
ASM-19-07-001
4. Plug (1)
5. Hexagon nut (1)
6. Set screw (1)
Issued 08-2008
8011-32
NOTES
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ASM-19-07-001
Issued 08-2008
8012
Copyright
Section
8012
ASSEMBLY AND DISASSEMBLY OF THE
CNH
Lep SM75SR8012-0EN

Printed in France
August 2008
Copyright
8012-2
Lep SM75SR8012-0EN
Issued 08-2008
Copyright
8012-3
TABLE OF CONTENTS
CYLINDER ............................................................................................................................................................... 4
STRUCTURAL DRAWINGS ....................................................................................................................................... 4
Boom cylinder ................................................................................................................................................... 4
Dipper cylinder (mono boom spec.) .................................................................................................................. 6
Dipper cylinder (offset boom spec.) .................................................................................................................. 8
Bucket cylinder (mono boom spec.)................................................................................................................ 10
Bucket cylinder (offset boom spec.) ................................................................................................................ 12
Offset cylinder (offset boom spec.) ................................................................................................................. 14
Blade cylinder.................................................................................................................................................. 16
Swing cylinder ................................................................................................................................................. 18
MAINTENANCE INSTRUCTIONS .............................................................................................................................. 20
Description of functions................................................................................................................................... 20
Maintenance/Inspection and Servicing ........................................................................................................... 24
Error diagnosis ................................................................................................................................................ 25
Storage standards........................................................................................................................................... 29
Instructions for disassembling and assembling............................................................................................... 30
SPECIAL JIGS FOR REPAIR ................................................................................................................................... 44
Dimensions of Tools........................................................................................................................................ 44
Handling the Jigs for Cylinder Repair.............................................................................................................. 45
Structure and features of jigs for cylinder repair ........................................................................................... 46
List of jigs ...................................................................................................................................................... 48
Handling jigs.................................................................................................................................................. 49
Lep SM75SR8012-0EN
Issued 08-2008
Copyright
8012-4
CYLINDER
1 Structural drawings
KAV2434X-B
1 Boom cylinder
CX75SR - CX80
ASM-17-24-002
Issued 08-2008
Copyright
8012-5
No.
Part name
Qty
No.
Part name
Qty
No.
Part name
Qty
Tube
13
Cushion seal
25
Pipe
Rod
14
Collar
26
Pipe
Cylinder head
15
Backup ring
27
Plug
Bushing
16
Cushion seal
28
O-ring
Snap ring
17
Piston
29
Nipple
Buffer ring
18
Seal ring
30
O-ring
U-ring
19
Slide ring
31
Pipe holder
Wiper ring
20
Nut
32
Bolt
O-ring
21
Set screw
33
Grease nipple
10
Backup ring
22
Steel ball
34
Grease nipple
11
O-ring
23
Pin bushing
12
Holder
24
Wiper ring
Weight: 103 kg
ASM-17-24-002
Issued 08-2008
Copyright
8012-6
HOLE (1)
KAV2436X-B
2 Dipper cylinder (mono boom spec.)

CX75SR - CX80
ASM-17-24-002
Issued 08-2008
Copyright
8012-7
No.
Part name
Qty
No.
Part name
Qty
No.
Part name
Qty
Tube
14
Spacer
27
Pin bushing
Rod
15
Collar
28
Wiper ring
Cylinder head
16
Backup ring
29
Pin bushing
Bushing
17
Cushion seal
30
Wiper ring
Snap ring
18
Piston
31
Nipple
Buffer ring
19
Seal ring
32
Pipe
U-ring
20
Slide ring
33
Plug
Wiper ring
21
Set screw
34
O-ring
O-ring
22
Steel ball
35
Pipe holder
10
Backup ring
23
Cushion seal
36
Bolt
11
O-ring
24
Pin bushing
37
Grease nipple
12
Holder
25
Stopper
13
Cushion seal
26
Snap ring
Weight: 78 kg
ASM-17-24-002
Issued 08-2008
Copyright
8012-8
KAV2438X-B
3 Dipper cylinder (offset boom spec.)

CX75SR
ASM-17-24-002
Issued 08-2008
Copyright
8012-9
No.
Part name
Qty
No.
Part name
Qty
No.
Part name
Qty
Tube
14
Spacer
27
Snap ring
Rod
15
Collar
28
Pin bushing
Cylinder head
16
Backup ring
29
Wiper ring
Bushing
17
Lock washer
30
Pin bushing
Snap ring
18
Cushion seal
31
Pipe
Buffer ring
19
Piston
32
Pipe
U-ring
20
Seal ring
33
Plug
Wiper ring
21
Slide ring
34
O-ring
O-ring
22
Set screw
35
Nipple
10
Backup ring
23
Steel ball
36
O-ring
11
O-ring
24
Cushion ring
37
Pipe holder
12
Holder
25
Cushion seal
38
Bolt
13
Cushion seal
26
Stopper
39
Grease nipple
Weight: 81 kg
ASM-17-24-002
Issued 08-2008
Copyright
8012-10
KAV2440X-B
4 Bucket cylinder (mono boom spec.)

CX75SR - CX80
ASM-17-24-002
Issued 08-2008
Copyright
8012-11
No.
Part name
Qty
No.
Part name
Qty
No.
Part name
Qty
Tube
11
O-ring
21
Pipe
Rod
12
Piston
22
O-ring
Cylinder head
13
Seal ring
23
Bolt
Bushing
14
Slide ring
24
Pipe
Snap ring
15
Set screw
25
Plug
Buffer ring
16
Steel ball
26
O-ring
U-ring
17
Pin bushing
27
Pipe holder
Wiper ring
18
Wiper ring
28
Bolt
O-ring
19
Pin bushing
29
Grease nipple
10
Backup ring
20
Wiper ring
Weight: 61 kg
ASM-17-24-002
Issued 08-2008
Copyright
8012-12
KAV2441X-B
5 Bucket cylinder (offset boom spec.)

CX75SR
ASM-17-24-002
Issued 08-2008
Copyright
8012-13
No.
Part name
Qty
No.
Part name
Qty
No.
Part name
Qty
Tube
11
O-ring
21
Pipe
Rod
12
Piston
22
Plug
Cylinder head
13
Seal ring
23
O-ring
Bushing
14
Slide ring
24
Nipple
Snap ring
15
Set screw
25
O-ring
Buffer ring
16
Steel ball
26
Pipe holder
U-ring
17
Pin bushing
27
Bolt
Wiper ring
18
Wiper ring
28
Grease nipple
O-ring
19
Pin bushing
29
Grease nipple
10
Backup ring
20
Wiper ring
Weight: 61 kg
ASM-17-24-002
Issued 08-2008
Copyright
8012-14
KAV2442X-B
6 Offset cylinder (offset boom spec.)

CX75SR
ASM-17-24-002
Issued 08-2008
Copyright
8012-15
No.
Part name
Qty
No.
Part name
Qty
No.
Part name
Qty
Tube
11
O-ring
21
O-ring
Rod
12
Piston
22
Nipple
Cylinder head
13
Seal ring
23
O-ring
Bushing
14
O-ring
24
Pipe holder
Snap ring
15
Set screw
25
Bolt
Buffer ring
16
Steel ball
26
Grease nipple
U-ring
17
Pin bushing
Wiper ring
18
Wiper ring
O-ring
19
Pipe
10
Backup ring
20
Plug
Weight: 41 kg
ASM-17-24-002
Issued 08-2008
Copyright
8012-16
KAV2085X-B
7 Blade cylinder
CX75SR - CX80
ASM-17-24-002
Issued 08-2008
Copyright
8012-17
No.
Part name
Qty
No.
Part name
Qty
No.
Part name
Qty
Tube
11
Seal ring
21
Pipe holder
Rod
12
Slide ring
22
Bolt
Cylinder head
13
Set screw
23
Grease nipple
Bushing
14
Steel ball
Snap ring
15
Pin bushing
Buffer ring
16
Wiper ring
U-ring
17
Pin bushing
Backup ring
18
Pipe
O-ring
19
Plug
10
Piston
20
O-ring
Weight: 34 kg
ASM-17-24-002
Issued 08-2008
ASM-17-24-002
INSIDE DETAIL
FREE SCALE
HOLE(1)
TYPE-A
PT1/8
LOCATION OF THE SLIT IS

SHOWN IN THE DRAWING
2-PT1/8(WITH PLASTIC CAP)
STROKE 640
CUSHION STROKE
TIGHTENING TORQUE 1830 Nm

(M45 x 3 HEX WAF 70)
CUSHION STROKE
S SECTION DETAIL
(NOT SCALED PROPORTIONALLY)
TIGHTENING TORQUE
17.2 0.9 Nm (2-M8 x 1.25)
CLOSED 1085
FROM BOTTOM
PIN CENTER
LOCATION OF THE SLIT IS
SHOWN IN THE DRAWING
TIGHTENING TORQUE 31.5 5.88 Nm

(M10 x 1.5)CAULKING(2 PLACES)
MANUFACTURING No. STAMPING POSITION
TIGHTENING TORQUE 669 Nm(M102 x 2)

APPLY THREE BOND #1901 TO THE THREADS
PS1/8
WITH PLASTIC CAP
PIPE ATTACHMENT (2 PLACES)
KAV2787P1C01
SECTION Y-Y
PORT DETAIL (2 PLACES)
TIGHTENING TORQUE
76.4 3.8 Nm (M16 x 1.5)
THE SPACER HAS AN IDENTIFICATION

GROOVE ON ITS CIRCUMFERENCE
WEIGHT: 56 kg
Copyright
8012-18
8 Swing cylinder
CX80
Issued 08-2008
Copyright
8012-19
No.
Part name
Qty
No.
Part name
Qty
No.
Part name
Qty
Tube
13
Cushion seal
25
Stopper
Rod
14
Spacer
26
Snap ring
Cylinder head
15
Collar
27
Pin bushing
Bushing
16
Backup ring
28
Wiper ring
Snap ring
17
Cushion seal
29
Pipe
Buffer ring
18
Piston
30
Pipe
U-ring
19
Seal ring
31
Plug
Wiper ring
20
Slide ring
32
O-ring
O-ring
21
Set screw
33
Pipe holder
10
Backup ring
22
Steel ball
34
Bolt
11
O-ring
23
Cushion seal
35
Grease nipple
12
Holder
24
Pin bushing
Weight: 56 kg
ASM-17-24-002
Issued 08-2008
Copyright
8012-20
1 Description of functions
1) Basic functions
The hydraulic piston system is a kind of hydraulic actuator which converts hydraulic energy supplied from the
hydraulic pump into a larger force for linear movement via a piston. In addition, it switches its operational direction
between extension and retraction by way of lever operation on the hydraulic oil direction switch-over valve.
This larger force, linear movement, and operational direction switching over are the basic functions.
2) Function by section
1) Cylinder head assembly

The piston assembly has a bearing function for the piston rod (2) provided by means of bushing (4) press fitted into the inside surface of cylinder head (3). It prevents external oil leakage by means of a buffer ring
(6), U-ring (7) and backup ring (8) inserted into the inside surface of cylinder head. It also prevents dust
from the outside by means of a wiper ring (9) press fitted into the inside surface of the cylinder head.
Engaging with the cushion bearing (13) at the cylinders most extended position, it generates high pressure in the cushion chamber and this softens the cylinders impact at the most extended position.
In addition, it also supplies and drains high-pressure oil from the inside of cylinder tube to the ports.
C
A
AQ24002-001
A: Black, B: Green, C: Split

Bushing (4)
The bushing is press fitted into the inner face of the cylinder head and is in contact with the piston rod. It
reduces eccentricity, which adversely affects the seal performance, by sharing lateral load applied on the
cylinder together with the slide ring located on the outer circumference of the piston, performing high-bearing linear motion against the piston rod, as well as supporting one end of the piston rod.
ASM-17-24-002
Issued 08-2008
Copyright
8012-21
Buffer ring (6)
The buffer ring is composed of a slide ring and a square ring and is located between the
U-ring and bushing. It prolongs the life of the U-ring, which is the main seal, by relieving high pressure with
the auxiliary seal which is directly in contact with the high pressure oil in the cylinder, and reducing the load
acting on the U-ring.
U-ring (7)
The U-ring is located between the wiper ring and the buffer ring. The U-ring seals the annular space formed
between the piston rod and cylinder head against the pressure oil
between the U-ring and the backup ring. It also forms suitable oil films on the piston rod to prevent rust.
Wiper ring (9)
The wiper ring is located at the opening end where the piston rod enters into and exits from the cylinder. It
prevents dust and water from entering into the rod seal section of the U-ring and the buffer ring in the cylinder from the outside. It also scrapes off mud attached on the surfaces of piston rod through piston rod movements.
2) Piston assembly
The piston assembly has the function of transmitting the propulsion of the cylinder. A seal ring (16) is
mounted on the center of the piston (15) to prevent the flow of pressurized oil from either the left or right
chamber to the other chamber. There are slide rings (18) and (19) mounted at each end of the seal ring.
They have the function of a bearing to receive the cylinder lateral load.
2
13
14
15
16
17
18
19
20 21
25
23
22
24
Use caution with the direction of the cut surfaces during installation
Face "the split" to the piston side.
RM15001-070
1.
2.
13.
14.
15.
16.
17.
18.
Cylinder tube
Piston rod
Cushion ring
Cushion seal
Piston
Seal ring
Backup ring
Slide ring
ASM-17-24-002
19.
20.
21.
22.
23.
24.
25.
Slide ring
Locking screw
Steel ball
Cushion ring
Cushion seal
Stopper
Snap ring
Issued 08-2008
Copyright
8012-22
For some cylinder sizes, the piston (15) and nut (21) are separate.
13
14
15
16
17
18
19
20
21
22 23
27
25
24
26
Use caution with the direction of the cut surfaces during installation
Face "the split" to the piston side.
RM15001-071
1.
2.
13.
14.
15.
16.
17.
18.
19.
Cylinder tube
Piston rod
Cushion ring
Cushion seal
Piston
Seal ring
Backup ring
Slide ring
Slide ring
20.
21.
22.
23.
24.
25.
26.
27.
Shim
Nut
Locking screw
Steel ball
Cushion ring
Cushion seal
Stopper
Snap ring
Example of parts numbers for separated piston and nut.

Seal ring (16) and backup ring (17)
The seal ring (16) is positioned at the center of the piston (15) and uses the tension force of the O-ring to
seal the ring-shaped gap between the piston and the cylinder tube (1) and form chambers with a high-pressure side and a low-pressure side with the piston as the boundary. The backup ring (17) has the function of
suppressing extrusion of the seal ring into the gap between the piston and the cylinder tube when the pressure operates and of improving durability.
Slide ring (18) and (19)
Slide rings are positioned at both ends of the seal ring (16) and contact the inside surface of the cylinder
tube (1). Together with the bushing (4) positioned on the inside surface of the cylinder head (3), the slide
ring divides the lateral load applied to the cylinder and moves linearly relative to the inside surface of the cylinder tube.
Furthermore, it supports one end of the piston rod (2) and has the functions of minimizing eccentricity, which
has a negative impact on the sealing, and buries and captures any impurities trapped between the cylinder
tube and the slide rings (18) and (19).
Cushion ring (13) and (24)
When the cylinder is fully extended, the cylinder head (3) and the cushion ring (13) fit together. When it is
fully retracted, the cylinder bottom and the cushion ring fit together. In both cases, this forms a ring-shaped
gap and squeezes the oil to reduce the cylinder collision speed at full extension or full retraction and thus
soften the impact.
ASM-17-24-002
Issued 08-2008
Copyright
8012-23
3) Pipes (28) and (29)
A pair of pipes are located on each port on the extension and retraction side on the cylinder tubes (1). The
pipes supply and drain high-pressure oil from the flexible hose connection end to the cylinder tube port.
000-7-05-02-19c
ASM-17-24-002
Issued 08-2008
Copyright
8012-24
2 Maintenance/Inspection and Servicing
To gain full functions of hydraulic cylinder for a long time, conduct periodic inspections and servicing based on the
inspection table below.
Repair faulty sections as soon as possible.
NOTE: When conducting routine inspections and servicing, the first priority should be placed on the operators safety.
Conduct the operation using common knowledge and expertise.
Locations for
inspection /
servicing
Appearance
Operation
Hydraulic oil
Fitting section
onto the main
machine
Inspecting and servicing points
Daily
Is cylinder clean (especially sliding part of the rod)?
Is there any oil leakage from the piping fitting part?

O
Is movement smooth? Any abnormal noises?
Is response good?
Is there any oil leakage from the sliding parts?
Is there any internal leakage?
ASM-17-24-002
Notes
Is working pressure normal?
Is set pressure on over load relief valve normal?
Is the hydraulic oil dirty or deteriorated?
Is the hydraulic oil changed regularly?
Are filters changed regularly?
Is there enough grease on the pins?
Do the pins make noise or seize up?
Is there any looseness or wear on the pins?
Are the pin seals normal?
O
O
Retighten fitting screws.
Is there any wear on sliding parts?
Are there any scratches or dents on the sliding

parts?
Is plating scraped off on the sliding part?
Are any sliding parts bent?
Cylinder tubes
(including
piping)
Annually
Is there any paint peeling, scaling or rust?
Are there any loose or missing screws?
Piston rod
Monthly
If the sliding
part of the
rod is
exposed for
a long time,
apply corrosion inhibitor.
Are there any cracks on or damage to welded

parts?
Are any bolts, nuts (screws) loose?
Retighten bolts and nuts (screws).
Are there any cracks on or damage to welded

parts?
Are there any cavity or dents on the tube?
Issued 08-2008
Copyright
8012-25
3 Error diagnosis
1) Hydraulic cylinder errors and their remedy measures
It is not easy to locate faulty parts. General symptoms, possible reasons and remedy measures are shown in the
table below. For repairs, refer to the possible causes and remedy measures in the table.
However, it is often the case that machine troubles occur because not only one part but many other relating parts
have problems.
Measures other than ones shown in the table may be required.
Item
Symptom
Oil leakage on the sliding section of piston rod (for assessment values, refer to 5-(4) Inspections after
assembly).
Oil leakage from cylinder head fitting section
Oil leakage from welded section between pipe and cylinder tube
Bad operation
Item
Symptom
Related parts
Error item
Scratches and rust

caught by claws on
the sliding surface
1) Remove scratches with oilstone and smooth

the sliding surfaces (less than 1.5s). If the oil
leakage persists after smoothing the rod surfaces, disassemble and inspect the rod
because of possible damage in the U-ring
caused by the scratches.
2) If scratches and rust are too widespread to
repair, replace piston rod and seals such as
U-ring, wiper ring, etc. and piston rod bearing materials.
Plating is flaking
1) Re-plate or replace piston rod.

2) At this time, check seals and piston rod
bearing materials, and if damage is found,
replace them.
Foreign substances engaged

in the inside and
outside surfaces
1) Remove foreign substances.

2) If a packing is damaged, replace it.
Piston rod
Oil leakage on piston rod sliding

section
Scratches on
inside and outside
Rod packing
(buffer ring and surfaces
U-ring)
Lips and grooves
are locally carbonized (burned).
ASM-17-24-002
Preventive/remedy measures
Replace
1) Regarded as burning damage by air adiabatic compression caused by remaining air
in the cylinder.
2) Perform initial operation at low pressure and
low speed to bleed air fully after changing
packing.
Issued 08-2008
Copyright
8012-26
Item
Symptom
Related parts
Rod packing
(buffer ring and
U-ring)
Backup ring
Oil leakage on piston rod sliding

section
Wiper ring
Bearing
material
(Bushing)
Cylinder head
Oil leakage from

cylinder head fitting section
ASM-17-24-002
O-ring
Error item
Packing has lost

rubber elasticity
and is crumbling.
The whole lip is
also missing.
1) Replace.
2) The life of the packing or hydraulic oil deterioration or high temperature may e the
cause.
1. Change hydraulic oil.
2. Check hydraulic oil temperature.
(The oil temperature should be 80 C or
less.)
3. Check for uneven hot temperatures.
Heel part of the

packing.
Too much extrusion.
1) Replace.
2) Abnormal high pressure may act on the
packing.
1. Check the pressure when starting operation.
2. Abnormality in the buffer ring if the buffer
ring is attached. Inspect buffer rings.
Visible distortion
1) Change rod packings together, as a general

rule. (Buffer rings should be replaced at the
same time if attached).
2) Abnormally high pressure may have caused
this. In this case, check it by following the
same steps described above for the packing
heel extrusion.
Foreign substances engaged

in the lip
Remove foreign substances.
The lip is damaged.

Other abnormal
damages
Replace.
Extreme wear, the

clearance with piston rod exceeds
the allowable maximum value
(see 5-3. Maintenance reference)
Replace.
Significant damage in sliding surfaces
1) Replace.
2) Inspect the piston rod.
Scratches or rust
in seal fitting area.
1) Remove scratches and rust with an oil

stone.
2) If repair is not possible, replace the cylinder
head
Foreign substances on the

inside and outside
surfaces Damaged O-ring
1) Remove foreign substances.

2) If O-ring is damaged, replace it.
3) Inspect the tube inside: If scratches and rust
are found, smooth the surfaces with oilstone.
4) Check O-ring grooves in the cylinder head:
Same as above
5) Check backup rings:If distortion or extrusion
is found, replace it.
Change O-rings after confirming items
above.
Issued 08-2008
Copyright
8012-27
Item
Symptom
Related parts
Backup ring
Bad operation
4-1
Does not move
smoothly
1) Disassemble cylinder head to check O-rings

and backup rings.
If damage is found, replace it.
2) Check tube and cylinder head threaded sections to ensure that there is no damage.
If damage is found, replace it.
3) Upon completion of inspection, fasten with
specified tightening torque. Refer to Tightening torque.
Bolt
Looseness,
extension and
breakage
Replace all bolts and fasten them with specified

tightening torque.
Abnormal swelling
Replace with new ones.

Oil leakage on the fitting section may be caused by
abnormally high pressure
(including cushion pressure).
Check for bulging, deformation and circuit pressure
on the tubes.
Cracks on welded
section

WARNING:
Cracks will progress and end up with breakage.
- Breakage is a very dangerous condition.
- If cracks are found, immediately stop the operation and replace the parts.
- No effect can be gained if additional welding is
performed on cracked surfaces.
Cylinder tube
pipe
(hollow piston
rod)
Curved too much;

exceeds specified
curve distortion
level.
Piston rod,
(For curve distorcyclinder tubes
tion, see the corresponding section
in 5-3. Maintenance reference)

Check seals and sliding materials also
because they may be damaged. If abnormality is
found, replace.
Cylinder tubes
Replace with new ones. Same as above described,

check seals and sliding materials.
Dents
Abnormal wear
and damage on
the sliding parts
Piston rod,
cylinder tubes, Foreign sustances
sliding materals engaged in the piston and cylinder
head sliding parts
ASM-17-24-002
Change together with O-ring.
Looseness
Cylinder tubes
Distortion and
extrusion.
Cylinder head
Oil leakage from
cylinder head fitting section
Oil leakage from

welded section
between pipe
and cylinder tube
Error item
1) Replace with new ones. Same as above

described, check seals and sliding materials.
2) Remove foreign substances. Same as
above described, check seals and sliding
materials.
Issued 08-2008
Copyright
8012-28
Item
Symptom
4-2
Internal oil leakage makes the
piston rod extend
or retract or fall
abnormally while
operating or can
not give specified
speed output.
Related parts
Error item
Piston seal
Damage such as
scratches and
wear is found.
Cylinder tubes
Scratches and rust

on the inside surface.
Piston nut
Loose tightening.
Fasten with specified tightening torque. Refer to

Tightening torque.
Valves
Leakage from
valves.
Check the valve leakage volume and repair if necessary.
Replace with a new one. Also check the cylinders

inner face.
1) Remove scratches and rust by honing or
with oilstone to smooth the surfaces.
If scratches are too big to repair, replace cylinder tubes with new ones.
2) Replace piston seals with new ones.
WARNING: Hydraulic oil tends to expand and shrink according to changes in

temperature and pressure. This also causes cylinders to extend and retract; therefore, we
sometimes see this as internal oil leakage. Check internal oil leakage under a given
pressure condition.
4-3
Operation is not
stable.
Air
Air remains in the

cylinder.
1. Bleed air.
1) Cylinder without air bleeder: Bleed air by
operating the cylinder several full strokes
under low pressure and at a slow speed.
2) Cylinder with air bleeder: To prevent high
temperature inside the cylinder, remove the
load and loosen air bleeder to release air
fully.
When the cylinder stops suddenly, it can
extend or retract to a certain extent.
This phenomenon is caused by hydraulic oil
compressibility.
This phenomenon tends to occur especially
on long stroke cylinders.
4-4
Strong impact
when switching
over between
extension and
retraction.
Pin bushing
Pin
Too much clearance between the

fitting section and
pin bushing.
Measure the dimensions of pin and pin bushing,

replace the parts that exceed the measured dimensions.
Lubrication
Lack of lubrication.
Lubricate.
Pin bushing
Pin
Scuffing on fitting
surfaces.
Replace with a new one and lubricate.
4-5
Cylinder sliding
operation makes
noise.
WARNING: Hydraulic oil tends to expand and shrink according to changes in temperature and pressure.
This also causes cylinders to extend and retract; therefore, we sometimes see this as internal oil leakage.
Check internal oil leakage under given temperature and pressure conditions.
ASM-17-24-002
Issued 08-2008
Copyright
8012-29
4 Storage standards
We take all possible measures at the time of shipping hydraulic cylinders. However, in order to avoid trouble when
storing them, please handle them following the precautions below.
1) Storing one unit only (as a general rule, store indoors)
Avoid a place with high temperature and high humidity or a place where corrosive gas or liquid is stored. Store
the unit off the floor. To prevent condensation due to temperature difference, we conduct inspections by using test
oil with a given volume of volatile corrosion inhibitor, retract the piston rod using super dry air (dew point 35 C),
put caps when shipping.
Therefore, do not leave a cylinder with the cap removed or drain the remaining oil from the cylinder without clear
intention.
Storage for more than 1 months
Storage for more than 6 months

(3 months for single-acting cylinder)
Storage for more than one year
Clean dust from the cylinder and

apply corrosion inhibitor to flange
section, piston rod and other locations that rust easily.
1. Using clean hydraulic oil, let the

cylinder reciprocate to introduce corrosion inhibitor into the cylinder following the steps described in the left
column for 1 month storage.
1. As packing may be deteriorated, it

is desired to disassemble and
inspect, and replace the packing.
Also, check rust conditions on the
cylinder inner walls.
2. If the cylinder does not operate,

add corrosion inhibitor only.
2. If cylinders, which have been

stored for a long time, are used as
they are, there is possibility of oil
leakage because of temporary poor
sealing conformity.
3. Care is needed to avoid falling, collision, dislodgment and dents while storing.
2) At the time of installing devices
1.
Operate cylinder at least once every 1 months.
2.
Keep the piston rod in its retracted position, avoid exposure to outside air and apply corrosion inhibitor or grease to the
exposed parts at least once a month.
3.
Careful handling is necessary to avoid damage to piston rods.
4.
If cylinders are placed under conditions where they are exposed to salty wind (e.g. during exports), always apply corrosion inhibitor to piston rods and protect them as much as possible with polyethylene or V.C.I paper.
5.
Solutions such as corrosion inhibitors may have adverse effects on sealing materials. Therefore, careful selection and
handling is required to avoid getting oil on dust seals. (Recommended corrosion inhibitors are listed below.)
ASM-17-24-002
Issued 08-2008
Copyright
8012-30
5 Instructions for disassembling and assembling
1) Preparation
Before starting the disassembly, prepare the following items:
1) Prepare a workbench
2) Choose and prepare a stable and strongly built workbench large enough to arrange and keep parts and perform jobs.
2) General precautions for work
1) Before disassembly, fully rinse soil and dust attached to the cylinder outside walls.
2) As each part is a precision component, handle parts carefully and do not drop them or allow them to hit
each other.
3) Do not attempt to hit or pry parts forcedly because they are tightly fitted. Take time and carry out the operation carefully in order to avoid causing burrs or damage resulting in inability to reassemble a part, oil leakage
or lower efficiency.
4) If components are left disassembled or half-disassembled, the parts may rust because of moisture and dirt.
Rust prevention and dirt-proofing should be considered if the operation is suspended for unavoidable reasons.
3) Maintenance reference
For sliding parts and sealing parts, replace them following the items below:
1) Bushing
When a whole quarter of the circumference has worn and turned reddish
copper color
2) Seals and slide rings
Replace with new ones when disassembling cylinders
3) Pin bushing
When serious scuffing has occurred
ASM-17-24-002
Issued 08-2008
Copyright
8012-31
4) Inspection after assembly
Dimension inspection
Check the fully retracted length and stroke as instructed on the diagram.
Pressure withstand inspection
Check for looseness, permanent deformation, and external leaks when the test
pressure instructed on the diagram is applied to each stroke end for at least 3 min.
Check the amount of oil leak at the rod section.
Judgment value for rod section oil leak
Move the piston rod back and forth 20 times with the oil at a temperature from 20
C to 40 C, and then judge by the state of the oil ring formed on the rod surface. If
the oil ring is in a broken down A state, this is judged to be trouble. See "5. Trouble
Diagnostics" for information on how to solve this.
Oil ring
External leak inspection

2 mm
Not acceptable
1 mm
E F G
Acceptable
Oil leak unit: ml/10 min.
Internal leak inspection
ASM-17-24-002
Interior
diameter
mm
Oil leak
amount
160
10.0
4.0
180
12.6
125
5.6
200
15.6
140
6.0
220
20.0
250
22.0
Interior
diameter
mm
Interior
diameter
mm
Oil leak
amount
32
0.4
40
0.6
100
50
1.0
63
1.6
80
2.3
Oil leak
amount
Issued 08-2008
Copyright
8012-32
5) Required tools
1) General tools
1 9
2 6
2 5 6 7
2 6
1 3 9
2 6
4 8
RM15001-080
Tool name
Screwdriver (flathead screwdriver) (1)
RM15001-081
Hexagon wrench (1 set)
RM15001-082
Vise (1)
RM15001-083
Wrench (for piston nuts) (1 set)
RM15001-084
Punch (1)
RM15001-085
Torque wrench (1 set)
RM15001-086
Hammer (Plastic hammer) (1)
RM15001-087
Monkey wrench (1)
RM15001-088
Scoop (1 set)
RM15001-089
ASM-17-24-002
Issued 08-2008
Copyright
8012-33
2) Special jig
Cylinder assembly requires the following special jigs.
ASM-17-24-002
Issued 08-2008
Copyright
8012-34
For bushing removal and press fitting
RM15001-090
For wiper ring press fitting
RM15001-091
Seal ring insertion jig
RM15001-092
Seal ring calibration jig
RM15001-130
For cylinder head insertion
RM15001-093
For piston insertion
RM15001-094
Consult with our company about jigs.
ASM-17-24-002
Issued 08-2008
Copyright
8012-35
6) Instructions for disassembling
1) Drain oil.
2) Remove piping.
3) Secure cylinder.
Secure the cylinder in a vertical or horizontal position.
Vertical securing facilitates the disassembly and
reassembly.
When securing it, stop rotations and axial movement using the bottom pin holes.
Band for piping (not necessary to remove unless

replacement is needed
000-7-05-02-19z1
4) Loosen and remove cylinder head tightening bolts

using hexagonal bar spanner.
Inserting a pipe as shown below facilitates the
operation.
1.5 m
5) Pull out the piston rod.

1. Ensure that the piping ports are open.
2. Place an oil sump at the port on the retraction
side (cylinder head).
3. Pull the cylinder head slowly with the piston
head fully pulled.
AQ24002-050
4. Pull out the cylinder head together with the piston rod and place them on the sleeper.
WARNING: When carrying out this operation in a vertical position, pay special attention to the following:
When the piston rod is first pulled out with all the screws on the
cylinder head removed, pulling the cylinder head out from the
tube makes a space between the piston rod and piston. In this
situation, it is possible that when the cylinder head reaches a
given height, it may slide down suddenly, causing injury to the
operator. Always keep the cylinder head in contact with the
piston while carrying out this operation.
DANGER!
It may fall
When performing the operation in a vertical position

AQ24002-051
ASM-17-24-002
Issued 08-2008
Copyright
8012-36
WARNING: When the piston rod is pulled out in a horizontal
position, it may drop immediately after it is pulled out, causing
damage to the parts. Pull out the rod using a sleeper to hold it in
a horizontal position.
When performing th operation in a horizontal leval position
DANGER! It may fall
000-7-05-02-19ab
6) Secure the piston rod.

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

Piston nut
1. Remove set screws.

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

The piston nuts are tightened to the torque
listed in the assembly drawing.To loosen the
piston nut, about 1.5 times as much torque is
required. If larger torque is necessary, prepare
a powered wrench that utilizes a hydraulic jack
or a hydraulic cylinder.
Hydraulic cylinder
000-7-05-02-19ad
8) Remove piston, cushion bearing, and cylinder head in this order.

Cylinder head
Cushion bearing
Cushion seal
Piston
000-7-05-02-19ae
ASM-17-24-002
Issued 08-2008
Copyright
8012-37
9) Disassembly on the retraction side (arm cylinder).
4
5
Flattening
Screw
3
6
000-7-05-02-19af
Hit with plastic hammer while holding one side
1. Remove piston nut (1). With the nut attached, the disassembly cannot proceed.
2. Remove snap ring (2). Remove it by softly hitting with a plastic hammer while being careful to avoid damage to piston rod (3) and cushion bearing (4).
3. Slide cushion bearing to the threaded side of the piston rod, and the stopper (5) (two-piece) will come off.
4. Remove cushion bearing.
5. The cushion seal (6) has a one slit (A). Use it to enlarge the opening.
Remove piston seal.
1. The slide ring (7) and backup ring (8) can be
easily removed manually.
2. Cut and remove the seal ring (9) by placing a
screwdriver on the ring as shown in the right figure and hitting it with a hammer.
B
D
C
3. Pull out and remove O-ring (10) with a spatula.

4. Do not reuse the removed seal parts.
B: Piston
10
8
000-7-05-02-19ag
C: Vise
D: Hardwood
ASM-17-24-002
Issued 08-2008
Copyright
8012-38
10) Disassembling buffer ring (11)
1. Buffer rings (11) (Teflon seal) is fitted in the inner grooves of the cylinder head.
When removing this seal, pierce it with a sharp tool and lift it up, then insert a spatula and remove it.
2. Do not reuse the removed seals.
11) Disassembling U-rings, backup rings and wiper ring.
17, 18
15
14
11
13
16
12
000-7-05-02-19ah
1. Remove U-ring (12) and back-up ring (13, 18) using screwdriver or equivalent.
2. Wiper rings(14) are press fitted.
Pierce with a tool such as screwdriver on the rubber, hit the tool and remove it.
3. Do not reuse the removed seal parts.
12) Disassembling DU bushing (15).
Push with press
1. Remove the snap ring (16) by prying with a

screwdriver from the cylinder head (19).
2. Push out the DU bushing with a press using a
jig (E).
13) Cleaning and Storage
15
1. Apply hydraulic oil to the removed parts after

cleaning with white kerosene. Cover and store
them.
2. If components are left disassembled, they may
not operate fully as expected after reassembly
because of rusting and dust.
000-7-05-02-19ai
7) Instructions for assembly

WARNING: Careful handling is needed when reassembling because peeled paint from parts may enter into the cylinder.
1) Changing seals
1. Change all seals when the cylinder is disassembled.
2. O-ring
Before fitting backup rings (18) and O-rings
(17), clean the fitting grooves fully. Foreign substances in the grooves may cause oil leakage.
Pay attention to the positions of backup rings.
Apply grease or hydraulic oil before fitting to the
backup ring and O-ring to make them move
smoothly.
If they do not move smoothly, the O-ring will distort when being installed and cause oil leakage.
ASM-17-24-002
18
17
Pressure side
19
000-7-05-02-19aj
Issued 08-2008
Copyright
8012-39
2) Cylinder head
1. Press fit the DU bushing (15) with press using a
jig (F).
2. Press fit the wiper ring (14) with press using a
jig (G).
Press

Press holder
CM
3. Fit backup ring (13) and U-ring (12) in the Uring groove (H) in this order.
Ensure that there is no remaining permanent
deformation such as creases after fitting.
14
G
H
Push with
press
000-7-05-02-19al
3) Buffer ring (11) assembly

1. Install the backup ring (a) and slide ring (b) in
this order by forming U-shape (d) with the fingers, placing them into the groove and pushing
out them toward the outer circumference after
fitting the square ring (c) in the groove. If the
rings are shaped with too small a radius,
creases will remain after fitting. Therefore, use a
radius of 6 mm or more to make a curve.
Ensure that there is no crease after fitting.
Pay attention to the fitting directions of seals.
Reversing them will cause high pressure
between the seal and U-ring and lead to deformation on the cylinder head.
a, b
d
000-7-05-02-19am
2. Fit DU bushing locking snap ring (16).

11
b
16
AQ24002-052
ASM-17-24-002
Issued 08-2008
Copyright
8012-40
4) Piston
1. Place the piston (B) on the press and install a seal ring (9) using a jig as shown in the figure to the right.
(Pre-fit O-ring (10) and back up ring (9) to one side.)
2. Immediately after fitting seal ring and backup ring on the other side, correct the seal ring using a correction jig so that it does not remain expanded.
(This must be strictly observed.)
Reinforcing plate
Push with press
Push with press
Jig (A) (nylon pipe)
Correction jig (C)
Jig (B)
10
AQ24002-053
5) Assembling piston rod

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

and piston (B). (Cushion seals are not required
for bucket cylinders)
Then, fit shim and fasten the piston nut. (Direct
the slit (A) on the cushion seal toward the piston side.)
B
4
1a
1
A
000-7-05-02-19aq
ASM-17-24-002
Issued 08-2008
Copyright
8012-41
4. Tighten piston nuts using torque listed in the
assembly drawing. Pay attention to a lack of
tightening torque because it may cause internal
leakage, loose nuts, and screw breakage.
5. After tightening the piston nut, put in the steel

ball (20) and tighten set screw (21) using torque
listed in the assembly drawing.
Crimp (J) with a punch (K) at two places on the
outer circumference.
21
20
000-7-05-02-19ar
6) Installing cushion bearing on the retraction side

1. Install the cushion bearing (4) before fitting the piston nut (1).
With nut attached, the installation cannot proceed.
2. Insert the cushion seal (6) into the groove by facing its slit (A) processed side toward the threaded side.
3. Install the cushion bearing by facing the flattened part as shown in the drawing.
4. Insert stopper (5) into the groove.
5. Push the cushion bearing up to the stopper fully and knock in the snap spring (2).
Softly hit it with a plastic hammer while paying attention to avoid damage to the rod (3) and cushion bearing.
WARNING: Be aware that installing directions of cushion seals and cushion rings are different.
Make sure that the cushion ring moves smoothly up/down and right/left after fitting snap rings.
4
5
3
6
AQ24002-054
ASM-17-24-002
Issued 08-2008
Copyright
8012-42
7) Insert the piston rod into the tube.
Jigs, nylon type
1. Secure the tube vertically or horizontally.

Insert the piston rod into the tube.
When securing vertically, piston rod enters into
the tube by the act of its self-weight.
When securing horizontally, push in using lever
hoist or forklift.
Slide rings
2. Careful handling is needed to prevent the slide

ring from dropping when the piston enters the
tube.
000-7-05-02-19at
8) Installing cylinder head

1. Align the cylinder head according to the assembly drawing and set the tightening bolts by specified torque in the order shown in the drawing
after fastening them alternatively.
The example in the diagram has 8 bolts, but this
number will vary depending on the cylinder
type.The tightening method is fundamentally
the same.
Depending on the cylinder type, the cylinder
head may be threaded or the cylinder may
screw into a tube.
000-7-05-02-19au
9) Fitting piping
1. Ensure that the O-rings are placed correctly in the grooves.
2. First, fit the bolts for port sections.
3. Tighten the bolts using torque listed in the assembly drawing.
4. Tighten the band for piping using torque listed in the assembly drawing so that there is no gap.
Tighten the bolt
Gap closed
Gap closed
Band for piping
Be careful of O-rings
000-7-05-02-19av
ASM-17-24-002
Issued 08-2008
Copyright
8012-43
8) Trial run
1) After fitting the cylinder on the machine, move slowly more than 8 times at the full stroke by operating the switch-over valve. The inside of the cylinder will be filled with oil.
Quick and sudden movement at the initial stage can cause aeration by the hydraulic oil.
2) If air bleeder is attached (boom cylinder), apply pressure to bleed by making its air bleeding side the pressured side (return oil side).
3) Lubricate pins on both ends.
9) Use limits
Wear limits on piston rod outside surfaces
Nominal diameter
(mm)
Minimum outer
diameter (mm)
Measures
50 to 80
-0.023
Replacement or re-plating
85 to 120
-0.027
Replacement or re-plating
Wear limits on rod bushing inside surfaces

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

Nominal diameter
(mm)
Standard thickness
(mm)
Maximum thickness
(mm)
Measures
95 to 160
2.42 to 2.48
2.37
Replacement slide ring
165 to 250
2.92 to 2.98
2.87
Replacement slide ring
ASM-17-24-002
Issued 08-2008
Copyright
8012-44
3 Special jigs for repair

1 Dimensions of Tools
Wrench for piston nuts
AQ24002-002
Unit: mm
Piston nut
Wrench size
Nominal diameter
Width across flats
R1
R2
M42
65 +0
-1.2
65 +0.8
-0.3
125
350
40
20
20
50
20
M45
70 +0
-1.2
70 +0.8
-0.3
130
350
40
20
20
50
20
M48
75 +0
-1.2
75 +0.8
-0.3
140
350
40
20
20
50
20
M52
80 +0
-1.2
80 +0.8
-0.3
150
350
40
20
20
50
20
M55
85 +0
-1.4
85 +0.8
-0.3
160
350
40
20
20
50
20
M58
85 +0
-1.4
85 +0.8
-0.3
160
350
40
20
20
50
20
M62
90 +0
-1.4
90 +0.8
-0.3
160
350
40
20
20
50
20
M65
95 +0
-1.4
95 +0.8
-0.3
170
350
40
20
20
50
20
M70
100 +0
-1.4
100 +0.8
-0.3
180
400
50
25
25
50
25
M80
115 +0
-1.4
115 +0.8
-0.3
200
400
50
25
25
50
25
M85
120 +0
-1.2
120 +0.8
-0.3
220
400
50
25
25
50
25
M95
1355 +0
-1.2
135 +0.8
-0.3
245
400
60
30
30
50
30
M105
150 +0
-1.2
150 +0.8
-0.3
270
400
60
30
30
50
30
M110
155 +0
-1.2
155 +0.8
-0.3
280
400
60
30
30
50
30
WARNING: Use wrenches of S45C steel with the hardness ranging from HB201 to 269.
ASM-17-24-002
Issued 08-2008
Copyright
8012-45
2 Handling the Jigs for Cylinder Repair
Arm cylinder
Boom cylinder
Bucket cylinder
AQ24002-003
1: Jigs for press fitting wiper ring

2: Jigs for extraction bushings
3: Jigs for press fitting bushings
4: Jigs for press fitting wiper ring
5: Jigs for guiding cylinder head insertion
ASM-17-24-002
Issued 08-2008
Copyright
8012-46
1 Structure and features of jigs for cylinder repair
1) Jigs for insertion and correction of seal rings
1) Structure of jigs
Item number
KHV0530
Item name
quantity
Seal ring insertion / correction jig set
Inner guide
Outer guide
Plate
Correction
remarks
NOTE: The item number indicates that the item is intended for seal rings with the tube diameter of 120 mm.
2) Features
Although it normally requires a tremendous amount of time and effort to insert a seal ring due to its extreme
hardness, the use of the jig facilitates quick, easy and secure seal ring insertion into a piston without
scratching the seal ring.
2) Jigs for injection and ejection of bushings and wiper rings
Item number
KHV0514
Item name
quantity
remarks
Bushing and wiper ring injection / Ejection jig set
The jigs for press fitting wiper rings can

be used for this job.
Chuck assembly
The jigs for press fitting wiper rings can

be used for this job.
Retainer
Block
Prepare this item at each service shop.
Lever
Hexagon bar wrench
NOTE: The item number indicates that the item is intended for bushings with the rod diameter of 80 mm.
2) Features
This special jigs facilitate quick, easy and secure slide fit of a cylinder head assembly to a piston rod without
scratching any seals.
ASM-17-24-002
Issued 08-2008
Copyright
8012-47
3) Jigs for insertion of cylinder heads
Item number
KHV0550
Item name
Jigs for insertion of cylinder heads
quantity
remarks
NOTE: The item number indicates that the item is intended for cylinder heads with the rod diameter of 80 mm.
2) Features
It normally requires a tremendous amount of time and effort to extract a bushing because it is press fit with a
hydraulic press near the center of the cylinder head.
The use of the jig, however, facilitates quick, easy and secure extraction of a bushing from a cylinder head
without scratching the inner surface of the cylinder head.
ASM-17-24-002
Issued 08-2008
Copyright
8012-48
2 List of jigs
1. Jigs for insertion and correction of seal rings
Model
CX75SR
Cyl. name
Part no.
KHV10150
KHV0525
KHV0526
KHV0528
Bore dia.
85
95
100
110
Boom
110
Dipper
95
Bucket
85
Offset
95
Blade
100
O
O
O
O
O
2. Jigs for injection and ejection of bushings and wiper rings
Model
CX75SR
Cyl. name
Part no.
KHV10130
KHV10140
KHV0512
Bore dia.
55
60
70
Boom
70
Dipper
60
Bucket
55
Offset
55
Blade
60
3. Jigs for insertion of cylinder heads

Part no.
Cyl. name
Rod thread size
KHV10160
Bucket
M42
KHV10170
Offset
M45
KHV10180
KHV10200
ASM-17-24-002
Dipper
Blade
Boom
Rod dia.
Cushion type
Model
Fastened
CX75SR
55
M45
60
M52
70
Issued 08-2008
Copyright
8012-49
3 Handling jigs
1) Inserting / correcting seal rings
1) Installing an O-ring
Stretch the O-ring by hand and install it in the
groove of the piston.
O-ring
Piston
AQ24002-004
CAUTION: Install O-rings securely without distorting them. Distorted O-rings will cause oil leakages.
Installed properly
O-ring distorted
AQ24002-005
2) Attaching the inner guide jig

Install the inner guide jig from the top side of the
piston.
Inner guide jig

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

Apply hydraulic oil to the perimeter of the inner
guide and place the seal ring level with the inner
guide.
Inner guide jig
Seal ring
O-ring
CAUTION: Use caution to keep foreign substances such as dirt,

particles and lint from the outside of the inner guide jig.
AQ24002-008
4) Installing an outer guide jig

Place a plate on top of the outer guide jig and
press down with hand until the seal ring contacts
the outer guide jig.
CAUTION: The seal ring must not be installed in the inner guide
jig, nor could it be at an angle.
Plate
Outer guide jig
Inner guide jig
Seal ring
O-ring
Piston
AQ24002-009
ASM-17-24-002
Issued 08-2008
Copyright
8012-50
5) Press fitting
Use a press and push down the seal ring until it
fits in the groove of the piston.
Press rod
Plate
CAUTION: Use caution while pushing down the seal ring

because it may not be properly fit in the groove if it is at an angle
in the inner guide jig.
Installation of the ring must be carried out swiftly.
Seal ring
Outer guide jig
O-ring
inner guide jig
Piston
AQ24002-010
6) Removing the jigs

Remove the jigs in the following order, once confirmed that the seal ring has been completely
installed in the groove of the piston.
1. Remove the press rod.
2. Remove the plate.
3. Remove the outer guide jig.
4. Remove the inner guide jig.
Press rod
Plate
Outer guide jig
inner guide jig
The installation of a seal ring is now complete.

The instructions for aligning a seal ring using a correction jig
will be given next.
Piston
Seal ring
(O-ring located inside)
#3
7) Preparing a correction jig

Place a correction jig under a press.
CAUTION: Apply a light coat of oil to the tapered area of the correction jig and place the jig with the tapered side up.
Use caution to keep foreign substances such as dirt, particles
and lint off the jig.
Press rod
Correction jig
Knurl
AQ24002-012
ASM-17-24-002
Issued 08-2008
Copyright
8012-51
8) Inserting a piston
Install a seal ring to the piston and slowly insert
into the correction jig.
CAUTION: Insert the piston into the correction jig so that the piston rests level.
Piston
Seal ring
Correction jig
AQ24002-013
9) Press fitting
Press rod
Correction jig
Correction range
Piston
AQ24002-014
10) Removing the correction jig

After the alignment of the seal ring has been completed, remove the jig in the following order.
1. Remove the press rod.
2. Remove the correction jig.
Press rod
Correction jig
The installation and the alignment of the seal ring is now complete.
Piston
Seal ring
(O-ring located inside)
AQ24002-015
Other precautions
1. A specific cylinder bore size requires a specific jig. Refer to
the applicable table to choose the correct jig for a specific
bore size.
2. The lower part of the inner guide is structurally very thin,
requiring extra care and attention for handling and storage.
3. Clean the seal, piston and jigs with compressed air or by
other suitable method before installation. Insufficient cleaning
may lead to failures such as oil leakage due to foreign substances (dirt, etc.).
ASM-17-24-002
Inner guide jig
Thin edge
AQ24002-016
Issued 08-2008
Copyright
8012-52
2) Extracting bushings
1) Setting the cylinder head

Place the cylinder head (A) on a workbench
with the mating surface (B) with the cylinder
tube up.
CAUTION: The workbench must be clean. Use caution to keep

the pipe joint portion from getting scratched by foreign substances such as dirt and particles.
AQ24002-017
2) Extracting the snap ring

Remove the snap ring (C) that is assembled inside
the cylinder head for preventing the bushing from
falling out.
CAUTION: Secure the cylinder head with a vise, etc. Using the
tip of the jig, pry out and remove the snap ring.
Screwdriver
AQ24002-018
ASM-17-24-002
Issued 08-2008
Copyright
8012-53
3) Setting the chuck assembly (jig)
Gradually insert the chuck assembly in the cylinder head (A) until the blade (D) of the chuck
assembly reaches the edge of the bushing.
A
Chuck assembly jig
Working face of head bushing
Chuck assembly jig
AQ24002-01
CAUTION: Gradually insert the chuck assembly in cylinder

head. Use extra caution to prevent the inner surface of the cylinder head and such from getting damaged by the blade.
Also use caution to keep the blade from sticking out the end of
bushing.
Chuck assembly jig

End face of head bushing
Blade must not stick out

AQ24002-020
4) Temporal tightening
1. Insert the hexagon bar wrench (E) in the head
of the chuck assembly (jig). Also, insert a lever
in the round hole on the end section of the
chuck assembly at the same time.
2. Tip the hexagon bar wrench and the lever (F)
back and forth and tighten the chuck assembly
to the point that the jig does not fall out with the
cylinder head lifted up.
CAUTION: Less than 0.49 Nm of tightening torque is good
enough.
CAUTION: With the chuck assembly installed in the cylinder

head, firmly grasp both ends of the cylinder head and carefully
move to the press workbench.
Chuck assembly jig

AQ24002-021
ASM-17-24-002
Issued 08-2008
Copyright
8012-54
5) Attachment the retainer (jig)
Place the retainer gently on the notches of the
wedge, which is inside the chuck assembly (jig),
so the wedge will be covered by the retainer.
Retainer jig
CAUTION: Place the retainer with its larger diameter end up.
See the figure to the left.
The workbench must be clean. Use caution to keep the chuck
assembly bottom from getting scratched by foreign substances
such as dirt and particles. Keep it from tipping, also.
Chuck assembly jig

Larger diameter
end
Retainer jig
Wedge
AQ24002-022
6) Secondary tightening
Gradually press down the top of the retainer (jig)
so the blade section of the chuck assembly jig
bites into the bushing face.
Press retainer jig
CAUTION: Apply 2 to 3 tons of press load.

CAUTION: The retainer jig must be used for the pressing procedure.
Cylinder head
AQ24002-023
ASM-17-24-002
Issued 08-2008
Copyright
8012-55
7) Preparing the block (jig)
Place the cylinder head on top of the block with
the shaft centers aligned.
Block jig
AQ24002-024
Refer to the table and choose the block with the proper figuration and size.
Category
d1
d2
Nominal size
For dia. 75
82
110
80
75
80
87
112
80
80
85
92
124
80
85
90
97
130
80
90
95
102
136
80
95
100
107
140
80
100
105
112
146
80
105
110
117
150
80
110
8) For extracting bushings

1. Move the block (jig) and the cylinder head assembly (with the retainer jig and the chuck assembly jig
attached) directly underneath the press.
2. Gradually press down the top of the retainer (jig)
until the bushing comes out from the cylinder head
(until the bottom of the chuck assembly jig falls on
the bench and you actually hear it).
AQ24002-0
Retainer jig
Cylinder head
CAUTION: Usually a load of 3 tons or less is needed for the

extraction.
CAUTION: The stroke of press ram is approximately 32 to 52
mm, depending on the size of the cylinder head.
CAUTION: The retainer jig must be used for the pressing procedure.
If the shaft centers of the block and the cylinder head assembly
do not align with each other, stop the procedure, move the block
and align the shaft centers before resuming the operation.
ASM-17-24-002
Block jig
#3
Issued 08-2008
Copyright
8012-56
9) Removing the chuck assembly (jig) with the bushing attached
1. Pull the cylinder head assembly (with the
retainer jig and the chuck assembly jig attached)
and the block (jig) toward you from right beneath
the press. Remove the retainer from the cylinder
head. Grab both ends of the cylinder head with
both hands and move from there.
2. Remove the assembly with the bushing
attached out of the block and move to the workbench.
Retainer jig
Cylinder head
WARNING: Do not ever attempt to work under the press. Stay

safe.
Chuck assembly jig
(with bushing attached)
Bushing
Block jig
AQ24002-027
10) Removing the bushing

1. Place the chuck assembly (B) with the bushing
attached (jig) sideways on the workbench. Insert
the hexagon bar wrench (A) in the adjuster head
on the chuck assembly tip, plus insert the lever (C)
into the round hole at the back of the chuck
assembly at the same time.
2. Tip the hexagon bar wrench and the lever back
and forth to loosen the adjuster.
3. Reposition the chuck assembly so it stands vertically. Rotate the adjuster with fingers until about
5 mm of the wedge comes out.
4. Verify that the bushing is disconnected from the
blade section of the chuck, then gently remove the
bushing from the assembly.
the chuck bottom and the periphery from getting scratched by
foreign substances such as dirt and particles. Keep it from tipping also.
C
A
Bushing
AQ24002-028
ASM-17-24-002
Issued 08-2008
Copyright
8012-57
11) Tightening back the adjuster(A)
Once the bushing is removed from the chuck
assembly (jig), rotate its adjuster with fingers and
tighten until there is no gap between the adjuster
and the top surface of the wedge.
CAUTION: Do not remove the adjuster and the wedge from the
chuck assembly. Keep them in the condition as close to the original as possible.
AQ24002-029
Other precautions
1. A specific piston rod diameter requires a specific jig. Refer to the applicable table to choose the correct jig for a specific diameter size.
2. The blade section of the chuck assembly is a vital portion and must be handled and stored with extreme care.
ASM-17-24-002
Issued 08-2008
Copyright
8012-58
3) Press fitting bushings
1) Setting the cylinder head (A)

Place the cylinder head on a workbench with
the mating surface (B) with the tube up.

the cylinder head bottom from getting scratched by foreign substances such as dirt and particles. Keep it from tipping also.
Before starting the procedure, remove foreign substances thoroughly with air, etc.
A
AQ24002-030
2) Temporarily setting the bushing(B)

Temporally place the bushing level inside the cylinder head (A).
CAUTION: Verify that inner/outer surfaces of the bushing are

free of foreign substances.
A
AQ24002-031
3) Setting the chuck assembly (jig)

Secure the chuck assembly with fingers and gradually insert into the cylinder head.
A
AQ24002-032
CAUTION: Verify that the chuck assembly adjuster sits by the

wedge with no gap in between.
Chuck assembly jig
Gap between adjuster and

wedge
Wedge
AQ24002-033
ASM-17-24-002
Issued 08-2008
Copyright
8012-59
4) Attaching the retainer (jig)
Align and gently place the retainer (A) on the
notches (B) of the wedge in the chuck assembly.
CAUTION: Place the retainer with its larger diameter end up.
See the figure to the left.
AQ24002-034
5) Preparing for press fitting

With the retainer (B) (jig) and the chuck assembly
(C) (jig) attached, move the cylinder head (A) right
underneath the press.
A
CAUTION: Align the press (ram) axis with the retainer and the
chuck assembly axes.
AQ24002-035
Press (ram)
Retainer jig
Chuck assembly jig
Bushing
Snap ring
grooves
Insert bushing here
Cylinder head
AQ24002-036
ASM-17-24-002
Issued 08-2008
Copyright
8012-60
6) Press fitting the bushing
Use a press to push down the bolt head of the
adjuster until the bushing reaches the proper position in the cylinder head (A).
Keep the press load below 5 tons.
Retaining jig
CAUTION: Check to see if the bushing edge sits at the back of

the snap ring grooves. Press fit again if not.
7) Removing the retainer (jig) and the chuck assembly (A) (jig)
Once the press fitting of the bushing is complete,
remove the retainer and the chuck assembly from
the cylinder head. Then, attach the seals and
press fit the wiper ring.
AQ24002-037
A
Retaining jig
CAUTION: Examine to see if the bushing is press fit properly.
AQ24002-038
Other precautions
1. A specific piston rod diameter requires a specific jig. Refer to the applicable table to choose the correct jig for a specific diameter size.
2. The blade section of the chuck assembly is a vital portion and must be handled and stored with extreme care.
ASM-17-24-002
Issued 08-2008
Copyright
8012-61
4) Press fitting wiper rings
1) Setting the cylinder head

Place the cylinder head (A) on a workbench
with the mating surface with the tube facing
down.
the cylinder head bottom from getting scratched by foreign substances such as dirt and chips from cutting.
AQ24002-039
2) Inserting the wiper ring

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

Gently place the retainer on top of the cylinder
head (A) with the side for wiper ring insertion facing down.
CAUTION: Place the retainer gently on top of the cylinder head

making sure that it is level with the work bench.
ASM-17-24-002
AQ24002-041
Issued 08-2008
Copyright
8012-62
4) Preparing for press fitting
With the retainer (jig) on top, move the cylinder
right underneath the press.
AQ24002-042
CAUTION: Align the press (ram) axis with the retainer axis.
Press (ram)
Retainer jig
Wiper ring
Cylinder head
AQ24002-043
5) Press fitting the wiper ring

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

Once the press fit of the wiper ring (C) is complete, remove the retainer from the cylinder head
(A).
CAUTION: Examine if the wiper ring is properly press fit.
B
C
A
AQ24002-045
ASM-17-24-002
Issued 08-2008
Copyright
8012-63
5) Inserting cylinder head
1) Securing the piston rod

Position the piston rod thread (A) in a direction for carrying out the procedure the easiest, then secure.
CAUTION: Use extreme care while handling the piston rod to

avoid scratches on the outer surface.
AQ24002-046
2) Attaching the guide (A) (jig)

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

Push in the cylinder head assembly till it reaches
the proper position: let the assembly slide on the
outer surface of the guide (jig) with the side to
attach the wiper ring facing the piston rod head.
CAUTION: Firmly grab the cylinder assembly by both hands.
Use extreme care and do not allow it to drop on your foot.
Applying a thin coat of oil to the guide and the outer surface of
the piston rod facilitates smooth insertion.
AQ24002-048
ASM-17-24-002
Issued 08-2008
Copyright
8012-64
4) Removing the guide (jig)
Check to confirm that the cylinder head assembly
is completely inserted into the piston rod.Then
remove the guide from the piston rod. Then,
assemble the piston and the other parts on the
piston rod.
CAUTION: When removing the guide, use extra care to keep
the piston rod thread from being damaged.
AQ24002-049
ASM-17-24-002
Issued 08-2008
Copyright
8013
Section
8013
HAND CONTROL LEVERS
CNH
SM75SR8013-0EN

Printed in France
July 2008
Copyright
8013-2
TABLE OF CONTENTS
ASSEMBLY/DISASSEMBLY OF OPERATION CONTROL VALVE ...................................................................... 3
MAINTENANCE PROCEDURES ................................................................................................................................. 3
Required tools and tightening torque ................................................................................................................ 3
Maintenance standards ..................................................................................................................................... 3
DISASSEMBLY PROCEDURES ................................................................................................................................. 4
Preparations ...................................................................................................................................................... 4
General work precautions ................................................................................................................................. 4
Disassembly procedure..................................................................................................................................... 4
ASSEMBLY PROCEDURES .................................................................................................................................... 10
Preparations .................................................................................................................................................... 10
General work precautions ............................................................................................................................... 10
Assembly procedures...................................................................................................................................... 10
CAUSES OF TROUBLE AND COUNTERMEASURES .................................................................................................. 15
ATTACHED DIAGRAM 1. REMOTE CONTROL VALVE ASSEMBLY CROSS-SECTION DIAGRAM ....................................... 16
ATTACHED DIAGRAM 2. JOINT DISASSEMBLY JIG .................................................................................................. 17
Lep SM75SR8013-0EN
Issued 03-08
Copyright
8013-3
ASSEMBLY/DISASSEMBLY OF OPERATION CONTROL VALVE

1 Maintenance Procedures
1 Required tools and tightening torque
Tool
Dimensions
(mm)
Part number
Hexagon bar wrench
125
Wrench
22
32
Special jig (diagram in

Attached diagram 2.
Joint disassembly jig)
24
Part name
Screw size
Tightening torque (Nm)
M8
20.61.5
312
302
Hexagon
socket head
bolt
Adjusting nut
Disk
M14
M14
68.64.9
301
Joint
M14
47.12.9
2 Maintenance standards
Maintenance
inspection item
Leak amount
Remarks
When handle is in neutral: 1000 cc/min or

Conditions
more
Primary pressure 2.94 MPa
During operation: 2000 cc/min or more
Oil viscosity 23 mm2/s
If either condition occurs, replace the remote
control valve as one unit.
When wear on the sliding sections exceeds
The same approximate conditions as those
wear on the non-sliding sections by 10 m or
listed above for leak amount are expected
more, replace the remote control valve as one
when the condition on the left occurs.
unit.
If the end section is worn by 1 mm or more, perform replacement.
(7)
Spool
Standard
Push rod
1 mm
RM10001-005
Operation section backlash
Operation stability
Replace the operation section disk (302) and

joint section (301) if there is backlash of 2 mm
or more due to wear.
If abnormal noise, hunting, or a drop in primary
pressure occurs and the problem cannot be
resolved with "4. Causes of Trouble and Countermeasures", replace the remote control valve
as one unit.
Make adjustments if the backlash is due to

looseness in the tightening sections.
NOTE: It is desirable for seal materials such as O-rings to be replaced with each disassembly, but it is acceptable to
reuse these after it is confirmed that they are not damaged.
Always replace seal washer (121) when a hexagon socket head bolt (125) is loosened.
Lep ASM-17-25-002-EN
Issued 08-08
Copyright
8013-4
2 Disassembly Procedures
1 Preparations
[1] Prepare a sufficiently spacious, solid and stable work platform so that parts will not fall or move during work.
[2] Prepare the tools and materials indicated in "1. Maintenance Procedures (1) Required tools and tightening
torque".
[3] When disassembling the valve, read the disassembly procedures thoroughly before following the sequence
below.
The numbers in the parentheses after the part names indicate codes in "Attached diagram 1. Remote control
valve assembly cross-section diagram Attached diagram 1. Remote control valve assembly cross-section diagram".
2 General work precautions
[1] Each part has been manufactured with a high degree of precision, so be careful not to let parts bump each other
or fall when handling them.
[2] If parts are struck or pulled with excessive force during work because they are tight, this may cause burrs or damage which lead to faulty assembly causing reduction in performance or oil leaking. Perform work carefully and
thoroughly.
[3] Rust may form on parts due to moisture or debris if the valve is left disassembled or if work is abandoned in the
middle of disassembly. If work must be halted, be careful about preventing rust from forming and dust settling on
parts.
3 Disassembly procedure
[1] Clean the remote control valve with white kerosene.
Place plugs in each port.
[2] Use copper plate (or lead plate) to secure the
remote control valve in a vise.
[3] Remove the bellows (501).
Be careful not to tear the bellows.
RM10001-006
Issued 08-08
Copyright
8013-5
[4] Use a wrench on the bolt width of the adjusting
nut (312) and disk (302) to loosen them, and
remove the adjusting nut and disk.
RM10001-007
RM10001-008
RM10001-009
Issued 08-08
Copyright
8013-6
[5] Use a jig to rotate the joint (301) to the left and
loosen it.
The diagram shows the valve with the jig
installed.
If the return springs (221) are strong, the plate
(151), plugs (211), and push rods (212) will rise at
the same time the joint is loosened, so be careful of
parts flying off when removing the joint.
RM10001-010
RM10001-011
[6] Remove the plate (151).
RM10001-012
[7] If the return springs (221) are weak, the plugs

(211) will remain in the casing (101) due to the
sliding resistance of the O-rings (214), so use a
flathead screwdriver to remove them.
Use the groove in the outer circumference of the
plugs and remove them while making sure they are
not damaged by an unbalanced load.
Use caution as plugs may fly off when they are
being removed due to the return springs.
RM10001-013
Issued 08-08
Copyright
8013-7
[8] Remove the push rods (212), plugs (211), pressure
reducing valve assemblies and the return springs
(221) from the casing (101). Record the relation of
parts to the casing hole positions through marking,
etc).
RM10001-014
[9] Secure the pilot valve on the vise by facing port

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

from the casing (101). Draw out the bushing (131)
from the casing (101).
Issued 08-08
Copyright
8013-8
[12]For disassembly of pressure reducing valves, press
in the spring seats, move the spring seats (216) to
the side while bending the secondary pressure
springs (241), and remove the springs from the
spools (201) by passing the springs through the
larger hole of the spring seats.
Next, separate the spools, spring seats, secondary
pressure springs, and washers (217).
Be careful not to scratch the surface of the spools.
Do not lower the spring seats by 6 mm or more.
Handle these parts as assemblies until assembly of
the remote control valve.
RM10001-015
RM10001-016
[13]Remove push rods (212) from the plugs (211).
RM10001-018
Issued 08-08
Copyright
8013-9
[14]Remove O-rings (214) and seals (213) from the
plugs (211). Use a small flathead screwdriver, etc. to
remove seals.
O-rings and seals cannot be reused.
Replace them with new parts.
RM10001-019
RM10001-020
[15]Cleaning parts
1) Clean all parts by placing them in a rough cleaning container filled with white kerosene (rough cleaning).
2) Clean all parts by placing them in a finish cleaning container filled with white kerosene, and thoroughly clean
them up to the interior while slowly rotating them (finish cleaning). Use a rag to thoroughly remove white kerosene adhered to parts.
Scratching can easily occur if cleaning of parts is begun just after parts are immersed in white kerosene, so let
parts sit in white kerosene until debris and grease sufficiently loosen off from the surface of parts and float to the
surface.
If the white kerosene is dirty, this will encourage damage to parts and result in reduced performance after reassembly. Thoroughly manage the level of cleanliness of the white kerosene.
Do not dry parts with compressed air, as this will damage parts and cause rust to form due to debris and moisture
being dispersed into the atmosphere.
[16]Preventing rust on parts
Apply an anti-rust agent to each part.
Rust will form on parts if they are left as is after cleaning, and this will cause reduced performance of functions
after reassembly.
Issued 08-08
Copyright
8013-10
3 Assembly Procedures
1 Preparations
[1] As with disassembly, prepare a work platform, tools and materials.
2 General work precautions
[1] Observe the same general work precautions as with disassembly.
[2] When performing assembly, remove metal fragments and foreign matter from all parts, and check that there are
no burrs or nicks on parts. If there are burrs or nicks, use a whetstone to remove them.
[3] As a rule, replace all O-rings and backup rings with new parts.
[4] When installing O-rings and backup rings, be careful not to damage them. (Apply a thin layer of grease to ensure
smooth installation.)
[5] When installing parts, using grease is good for preventing parts from falling.
[6] Tighten bolts, etc. to the torque values indicated in "Attached diagram 1. Remote control valve assembly crosssection diagram". Use the torque wrench to measure the tightening torque.
[7] After assembly is complete, place plugs in all of the ports to prevent entry of debris.
3 Assembly procedures
[1] Assemble the bushing (131) and O-ring (122) in the
casing (101).
[2] Fit the port plate (111) to the casing (101) using the
hexagon socket head bolts (125) and seal washers
(121).
Check the assembling positions so that the spring
pin (126) are inserted into the casing holes.
Replace the seal washers (121).
Issued 08-08
Copyright
8013-11
[3] Tighten the hexagon socket head bolts (125) by
specified torque.
Tighten two screws gradually and alternately.
[4] Insert washers (217), secondary pressure springs

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

them to the side while bending the secondary pressure springs to pass the seats over the larger holes
and install them on each of the spools.
Do not lower the spring seats by 6 mm or more.
RM10001-022
Issued 08-08
Copyright
8013-12
[5] Install the return springs (221) in the casing (101).
Install the pressure reducing valve assemblies in the
casing.
Install them in the positions they were in before disassembly.
RM10001-023
[6] Install O-rings (214) on the plugs (211).
RM10001-024
[7] Install seals (213) on the plugs (211).

Install so that the seal lips are as shown in the diagram below.
RM10001-027
*1
RM10001-025
Seal
*2
Plug
*3
Push rod
*4
Hydraulic oil application
Issued 08-08
Copyright
8013-13
[8] Install push rods (212) into the plugs (211).
Apply hydraulic oil to surface of the push rods.
RM10001-026
[9] Install the plug assemblies into the casing (101).

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

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

[11]Use a jig, and tighten the joint (301) to the casing
(101) to the specified torque.
Tightening torque: 47.12.9 Nm
RM10001-031
Issued 08-08
Copyright
8013-14
[12]Install the disk (302) onto the joint (301).
Screw the disk in until it is equally touching each of
the 4 push rods (212).
Secondary pressure will cause faulty operation of
the machine if the disk is screwed in too much, so
pay attention to adjustment of the tightening position.
RM10001-032
[13]Install the adjusting nut (312), use a wrench on the

bolt width of the disk (302) to secure it, and tighten
the adjusting nut to the specified torque.
Tightening torque: 68.64.9 Nm
During tightening, do not move the disk position.
RM10001-033
[14]Apply grease to the rotating section of the joint

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

Be careful not to tear the bellows.
[16]Inject vapor corrosion inhibitor into each port and
then place plugs in the ports.
RM10001-035
Issued 08-08
Copyright
8013-15
4 Causes of Trouble and Countermeasures

It is not always easy to find where the source of trouble is located. A few problems that may sometimes occur are
listed in the table below. Repair of these problems can be difficult, so see the suggested causes and solutions in the
table for assistance.
The table below shows general symptoms, suggested causes and also solutions. However, the cause of machine
problems are often not rooted in just a single part. Problems are often due to the relationship of one part with
another. Also keep in mind that solutions other than those listed in the table may sometimes be necessary.
The table below does not include all possible causes and countermeasures. Accordingly, further investigation of
problems and causes should be done by an experienced and qualified repair person, as necessary.
Symptom
Secondary pressure is
not rising.
Cause
1 Insufficient primary pressure
2 Secondary pressure spring(s) (241) is
(are) broken or worn.
3 The gap between spool(s) (201) and the
casing (101) is abnormally large.
4 There is backlash in the handle section.
unstable.
1 Sliding parts are sticking.

2 Tank line pressure is variable.
3 Air is getting into lines.
high.
1 Tank line pressure is high.

2 Sliding parts are sticking.
Solution
1 Maintain primary pressure.
2 Replace it (them) with new part(s).
3 Replace the remote control valve as one
unit.
4 Disassemble and assemble or replace
the handle section.
1 Repair the sticking sections.
2 Return directly to the oil tank.
3 Perform operation several times and let
out air.
1 Return directly to the oil tank.
2 Repair the sticking sections.
Issued 08-08
Copyright
8013-16
5 Attached diagram 1. Remote control valve assembly cross-section diagram
Tightening torque list

No.
Screw size
Tightening torque
125
M8
20.6 1.5 Nm
301
M14
47.1 2.9 Nm
312
M14
68.6 4.9 Nm
Grease application to rotating sliding sections. Use caution with

installation direction.
Grease application to top
Grease application to top
Contain one secondary pressure

adjustment shim.
Design main value: t = 0.4 x 1
Not to be reused
Ports
Code
101
111
121
122
125
126
131
Part name
Casing
Port plate
Seal washer
O-ring
Hexagon socket head bolt
Spring pin
Bushing
Ports
Qty
1
1
2
1
2
1
1
Code
214
216-1
216-2
217
221-1
221-2
221-3
151
Plate
241-1
201
Spool
241-2
Plug
Push rod (port 1, 3)
Push rod (port 2, 4)
Seal
4
2
2
4
301
302
312
501
211
212-1
212-2
213
Part name
O-ring
Spring seating (port 1, 3)
Spring seating (port 2, 4)
Washer
Return spring (port 1)
Return spring (port 3)
Return spring (port 2, 4)
Secondary pressure spring
(port 1, 3)
Secondary pressure spring
(port 2, 4)
Joint
Disk
Adjusting nut
Bellows
Qty
4
2
2
4
1
1
2
2
2
1
1
1
1
Issued 08-08
Copyright
8013-17
6 Attached diagram 2. Joint disassembly jig
Bushing
A -A
1 Material: SCM145 N carburized

WAF
2 Material: S45C
Joint installation state
Hole
Shaft
Detailed diagram of jig main unit
Detailed diagram of bushing
1 and 2 are inserted by tightening
Material: SCM145 N carburized

Quantity: 2
RM10001-037
Issued 08-08
Copyright
8013-18
NOTES
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Issued 08-08
Copyright
Section

FOOT CONTROL PEDALS
CNH
Lep SM75SR8014-0EN

Printed in France
August 2008
8014
8014
Copyright
8014-2
TABLE OF CONTENTS
TRAVEL REMOTE CONTROL VALVE................................................................................................................... 3
OFFSET AND BLADE REMOTE CONTROL VALVE ........................................................................................... 10
At neutral....................................................................................................................................................... 10
During operation (same for port A and port B sides)..................................................................................... 10
Lep SM75SR8014-0EN
Issued 08-2008
Copyright
8014-3
TRAVEL REMOTE CONTROL VALVE

Description
T
P
4
32
Hydraulic Circuit
22
34
27
30
27
26
21
33
19
26
30
31
20
25
4
25
24
5
31
20
2 ,4
2, 4
32
18
23
32
23
11
17
35
16
1
11
28
16
29
1
29
8
12
12
13
13
14
14
3, 15
28
10
10
3 ,1 5
C-C
AQ25002-001
ASM-17-25-002
Issued 08-2008
Copyright
8014-4
No.
Part name
Qty
No.
Part name
Qty
No.
Part name
Qty
Shim
13
Compression spring
25
Washer
Orifice
14
Compression spring
26
Rivet
Shim
15
Shim
27
Pin
Orifice
16
Ring
28
Snap ring
Pin
17
Cover
29
Steel ball
Body
18
Boot
30
Steel ball
Cam
19
Name plate
31
Steel ball
Sleeve
20
Holder
32
Packing
Piston
21
Plug
33
O-ring
10
Spool
22
Plug
34
O-ring
11
Pusher
23
Hexagon socket head

bolt
35
O-ring
12
Retainer
24
Set screw
ASM-17-25-002
Issued 08-2008
Copyright
8014-5
Operational Description
This pump has ports P, T and 1 through 4. Because the function and operation of ports 1 through 4 are the same,
port 1 will be described here.
Pressure reduction function
Lever operation range: 0 to 1.8 (Figure 2)
The flow of pressurized oil supplied from port P is cut off from ports 1 and T by spool (10).
Since port 1 communicates with port T by an internal circuit in spool (10) and is connected to the tank through
port T, the pressure on port 1 is equal to the tank pressure.
T
10
P
Figure 2
AQ25002-002
Lever operation range: 1.8 to 11 (Figure 3)

When the lever [cam (7)] is operated, the spool is pushed downwards together with pusher (11), piston (9),
retainer (12) and spring (14).
When the angle of operation reaches 1.8, port P and port 1 are connected by means of section I, and the connection between port 1 and port T is closed by means of section II. As a result, pressure is generated at port 1.
At this time, the following upward force F acts on spool (10):
Pressure P1 at port 1 x spool area a (A)
When P1 increases and F exceeds the force (FS) of spring (14), spool (10) moves upwards, closing section I
and opening section II, reducing the pressure on port 1. Repetition of this process causes spool (10) to be balanced in the position shown in Figure 3, and the pressure on port 1 is kept at a constant pressure sufficient to
balance the force of spring (14).
FS = F = P1 x A
ASM-17-25-002
Issued 08-2008
Copyright
8014-6
As the lever is operated further, spring (14) is deflected by pusher (11), piston (9) and retainer (12), increasing
the force (FS) of spring (14). At this time, spool (10) generates pressure at port 1 corresponding to the force of
spring (14) while balanced in the position shown in Figure 3.
7
11
9
12
T
13
14
ll
l
10
Figure 3
AQ25002-003
Lever operation range: 11 to 12.4 (Figure 3)

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

lll

6

ll
l

ASM-17-25-002
Figure 4
AQ25002-004
Issued 08-2008
Copyright
8014-7
Damper function
When the lever is pressed, the hydraulic oil in damper chamber IV is expelled into port T through restrictor V. At
this time, a damping effect is obtained by means of the passage resistance at section V (Figure 5).
When the lever is returned to its original position, the force of spring (13) causes piston (9) to return, and
because damper chamber IV becomes a vacuum, the steel ball is lifted, drawing hydraulic oil in through port T,
and all the parts return smoothly to neutral position (Figure 6).
lV
30
Figure 5
Figure 6
AQ25002-005
ASM-17-25-002
Issued 08-2008
Copyright
8014-8
Disassembly and Assembly
General precautions
Because all the parts in hydraulic valves are precision components, perform valve disassembly and assembly in
a clean and dust-free area. Use clean tools and cleaning solvent.
Clean disassembled parts and apply a corrosion inhibitor.
Number parts when disassembling so that they can be put back in their original locations when assembling.
Clean each part thoroughly, remove foreign substances, and make sure that there are no burrs or dents. If burrs
or dents are found, remove them with an oilstone.
Replace seals with new ones each time the valves are disassembled.
When assembling, apply a thin coat of hydraulic oil to sliding surfaces and grease to seals.
During the operation, if a part does not move smoothly, never hit or pry it.
Disassembling procedure
(Assembly should be done in the reverse order of disassembly).
Precautions
When disassembling, make note of where each part was assembled, using tags and the like, and be sure to
assemble each part into its original location when reassembling.
[1] See figure 7.
18
Remove boots (18). (x 2)
Remove Hexagon socket set screws. (x 2)
Withdraw pins (5). (x 2)
24
7
Remove cams (7). (x 2)

Remove Hexagon socket head bolts. (x 4)
Remove covers (17). (x 2)

Remove pushers (11). (x 4)
Remove steel balls (31) and holders (20). (4 each)
24
Remove shims (2 and 4).
17
Remove U packings. (x 4)
Tightening torque:
Hexagon socket head bolt: 9.8 1.0 Nm
33
31
20
2,4
Hexagon socket set screw: 9.8 1.0 Nm

Disassembly may not be possible if hexagon socket set
screws are secured with loctite. In this case, remove
the hexagon socket head bolt together with cam (7), pin
(5) and cover (10).
11
6
Figure 7
ASM-17-25-002
AQ25002-006
Issued 08-2008
Copyright
8014-9
[2] See figure 8.
Pull out pistons (9). (x 4)
Remove wires (16) from pistons (9). (x 4)
Remove snap rings. (x 4)
Remove washers (1). (x 4)
Remove steel balls. (x8)
(They are very small. Be careful not to lose them.)
Remove sleeves (8). (x 4)
Remove spool assemblies. (x 4)
Remove springs (13). (x 4)
Remove O-rings. (x 2)
If wire (16) is deformed during disassembly, replace it
with a new one.
When attaching snap rings, be careful not to damage
the inner surface of body (6).
AQ25002-006
Figure 8
[3] See figure 9.

Disassemble spool assemblies. (x 4)
Remove retainer (12).
Remove spring (14).
Remove shims (3 and 15).
AQ25002-006
ASM-17-25-002
Figure 9
Issued 08-2008
Copyright
8014-10
[4] See figure 10.
Remove flanged plug (21) and remove O-ring(33).
(1 each)
Remove flanged plug (22) and remove O-ring (34).
(1 each)
Tightening torque:
No.22 Flanged plug: 24.5 2.0 Nm
No.21 Flanged plug: 9.8 1.0 Nm
AQ25002-009
Figure 10
Troubleshooting
Symptom
External oil leakage.
Secondary pressure
does not rise smoothly
or is outside specified
range.
Lever does not move
smoothly, or does not
return to neutral position.
Damping force is weak.

Damping force is too
strong.
ASM-17-25-002
Cause
Scratches on O-ring sealing surface in port
sections.
Sealing part breakage.
Spring (14) is fatigued or broken.
Foreign substances lodged in spool (10).
Foreign substances lodged in piston (9).
Foreign substances lodged in pusher (11).
Foreign substances lodged in pin (5) or cam (7).
Spring (13) is broken or fatigued.
Wire (16) has fallen off.
Foreign substances lodged in seat parts in
steel ball of sleeve (8).
Foreign substances lodged in orifice section
(9).
Solution
Repair or replace ports.
Replace defective sealing parts.
Replace springs (16).
Disassemble, clean and repair. (Replace as
an assembly if repair is impossible).
Disassemble, clean and repair.
Replace springs (15).
Issued 08-2008
Copyright
8014-11
OFFSET AND BLADE REMOTE CONTROL VALVE

1. Operational Description
The numbers in parentheses before the part names correspond to the part numbers in the structural drawing.
1) At neutral
P is blocked by spool (11) and ports A and B are connected to T via a small hole inside spool (11). At this time, spool
(11) is pressed onto holder (12) by spring (13) and end spool. The holder (12) is pressed onto cover (2) and pusher
assembly (23) by spring (6), maintaining the neutral position.
2) During operation (same for port A and port B sides).
[1] Rising port pressure
As the incline of cam (4) increases, pusher assembly (23) and holder (12) are pressed in, and at the same time,
spool (11) moves toward the bottom of cross-section X. Spool (11) blocks T at section (a) (closing A -> T), and as
it moves further downward, P -> A opens at section (b), and hydraulic oil enters port A increasing the pressure.
This pressure pushes the spring back to block P at section (b), re-opening A -> T and reducing the pressure at
port A to balance with the spring force F of spring (13). When the pressure at port A falls below the spring force F
of spring (13), spring (13) moves spool (11) downward again, opening P -> A at section (b) and increasing the
pressure at port A to balance with spring force F of spring (13).
In this way, pressure that balances with the spring force F of spring (13), is generated at port A by the repeated
opening and closing of P and T. Spool (11), during this time, stays within the range defined by the opening and
closing of P and T.
As cam (4) is inclined further, pusher assembly (23) and holder (12) are pressed to an extent corresponding to
the angle of incline, and spring (13) bends and the spring force increases. Spool (11), responding to the increase
in the force of spring (13), causes repeated opening and closing of P and T as described above, generating pressure at port A that balances with the force of spring (13).
In this way, pressure corresponding to the incline angle of the cam is generated linearly at port A.
[2] Falling port pressure
When cam (4) returns towards the neutral position, spring (6) returns holder spring (12) and pusher assembly
(23) upward, towards cross-section X. By this means, the bend of spring (13) decreases and the force is reduced.
Spool (11) then opens and closes P and T, generating pressure at port A corresponding to the force of spring
(13).
2. Replacing Parts at Servicing
[1] Replace sealing parts such as O-rings and backup rings at every disassembly/reassembly.
[2] If any of the following symptoms affects a related system, replace the body and spool assembly.
1) When the amount of leakage increases.
2) When the secondary pressure is unstable and is not stabilized by disassembly and adjustment.
3) When hunching or abnormal noises do not go away after disassembly and adjustment.
[3] If the steel ball does not rotate in the pusher assembly, replace the pusher assembly.
[4] If the cam chatters badly enough to affect operation, replace the parts that are worn
3. Troubleshooting
Symptom
Secondary pressure
does not rise.
unstable.
too high.
ASM-17-25-002
Cause
Insufficient primary pressure.
Spring fatigue.
Abnormal wear of spool and body.
Abnormal wear of cam and pusher.
Malfunctioning of sliding parts.
Air trapped in piping.
Fluctuating pressure in circuit T.
Malfunctioning of sliding parts.
High pressure in circuit T.
Solution
Secure primary pressure.
Replace or add shims (8) or (9) or (10).
Replace the assembly.
Overhaul.
Bleed air.
Adjust pressure in circuit T.
Overhaul.
Adjust pressure in circuit T.
Issued 08-2008
Copyright
8014-12
4. Disassembling/Assembling Instructions
As a general rule, disassembly and reassembly should be done at the factory, but if unavoidable, they should be performed at a service facility with a thorough knowledge of hydraulic devices. Because hydraulic devices are made of
precision components put together with small tolerances, disassemble and assemble them in a clean area that is free
of dust and handle them carefully, following the instructions below. Never hit a device when it does not move
smoothly.
[1] Tools required
1)
2)
3)
4)
Hexagon bar wrenches: Nominal size: 2, 2.5, 6 mm

Torque wrench: Capable of applying tightening torque of 0 - 40 Nm.
Hexagon bar for wrench: Nominal size: 2, 2.5, 6 mm
Scriber
[2] Disassembling Instructions

1)
2)
3)
4)
5)
Remove boots (7).

Remove set screws (16).
Pull out pins (5).
Take out cam (4).
Secure the whole assembly in a vise, then loosen hexagon socket head bolts (15) with a 6 mm hexagon bar
wrench.
Cover (2) may float up due to the force of the spring.
6) Remove cover (2).
7) Pull out pusher assembly (23) from cover (2), then remove O-ring (21) with a scriber.
Be careful not to scratch the inside of the cover when removing the O-ring.
8) Remove the spool assembly and O-ring (22) from the body.
Record the relative positions of the spool assembly and the hole in the body.
9) To disassemble the spool assembly, secure spool (11) in a vise and fasten end spool with a 2.5 mm hexagon bar wrench.
When securing the spool in the vise, use a copper plate to avoid scratching the spool.
The pressure of the spool assembly is regulated by shims, and it should not be disassembled if possible.
10) Take out spring (13).
[3] Assembling Instructions
Fully clean and degrease parts before assembling. The body, in particular, should be cleaned using a nylon
brush. Always use new sealing parts, and apply a thin coat of hydraulic oil or grease to them prior to assembly.
1) Assemble O-ring (21) and pusher assembly (23) into cover (2).
2) To assemble the spool assembly, secure spool (11) in a vise, then install flat washer (17), shim (3), (10),
spring (13) and spring (12) in that order, and screw on end spool.
Tightening torque: 2.94 Nm
When securing the spool in the vise, use a copper plate to avoid scratching the spool.
Apply loctite 242 to the threaded part.
3) Insert spring (6) into body (1), then install the spool assembly and O-ring (22).
The spool assembly is installed in the same hole in the same position as before disassembly.
4) Install shims (8, 9) to each spring holder section (12).
Install them in the same position as before disassembly.
5) Secure body (1) in a vise, then fasten cover (2) with hexagon socket head bolts (15).
6) Fasten cam (4) with pin (5).
7) Fasten the pin with hexagon socket set screw (16).
Apply loctite 262 to the threaded part.
8) Install boots (7).
ASM-17-25-002
Issued 08-2008
Copyright
8014-13
5. Structural drawings
T
P
B
A
Hydraulic Circuit
20
T
14
19
23,24,25
4
25
16
21
18
15
12
22
13
8,9
3,10,17
6
11
1
b
A-A
AQ25002-010
ASM-17-25-002
Issued 08-2008
Copyright
8014-14
No.
Part name
Qty
No.
Part name
Qty
No.
Part name
Qty
Body
10
Shim
19
Rivet
Cover
11
Spool
20
Pin
Shim
12
Holder
21
O-ring
Cam
13
Compression spring
22
O-ring
Pin
14
Plate
23
Pusher
Compression spring
15
Hexagon socket head

bolt
24
Pusher
Boot
16
Set screw
25
Steel ball
Shim
17
Washer
Shim
18
Washer
ASM-17-25-002
Issued 08-2008
Copyright
Section
DISASSEMBLY AND REASSEMBLY

OF THE THREE SOLENOID VALVES BLOCK
CNH
Lep SM130B8005-0EN

Printed in France
March 2008
8015
8005
Copyright
8015-2
TABLE OF CONTENTS
SOLENOID VALVE.................................................................................................................................................. 3
ASSEMBLY DRAWINGS ........................................................................................................................................... 3
THEORY OF OPERATION ......................................................................................................................................... 4
MAINTENANCE ...................................................................................................................................................... 4
Assembling and disassembling precautions ..................................................................................................... 4
Assembling and Disassembling a Solenoid Operated Directional Valve .......................................................... 4
Maintenance Standards .................................................................................................................................... 6
Troubleshooting ................................................................................................................................................ 6
Lep SM75SR8015-0EN
Issued 08-2008
Copyright
8015-3
SOLENOID VALVE
1 Assembly drawings
Normally closed type solenoid: SP, S1
Normally open type solenoid: S2

MQ26001-002
1.
2.
3.
4.
5.
6.
7.
8.
9.
Body (1)
Spool (2)
Spool (1)
Spring (2)
Spring (1)
Adaptor (3)
Snap ring(3)
Name plate(1)
Spring washer (6)
MSM-17-26-001
10.
11.
12.
13.
14.
15.
16.
17.
18.
Binding band (blue) (1)

Binding band (red) (1)
Binding band (pink) (1)
Solenoid (3)
O-ring (3)
Hexagon socket head bolt (6)
Plug (4)
Plug (4)
Rivet (2)
Issued 08-2008
Copyright
8012-4
2 Theory of operation
The hydraulic fluid supplied from the port P is fed to the
solenoid operated directional valves S1 @ when the
valve SP is energized. The hydraulic fluid is then fed to
the ports C1 depending on whether or not the valves
S1 is energized.
Electromagnetic selector valves S1:
Oil passes through when energized
Electromagnetic selector valves S2:
Oil passes through when not energized
NN16001-002
3 Maintenance
1 Assembling and disassembling precautions
[1] Disassemble the valve with due attention not to damage the O-ring and other parts, and store the parts in a safe
place.
[2] If there is any flaw on the O-ring, replace it with a new one.
[3] Be careful to assemble the parts in the correct orientation and without forgetting any of the parts.
[4] When assembling, reverse the order of disassembling and pay attention not to allow any foreign matters such as
dirt to get into the valve.
2 Assembling and Disassembling a Solenoid Operated Directional Valve
[1] Remove the mounting bolts from the solenoid (C) and remove the coil part. (Tool: 3 mm Hexagon wrench)
[2] Remove the tube, while paying attention not to damage the edges of the flat portion of the core. However, if the
core is removed, replace the O-ring (A) with a new one. (Tool: 23 mm spanner)
[3] Take out the spools (2) and (3) and the springs (4) and (5).
[4] Pry the snap ring (7) off by inserting a flat head screwdriver or the like in the notch, and remove the adapter (6).
[5] Assemble the valve by reversing the order of disassembling. When tightening the core, pay attention not to damage the edges of the flat portion of the core.
When mounting the adaptor, apply grease or other appropriate lubricant to the O-ring (B) and pay attention not to
damage the O-ring.
MSM-17-26-001
Issued 08-2008
Copyright
8015-5
1.7VQ2.0 Nm
O-ring
SO-NA-A022
14.4VQ17.6 Nm
O-ring
SO-NB-P18
Item 2 assembly: electronic selector valve SP, S1

Item 3 assembly: electronic selector valve S2
NN16001-003
MSM-17-26-001
Issued 08-2008
Copyright
8012-6
3 Maintenance Standards
MQ26001-001
Measure the clearance between the body and the spool.

Clearance = D - d
Reference value: approx. 0.01mm
4 Troubleshooting
Symptom
Spool malfunction.
Solenoid malfunction.
Fluid leakage to outside
MSM-17-26-001
Cause
Foreign matters galling the spool.
Damaged parts or abnormal wear.
Terminal disconnection.
Damaged coil.
Broken lead wire.
Loose bolts.
Damaged O-ring.
Loose hex socket plug.
Solution
Remove the foreign matters, dismount the
valve, perform flashing, or replace the fluid.
Replace the valve.
Insert the terminal.
Replace the solenoid
Tighten the bolt to the specified torque.
Replace the O-ring.
Fasten the plug.
Issued 08-2008
Copyright
Section
8016
8016

CUSHION CONTROL VALVE
CNH
Lep SM75SR8016-0EN

Printed in France
March 2008
Copyright
8016-2
TABLE OF CONTENTS
CUSHION VALVE.................................................................................................................................................... 3
STRUCTURE .......................................................................................................................................................... 3
OPERATIONAL DESCRIPTION .................................................................................................................................. 4
DISASSEMBLY AND ASSEMBLY .............................................................................................................................. 5
General Precautions ......................................................................................................................................... 5
Disassembling procedures ................................................................................................................................ 5
Lep SM75SR8016-0EN
Issued 08-2008
Copyright
8016-3
CUSHION VALVE
1 Structure
G 1/4
G 1/4
7
1
6 15
13
10
11
12
13
Figure 1
AQ27002-001
1.
2.
3.
4.
5.
6.
7.
Spring
Orifice
Body
Connector
Sleeve
Plunger
Name plate
ASM-17-24-002
8.
10.
11.
12.
13.
15.
Ring
Snap ring
O-ring
O-ring
O-ring
Plunger assembly
Issued 08-2008
Copyright
8016-4
2 Operational description
A -> B: Flow control (Figure 2)
Hydraulic oil supplied from port A passes through orifice (2) and the hole around plunger (6) and drains out to port
B.
At this time, the resistance of oil passing through orifice (2) causes the pressure in chamber (1) to become greater
than the pressure in chamber (2).
The plunger therefore moves to the right.
As plunger (6) moves to the right, section (I) is closed, creating a blind circuit, and the pressure in chambers (1)
and (2) is equalized.
As the pressure in chambers (1) and (2) is equalized, the force of spring (1) returns plunger (6) to the neutral position.
Repetition of this process causes plunger (6) to be balanced in a position where the force of spring (1) and the
resistance of orifice (2) are equal. (As the flow rate through orifice (2) increases and the resistance increases,
section (I) closes).
FS = FA - FB (FA = P1 x a > P2 x b = FB)
FS:
force of spring (1)
FA:
force to push the plunger to the right
FB:
force to push the plunger to the left
P1:
pressure in chamber (1)
P2:
pressure in chamber (2)
a, b:
outer diameter of plunger (a = b)
Consequently, a flow rate of oil passing through orifice (2) necessary to generate a passing resistance that balances the force of spring (1), is maintained, controlling the flow rate from port A into port B at a constant level.
6
(1)
(I)
(2)
Figure 2
AQ27002-002
ASM-17-24-002
Issued 08-2008
Copyright
8016-5
B -> A: Free flow (Figure 3)
Hydraulic oil supplied from port B first passes through orifice (2) and drains out to port A.
Resistance of oil passing through orifice (2) causes the pressure in chamber (1) to become less than the pressure
in chamber (2), moving plunger (6) to the left.
As plunger (6) moves to the left, section (II) opens and hydraulic oil passes through the circuit in section (II) and
the opening around plunger (6), and the entire flow drains out to port A.
When the supply of hydraulic oil is cut, plunger (6) is returned to the neutral position by the force of the 2 springs
(1).
3
(1)
(II)
(2)
Figure 3
AQ27002-003
3 Disassembly and Assembly

1 General Precautions
Hydraulic valves all consist of precision components. Disassemble and assemble them in a clean area that is free
of dust. Use clean tools and solvent.
After disassembly, clean parts and apply a corrosion inhibitor.
During disassembly, number each part to ensure that it is reassembled into its original position.
When reassembling, clean each part well, remove foreign substances, and verify that parts have no burrs or
dents. If burrs/dents are found, remove them with an oil stone.
Replace all seals with new ones each time the hydraulic valve is disassembled.
When reassembling, apply hydraulic oil to sliding parts and a thin coating of grease to all seals.
Never attempt to forcibly hit or pry parts when they cannot be moved easily.
2 Disassembling procedures
(Reassembly is done in the reverse order of disassembly.)
[1]
See figure 4
Remove snap ring (10).
Remove sleeve (5).
Remove O-rings (13). (x 2)
13
10
Figure 4
AQ27002-004
ASM-17-24-002
Issued 08-2008
Copyright
8016-6
[2] See figure 5
Disconnect connector (4).
Tightening torque of connector (4): 24.5 2.9 Nm
Remove O-ring (11).
11
Figure 5
AQ27002-005
[3]
See figure 6
Remove spring (1).
Remove the plunger assembly (15). [Orifice (2) and ring (8) cannot be disassembled.]
Remove spring (1).
Remove O-ring (12).
Plunger assembly (15) must be oriented correctly at reassembly. (Install so that ring (8) is visible when viewed
from the port A side.)
1
15
12
Figure 6
AQ27002-006
3 Troubleshooting
Symptom
External oil leak
Unstable flow rate at A -> B

Oil flow of B -> A blocked
from running its entire volume
ASM-17-24-002
Cause
Scratches on O-ring seal surfaces at
each port.
O-ring breakage.
Spring (1) is fatigued or breakage.
Foreign substance lodged in plunger
assembly (15).
Foreign substance blocking in orifice (2).
Foreign substance lodged in plunger
assembly (15).
Solution
Repair or replace
Replace
Replace spring (1)
Disassemble to clean and repair or
replace.
Disassemble and clean.
Disassemble to clean and repair or replace.
Issued 08-2008
Copyright
Section
8018
8018
DISASSEMBLY AND REASSEMBLY

OF THE HYDRAULIC SWIVEL
CNH
Lep SM75SR8018-0EN

Printed in France
August 2008
Copyright
8018-2
TABLE OF CONTENTS
ROTATING JOINT ................................................................................................................................................... 3
COMPONENT DIAGRAM .......................................................................................................................................... 3
TOOLS AND JIGS ................................................................................................................................................... 4
DISASSEMBLY INSTRUCTIONS ................................................................................................................................ 5
ASSEMBLY INSTRUCTIONS ..................................................................................................................................... 7
ASSEMBLY DRAWINGS ........................................................................................................................................... 9
Lep SM75SR8018-0EN
Issued 08-2008
Copyright
8018-3
ROTATING JOINT
1 Component diagram
1
2
5
3
4
10
11
6
7,8
1.
2.
3.
4.
5.
6.
Axle
V-ring
O-ring
Paking ring
Rotor
Cover
ASM-17-17-002
9
7.
8.
9.
10.
11.
AQ17002-001

Loctite
Snap ring
Thrust ring
O-ring
Issued 08-2008
Copyright
8018-4
2 Tools and jigs

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

L = 350-400 mm
M16-M20 Female

(7) x 25
Cover (6) fitting

size
AQ17002-003
ASM-17-17-002
Issued 08-2008
Copyright
8018-5
Prior to disassembly
[1] As this is a hydraulic device, follow the cautions below.
- Rough handling should be avoided (e.g. forcedly prying and hitting).
- Be careful when handling parts; do not drop or hit against other parts.
- Do not allow foreign substances such as dirt or moisture to enter into the parts.
[1] Always use jigs when disassembling axles and rotors.
[1] Use a strongly-built, stable workbench which has enough space. The workspace should be clean and free of dirt
and moisture. Remove all dirt and moisture before starting work.
[1] Inspect the tools and jigs before starting work. Remove dirt and moisture to make them clean.
[1] Use suitable tools and jigs which meet requirements for the job.
[1] Follow the procedure below to disassemble rotating joints..
Disassembling procedure
1.
Remove the cover (6) together with the bolt (7).
AQ17002-004
2.
Remove the O-ring (11).
11
AQ17002-005
3.
Remove the shaft snap ring (9), then remove thrust ring
(10).
9
10
AQ17002-006
ASM-17-17-002
Issued 08-2008
Copyright
8018-6
4.
Push out the axle (1) from the rotor (5) using a jig.
NOTE: Do not hit the parts with a hammer while carrying out this
operation.
AQ17002-007
5.
Remove the V-ring (2) from the axle (1).
AQ17002-008
6.
Remove the O-ring (3) and packing rings (4) from the rotor
(5).
4
3
AQ17002-009
ASM-17-17-002
Issued 08-2008
Copyright
8018-7
Prior to assembly
[1] Clean all the parts.
Change sealing parts such as O-rings and packing ring with new ones.
[1] Prior to the disassembly described in the Section 3-(1), perform the same cautions and measures mentioned in
this section.
1.
1) Clean the rotor (5) using cleaning liquid or compressed air.
2) After cleaning, check for scratches, flashes, burrs
or dents on the inner sides or grooves of the rotor.
NOTE: Do not reuse back-up ring (2) and O-ring (3).
AQ17002-010
2.
Check the number of packing rings (4) and the O-rings (3).
Apply grease and install them following the steps shown
below.
1) Set one packing rings (4) in each groove up to the

second from the top.
2) Set the O-ring (3) in the top groove.

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

or twists using a mirror. Also check for installation errors.
After the check is complete, apply grease.
After the grease application, check again for extrusion.
AQ17002-012
ASM-17-17-002
Issued 08-2008
Copyright
8018-8
4.
Install the V-ring (2) to the axle (1), and apply plenty of
grease.
Ensure that no water or dirt mixes into the grease
NOTE: Do not reuse V-ring (2).
AQ17002-013
5.
Install the axle (1) to the rotor (5).
NOTE: Be careful not to cause any cuts or damage to the V-ring

(2) while setting.
1
2
AQ17002-014
6.
Install thrust ring (10) and snap ring (9) onto axle (1).
9
10
1
AQ17002-015
ASM-17-17-002
Issued 08-2008
Copyright
8018-9
5 Assembly drawings
Apply grease before

assembly
Max gap 10.04

Min gap 8.30
Max gap 0.90

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

NOTE: Do not paint M marked surface and port machine surface.
1.
2.
3.
4.
5.
6.
7.
Axle (1)
V-ring (1)
O-ring (1)
Paking ring (9)
Rotor (1)
Cover (1)
Hexagon socket head bolt (4)
ASM-17-17-002
8.
9.
10.
11.
12.
13.
Loctite (-)
Snap ring (1)
Thrust ring (1)
O-ring (1)
Drive screw (2)
Trade mark plate (1)
Issued 08-2008
Copyright
8018-10
NOTES
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ASM-17-17-002
Issued 08-2008
Copyright
Section
8019
8019

SWING MOTOR
CNH
Lep SM75SR8019-0EN

Printed in France
March 2008
Copyright
8019-2
TABLE OF CONTENTS
SWING UNIT............................................................................................................................................................ 3
MAINTENANCE INSTRUCTIONS ................................................................................................................................ 3
Motor function ................................................................................................................................................. 3
Function of valves integrated in motor ............................................................................................................ 5
Parking brake function / hydraulic timer function ............................................................................................ 8
Tools used....................................................................................................................................................... 10
Disassembly .................................................................................................................................................... 13
Removing the anti-reverse valve................................................................................................................... 13
Separating the motor and the reduction gears.............................................................................................. 14
Disassembling the motor section .................................................................................................................. 14
Disassembling the reduction gears ............................................................................................................... 19
Assembling the motor section ....................................................................................................................... 23
Assembling the reduction gears.................................................................................................................... 29
Reassembling the entire motor assembly ..................................................................................................... 34
Installing the anti-reverse valve..................................................................................................................... 34
Checking Quality after Assembly .................................................................................................................... 35
Check for air leaks in the motor section ........................................................................................................ 35
Inspection before and after operation ........................................................................................................... 35
Maintenance Standards .................................................................................................................................. 36
Motor section................................................................................................................................................. 36
Reduction gear section ................................................................................................................................. 37
Valve section................................................................................................................................................. 37
Other ............................................................................................................................................................. 37
Exploded views ............................................................................................................................................... 38
Stracture drawing ............................................................................................................................................ 40
ANTI-REVERSE VALVE.......................................................................................................................................... 42
Troubleshooting .............................................................................................................................................. 42
Tools used....................................................................................................................................................... 43
Disassembling instructions.............................................................................................................................. 43
Precautions prior to disassembly .................................................................................................................. 43
Disassembly.................................................................................................................................................. 43
Precautions prior to reassembly.................................................................................................................... 44
Assembly....................................................................................................................................................... 44
Anti-reverse valve: Exploded view .................................................................................................................. 46
Lep SM75SR8019-0EN
Issued 08-2008
Copyright
8019-3
SWING UNIT
1 Troubleshooting
If any problems occur in the swing motor, as a general rule, replace the entire assembly.
Problems, causes and remedies are described below for reference and understanding.
1 Motor function
Problem
1. Motor does not

rotate.
2. Motor rpms are

insufficient.
3 .Large variation in
motor rotation.
ASM-17-22-002
Cause
Remedy
1. Malfunction of something other than

the piston motor, valves (integrated in
motor) or reduction gears.
Check to see if the oil pressure at the entry side of

the motor is correct. Then inspect/repair each
device.
2. Escaping hydraulic oil due to abnormal wear on motor sliding sections.
Replace parts with abnormal wear. Clean all parts

completely and remove surface burrs and
scratches. Reassemble, taking care to keep foreign substances out of parts.
3. Malfunction due to breakage of major

motor components. In this case, the
motor itself makes abnormal sounds.
After disassembly, replace damaged parts. Clean

all parts completely and reassemble, taking care
to keep foreign substances from getting into parts.
4. Malfunction due to breakage of major

reduction gear components. In this
case, the reduction gears make abnormal sounds.
After disassembly, replace damaged parts. Clean

all parts completely and reassemble, taking care
to keep foreign substances out of parts.
5. Too much load on the motor activates

the relief valve.
Check load and run motor with a load that

matches relief set pressure.
1. Insufficient motor revolutions due to

lack of oil supply to motor, caused by
problems related to hydraulic pump,
pressure control valves, etc.
Check to see if the amount of oil supplied to the

entry side of the motor is correct. Then inspect/
repair each device.
2. Motor rpms are reduced due to

decreased motor volumetric efficiency.
Disassemble and check sliding sections for

abnormal wear, then repair or replace.
1. Wear on sliding sections causes a

large amount of highly-pressurized
hydraulic oil to leak and flow out from
the drain port, reducing rpms significantly and causing rotation to vary. Variation in rotation is also caused by wear
on shaft bearings.
After disassembly, replace parts that show abnormal wear. Clean all parts completely and reassemble. Take measures to prevent foreign
substances from getting into parts.
Issued 08-2008
Copyright
8019-4
Problem
4. Oil leak.
5. Abnormal noises,
fluctuation in rotation/
pressure due to cavitation.
ASM-17-22-002
Cause
Remedy
1. Damaged oil seal or O-ring causes oil

to leak.
Replace damaged oil seal or O-ring with new one.

Special care should be taken when inserting oil
seals so that lips will not be damaged.
Maximum temperature for safe use of oil seals
and O-rings is 80 C.
If the hydraulic oil temperature is likely to be
higher than 80 C, measures such as installation
of a cooling system in the hydraulic circuit are
required.
2. A broken oil seal, caused by

increased pressure inside the motor
case from the causes listed in 1.2 and
3.1, results in oil leakage.
- Oil seal
- Withstand pressure: 3 kgf/cm2 (instantaneous maximum)
- Normal use:1 kgf/cm2 or less
Repair motor according to instructions in 1.2 and

3.1 and then replace oil seal with new one. Special care should be taken when inserting oil seals
so that lips will not be damaged.
3. Drain pipe is blocked by foreign substances, or long narrow piping causes

increased back pressure, leading to oil
seal breakage and oil leakage.
- Oil seal
- Withstand pressure: 3 kgf/cm2 (instantaneous maximum)
- Normal use:1 kgf/cm2 or less
Clean drain pipe.

Recheck piping system to reduce resistance.
After taking these measures to ensure that the pressure on the oil seals does not exceed 3 kgf/cm2,
replace oil seal with new one.
Special care should be taken when inserting oil
seals so that lips will not be damaged.
1. Increased drain volume due to low

motor efficiency.
Take measures described in 2.2 and 3.1.
2. Makeup valve malfunction.
Take measures described 1.4 under Valve functions.
3. Insufficient pressure on makeup valve

due to lack of supply flow.
Check makeup supply pressure and oil level, then

reset to defaults.
Issued 08-2008
Copyright
8019-5
2 Function of valves integrated in motor
Problem
Cause
Remedy
1. Malfunction of something other than

the piston motor, valve
(integrated in motor), or reduction gears.

the motor is correct. Then inspect/repair each
device.
2. Increased internal leakage due to Oring seal breakage in relief valve.
Replace O-rings and backup rings with new ones.
3. Increased leakage due to bad seal in

valve and piston section.
Repair, or replace piston and rear cover with new

ones.
4. Faulty seat or malfunction in makeup

valve.
1) Foreign substances present.
1. Motor does not

rotate or rotational
speed is low.
2) Roughness or breakage on sliding faces of check valve.

3) Damaged spring.
5. Faulty seat in relief valve.

2) Damaged spring.
Cracking pressure on relief valve is
reduced.
1) Spring fatigue.
2) Poppet and orifice are blocked.
6. Increased leakage.
1) Increased internal leakage due
to broken O-ring in valve.
2) Increased leakage caused by
faulty seal on valve or piston.
ASM-17-22-002
1) Remove foreign substances completely

and repair where damaged. Clean and
reassemble. Replace if scratches are deep
and leak is large.
2) Repair sliding faces or replace part with
new one.
3) Replace spring. Then remove foreign substances completely and repair valve where
damaged. Clean and reassemble. Replace
if scratches are deep and leak is large.
and leak is large.
2) Replace relief valve assembly.

2) Clean with mineral oil, then reassemble.
1) Take measures described in 1.2 and 1.3 to

solve problem.
Issued 08-2008
Copyright
8019-6
Problem
Cause
1. Faulty seat or malfunction in makeup
valve.
2) Roughness or breakage on sliding faces of check valve.

3) Damaged spring.
2. Motor does not stop,

or does not stop immediately.
2. Faulty seat in relief valve.

2) Damaged spring.
3. Cracking pressure on relief valve is
reduced.
1) Spring fatigue.
2) Poppet and orifice are blocked.
4. Increased leakage.
1) Increased internal leakage due
to broken O-ring in valve.
2) Increased leakage caused by
faulty seal on valve or piston.
1. Make-up valve malfunction.
2) Damaged spring.
3. Abnormal noises.
ASM-17-22-002
Remedy

and leak is large.
2) Repair sliding faces or replace part with
new one.
damaged. Clean and reassemble. Replace
if scratches are deep and leak is large.
and leak is large.

2) Clean with mineral oil, then reassemble.
1) Take measures described in 1.2 and 1.3 to

solve problem.

and leak is large.
damaged. Clean and reassemble. Replace if
scratches are deep and leak is large.
2. Insufficient pressure/oil flow to

makeup valve.
Check makeup pressure and oil flow and reset to

specified values.
3. Relief valve set pressure changes,

causing resonance in other relief valves.
Readjust relief valve set pressure.
Issued 08-2008
Copyright
8019-7
Problem
Cause
1. Shockless feature does not operate.
4. Greater than usual

shock at swing stops.
ASM-17-22-002
2) Hydraulic oil is not supplied to

piston chamber.
3) Increased leakage due to abnormal wear on piston sliding part.
Remedy
1) Remove foreign substances completely.
Clean damaged parts and repair, then
and leak is large.
2) Clean relief valve assembly and remove foreign substances blocking orifice section.
3) Repair or replace sliding part.
2. Relief valve set pressure is increased.
Readjust relief valve set pressure.
3. Relief valve does not operate.

Foreign substances present in sliding
section.
Remove foreign substances completely. Clean

damaged parts and repair, then reassemble.
Replace if scratches are deep and leak is large.
Issued 08-2008
Copyright
8019-8
3 Parking brake function / hydraulic timer function
(References to models with parking brake/hydraulic timer specifications only are indicated in parentheses).
Problem
1. Motor does not

rotate.
Parking brake does not
release.
Cause
1. Release pressure PB (PG) and
valve switching signal pressure SH
(models with hydraulic timer specifications only) are not generated, or pressure supplied is low (not meeting
specified values) As a result, brake
piston does not operate. Timer valve
does not switch over.
Adjust PB (PG) and SH pressure to specified values.
2. Valve does not operate because

motor drain pressure is high.
Measure motor drain pressure, inspect drain circuit for blockage and repair.
If motor drain volume is abnormally large, inspect
and repair motor.
3. Timer valve does not switch over

(models with hydraulic timer specifications only).
1) Malfunction due to wear or damage to sliding section of valve
body.
2) Malfunction due to foreign substances engaged in sliding section of valve body.
3) Damaged spring.
4. Brake piston does not operate.
1) Hydraulic oil escapes due to
abnormal wear or breakage of
O-ring in brake piston.
2) Piston malfunction due to wear
or damage to brake piston or
sliding section.
3) Malfunction due to foreign substances lodged in piston sliding
section.
ASM-17-22-002
Remedy
1) Inspect and repair damaged parts. Replace

if damage to sliding section is serious.
2) Clean sliding section and remove foreign
substances.
3) Replace spring.
1) Inspect damaged parts and repair.
2) Replace if damage to sliding section is serious.
3) Clean sliding section and remove foreign

substances.
Issued 08-2008
Copyright
8019-9
Problem
Cause
Remedy
1. Worn abrasive material on disks.
Replace disks with new ones.
2. Fatigue or breakage of springs in piston section.
Replace springs with new ones.
3. Faulty sliding section or warping in

brake piston, or deformation of abrasive
face of disk.
Repair sliding face, or replace parts if damage is

serious. Surfaces of abrasive material cannot be
repaired.
4. Timer valve does not switch over

and pressure cannot be released from
cylinder chamber (models with
hydraulic timer specifications only).
2. Poor braking power.
No braking power.
1) Valve spring fatigue.
1) Replace spring.
2) (Models with hydraulic timer

specifications only:) Signal pressure SH is supplied or signal system back pressure is high.
3) For other problems,
see 1.3. 1) - 3).
2) Check pressure in SH signal system. If

back pressure is high, take measures to
reduce to specified value.
5. Pressure cannot be released from

cylinder chamber because of blockages in orifice and filter.
3) For other problems, see 1.3. 1) - 3).
Clean filter and orifice, or replace with new ones.
1. Brake piston rubs on disk because

release pressure PB (PG) is low.
2. Decreased pressure in cylinder
chamber due to abnormal wear or
breakage of O-ring in brake piston.
3. Parking brake does

not release completely,
generating noises,
vibratory shocks,
abnormalities and heat.
3. For malfunctioning timer valve, see

2.4. 1) - 3).
4. Faulty hydraulic timer section.
(Models with hydraulic timer specifications only:) Parking brake operates as
a dynamic brake because timer is set
too early.
1) Orifice is not positioned correctly.
2) Faulty valve seat.
3) Foreign substances engaged in
the above valve seat.
4) Spring fatigue or breakage.
ASM-17-22-002
1) Disassemble to inspect valve, then assemble orifice correctly.

2) If abnormal damage is found on seat surface,
repair or replace with new one.
3) Clean new parts and remove foreign substances.
4) Replace spring with new one.
Issued 08-2008
Copyright
8019-10
2 Tools used
No
Name
Plastic hammer
Hexagon wrench
Screwdriver (flathead)
Snap ring pliers (internal)
Snap ring pliers (external)
Hand press
Vise
Hexagonal wrenches
Width across flats

2.5 mm
3 mm
5 mm
6 mm
8 mm
12 mm
Torque wrench
Troque settings
2.45 Nm
15.7 Nm
24.5 Nm
32.4 Nm
39.2 Nm
70 Nm
157 Nm
177 Nm
373 Nm
Bits for torque wrench
Width across flats

2.5 mm
3 mm
5 mm
6 mm
8 mm
12 mm
10
Socket
Width across flats: 27
11
Tweezers
12
Needle nose pliers
ASM-17-22-002
Issued 08-2008
Copyright
8019-11
Tool name............................................................................................................................... Configurations for reference
1.
Ball bearing press fitting jig (2-3).
AQ22002-001
2.
Ball bearing press fitting jig (2-28).
AQ22002-002
3.
Oil seal press fitting jig (1-7).
AQ22002-003
ASM-17-22-002
Issued 08-2008
Copyright
8019-12
Tool name............................................................................................................................... Configurations for reference
4.
Collar press fitting jigs (1-10).
AQ22002-004
ASM-17-22-002
Issued 08-2008
Copyright
8019-13
3 Disassembly
WARNING: Precautions prior to disassembly

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

1) Part numbers in the text correspond to numbers shown in the Sectional Parts Listing and Exploded View.
2) Parts marked (*1) apply only to models with anti-reverse valve specifications only.
3) Parts marked (*2) apply only to models with parking brake specifications only.
4) Parts marked (*3) apply only to models with hydraulic timer specifications only.
1 Removing the anti-reverse valve

*1, anti-reverse valve specifications only
Remove socket head bolts (2-39), and remove antireverse valve (2-34) and O-ring (2-38). See the Antireverse Valve Instruction.
2-38
2-36
2-34
2-39
AQ22002-006
ASM-17-22-002
Issued 08-2008
Copyright
8019-14
2 Separating the motor and the reduction gears
[1] Secure the entire motor assembly firmly in a vise or the
like, then remove socket head bolts (3).
AQ22002-007
3 Disassembling the motor section

1 Secure the motor assembly firmly in a vise or the
like.
Remove socket head bolts (2-33) and separate off
cover assembly (2-27).
2-33
2-33
NOTE: Handle carefully so that valve plate (2-30) does not fall
when cover assembly (2-27) is separated off.
2-33
2-30
2-33
2-27
AQ22002-008
ASM-17-22-002
Issued 08-2008
Copyright
8019-15
2 Remove valve plate (2-30) and pins (2-32, 2-29).
2-30
2-29
2-32
WARNING: Valve plate (2-30) may remain on the

motor side.
3 Remove bearing (2-28).
WARNING: Do not disassemble unless absolutely

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

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

1) Loosen plug (2-27-6-6) and remove relief valve
assembly (2-27-6).
WARNING: Do not touch set screws and nuts (2-276-13 and 14).
Doing so will change the pressure settings.
Relief valve assembly (2-27-6) is a functional
component and should not be disassembled.
2-27-6-13
2-27-6-3
2-27-6-14
2-27-6-6
AQ22002-013
WARNING: When removing the relief valve

assembly, poppet sheet (2-27-6-3) may remain on
the cover side.
ASM-17-22-002
Issued 08-2008
Copyright
8019-16
6 Remove pin (2-31) and O-ring (2-24).
WARNING: Pin (2-31) may remain on the cover

assembly side.
2-31
2-24
AQ22002-014
7 (*2, parking brake specifications only)

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

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

(*2, parking brake specifications only)
2-17
2-15
WARNING: Removing one disk (2-15) first makes

this procedure easier.
NOTE: Be careful not to deform the friction plate while removing the collar.
AQ22002-016
9 Remove the cylinder block and related parts:

Cylinder block (2-6), etc.
- Pin (2-11)
- Retainer holder (2-13)
- Retainer plate (2-12)
- Piston assembly (2-14)
(*2, parking brake specifications only)
Remove disk (2-15) and friction plate (2-16).
2-11
2-6
2-14
2-16
2-15
2-12
2-13
AQ22002-017
ASM-17-22-002
Issued 08-2008
Copyright
8019-17
10 Remove retainer plate (2-12) and piston assembly
(2-14).
2-12
2-14
AQ22002-018
11 Remove pin (2-11) and retainer holder (2-13).

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

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

necessary.
As a general rule, rotary parts (B1) should be replaced
as a cylinder block assembly.
AQ22002-020
13 Remove collar (2-7), spring (2-8) and washer (29).
2-9
2-7
2-8

necessary.
As a general rule, rotary parts (B1) should be replaced
as a cylinder block assembly.
AQ22002-021
ASM-17-22-002
Issued 08-2008
Copyright
8019-18
14 Remove thrust plate (2-5).
2-5
AQ22002-022
15 Remove shaft (2-4) by tapping the end of the shaft

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

2-3
2-4

necessary.
Bearings, once removed, cannot be reused.
AQ22002-024
ASM-17-22-002
Issued 08-2008
Copyright
8019-19
4 Disassembling the reduction gears
1) Remove:
- O-ring (1-37)
- Thrust plate (1-24)
- Drive gear (1-25)
- Planetary gear (1-23)
- Needle bearing (1-22)
- Inner race (1-21)
- Thrust washer (1-20)
- Holder (1-19)
1-23
1-20
1-21
1-25
1-22
1-24
1-37
1-19
AQ22002-025
2) Remove planetary gear (1-18).

1-18
AQ22002-026
ASM-17-22-002
Issued 08-2008
Copyright
8019-20
3) Remove holder (1-11) etc.
1-11
AQ22002-027
4) Loosen screw (1-17) and remove thrust plate (1-16).
WARNING: This screw may be hard to remove

because Loctite is used in the assembly.
In this case, heating the screw section with a dryer
facilitates its removal.
1-16
1-17
1-11
AQ22002-028
5) Remove:
- Planetary gear (1-15)
- Inner race (1-13)
1-13
1-14 1-15
1-12
AQ22002-029
ASM-17-22-002
Issued 08-2008
Copyright
8019-21
WARNING: About disassembling parts related to

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

1-2
1-3
AQ22002-030
7) Remove pinion shaft (1-2).

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

(1-8).
1-8
AQ22002-032
ASM-17-22-002
Issued 08-2008
Copyright
8019-22
9) Break oil seal (1-7) and remove.
NOTE: Oil seals that have been removed cannot be reused.
Be careful not to damage the outer races of tapered roller
bearings (1-6, 1-8) during removal.
1-7
AQ22002-033
10) Remove plug (1-35).
1-35
AQ22002-034
ASM-17-22-002
Issued 08-2008
Copyright
8019-23
WARNING: Precautions prior to assembly

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

Tapered face
Cylinder block
AQ22002-036
2 Install snap ring (2-10) while pressing on washer (29).
AQ22002-035
2-9
2-10
NOTE: Make sure that the snap ring is firmly secured.
AQ22002-037
3 Apply grease to pins (2-11) and install them in cylinder block (2-6).
4 Install retainer holder (2-13).
2-13
2-11
2-6
AQ22002-038
ASM-17-22-002
Issued 08-2008
Copyright
8019-24
5 Place retainer plate (2-12) on piston assembly (2-14)
and install on cylinder block (2-6).
Coat sliding sections thoroughly with hydraulic oil
before installing.
2-12
2-14
2-6
NOTE: Be careful to orient the retainer plate correctly.
AQ22002-039
6 Press fit ball bearing (2-3) onto shaft (2-4).

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

case (2-1).
2-4
AQ22002-041
ASM-17-22-002
Issued 08-2008
Copyright
8019-25
8 Apply grease to back surface of thrust plate (2-5)
and install.
2-5
NOTE: Thrust place must be oriented correctly.
Please tapered side on motor case side

AQ22002-043
AQ22002-042
9 Apply grease to front surface of thrust plate (2-5)

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

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

locations on the spline without teeth.
AQ22002-045

Apply grease to O-ring (2-18) and install on collar (217).
2-17
2-18
WARNING: Always press fit using a press or the like.

If hit with a plastic hammer or the like, the cylinder
block will bounce and cause the disk plate and
friction plate to fall off.
AQ22002-046
ASM-17-22-002
Issued 08-2008
Copyright
8019-26
Apply grease to O-rings (2-20, 2-21) and install on
brake piston (2-19).
2-19

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

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

positioned at this location
AQ22002-048
14 Apply grease to 12 large springs (2-22), 8 small

springs, (2-23) and O-ring (2-24), then install.
2-23
2-22
2-19
2-24
AQ22002-049
Pin hole
WARNING: Install small springs (2-23) in the

locations shown below.
Pin hole
AQ22002-050
ASM-17-22-002
Issued 08-2008
Copyright
8019-27
15 Install greased O-rings (2-27-6-7, 15, 17) and
backup rings (2-27-6-16, 18) on relief valve (2-27-6),
and then install it on cover (2-27-1).
2-27-6-7
2-27-6-18
2-27-6-16 2-27-6-3
Tightening torque: 3720 Nm (Width across flats: 27)

NOTE: Poppet sheet (2-27-6-3) may remain inside the cover.
2-27-6-17
2-27-6-15
AQ22002-051
16 Attach check valve (2-27-2) and spring (2-27-5)

onto cover (2-27-1). Install plug on cover (2-27).
2-27-5
2-27-2
AQ22002-052
17 Apply grease to O-ring (2-27-4) and install onto

plug (2-27-3). Install plug on cover (2-27).
2-27-4

2-27-3
AQ22002-053
18 Press fit ball bearing (2-28).

(Reference jig No. 22)
Install pins (2-31, 32) onto cover (2-27-1) and then
screw in orifice (2-27-7).
2-27-7
2-31
2-28
2-32
NOTE: After orifice (2-27-7) is screwed in, crimp it around the

perimeter.
2-27-1
ASM-17-22-002
AQ22002-054
Issued 08-2008
Copyright
8019-28
19 Install pin (2-29) and attach valve plate (2-30).
Apply grease to back face to keep it from falling off.
2-31
2-30
2-29
AQ22002-055
NOTE: After installing pin (2-29), crimp the following locations

using a punch:
6 (range crimped with punch
2-29
Crimp one location with punch

(center side of motor)
Pin (2-29) crimping location
AQ22002-056
20 Install cover assembly (2-27) on case (2-1), keeping an eye on the locations of pins (2-31, 2-32).
2-31
2-30
2-27
2-32
NOTE: Be careful not to drop the pin or the valve plate.

NOTE: Refer to notes in section 1-13: Installing Brake Piston
for location of pin (2-32).
AQ22002-057
21 Finger tighten socket head bolt (2-33), then

tighten to specified torque.
2-33
2-33
2-33
2-33

NOTE: Parts related to the pinion shaft should be replaced as
a housing assembly (B6). Description below is for reference
purposes only.
AQ22002-058
ASM-17-22-002
Issued 08-2008
Copyright
8019-29
1 Press fit oil seal (1-7).

Press fitting dimension: 4.25 (shown in the figure to
the left).
Prior to press fitting, apply grease to the mounting
site of the oil seal in the housing and the outer surface of the oil seal. (Reference jig No. 23).
Dimension of oil seal after press fitting: 4.25
2 Assembling the reduction gears

(reference)
1-7
AQ22002-059
2 Apply grease to the inner race of tapered roller

bearing (1-6), which is installed in pinion shaft (1-2).
Amount of grease packed: 80 to 90 cm2 (approx. 66
to 75 g).
1-2
1-6
AQ22002-060
ASM-17-22-002
Issued 08-2008
Copyright
8019-30
3 Install pinion shaft (1-2), etc. Install inner race of
tapered roller bearing (1-8).
Apply grease to lip of oil seal (1-7) before installing
pinion shaft (1-2), etc.
Before installing pinion shaft, verify that plug (1-35) is
not attached.
Installing the pinion shaft with the plug attached
increases the air pressure inside, and this may cause
damage to oil seal (1-7).
1-7
1-8
1-2
AQ22002-061
4 Install collar (1-10) while applying load 1177ON to

the inner race of tapered roller bearing (1-8).
(Reference jig No. 24)
Apply grease to O-ring (1-36) and install on plug (1-35).
Install plug in housing (1-1).
1-1
1-8
1-9
1-10
Tightening torque: 15.70.8 Nm (Width across flats: 5)

1-35
1-36
AQ22002-062
ASM-17-22-002
Issued 08-2008
Copyright
8019-31
5 Install thrust washer (1-12), inner race (1-13), needle bearing (1-14) and planetary gear (1-15) onto
holder (1-11).
1-13
1-14
1-11
1-15
1-12
AQ22002-063
6 Install thrust plate (1-16) and screw (1-17) onto

holder (1-11).
Apply Loctite 242 to screw before fastening.
1-16
Tightening torque: 24.54.9 Nm (Width across flats)
1-17
1-11
AQ22002-064
7 Install holder (1-11), etc.
1-11
AQ22002-065
8 Install snap ring (1-26) on sun gear (1-18).

1-26
1-18
Install snap ring with side marked with R facing this way.
AQ22002-066
ASM-17-22-002
Issued 08-2008
Copyright
8019-32
9 Install sun gear (1-18).
1-18
AQ22002-067
10 Install holder (1-19).
1-19
AQ22002-068
ASM-17-22-002
Issued 08-2008
Copyright
8019-33
11 Install
- Inner race (1-21)
- lanetary gear (1-23)
- Thrust plate (1-24)
- Drive gear (1-25)
- O-ring (1-37)
1-23
1-20
1-21
1-25
1-22
1-24
1-37
AQ22002-069
WARNING: When replacing any component part of

the reduction gear, measure the dimensions shown
below and select one thrust plate (1-24) from thrust
plate kit (B5) according to the selection table.
Thrust Plate Selection Table (1-24)
(Reference)
Dimension E
(Measured dimension)
5.3 to <5.8
5.8 to <6.5
6.5 to 7.0
B0841-23031
2.8 0.14
B0841-23030
2.3 0.12
B0841-23029
1.8 0.10
7.96 to 8.74
7.98 to 8.72
8.2 to 8.9
(Between inner rance and housing)
Part No.
(plate thickness)
For thrust plate

(1-24)
Dimension F
(Measured dimension)
AQ22002-070
ASM-17-22-002
Issued 08-2008
Copyright
8019-34
3 Reassembling the entire motor assembly
1 Place the reduction gear assembly on the motor
assembly, verify its orientation, finger tighten socket
head bolt (3), and then tighten to the specified torque.
Tightening torque: 17710 Nm (Width across flats: 12).
AQ22002-071
4 Installing the anti-reverse valve

(*anti-reverse valve specifications only)
2-38
2-27-1
1 Install O-ring (2-38) on cover (2-27-1).

2 Place valve assembly (2-34) on cover (2-27-1) and
fasten socket head bolt (2-39).
Tightening torque: 32.42.0 Nm (Width across flats: 6)
NOTE: (Refer to the Anti-reverse Valve Instruction (40 page)
for instructions for disassembling and reassembling antireverse valves.) Remove deep groove ball bearing (149) from
shaft (102) by pressing on the shaft end with press.
2-34
2-39
AQ22002-072
ASM-17-22-002
Issued 08-2008
Copyright
8019-35
5 Checking Quality after Assembly
WARNING: Check the following before and after

operation.
1 Check for air leaks in the motor section

Fill the motor case with compressed air (0.3 MPa) through the drain port, and verify that no bubbles are given off
in water for a period of two minutes.
2 Inspection before and after operation
1 Prior to starting the motor, fill the piston motor case with clean hydraulic oil.
2 Bleed air at each piping section.
3 Operate at low speed at first, and then increase the engine rotations and apply load after confirming that
there are no abnormal sounds or vibrations.
4 Check the following after operation:
1) Is there any oil leakage?
2) Are the rpm and direction of rotation correct?
3) Is the oil temperature abnormally high?
4) Is the temperature of the piston motor case abnormally high?
5) Are there any abnormal sounds or vibrations?
6) Are there any other abnormalities?
ASM-17-22-002
Issued 08-2008
Copyright
8019-36
6 Maintenance Standards
Replace each part according to the table below.
1 Motor section
Name of part
Piston assembly
Maintenance standards
1. If there are deep scratches on the sliding section, or the sliding section is rough.
2. If the gap between the cylinder block bore and the piston assembly is too large.
Upper limit of diameter clearance: 0.04 mm
3. If the shoe ball section is too loose.
Maximum play (distance): 0.4 mm
Thrust plate
Retainer holder
Retainer plate
If there are deep scratches on the sliding sections, or the sliding sections are rough.
Valve plate
Brake piston
( *2. parking brake specifications only)
Cylinder block
1. If there are deep scratches on the sliding section, or the sliding section is rough.
2. If there is abnormal wear or breakage on the engaging surfaces.
Disk
( *2. parking brake specifications only)

1. If there are deep scratches or peeling on the disk (abrasive material).
2. If there is abnormal wear or breakage on the engaging surfaces.
Ball bearing
1. If there is flaking or peeling on the rolling surfaces.

2. If there are impressions on the rolling surfaces.
3. If bearing rotations are abnormal (noises, irregular rotations).
Spring
If there is breakage or serious deformation.
O-ring
If there are scratches causing oil leakage, scratches compromising seal performance, or
it is permanently deformed.
ASM-17-22-002
Issued 08-2008
Copyright
8019-37
2 Reduction gear section
Name of part
Pinion shaft
If there is abnormal damage, wear or flaking on gear tooth surfaces.

*Always replace as a housing assembly.
Plate
If there is abnormal damage or wear.
Tapered roller bearing
1. If there are scratches, impressions or flaking on the roller or race section.

2. If it does not rotate smoothly without unusual noise.
Oil seal
1. If there is damage, deformity or abnormal wear on the lips.

2. If lips have become hard.
Housing
Holder
Drive gear
Sun gear
If there are scratches, wear or flaking on gear tooth surfaces.

Inner race
If there are scratches, wear or flaking on the rolling surfaces of the needle bearing.
Needle bearing
If there are scratches, wear or flaking on the rolling surfaces of the needle bearing.
Planetary gear
1. If there are scratches, wear or flaking on gear tooth surfaces.

2. If there are scratches, wear or flaking on rolling surfaces of the needle bearing.
Thrust plate
If there are scratches, wear or seizure on sliding surfaces.
3 Valve section
Name of part
Piston (relief valve section)

Case
1. If there are deep scratches or roughness on the sliding section.

2. If the clearance between the piston and the case hole is too large.
Upper limit of diameter clearance: 0.04 mm
Valve body
Spool
(Hydraulic timer valve)
(*3. hydraulic timer specifications only)

1. If there are deep scratches or roughness on the sliding section.
If the clearance between the spool and the valve body hole is too large.
2. Upper limit of diameter clearance: 0.04 mm
Spring
If there is breakage or serious deformation.
Plug
Check valve
O-Ring
Backup ring
4 Other
Name of part
Other plugs and O-rings
ASM-17-22-002
Issued 08-2008
Copyright
8019-38
7 Exploded views
1-1
1-38
1-6
1-8
1-5
1-7
1-4
1-3
1-2
1-26
1-36
1-18
1-35
1-17
1-16
1-15
1-14
1-13
1-12
1-11
1-10
1-9
1-37
A
1-24
1-23
1-22
1-21
1-20
1-19
1-25
AQ22002-073
ASM-17-22-002
Issued 08-2008
Copyright
8019-39
2-14
2-13
2-12
2-5
2-4
2-3
3
2-24
2-1
2-19
2-21
2-20
2-17
A
2-18
2-22
2-23
2-15
2-10
2-9
2-8
2-7
2-6
2-16
2-34
2-11
-5
-8
-7
-2
2-27
-3
-4
-1
2-39
2-34
-5
10
-2
2-34
-8
-6
-3
-1
11
-11
-10
-9
2-34
-4
-2
2-46
2-27
-6
2-38
2-29
2-27
-12
2-33
2-27
-2
-7
-15
2-28
2-30
2-31
-16
-8
2-34
2-45
2-32
-3
-5
-13
-5
-4
-3
2-27
-3
-2
-18
-6
-17
-10
-1
-6
2-27
-4
-5
-9
-10
-8
-11
-12
-7
-13
-14
AQ22002-074
ASM-17-22-002
Issued 08-2008
ASM-17-22-002
2-45 2-46
2-33
-3
-5
2-31
-8
-2
-1
-6
-2
-7
2-31
-5
-4
2-3
-4
2-27
-3
-12 -13
-8
-6
2-2
-1
2-4
2-1
2-27-7
-10
-9
2-34
-11
-19
-22
-23
-30
-11
-39
-38
-34
-28
-9
-7
11
10
-10
-8
-29
-6
-32
-17 -18
-24 -21 -20
-1
-4
-3
-16 -41 -40 -13 -14 -12
-5
-2
-3
-15 -16
-5
-10 -9
-1 -18 -17 -4
-8
-37 -22 -21 -23 -20
-24
-10
-7
-19 -16
-6
-17
-12
-26
-25 -14 -15 -13 -12
-14
-13
-11
-18
-11
-35 -36
2-27-6
-10
-9
-6
-5
-4
-3
-2
-7
-1
-8
1
Copyright
8019-40
8 Stracture drawing
AQ22002-075
Issued 08-2008
Copyright
8019-41
No.
Qty
No.
Qty
No.
Reduction gear
2-10
Snap ring
2-28
Ball bearing
1-1
Housing
2-11
Pin
2-29
Pin
1-2
Pinion shaft
2-12
Retainer plate
2-30
Valve plate
1-3
Coller
2-13
Reainer holder
2-31
Pin
1-4
Plate
2-14
Piston assembly
2-32
Pin
1-5
Plate
2-16
Friction plate
2-33
Hex. socket bolt
1-6
Taper roller bearing
2-17
Coller
2-34
Valve assembly
1-7
Oil seal
2-18
O-ring
2-34-1
Body
1-8
Taper roller bearing
2-19
Brake piston
2-34-2
Check valve assembly
1-9
Plate
2-20
O-ring
2-34-2-1
Check valve
1-10
Coller
2-21
O-ring
2-34-2-2
Valve
1-11
Holder
2-22
Spring
12
2-34-2-3
Spring
1-12
Thrust washer
2-23
Spring
2-34-2-4
Plug
1-13
Inner race
2-24
O-ring
2-34-3
Spring
1-14
Needle bearing
2-27-1
Cover
2-34-4
Sleeve
1-15
Planetary gear
2-27-2
Poppet
2-34-5
Plug
1-16
Thrust plate
2-27-3
Plug
2-34-6
Orifice
1-17
Screw
2-27-4
O-ring
2-34-7
Plug
1-18
Sun gear
2-27-5
Spring
2-34-8
O-ring
1-19
Holder
2-27-6
Relief valve assembly
2-34-9
Filter
1-20
Thrust washer
2-27-6-1
Relief housing
2-34-10
Washer
1-21
Inner race
2-27-6-2
Poppet
2-34-11
Orifice
1-22
Needle bearing
2-27-6-3
Poppet seat
2-34-12
Plug
1-23
Planetary gear
2-27-6-4
Spring seat
2-34-13
O-ring
1-24
Thrust plate
2-27-6-5
Spring
2-38
O-ring
1-25
Drive gear
2-27-6-6
Plug
2-39
Hex. socket bolt
1-26
Snap ring
2-27-6-7
O-ring
2-40
Disk
1-35
Plug
2-27-6-8
Piston
2-41
Friction plate
1-36
O-ring
2-27-6-9
O-ring
2-45
Plug
1-37
O-ring
2-27-6-10
Backup ring
2-46
O-ring
Piston motor
2-27-6-11
Spring guide
Hex. socket bolt
2-1
Case
2-27-6-12
O-ring
2-3
Ball bearing
2-27-6-13
Set screw
2-4
Shaft
2-27-6-14
Nut
2-5
Thrust plate
2-27-6-15
O-ring
2-6
Cylinder block
2-27-6-16
Backup ring
2-7
Coller
2-27-6-17
O-ring
2-8
Spring
2-27-6-18
Backup ring
2-9
Coller
2-27-7
Orifice
Part name
ASM-17-22-002
Part name
Part name
Qty
Issued 08-2008
Copyright
8019-42
2 Anti-reverse valve
1 Troubleshooting
If any problems occur during operation, refer to the troubleshooting table shown below to determine the cause of the
problem and measures for remedying it.
Troubleshooting table
Problem
Cause
Remedy
1. Malfunction in something other than

the piston motor, valve unit or antireverse valve.

the valve is correct. Then inspect/repair each
device.
2. Faulty seat in check valve assembly.
1. Motor does not

rotate or rotates slowly.
Remove foreign substances completely and repair

where damaged. Clean and reassemble.
2) Excessive torque on anti-reverse

valve bolts.
Fasten bolts to specified torque.
3. Faulty sleeve

1. Faulty seat in check valve assembly.
2. Motor does not stop,

or takes a while to stop.

2) Excessive torque on anti-reverse

valve bolts.
Fasten bolts to specified torque.
2. Faulty valve inside check valve

assembly.

Replace if sliding section is scratched
2) Valve orifice is blocked with dirt or

dust.
Remove dirt or dust completely. Clean and reassemble.
3. Faulty sleeve

1. Faulty valve inside check valve

assembly.
3. Greater than usual

shock at swing stops
ASM-17-22-002
Remove foreign substances completely. Clean and

reassemble. Replace if sliding section is scratched
2) Valve orifice is blocked with dirt or

dust.
Remove dirt or dust completely. Clean and reassemble.
2. Orifice is blocked with dirt or dust.

1) Orifice section of anti-reverse
valve is blocked with dirt or dust.
Remove all dirt or dust. Clean and reassemble.
2) Orifice on valve unit side is

blocked with dirt or dust.
Remove all dirt or dust. Clean and reassemble.
Issued 08-2008
Copyright
8019-43
2 Tools used
No
Name
Location used
Remarks
Orifice (-7)
Torque setting: 2.45 Nm
Orifice (-22)
Plug (-5)
Plug (-8)
Orifice (-7)
Width across flats: 2.5 mm
Orifice (-22)
Width across flats: 3 mm
Plug (-8)
Width across flats: 8 mm
Plug (-5)
Width across flats: 22
Torque wrench
Hexagonal bits
6
7
Socket for socket wrench
3 Disassembling instructions
1 Precautions prior to disassembly
1 Remove mud and dirt from exterior surfaces completely. (Wash exterior surfaces thoroughly.)
2 Drain hydraulic oil from the valve unit body and the port oil passages.
3 Select a dirt-free area for work. Use caution to prevent any mud or dirt from getting on parts.
4 Handle parts carefully to avoid dropping them, or denting or scratching them by contact.
2 Disassembly
Disassemble the valve following the procedure below:
1 Removing the anti-reverse valve
Loosen socket head bolts and remove the antireverse valve from the motor. (See the instruction manual for the motor.)
2 Disassembling the anti-reverse operating section
1) Remove plug (-5) and pull out spring (-3). Tools
required
- Socket (No. 6)
- Torque wrench (No. 3)
-5
-3
AQ22002-076
2) Remove check valve assembly (-2).
-2
AQ22002-077
ASM-17-22-002
Issued 08-2008
Copyright
8019-44
3) Remove check valve assembly (-4).
-4
AQ22002-078
3 Removing the orifice
-7
-8
Remove plug (-8) and orifice (-7).

Tools required:
- Hexagonal bits (No. 4, 6)
- Torque wrench (No. 1, 3)
AQ22002-079
1 Precautions prior to reassembly
1 Clean each part with clean mineral oil and dry with air.
2 Handle cleaned parts carefully to keep them from getting dirty, dented or scratched.
3 Replace all seals with new ones.
4 Fasten all tightened parts to the specified torque.
5 Apply grease to seals before installing.
6 Once filters are removed, they cannot be reused. They must be replaced with new filters.
2 Assembly
Reassemble the valve following the procedure below:
1 Installing the orifice
1) Install filter (-20) and washer (-21)
Fasten orifice (-22) to the specified torque.
Tools required:
- Hexagonal bits (No. 5)
- Torque wrench (No. 2)
NOTE: Once filters are removed, they cannot be reused.
-20
-21
-22
AQ22002-080
ASM-17-22-002
Issued 08-2008
Copyright
8019-45
2) Fasten orifice (-7) and plug (-8) to the specified
torque.
Tools required:
- Hexagonal bits (No. 4, 6)
- Torque wrench (No. 1, 3)
-7
-8
AQ22002-081
2 Reassembling the anti-reverse operating section

1) Install sleeve (-4).
-4
AQ22002-082
2) Install check valve assembly (-2).

-2
AQ22002-083
3) Attach O-ring (-13) to plug (-5).

Insert spring (-3) into plug and fasten to specified
torque.
-5
-13
-2
-3
Tightening Torque: 61.8 Nm (6.3 kgfm)

NOTE: Handle carefully so that the spring does not fall out
during installation of the plug.
Tools required:
Socket (No. 7)
Torque wrench (No. 3)
Reassembly of the anti-reverse valve has now been completed. Refer to the instruction manual of the motor for motor
installation procedures.
ASM-17-22-002
AQ22002-084
Issued 08-2008
Copyright
8019-46
5 Anti-reverse valve: Exploded view
-8
-13
-22
-7
-21
-20
-1
-5
-4
-13
-2
-3
-2
-3
-13
-5
ASM-17-22-002
AQ22002-085
Issued 08-2008
Copyright
Section
8020
CNH

Printed in France
March 2008
8020
HYDRAULIC FUNCTIONS
Copyright
8020-2
TABLE OF CONTENTS
HYDRAULIC FUNCTIONS.............................................................................................................................................. 3
List of functions ........................................................................................................................................................... 3
HYDRAULIC COMPONENTS LIST ................................................................................................................................ 5
CONTROL VALVE CONFIGURATION TABLE............................................................................................................... 6
Overview .................................................................................................................................................................... 6
TRAVEL CIRCUITS ....................................................................................................................................................... 8
1. Travel Low-speed Circuit ....................................................................................................................................... 8
2. Travel High Speed Circuit .................................................................................................................................... 10
3. Straight Travel Circuit (Boom-up and Travel Forwar) .......................................................................................... 12
SWING CIRCUITS ....................................................................................................................................................... 14
1. Swing Parking Circuit ........................................................................................................................................... 14
Swing Override Throttle Circuit ................................................................................................................................ 16
BUCKET CIRCUIT (CX80) ........................................................................................................................................... 18
1. Bucket Opening Circuit ........................................................................................................................................ 18
2. Bucket Closing Circuit .......................................................................................................................................... 19
BOOM CIRCUITS ........................................................................................................................................................ 20
1. Boom-up 2-speed Circuit ..................................................................................................................................... 20
2. Boom-down Load Holding Valve Circuit ............................................................................................................... 22
BOOM SWING CIRCUIT (CX80) ................................................................................................................................. 24
Boom-Swing Circuit .................................................................................................................................................. 24
BLADE CIRCUITS (CX80) ........................................................................................................................................... 26
Blade Circuits ........................................................................................................................................................... 26
ARM CIRCUITS ........................................................................................................................................................... 28
1. Arm-in / Arm-out 2-speed Circuit .......................................................................................................................... 28
BACKUP CIRCUITS ..................................................................................................................................................... 30
Breaker and Crusher Circuit (2-speed confluence crusher circuit) .......................................................................... 30
Breaker and Crusher Circuit (backup line holding valve) ......................................................................................... 32
Breaker and Crusher Circuit (breaker circuit) Ultra Small Tail Swing Hydraulic Excavator ..................................... 34
Backup Reciprocating Circuit (ultra small swing hydraulic excavator) ..................................................................... 36
Secondary Backup Reciprocating Circuit (ultra small tail swing hydraulic excavator) ............................................. 38
Issued 03-08
Copyright
8020-3
HYDRAULIC FUNCTIONS
List of functions
Functions
Description
Pages
Travel Circuits
Low-speed
Travel circuit
Low speeds can be achieved by setting the two-stage incline angle of the travel
motor to the larger angle.
Page 8-9
High-speed
Travel circuit
High speeds can be achieved by setting the two-stage incline angle of the travel
motor to the smaller angle.
The load pressure for travel motor will automatically switch speeds to low when necessary.
Page 10-11
Straight-travel
circuit
Straight travel is maintained in spite of attachment/swing operations during travel.
Page 12-13
Swing Circuits
Swing parking
circuit
1.While the swing lever is positioned at neutral, the swing parking will be activated
to fully hold the swing.
2.Shifting through the swing lever will release the mechanical brake to start the
3.normal swing operation. The swing parking will also stay released if attachments such as boom, arm and bucket were operated following the swing operation.
The swing parking will be activated 5 s after the swing lever is put in neutral or the
attachment movement is stopped.
Page 14-15
Swing override
throttle circuit
Swing pushing is obtained by the swing override throttle integrated in the control
valve.
Page 16-17
Super shockless
relief valve
The valve is installed in the swing motor. It is designed to moderate shocks at

start-ups and stops by the two-stage relief valve that comes with a time-lag feature.
Swingback
Cushion Valve
An anti-reverse valve is installed in the swing motor.

The valve works to reduce the backlash occurrences when the swing brake is
applied.
Cushion valves work to moderate shocks.
They are equipped on the swing pilot line.
Bucket Circuits (CX80)
Bucket-opening
Opens the bucket by switching the bucket spool
Page 18
Bucket-closing
Closes the bucket by switching the bucket spool
Page 19
Boom Circuits
Boom-up
2-speeds circuit
Switch-over of boom (2) spools enables the internal confluence, thus achieving
higher speeds.
Page 20-21
Boom-down load
holding valve
circuit
1.The boom-down movement will be enabled by releasing the load holding valve
integrated in the control valve.
2.The bleed-off circuit works to control high pressures. It also reduces windage..
Page 22-23
Boom Swing Circuits (CX80)

Boom Swing
Swing the boom by switching the boom swing spool
Page 24-25
Blade Circuits (CX80)

Blade Operation
Operating the blade by switching the blade spool
Page 26-27
Arm Circuits
Arm-in/arm-out
2-speeds circuit
1. Switch-over of arm (2) spools enables the internal confluence, thus achieving
higher speeds.
Page 28-29
Issued 03-08
Copyright
8020-4
Functions
Description
Pages
Backup circuits
Breaker and
Crusher circuit
Backup circuit
(small tail swing
excavator)
Page 30-31
A backup section is provided in the main control valve as a standard feature to
accommodate special attachments such as a breaker and a crusher.
Page 34-35
Backup circuit
An additional backup section can be added as an option to accommodate special
(ultra small swing
attachments such as a slide arm
excavator)
Page 36-37
Secondary circuit
A secondary backup section can be added as an option to accommodate special
(small tail swing
attachments such as a rotating fork.
excavator)
Page 38-39
Other
Cushion Valve
Cushion valves work to moderate shocks.

They are installed on the boom pilot line.
NOTE: See the tables page 6 for the relationship between each specification and the optional equipment.
Issued 03-08
Copyright
8020-5
HYDRAULIC COMPONENTS LIST

NOTE: See hydraulic schematic at the end of this document.
1.
2.
4.
5.
6.
10.
15.
16.
21.
22.
23.
27.
28.
29.
30.
32.
38.
42.
44.
51.
53.
54.
55.
60.
72.
75.
76.
78.
79.
82.
83.
85.
86.
93.
94.
95.
96.
97.
98.
99.
100.
101.
102.
103.
104.
114.
115.
116.
B22.
B26.
B27.
B45.
Y2.
Y3.
Y4.
Y9.
HYDRAULIC RESERVOIR
BREATHER
BY-PASS VALVE
SCREEN FILTER
RETURN FILTER
MAIN HYDRAULIC PUMP
MAIN CONTROL VALVE
HYDRAULIC SWIVEL
TRAVEL MOTOR
SWING MOTOR
TRAVEL MOTOR BRAKE
DIPPER CYLINDER
BUCKET CYLINDER
BOOM SAFETY VALVE
DIPPER SAFETY VALVE
BOOM LOAD HOLDING VALVE
HBCV DOZER BLADE
OIL COOLER
OIL COOLER BY-PASS VALVE
ACCUMULATOR
BOOM & BUCKET CONTROL LEVER
SWING & DIPPER CONTROL LEVER
TRAVEL CONTROL PEDAL
PILOT SYSTEM MANIFOLD
CONTROL PEDAL (OPTIONAL)
FLOW RE-INJECTION BLOCK (OPTIONAL)
3-WAY SELECTOR (OPTIONAL)
RETURN FILTER (OPTIONAL)
CONTROL SHUTTLE BLOCK (OPTIONAL)
PILOT CIRCUIT FILTER
SHUT-OFF VALVE (OPTIONAL)
HAND/FOOT CONTROL PILOT FILTER
PILOT FILTER BY-PASS VALVE
PILOT CIRCUIT SUPPLY MANIFOLD
PILOT CIRCUIT RETURN MANIFOLD
BOOM/DIPPER PILOT CIRCUIT MANIFOLD
SWING PILOT CIRCUIT CUSHION VALVE
HYDRAULIC BREAKER FOOT CONTROL
OFFSET BACKHOE FOOT CONTROL
DOZER BLADE HAND CONTROL
DOZER BLADE CYLINDER
OFFSET BACKHOE CYLINDER
3 ELECTROVALVE BLOCK
BOOM CYLINDER
BOOM PILOT CIRCUIT CUSHION VALVE
BOOM FOOT DIRECTION CONTROL PEDAL
BOOM FOOT POSITIONING PILOT SHOCK ABSORBER
BOOM FOOT STEERING CYLINDER
SWING PILOT PRESSURE SWITCH
UPPER PILOT PRESSURE SWITCH (YELLOW BAND)
TRAVEL PILOT PRESSURE SWITCH
OVERLOAD INDICATOR PRESSURE SWITCH
PILOT PRESSURE SOLENOID VALVE (BLUE BAND)
SWING BRAKE SOLENOID VALVE (PINK BAND)
2 STAGE TRAVEL SOLENOID VALVE (RED BAND)
CRUSHER/BREAKER OPTION TWO FLOW SOLENOID
VALVE
Y25. OPTION 2 SOLENOID VALVE (RED BAND)
Y26. OPTION 2 SOLENOID VALVE (BLUE BAND)
Issued 03-08
Copyright
8020-6
CONTROL VALVE CONFIGURATION TABLE

Overview
Control valves are configured as follows according to model and specification.
MONO BOOM
with BLADE (CX75SR)
MONO BOOM
with BLADE (CX80)
Blade
Blade
PT
PT
Boom Swing
Standard
OFFSET BOOM
with BLADE (CX75SR)
(Specification for Europe)
Blade
PT
Buckup
Offset
Buckup
Secondary
backup
Blade
Secondary
backup
Blade
Buckup
Boom Swing
Option
Buckup
PT
PT
PT
Optional
Blade
Offset
Issued 03-08
Copyright
8020-7
This page has been left blank intentionally
Issued 03-08
Copyright
8020-8
Travel Circuits
1. Travel Low-speed Circuit
The travel patterns are normal. Turning the key OFF once and switching it back ON during high-speed travel will
always set the speed back to low.
The oil discharged from A1 enters port P1 of the control valve entry, while the oil from A2 enters into port P2 of the
control valve entry. Each flow goes into the travel motor through the switch-over of the left and right travel spool. By
these flows, the machine travels forward and backward. The 2-speed travel solenoid valve will be turned OFF and the
hydraulic oil in port P of the travel motor will be connected to the pilot tank line.
1.
10.
15.
16.
21.
51.
55.
60.
102.
HYDRAULIC RESERVOIR
MAIN HYDRAULIC PUMP
MAIN CONTROL VALVE
HYDRAULIC SWIVEL
TRAVEL MOTOR
ACCUMULATOR
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line
Issued 03-08
Copyright
8020-9
Travel Low-speed Circuit
21
21
16
15
55
51
INTERNAL CHANGEOVER SWITCH IN PANEL
MONITOR
SWITCH PANEL
102
60
10
Issued 03-08
Copyright
8020-10
2. Travel High Speed Circuit

With High-Speed Travel, high speeds can be achieved by setting the two-stage incline angle of the travel motor to the
smaller angle.
The circuit has a travel motor, which 5 switches over to lower speeds by utilizing load pressure on the travel motor
while traveling at high speeds.
The oil discharged from A1 enters port P1 of the control valve entry, while the oil from A2 enters port P2 of the control
valve entry. Each flow goes into the travel motor through the switch-over of the left and right travel spool. By these
flows, the machine travels forward and backward. To obtain high speeds, electronic signals are sent to the switch
panel through the travel change-over switch. Then electronic signals are sent from the switch panel to the solenoid
valve for 2-speed travel in the assembly valves to switch the assembly valves. This enables the original pilot pressure
(4.2 MPa) {609 psi} from port C1 of the assembly valves to be connected with port P of the left and right travel motors
through the rotating joint. The original pressure (4.2 MPa) {609 psi} that entered port P of the left and right travel
motors positions the incline angle of the travel motor to the smaller angle, enabling faster speeds.
1.
10.
15.
16.
21.
51.
55.
60.
102.
HYDRAULIC RESERVOIR
MAIN HYDRAULIC PUMP
MAIN CONTROL VALVE
HYDRAULIC SWIVEL
TRAVEL MOTOR
ACCUMULATOR
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line
Issued 03-08
Copyright
8020-11
Travel High Speed Circuit
21
16
21
15
55
51
INTERNAL CHANGEOVER SWITCH IN PANEL

102
60
MONITOR
SWITCH PANEL
10
Issued 03-08
Copyright
8020-12
3. Straight Travel Circuit (Boom-up and Travel Forwar)

The following applies when travel and boom-up operations are conducted at the same time.
The hydraulic oil that entered the pilot pump from PP, which was connected to the tank via travel spool, becomes
blocked off by the switch-over of travel spool. Also, the switch-over of the spool to the boom blocks off the branch
channels from PP via all spools for attachments (boom, arm, bucket, swing, including offset if equipped with this),
which were connected to the tank. Therefore, the hydraulic oil from the pilot pump entering through PP cannot flow
any further, and the circuit pressure rises up to the original pressure of (4.2 MPa) {609 psi} . This original pressure
acts on the pilot chamber of the straight travel valve and switches over the straight travel valve. The switch-over of the
straight travel valve enables P1 to achieve travel and P2 to drive attachments. The left and the right pressures are
equal for travel because one pump drives those motors, thus enabling straight travel. In addition, extra hydraulic oil
from P2 is supplied to the travel side through a check with travel confluence throttle to keep the speed loss to a minimum.
This also applies when travel and the upper actuators other than boom are operated at the same time.
1
10.
15.
16.
21.
51.
55.
60.
102.
103.
104.
HYDRAULIC RESERVOIR
MAIN HYDRAULIC PUMP
MAIN CONTROL VALVE
HYDRAULIC SWIVEL
TRAVEL MOTOR
ACCUMULATOR
BOOM CYLINDER
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line
Issued 03-08
Copyright
8020-13
Straight Travel Circuit (Boom-up and Travel Forward)
21
16
21
103
55
15
51
104
INTERNAL CHANGEOVER SWITCH IN

PANEL
MONITOR
SWITCH PANEL
102
60
10
Issued 03-08
Copyright
8020-14
Swing Circuits
1. Swing Parking Circuit
Once the engine is turned on and the swing lever is positioned in neutral, the swing brake solenoid valve will be turned
ON (SH75: 12V, SH135: 24 V) and the swing parking brake will be activated.
When the swing pressure switch is turned ON by the shifting of the lever, the output to the swing brake solenoid valve
from the switch panel will be turned OFF. This releases the swing parking brake and enables the swing operation. In
another case, if an attachment such as an arm is moved within 5 s after the swing lever was returned to neutral, a lateral force will be generated for the swing movement. In order to prevent the dragging caused by braking, the parking
bake will also be released.
Once the signals from attachment pressure switch (2.0 MPa {290 psi} : ON, 1.5 MPa {218 psi} : OFF) are sent to the
switch panel and the output to swing brake solenoid valve from switch panel is turned OFF, the swing parking brake
will be released.
5 s after the swing pressure switch and the attachment pressure switch are turned OFF, the solenoid valve will be
turned ON, enabling the swing parking brake to operate.
Key
switch
Swing
pressure
switch
Attachment
pressure
switch
Swing brake
solenoid valve
Swing motor
mechanical
brake
OFF
OFF
OFF
OFF
ON*
Key Switch OFF
ON
OFF
OFF
ON
ON
Key Switch ON
ON
OFF
ON
ON
ON
Attachment operations
ON
ON
ON
OFF
OFF
Independent operation of
swing
ON
ON
ON
OFF
OFF
Attachment + swing operation
ON
OFF
OFF
ON
(in 5 s)
ON
Attachment in neutral
Remarks
Notes:
The attachment pressure switch will be ON when the spool is switched over for either boom, arm,
bucket or swing (including offset if equipped with this) and activates the original pilot pressure.
When an asterisk (*) accompanies the swing motor mechanical brake ON statement, it indicates
that the swing parking release pressure automatically returns to the tank pressure because all else is
OFF, which in turn activates the mechanical brake.
1
10.
15.
22.
51.
60.
96.
102.
HYDRAULIC RESERVOIR
MAIN HYDRAULIC PUMP
MAIN CONTROL VALVE
SWING MOTOR
ACCUMULATOR
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line
Issued 03-08
Copyright
8020-15
Swing Parking Circuit (independent operation of swing)
22
15
MONITOR
SWITCH PANEL
51
102
96
60
SWING BRAKE
SOLENOID VALVE
10
Issued 03-08
Copyright
8020-16
Swing Override Throttle Circuit

Providing an override throttle on the parallel circuit enables the pressure to rise at combined operation of arm and
swing, thus securing the swing force for press digging operation.
1
10.
15.
22.
27.
51.
60.
96.
102.
HYDRAULIC RESERVOIR
MAIN HYDRAULIC PUMP
MAIN CONTROL VALVE
SWING MOTOR
DIPPER CYLINDER
ACCUMULATOR
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line
Issued 03-08
Copyright
8020-17
Swing Override Throttle Circuit
22
27
SWING
OVERRIDE
FIXED
THROTTLE
15
000
51
102
60
96
SWING BRAKE
SOLENOID VALVE
10
Issued 03-08
Copyright
8020-18
Bucket Circuit (CX80)

1. Bucket Opening Circuit
When the bucket control lever is moved to the opening side, the pilot pressured oil is supplied to Port pb7 of the control valve.
The bucket spool will be in a preparation state.
The hydraulic pressured oil delivered from the hydraulic pump A1 is supplied to a bucket spool through a center
bypass oil circuit also it is supplied to the rod side of a bucket cylinder.
Accordingly, the bucket opens by contraction of the rod of the bucket cylinder.
The returned oil from the bucket cylinder bottom runs into the tank oil circuit through a bucket spool.
1
10.
15.
28.
51.
53.
102.
HYDRAULIC RESERVOIR
MAIN HYDRAULIC PUMP
MAIN CONTROL VALVE
BUCKET CYLINDER
ACCUMULATOR
BOOM & BUCKET CONTROL LEVER
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line
Issued 03-08
Copyright
8020-19
2. Bucket Closing Circuit
28
102
51
15
53
10
Issued 03-08
Copyright
8020-20
Boom Circuits
1. Boom-up 2-speed Circuit
The oil discharged from A1 is supplied to the boom (2) spool through the parallel oil passage via the right travel spool
or the straight travel valve, and merges at the downstream of the boom (1) spool.
The oil discharged from A2 merges with the oil discharged from boom (2) by way of parallel oil passage and the boom
(1) spool, and flows into the bottom side of the boom cylinder via holding valve.
1
10.
15.
51.
60.
102.
103.
104.
HYDRAULIC RESERVOIR
MAIN HYDRAULIC PUMP
MAIN CONTROL VALVE
ACCUMULATOR
BOOM CYLINDER
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line
Issued 03-08
Copyright
8020-21
Boom-up 2-speed Circuit
103
15
104
51
102
60
10
Issued 03-08
Copyright
8020-22
2. Boom-down Load Holding Valve Circuit

The boom-down pilot pressure goes into port Pb8 of the control valve and the main control valve spool moves to the
left.
Also, the pilot pressure enters Port Pc2 and moves the load holding valve spool to the left. Through this movement,
the oil in the spring chamber of the load holding valve check passes the load holding valve spool, creating a connection to the tank. As a result, the pressure on the spring chamber decreases and the load holding valve check will be
released.
The pressurized oil on the boom cylinder bottom side returns to the tank line as the load holding valve opens. As a
result, the boom cylinder rod retracts and the boom is lowered.
Also, the bleed-off circuit controls high pressures, which in turn reduces windage.
1
10.
15.
32.
51.
60.
102.
103.
104.
HYDRAULIC RESERVOIR
MAIN HYDRAULIC PUMP
MAIN CONTROL VALVE
BOOM LOAD HOLDING VALVE
ACCUMULATOR
BOOM & DIPPER CONTROL SHOCK ABSORBER
BOOM CYLINDER
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line
Issued 03-08
Copyright
8020-23
Boom-down Load Holding Valve Circuit

TO TANK LINE
LOAD HOLDING
VALVE SPOOL
BOOM-DOWN PILOT LINE
32
BOOM CYLINDER
BOTTOM SIDE
DETAIL
BLEED-OFF
CIRCUIT
103
15
104
51
102
60
10
Issued 03-08
Copyright
8020-24
Boom Swing Circuit (CX80)

Boom-Swing Circuit
As the boom swing remote control valve is switched over, the pilot oil enters Port prb1 or pra1.
The oil at P2 from the hydraulic pump then flows into the boom swing cylinder via Port BR1 or AR1 through the boom
swing valve. The returning oil flows into the tank through Port AR1 or BR1.
1
10.
15.
51.
102.
114.
115.
116.
HYDRAULIC RESERVOIR
MAIN HYDRAULIC PUMP
MAIN CONTROL VALVE
ACCUMULATOR
BOOM FOOT DIRECTION CONTROL PEDAL
BOOM FOOT POSITIONING PILOT SHOCK ABSORBER
BOOM FOOT STEERING CYLINDER
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line
Issued 03-08
Copyright
8020-25
Boom-Swing Circuit
1
116
103
1
115
114
15
104
51
102
102
60
15
10
51
10
Issued 03-08
Copyright
8020-26
Blade Circuits (CX80)

Blade Circuits
As the blade remote control valve is switched over, the pilot oil enters Port prb2 or pra2.
The oil at PR5 from the gear pump then flows into the blade cylinder through the Parallel passage.
The returning oil flows into the tank through Port AR2 or BR2.
1
10.
15.
51.
99.
100.
102.
HYDRAULIC RESERVOIR
MAIN HYDRAULIC PUMP
MAIN CONTROL VALVE
ACCUMULATOR
DOZER BLADE CYLINDER
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line
Issued 03-08
Copyright
8020-27
Blade Circuit
100
103
15
104
51
99
102
60
15
10
102
51
10
Issued 03-08
Copyright
8020-28
Arm Circuits
1. Arm-in / Arm-out 2-speed Circuit
The oil discharged from A1 is supplied to the arm (1) spool via parallel oil passage through central bypass oil passage
or straight travel spool.
TheArm-in / Arm-out 2-speed circuit has a configuration where the discharged oil from A2 is supplied to the arm (2)
spool through the central bypass oil passage or parallel oil passage to merge at the upstream of the arm (1) spool.
The returning oil from the cylinder will be allowed to merge with the oil on the supply side through self regeneration
only when the arm is in (when the pressure of oil on the supply side becomes lower than the pressure of oil returning).
1
10.
15.
27.
51.
60.
102.
HYDRAULIC RESERVOIR
MAIN HYDRAULIC PUMP
MAIN CONTROL VALVE
DIPPER CYLINDER
ACCUMULATOR
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line
Issued 03-08
Copyright
8020-29
Arm-in / Arm-out 2-speed Circuit
Arm-In Self
Regeneration
27
15
51
102
60
10
NOTE: INDICATES THAT AN ARM-OUT OPERATION IS TAKING PLACE
Issued 03-08
Copyright
8020-30
Backup Circuits
Breaker and Crusher Circuit (2-speed confluence crusher circuit)
The solenoid valve will be turned ON by turning the switch inside the cab toward the crusher side.
By stepping on the backup pedal, the pilot pressure from the remote control valve passes through the solenoid valve
via shuttle valve and enters Port P of the holding valve and Port Pb2 of the backup (2) spool.
The backup (2) spool moves to the right and shuts off the central bypass.
The pilot pressure from the solenoid valve acts on Port pcc of the confluence spool and moves the spool to the left to
shut off the central bypass.
The oil in Port P2 thus flows into the holding valve through Port P3 of the control valve.
The holding valve acts on the holding valve release spool by communicating the pilot pressure from the solenoid valve
to Port P. The valve thus returns the oil in the spring chamber to the tank and releases the check in the holding valve.
The oil at Port P3 of the control valve enters Port P4, which is upstream of the control valve backup spool, through the
holding valve check. It then merges with the oil from P1.
1
10.
15.
51.
60.
72.
75.
76.
78.
79.
85.
102.
Y9.
HYDRAULIC RESERVOIR
MAIN HYDRAULIC PUMP
MAIN CONTROL VALVE
ACCUMULATOR
HAMMER/CRUSHER SELECTOR
CRUSHER/BREAKER OPTION TWO FLOW SOLENOID VALVE
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line
Issued 03-08
Copyright
8020-31
Breaker and Crusher Circuit (2-speed confluence crusher circuit)

72
85
Y9
79
1
75
SWITCH
LOCKER
15
51
76
60
102
78
10
Issued 03-08
Copyright
8020-32
Breaker and Crusher Circuit (backup line holding valve)
Hold-Release Spool
Holding Valve Check
Issued 03-08
Copyright
8020-33
This page has been left blank intentionally
Issued 03-08
Copyright
8020-34
Breaker and Crusher Circuit (breaker circuit) Ultra Small Tail Swing Hydraulic Excavator
By turning the switch in the cab to the breaker side and stepping on the pedal, the pilot pressure, which entered Pb2
in the control valve, switches over to the backup spool. As a result, the pressurized oil from A1 will be supplied to the
breaker through the direction valve.
1
10.
15.
51.
60.
72.
76.
78.
79.
85.
102.
Y9.
HYDRAULIC RESERVOIR
MAIN HYDRAULIC PUMP
MAIN CONTROL VALVE
ACCUMULATOR
CRUSHER/BREAKER OPTION TWO FLOW SOLENOID VALVE
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line
Issued 03-08
Copyright
8020-35
Breaker and Crusher Circuit (breaker circuit) Ultra Small Tail Swing Hydraulic Excavator
72
85
79
Y9
15
51
76
102
60
78
10
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Copyright
8020-36
Backup Reciprocating Circuit (ultra small swing hydraulic excavator)

As the back up remote control valve is switched over, the pilot oil enters Port pra1 or Port prb1. The oil at P2 then
flows into the backup valve AR1 or Port BR1 through the parallel passage.
The returning oil flows into the tank through Port BR1 or Port AR1.
1
10.
15.
51.
60.
83.
85.
98.
102.
HYDRAULIC RESERVOIR
MAIN HYDRAULIC PUMP
MAIN CONTROL VALVE
ACCUMULATOR
OFFSET BACKHOE FOOT CONTROL
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line
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Copyright
8020-37
Backup Reciprocating Circuit (ultra small swing hydraulic excavator)

98
85
1
15
83
51
102
60
10
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Copyright
8020-38
Secondary Backup Reciprocating Circuit (ultra small tail swing hydraulic excavator)
As the backup remote control valve is switched over, the pilot oil enters Port prb3 or Port pra3. The oil at PR5 from the
gear pump then flows into the backup valve BR3 or Port AR3 through the parallel passage. The returning oil flows into
the tank through Port AR3 or Port BR3.
Drain lines are pre-installed in the secondary backup section to accommodate special attachments such as a rotating
fork.
1
10.
15.
51.
60.
83.
85.
99.
102.
HYDRAULIC RESERVOIR
MAIN HYDRAULIC PUMP
MAIN CONTROL VALVE
ACCUMULATOR
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line
Issued 03-08
Copyright
8020-39
Secondary Backup Reciprocating Circuit (ultra small tail swing hydraulic excavator)
99
1
85
15
83
51
102
60
10
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Copyright
8020-40
NOTES
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Copyright
Section
8030
CNH

Printed in France
March 2008
8030
HYDRAULIC COMPONENT FUNCTIONS
Copyright
8030-2
TABLE OF CONTENTS
HYDRAULIC PUMP ................................................................................................................................................. 3
Configuration and Principle of Operation ......................................................................................................... 3
Flow Control..................................................................................................................................................... 5
CONTROL VALVE ................................................................................................................................................... 7
Operation with All Spools in Neutral ................................................................................................................ 7
Independent Operation .................................................................................................................................... 9
Combined Operations .................................................................................................................................... 19
Relief Valve.................................................................................................................................................... 20
SWING UNIT .......................................................................................................................................................... 23
Functional and Operational Description......................................................................................................... 23
Overview ........................................................................................................................................................ 31
TRAVEL UNIT (CX75SR)....................................................................................................................................... 35
External Dimensional Drawing....................................................................................................................... 35
Basic Structure and Drawings........................................................................................................................ 36
Operational Description ................................................................................................................................. 39
TRAVEL UNIT (CX80)............................................................................................................................................ 51
External Dimensional Drawing....................................................................................................................... 51
Basic Structure and Drawings........................................................................................................................ 52
Operational Description ................................................................................................................................. 55
Issued 03-08
Copyright
8030-3
HYDRAULIC PUMP
Configuration and Principle of Operation
The pump consists of a main pump (1), a blade pump (2) and a pilot pump (3), which are connected in
series.
The main pump is a swash-plate type variable displacement piston pump, which delivers two equal volumes using one cylinder block. The cylinder block has ten pistons inside. Those pistons divert and alternately deliver the oil to Delivery Ports (5 and 6).
Each group of 5 pistons works as one pump.
Issued 03-08
Copyright
8030-4
When the drive shaft (10), which is connected to the engine, rotates, the cylinder block (11) connected
to the shaft via spline and the piston section (12) rotates.
Since the piston section (12) is pushed towards the swash plate (14) via retainer (13), it rotates on the
inclined plane of the swash plate (14) and reciprocates within the cylinder block (11) according to the
incline angle of the swash plate (14).
The piston (12) draws in oil while going down the inclined plane of the swash plate (14) and discharges
oil while coming up.
The oil from the tank is taken from the inlet port (9), which is shared by all the pumps, and is divided
inside the cover (4) into the main pump (1), the blade pump (2) and the pilot pump (3). The oil to the
main pump (1) passes the control plate (15) and is drawn in by the piston (12) in cylinder block (11). The
oil delivered from the piston (12) is alternately divided into the passages (20, 21) in the control plate
(15), and will be discharged from the delivery ports (5, 6) of each group of 5 pistons.
The discharge volume of the pump fluctuates according to the changes in piston stroke in conjunction
with the changes in the incline angle of the swash plate (14). The operation of the swash plate (14) is
regulated by the discharge pressure in the main pump and the discharge pressure in the blade pump.
(See below for details).
Issued 03-08
Copyright
8030-5
Flow Control
1) Constant controlling of simultaneous output
The pump output will be maintained at a certain level by increasing / decreasing the flow
according to the pump discharge pressure.
The force generated by the discharge pressure acts on the swash plate (14) via the piston
section (12).
The force of the discharge pressure generates a moment (return moment) to decrease the
incline angle by using the difference between the center of piston and the center of incline
rotation in swash plate.
The return moment varies according to the discharge pressure and the incline angle.
Issued 03-08
Copyright
8030-6
Before the incline

When the discharge pressure is low, the return moment is also small and the spring (16) is not
bent.
Thus the swash plate (14) is at a maximum incline angle to maintain maximum discharge.
After the incline
When the discharge pressure increases, the return moment also increases. As a result the
spring (16) is bent and the incline angle of the swash plate (14) will move to the position where
the return moment and the spring force become balanced, reducing the discharge volume.
As the discharge volume further increases, the incline angle decreases accordingly. The spring
(17) will also start to bend to keep the volume decreasing.
2) Power-down control by discharge pressure of blade pump (blade shift)

An over-torque condition of the input shaft due to the simultaneous high-pressure operations of
the main pump and the blade pump is prevented by changing the output characteristics of the
main pump through the discharge pressure of the blade pump.
The discharge pressure on the blade pump acts on the shift piston (18) via passage (19).
When the discharge pressure on the blade pump increases, the force on the shift piston
increases and the moment counteracting the springs (16, 17) is generated on the swash plate
(14).
The moment acting on the swash plate (14) increases because extra moment generated by the
shift piston force is added to the return moment which is generated by the main pump discharge
pressure.
Therefore, when the discharge pressure on the blade pump is high, the swash plate (14) starts
its incline even if the discharge pressure on the main pump is low.
Thus, an over-torque on the input shaft will not take place because the main pump output
becomes low when the pressure on the blade pump is high.
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Copyright
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CONTROL VALVE
Operation with All Spools in Neutral
1) Main passage
The oil supplied from Port P1 passes the neutral passage (2) via passage (1) and flows through
Travel (Right), Backup, Boom 2 and Arm 1 sequentially. The oil passed through Arm 1 flows into
the tank passage through passage (3) to be discharged into the tank ports (T1, T2).
Also, the oil supplied from Port P1 through passage (4) is directed into the parallel passage (7)
through passage (6) by way of the bridge (5) and travel straight valve. Then, Backup, Swing,
Boom 2, and Arm 1 sections will be communicated via each check valve and the flow will be
stopped by the spools in each section. However, because the parallel passage (7) is connected
with the neutral passage (2) via passage (8) and check valve, the oil will flow into the parallel
passage (7) from Port P1 without passing the travel straight valve when Travel (Right) is not
taking place.
In the same manner, the oil supplied from Port P2 flows into the neutral passage (10) via
passage (9). It then returns to the main body via the inlet section through passage (11), and
flows into the tank passage through neutral cut spool via passage (12).
Also, the oil supplied from Port P2 is communicated with Travel (Left), Bucket, Boom 1 and Arm
2 sections via the parallel passage (13) and check valve. The flow is stopped by the spools in
each section.
The oil supplied from Port PR5 (the third pump) flows in the neutral passage (27) through the
inlet section passage (26). The oil passing the blade section (add-on) flows into tank 1 passage
through passage (28) via the outlet section.
Also, the oil supplied from Port PR5 is communicated with the blade section via parallel passage
(29) and check valve, and the flow is stopped by the spool.
2) Signal passage
Front control signals
The oil from the hydraulic power source for signals, which enters Port PP, is directed into Port PA
(Front signal) through throttle (13). It also flows into the 5-way valve side of the front control
section through passage (14). It then passes passage (15), inlet section, passage (16) and the
4-way valve side of the front section, and will be discharged from passage (17) into Port DR
(Drain Port).
Travel control signals
The oil from the hydraulic power source for signals, which enters Port PP, is directed into Port
PT (Travel signal) through throttle (18). It also will be discharged from passage (17) into Port DR
(Drain Port) by way of passage (20) and Travel left spool.
Travel straight valve switch-over signals
The oil from the hydraulic power source for signals which enters Port PP, flows from passage
(22) into the travel right spool passing throttles (13, 21) to be discharged from the neck part of
the spool into the tank passage. At the same time, it flows into the travel left spool through
passage (23), and will be discharged from the neck part of the spool into tank passage. At this
time, the oil which flows into passage (23), will be directed through the annular passage (24)
into the pressure chamber (25) for switching over travel straight valve.
Issued 03-08
BUCKET
TRAVEL
(RIGHT) TRAVEL
(STRAIGHT
BACKUP
TRAVEL
(LEFT)
SWING
ARM 2
BOOM 2
BOOM 1
ARM 1
BLADE
Copyright
8030-8
Issued 03-08
Copyright
8030-9
Independent Operation
1) Travel spool switch-over (Figure 1)
Because switching the travel right spool by adding pressure to Port Pa1 (Pb1) closes the neutral
passage (A) and shuts off the downstream flow, the oil supplied from Port P1 will pass the neck
of the travel right spool through neutral passage (A) and will flow into cylinder Port A1 (B1).
The returning oil from cylinder Port B1 (A1) passes the neck of the travel right spool and flows
into the tank passage.
In the same manner, because switching the travel left spool by adding pressure to Port Pa6
(Pb6) closes neutral passage (B) and shuts off the downstream flow, the oil supplied from Port
P2 flows into cylinder Port A6 (B6) by way of neutral passage (B), passage (C) and the neck of
the travel left spool.
The returning oil from cylinder Port B6 (A6) passes the neck of the travel left spool and flows
into the tank passage.
TRAVEL
(RIGHT)
TRAVEL
(LEFT)
2) Backup spool switch-over (Figure 2)

If this section is to be used, first remove the stopper plugs on the cylinder port and on the pilot
cap. Additionally, replace the shut off valve with an overload release valve and remove the
stopper plug on Port P4 if necessary. Because switching the backup spool by adding pressure to
Port Pa2 (Pb2) closes neutral passage (A) and shuts off the downstream flow, the oil supplied
from Port P1 pushes up the check valve (1) through parallel passage (B) and flows into cylinder
Port A2 (B2) by way of passage (C) and the neck of backup spool. The returning oil from
cylinder Port B2 (A2) passes the neck of the backup spool and flows into the tank passage. This
section can also be merged with an external source through Port P4.
Issued 03-08
Copyright
8030-10
3) Swing spool switch-over (Figure 3)

Because switching the swing spool by adding pressure to Port Pa3 (Pb3) closes neutral passage
(A) and shuts off the downstream flow, the oil supplied from Port P1 pushes up the check valve
(1) through parallel passage (B) and flows into cylinder Port A3 (B3) by way of passage (C) and
the neck of the swing spool.
The returning oil from cylinder Port B3 (A3) passes the neck of the swing spool and flows into
the tank passage.
4) Bucket spool switch-over (Figure 3)

Because switching the bucket spool by adding pressure to Port Pa7 (Pb7) closes neutral
passage (D) and shuts off the downstream flow, the oil supplied from Port P2 pushes up the
check valve (2) through parallel passage (E) and flows into cylinder Port A7 (B7) by way of
passage (F) and the neck of the bucket spool. The returning oil from cylinder Port B7 (A7)
passes the neck of the bucket spool and flows into the tank passage.
Issued 03-08
Copyright
8030-11
5) Boom spool switch-over

1] Neutral Position (Figure 4)
The valve has an anti-drift valve installed on the cylinder bottom side of Boom 1.
In the neutral position, the poppet (1) is firmly seated by the pressure on Port A7, which was
directed to the spring chamber (C) through passage (A), poppet (2) and passage (B).
2] Boom-up (2-pump confluence) (Figure 5)
Because switching the boom 1 spool by adding pressure to Port Pa8 closes neutral passage (A)
and shuts off the downstream flow, the oil supplied from Port P2 pushes up the check valve (1)
through parallel passage (B), passes passage (C) and the neck of the boom 1 spool, then
pushes open the poppet (2) in the anti-drift valve and flows into cylinder Port A7. Because switching the boom 2 spool and adding pressure to Port Pa4 at the same time will close neutral passage (D) and shut off the downstream flow, the oil supplied from Port P1 pushes up the check
valve (3) through parallel passage (E) and flows into cylinder port A7, by way of passage (F),
neck of the boom 2 spool and passage (G). The returning oil from cylinder Port B7 passes the
neck of the boom 1 spool and flows into the tank.
3] Boom-down (Figure 6)
Because switching the boom 1 spool by adding pressure to Port Pb8 closes neutral passage (A)
and shuts of the downstream flow, the oil supplied from Port P2 pushes up the check valve (1)
through parallel passage (B) and flows into cylinder Port B7 by way of passage (C) and the neck
of the boom 1 spool. Switching the boom 1 spool and adding pressure to Port pc2 at the same
time in order to switch poppet (3) in the anti-drift valve will reduce the pressure in spring chamber
(D) to open poppet (2). The returning oil from cylinder Port A7 will pass the neck of the boom 1
spool and flow into the tank passage.
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Copyright
8030-12
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Copyright
8030-13
6) Arm spool switch-over

1] Dump (2-pump confluence) (Figure 7)
Switching the arm 1 spool by adding pressure to Port Pa5 closes the neutral passage (A). The oil
supplied from Port P1 pushes up the tandem check valve (1) through neutral passage (A) and
flows into cylinder Port A5 by way of passage (C) and the neck of the arm 1 spool. At the same
time, part of the oil supplied from Port P1 will flows into cylinder Port A5 by way of parallel passage (B), annular restriction (D), parallel check valve (2) and passage (C). Switching the arm 1
spool and adding pressure to Port Pa9 at the same time in order to switch the arm 2 spool will
close the neutral passage (E). The oil supplied from Port P2 pushes up the tandem check valve
(3) through neutral passage (E) and flows into cylinder Port A5 by way of passage (G), neck of
the arm 2 spool and passage (I). At the same time, part of the oil supplied from Port P2 will flow
into cylinder Port A5 by way of parallel passage (F), annular restriction (H), parallel check valve
(4), passage (G) and passage (I).
The returning oil from the cylinder Port B5 flows into the tank passage through the neck of the
arm 1 spool and also flows into the tank passage by way of passage (J) and the neck of the arm
2 spool.
The annular restriction (D) works as a primary restriction for a simultaneous operation with swing
movements. The annular restriction (H) works as a primary restriction for a simultaneous operation with boom.
2] Crowd (2-pump confluence) (Figure 8)
Switching the arm 1 spool by adding pressure to Port Pb5 will close the neutral passage (A), and
the oil supplied from Port P1 pushes up the tandem check valve (1) through neutral passage (A)
and flows into cylinder Port B5 by way of passage (C) and the neck of arm 1 spool. At the same
time, part of the oil supplied from Port P1 flows into cylinder Port B5 by way of parallel passage
(B), annular restriction (D), parallel check valve (2) and passage (C).
Switching the arm 1 spool and adding pressure to Port Pb9 at the same time in order to switch
the arm 2 spool will close the neutral passage (E). The oil supplied from Port P2 pushes up the
tandem check valve (3) through neutral passage (E) flows into cylinder Port A5 by way of passage (G), neck of the arm 2 spool and passage (I). At the same time, part of the oil supplied from
Port P2 flows into cylinder Port B5 by way of parallel passage (F), annular restriction (H), parallel
check valve (4), passage (G) and passage (I).
The returning oil from cylinder Port B5 flows into the tank by way of the neck of the arm 1 spool,
passage (K) and annular restriction (L). At this time, part of the returning oil pushes the check
valve (5) with restriction and flows into passage (C) via passage (M), increasing the supply volume fed to cylinder Port B5 (Regenerative circuit).
Issued 03-08
Copyright
8030-14
Issued 03-08
Copyright
8030-15
7) Blade spool switch-over (Add-on) (Figure 9)

Because switching the blade spool by adding pressure to Port Pra2 (Prb2) closes the neutral
passage (A) and shuts off the downstream flow, the oil supplied from Port PR5 pushes up the
check valve (1) through parallel passage (B) and flows into cylinder Port AR2 (BR2) by way of
passage (C) and neck of the blade spool.
The returning oil from cylinder Port BR2 (AR2) passes the neck of the blade spool and flows into
the tank passage.
8) Boom Swing spool switch over (Add-on) (Figure 9A)

Because switching the boom swing spool by adding pressure to Port Pra1 (Prb1) closes the
neutral passage (A) and shuts off the downstream flow, the oil supplied from Port PR5 pushes
up the check valve (1) through parallel passage (B) and flows into cylinder Port AR1 (BR1) by
way of passage (C) and neck of the boom swing spool.
The returning oil from cylinder Port BR1 (AR1) passes the neck of the boom swing spool and
flows into the tank passage.
9) Relief valve
1] Main relief valve (Figure 10)
The oil in Port P1 is directly connected with the inlet passage (A) of the main relief valve via common check valve (1), while the oil in Port P2 is directly connected with the inlet passage (A) of the
main relief valve via common check valve (2).
The main relief valve prevents the maximum pressure in pumps P1 and P2 from exceeding their
programmed values. (The operational description for main relief valve is provided separately).
2] Overload relief valve
In each cylinder port of Boom 1, Arm 1, Bucket and Offset, an overload relief valve is installed to
prevent abnormal boosts of pressure on the actuator due to external forces.
The maximum pressure will also be regulated if the programmed pressure is lower than the pressure on main relief valve.
The overload relief valve also prevents cavitation by drawing oil in from the tank when the pressure on cylinder port becomes negative.
Issued 03-08
Copyright
8030-16
(The operational description for the overload relief valve is provided separately).
10)Anti-drift valve (Boom section)

The anti-drift valve is installed on the boom bottom side of cylinder port A7 to prevent the natural
drop of boom cylinder.
1] Neutral Status (Figure 11)
The pressure on cylinder Port A7 passes the hollow cavity in poppet (1) via passage (A) and will
be directed to the spring chamber (C) through passage (B).
The force of the spring and the pressure acting on the area differences in the poppet (2) areas
work to firmly seat poppets (1, 2).
2] Up (Figure 12)
The oil supplied from the pump pushes open poppet (1) and flows out from cylinder Port A7.
3] Down (Figure 13)
Switching poppet (1) by adding pressure to Port Pc2 will direct the oil in spring chamber (C) to
the drain Port dr2 by way of passage (B), the hollow cavities in poppet (1) and spool (3). This
opens poppet (2) and the returning oil from cylinder Port A7 flows into the tank passage through
the boom 1 spool.
The function can also be added to the cylinder port on the arm rod side.
Issued 03-08
Copyright
8030-17
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Copyright
8030-18
Issued 03-08
Copyright
8030-19
Combined Operations
1) Additional operation with travel (Figure 14)
Operating the frontal control (in any section other than Travel) during traveling straight forward/
backward or during a spin turn (simultaneous operation of travel right/left), or traveling straight
forward/backward or spin-turning during the operation of the frontal control will switch over the
travel straight valve (1) due to the oil from the hydraulic power source for signals, which entered
from Port PP. Therefore, the oil supplied from Port P2 (shown by arrows) is shut off from the
neutral passage (C) on the 4-way valve side and will flow into parallel passage (D) on the 4-way
valve side. It will also flow into parallel passage (B) on the 5-way valve side by way of the neck of
travel straight valve and passage (E). Thus, the actuator for the frontal control is operated by the
oil supplied from Port P2.
At this time, the oil supplied from Port P1 (shown by arrows) is shut off from parallel passage (B)
on the 5-way valve side and flows into cylinder Ports (A1, B1) in Travel Right Section through
neutral passage (A) on the 5-way valve side. It also flows into the neutral passage (C) on the 4way valve side past passage (F) and the neck of travel straight valve, then flows into cylinder
Ports (A6, B6) in the Travel Left Section through the hollow cavity in sleeve. Thus, travel is
operated by the oil supplied from Port P1 and straight travel is maintained.
Part of the oil supplied from Port P2 passes annular restriction (G), pushes up poppet (3) to be
supplied to the travel controls. This helps eliminate the decelerating shocks at the time of travel
straight valve (1) switch-over.
Issued 03-08
Copyright
8030-20
Relief Valve
1) Main relief valve
1] Operation of main relief valve
1- The relief valve is incorporated between the neutral passage HP and the tank passage
LP. The oil will flow through the throttle of main poppet (1) to fill in the internal cavity (C).
Also, the sleeve (2) and the main poppet (1) act on different areas A, B to ensure secure
seating.
2- When the pressure on neutral passage HP reaches the programmed pilot spring force,
the pilot poppet (3) opens. The oil flows around the peripheral of pilot poppet (3) and is
directed into tank passage LP by way of drilled hole (D) and annular space (E).
3- As the pilot poppet (3) opens, the pressure in the internal space (C) decreases. As the
main poppet (1) opens, the oil in HP flows directly into passage LP.
Issued 03-08
Copyright
8030-21
2) Overload relief valve

1] Relief valve operation
1- The relief valve is incorporated between the cylinder Port HP and the low-pressure
passage LP. The oil passes the hole on piston (C) and fills the internal space (G). It then
acts on different areas <A> and <B> to make sleeve (K) and main poppet (D) securely
seated.
2- When the pressure on neutral passage HP reaches the programmed pilot poppet spring
force, the pilot poppet (E) opens. The oil flows around the peripheral of poppet and is
directed into the low pressure side LP through the drilled hole (H).
3- As poppet (E) opens, the flow of oil passing the throttle (I) in piston (C) is generated, and a
difference in pressure grows between the passage HP and the back side of piston (C).
The piston (C) then moves and becomes securely seated with the poppet (E).
4- The oil flow from passage HP to the back side of poppet (D) will be restricted to the area
(F) only, which is the annular space between poppet (D) and piston (C) and the throttle. As
a result, the difference in pressure grows larger. Consequently, the poppet (D) opens and
the oil flows directly into passage LP.
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Copyright
8030-22
5- Intake
An anti-void unit is installed to supply oil when cavitation takes place in cylinder Port HP.
When the pressure on cylinder port HP is lower than the pressure on the low pressure side
LP, the sleeve (K) opens due to the area difference between <A> and <B>. The oil enters the
cylinder Port HP from the low pressure side LP to prevent cavitation.
Issued 03-08
Copyright
8030-23
SWING UNIT
Functional and Operational Description
1) Swash Plate Motor
Refer to Structural Drawing Figure 1.
The cylinder block has 9 pistons installed. Also, the end of the cylinder block contacts the valve
plates, which have two crescent-shaped ports A and B.
Principle of torque generation
When high pressure oil (Pressure P) is introduced into Port B, the oil pushes the swash plate by
force per one piston (F = P x Ap, where Ap is the sectional area of a piston). The piston receives
the reaction corresponding to the force from the swash plate. As a result, a component is
generated in the rotational direction of the reaction. Then, rotational force is generated on the
cylinder block by the collection of forces in the rotational direction of the piston on the high
pressure side. The torque then is transferred to the shaft via spline for rotation. On the other
hand, when the high pressure oil is introduced to Port A, the rotational direction will be reverse
to the case described above. The output torque and the number of revolutions are calculated
according to the following equations:
Issued 03-08
Copyright
8030-24
Figure 1. Structural Drawing of Motor
Issued 03-08
Copyright
8030-25
2) Parking Brake (for models equipped with parking brakes)

The parking brake is a hydraulic release type, wet multiple disc structure, having a shaft lock
mechanism where brake ON/OFF is switched by external signal pressure.
1] When parking brake is ON
See Figure 2-1: Structural drawing. When the hydraulic oil for brake release is shut off, the disc is
connected to the peripheral of the cylinder block via splines. The brake piston (secured to prevent
its rotation) is pushed by the force of spring, and the cylinder block and the case are secured by
the force of friction. The shaft, therefore, will be locked.
2] When parking brake is OFF
See Figure 2-2: Structural drawing. When the hydraulic oil for brake release is introduced to the
brake cylinder chamber (C) through Port PB (Port PG for models with parking brake), the brake
piston starts moving due to release pressure against the force of spring. The shaft then will be
free to rotate since there is no friction.
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Copyright
8030-26
3) Principle of Relief Valve Operation

The relief valve determines the driving force and the braking force at the time of hydraulic shovel swing.
They are installed on lines A and B of the main port. It also has a circuit which forces the returning oil
from relief valve to go back to the opposing main low pressure line via makeup valve. Also, it is designed
to reduce shocks at start of acceleration / deceleration. The relief valve structure has two components:
1] Area difference direct acting relief valve
2] Shockless piston
as shown in Figure 3-1.
Shockless type relief valves help eliminate shocks and stresses generated on intensified components.
Pressure Setting of Relief Valve versus Adjustment Volume of Relief Valve (for reference)
Per one time: Approximate 9.7 MPa {1406 psi}
Do not attempt to make adjustments as long as there are no problems.
Issued 03-08
Copyright
8030-27
The relief valve operates in two steps as follows:

Initial stage (see Figure 3-2)
At the beginning of the operation, the shockless pin moves to maintain low pressure in the
spring chamber. Thus, the area for receiving pressure on poppet will be the area of poppet seat
(S1). This is considerably large compared to the area for receiving pressure at the normal relief
setting (S1-S2). The relief operating pressure, therefore, will be held low until the shockless spin
has completely moved.
The duration for which the pressure is held low will be determined according to the orifice
diameter between poppet and piston, the area of free piston for receiving pressure, and the free
piston stroke.
Issued 03-08
Copyright
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Second stage (see Figure 3-3)

By the time the shockless piston has moved completely, the pressure in the spring chamber has
risen, and the front and the back pressures of the poppet have become equal. The relief valve,
therefore, operates on the pressure setting for normal operation.
Figure 4 compares the pressure waveforms between the conventional type and the shockless type.
Issued 03-08
Copyright
8030-29
4) Makeup Valve
The makeup valve functions in two ways as described below:
First it keeps the swing body from overrunning by preventing cavitation, which is caused by swing body
overrun. If the motor had pumped due to inertia of the swing body and the motor revolutions have
exceeded the adequate number of revolutions suitable for the oil inflow to motor, the shortage of oil will
be supplemented into the main motor circuit via the makeup valve. Thus, the generation of vacuum in
the circuit will be prevented. Secondly, it maintains the normal circuit conditions for braking by preventing the generation of vacuum in the circuit. The situation applies at the time of braking, for example,
when a closed circuit was formed between the control valve and the motor. The makeup valve supplements the amount of the motor drainage and the valve leakage to prevent the circuit from being vacuumized.
Issued 03-08
Copyright
8030-30
5) Reduction Gear (2-stage planetary gear)

See the sectional drawing below.
The motor shaft (1) is spline-jointed to the drive gear (2). The driving force from the hydraulic motor is
transferred to the planetary gear (3), which engages with the drive gear (2). The planetary gear (3)
engages with the ring gear in the reduction gear housing (4). The planetary gear thus revolves along the
gear ring while it rotates. The planetary gear (3) is held by the holder (5) via a bearing. The holder transfers the orbital motion of the planetary gear (3) to the sun gear (6), which is spline jointed to the holder.
The sun gear (6) engages with the planetary gear (7) and transfers orbital motion to the planetary gear
(7) in the same manner as in the first step. The planetary gear (7) revolves as it rotates because it
engages with the ring gear in housing (4). Since the planetary gear (7) is held by holder (8) via a bearing, the holder (8) transfers the orbital motion of the planetary gear (7) to the pinion shaft (9), which is
spline jointed to the holder.
Issued 03-08
Copyright
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Overview
1) Features
1- The valve enhances operability by reducing the number of reverse rotations when the
swing body stops.
2- As the valve has few components and is structurally simple, maintaining the valve is easy.
2) Operational Description
The anti-reverse valve prevents reverse rotational motion caused by entrapped pressure at the
time the swing body is stopped. This is achieved by directly connecting the motors main line to
the makeup line for a certain period of time when the motor stops.
The anti-reverse valve consists of the following parts as shown in Figure 1.
1- Check valve
2- Flow control valve (integrated in check valve)
3- Sleeve (Combined with check valve to form a high pressure selection valve).
4- Orifice A
5- Orifice B
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Issued 03-08
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When control valve is in neutral

(Ports P1, P2 on the motor at the same pressure). The check valve will be balanced at the center with
the spring force.
When the swing body is activated, the check valve on high pressure side is pushed and the check valve
will be seated.
At the time of applying the brake, the check valve is stroked by the brake pressure and will be seated.
Issued 03-08
Copyright
8030-34
After the motor has been stopped by the braking action of the valve unit, it will try to move in the reverse
direction due to the entrapped pressure in the main line. This reverse pressure will seat the shuttle valve
(sleeve) in check valve onto the check valve on low pressure side. An oil passage is thus formed
between the port on which reverse pressure is applied (Port Pv2) and the port which is connected to the
main makeup line (Port Cv). Through this oil passage, the reverse pressure will be released into Port Cv.
At the same time, the reverse pressure pushes the check valve in the direction opposite of the direction
of braking. The flow control valve integrated into the check valve, which now is the low pressure side,
releases oil in the damper chamber 1 at a fixed volume. The check valve, therefore, starts stroking at a
speed.
In the end, the check valve becomes seated and the oil passage formed between Port Pv2 and Port Cv
is blocked.
Issued 03-08
Copyright
8030-35
TRAVEL UNIT (CX75SR)

External Dimensional Drawing
Issued 03-08
Copyright
8030-36
Basic Structure and Drawings

1) Basic structure of GM motor
Reduction gears
The reduction gears are composed of a spur gearbox (referred to as primary reduction gears)
and a differential gearbox (referred to as secondary reduction gears) in which pericycloid tooth
profiles are adopted. The gears work to reduce the high-speed rotational motion from the
hydraulic motor and to convert it into a low speed rotation with high torque.
Hydraulic motor
The hydraulic motor is a swash plate type axial piston motor. The motor converts the force of
pressurized oil delivered from the pump into a rotational movement.
Brake valve
The brake valve consists of various types of valves. It stops the hydraulic motor smoothly,
prevents the motor from overrunning, and also prevents extreme high pressure from being
generated at the time the motor is stopped abruptly.
High/low 2-step switching mechanism
The valve consists of a switching valve and a piston. It switches the piston displacement of the
hydraulic motor in two different steps.
Parking brake
The parking brake has a friction-plate type braking mechanism and is integrated into the
hydraulic motor section.
Issued 03-08
Copyright
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Issued 03-08
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2) Parts list
PART NAME
SYM
QTY
Hub
Spindle
Carrier
Sun gear(1)
PART NAME
SYM
QTY
Oil seal
132
O-ring
135
O-ring
139
Snap ring
145
Planetary gear(1)
Ball bearing
149
Sun gear(2)
Ball bearing
150
Planetary gear(2)
Roller
151
Thrust coller(1)
Piston
161
Thrust washer(1)
10
Shoe
162
Thrust washer(2)
11
Pivot
167
Thrust washer(3)
12
Parallel pin
171
Cover
13
Spring
190
Ring nut
22
Valve seat
201
Ball bearing
24
Valve
202
27
Sleeve
203
28
Coller
204
Inner ring
29
Plug
205
SYM
QTY
Plug
383
O-ring
392
Name plate
399
Inner ring
30
Spring
206
Floating seal
31
O-ring
207
Plug
33
Backup ring
208
O-ring
35
O-ring
211
O-ring
37
O-ring
212
Socket plug
39
Shim
213
Hex.head bolt
40
Piston
214
Steel ball
41
O-ring
215
Parallel pin
42
Backup ring
216
O-ring
43
Rear flange
301
O-ring
44
Plug
321
Ring
45
Spool
323
Hex.socket set screw
47
Plug
324
Retainning ring
50
Spring retainer
325
Hex.head bolt
51
Valve
327
Shaft
102
Spring
328
Swash plate
103
Spring
330
Cylinder block
104
O-ring
336
Piston
105
O-ring
338
Shoe
106
Pallalel pin
342
Retainning plate
107
Hex.socket bolt
345
Thrust ball
108
Hex.socket plug
352
Timing plate
109
Spool
363
Washer
110
Spring
366
Washer
111
Steel ball
368
Piston
112
Hex.socket plug
375
Spring
113
10
Orifice
377
Spring
114
Filter
379
Friction plate
115
Orifice
380
Mating plate
116
Plug
382
PART NAME
Issued 03-08
Copyright
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1) Reduction gears
1] Functions
The reduction gears are composed of a spur gearbox (referred to as primary reduction gears)
and a differential gearbox (referred to as secondary reduction gears) in which pericycloid tooth
profiles are adopted. The gears work to reduce the high-speed rotational motion from the hydraulic motor and to convert it into a low speed rotation with a high torque.
2] Operational description
1- Primary reduction gears section
1)The rotational movement of the hydraulic motor is output from shaft (102). The rotation is
transferred onto the input gear (6) which is spline jointed with the shaft G (15). The input
gear (6) is engaged with three spur gears (7).
The spur gears (7) are reduced to lower speed and will rotate in the reverse direction. The
reduction gears section with input gear (6) and spur gears (7) is called the primary reduction
gears section. The reduction ratio (i1) of this section is as follows:
Issued 03-08
Copyright
8030-40
2- Secondary reduction gears section

1)Each of the three spur gears (7) is connected to the crankshaft (9). When the spur gear
(7) rotates, the crankshaft (9) rotates in the same direction and for the same number
revolutions. This rotational movement causes the eccentric body sections A and B of the
crankshaft (9) to start their eccentric movement (orbital motion). This eccentric movement
(orbital motion) is transferred to the RV gears A (4) and B (5) via the needle roller bearing
(23). In this manner, the RV gears A (4) and B (5) engage in eccentric movement in the
same direction and for the same number of revolutions as the spur gears and crankshaft.
Issued 03-08
Copyright
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2) The faces of teeth on RV gear A (4) and RV gear B (5) are always engaged with the pins
(17) (number of pins: Zp). When the RV gear A and the RV gear B start their eccentric
movements, the mesh point shifts on the faces of teeth sequentially while rolling. During
one turn of eccentric movement, the pin (17) rotates together with the hub (1) for the
difference value (Zp Zr), which is equal to the difference between Zr (the total gear teeth
number of RV gears A and B) and Zp (the number of pins). The rotational direction of hub
(1) is the same as the direction of eccentric movement on RV gear. The rotation of hub (1)
is the output rotation. The secondary reduction gears section is where the reduction takes
place through crankshaft, RV gear, pin and hub.
The reduction ratio (i2) in the secondary reduction gears section is as follows:
3) The entire reduction gear

The reduction gears will operate at the product ratio of the primary reduction gears section and
the secondary reduction gears section.
Therefore, the number of output revolutions (reduction ratio i) for the reduction gears after the
hydraulic motor shaft has made one complete turn will be as follows:
Issued 03-08
Copyright
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2) Hydraulic drive section

This section describes the hydraulic motor, brake valve, parking brake, which are driven by hydraulic oil,
and the high/low 2-step switching mechanism of the hydraulic motor.
1] Functions
1- Hydraulic motor
The hydraulic motor is a swash plate type axial piston motor. The motor converts the force of
pressurized oil delivered from the pump into a rotational movement.
2- Brake valve
1) The valve controls the inertial force at the time the hydraulic motor is stopped to enable a
smooth stopping of the motor.
2) The valve also keeps the hydraulic motor from overrunning when an external force causes the
motor to rotate.
This, in other words, will prevent hydraulic oil cavitation.
3) It also prevents the generation of extreme high pressure when the hydraulic motor is stopped
abruptly.
3- High/low 2-step switching mechanism
This switches the hydraulic motor in two steps: the high-speed rotation with a low-torque output and the low-speed rotation with a high-torque output.
4- Parking brake
The parking brake works when the hydraulic motor is being stopped and prevents the motor
from rotating due to an external force. It has a friction-plate type braking mechanism and is
integrated into the hydraulic motor section.
Issued 03-08
Copyright
8030-43
2] Principle and operational description
1- Hydraulic Motor
The pressurized oil supplied from the hydraulic pump enters the rear flange (201) in the GM
motor. The pressurized oil is directed into the cylinder block (104) through the brake valve and
the timing plate (109).
The oil will be directed into one side only of the area divided by the Y1-Y2 line drawn from the
top to the bottom dead centers of the piston (105) stroke.
The pressurized oil pushes each of the pistons (105) and generates a force F (= P x A). The
force will act on the inclined surface of the swash plate (103). Due to the angle of this inclined
surface, the force F will be divided into component forces F2 and F3. Of these component
forces, the radial component force F3 generates a torque (= F3 x ri).
The resultant force T (= [F3 x ri]) of each piston (105) is the rotational force for the hydraulic
motor. The rotational force will rotate the cylinder block (104) and the shaft (102) via piston
(105).
Issued 03-08
Copyright
8030-44
2- Brake valve
The ports A and B are the inlet/outlet for the hydraulic oil. The following describes the case in
which the hydraulic oil (pressurized oil) is supplied to Port A.
The flow and the operation will be reversed when the oil is supplied to Port B. The rotational
direction of the motor will also be reversed in this case.
1) During normal operation
The hydraulic motor will start rotating when the pressurized oil is supplied to Port A from the
pump. The details will be described as follows.
The pressurized oil supplied from the pump first enters Port A and opens the valve (227). The
pressurized oil which has passed the valve (227) and entered the hydraulic motor via Port C
will give the rotational force to the hydraulic motor.
Pressurized oil also enters Port A, passes the passage (a) through a small hole in spool (223)
and enters the chamber (b). The spool (223) slides from the neutral position to the left by the
force of the pressurized oil in chamber (b). At this time, a hydraulic oil passage is formed
between the Ports D and B due to the grooves in the spool. The hydraulic oil discharged from
the hydraulic motor flows in Port B from Port D. In this manner, the hydraulic motor rotates
and the hydraulic oil returns to the oil tank. On the other hand, the pressurized oil enters Port
E when the spool (223) slides to the left, and the oil in Port E flows into the parking brake and
the 2-step switching valve.
Issued 03-08
Copyright
8030-45
2) Stopping (by applying the brake)

The hydraulic motor will stop rotating when the supply of pressurized oil is stopped. The
details will be described as follows.
When the supply of pressurized oil to Port A is discontinued, the pressure in Port A and
chamber b decreases. As the pressure decreases, the spool (223) starts moving towards the
right from the left position to the neutral position by the force of spring (228).
In conjunction with the movement of spool (223), the passage area between the Ports D and
B becomes smaller. When the spool reaches the neutral, the passage will be shut off.
The hydraulic motor, on the other hand, keeps rotating due to inertial force even after the supply of pressurized oil stopped. The hydraulic oil discharged from the hydraulic motor thus
loses its passage to flow out from Port D. In this manner, the hydraulic oil on Port D increases
its pressure. The hydraulic oil with the boosted pressure passes the throttle of a valve (287)
on the right-hand side and enters chamber (g) through chamber (f). Because of the hydraulic
oil entering chamber (g), the piston (286) on the right-hand side will shift to the left portion to
keep the pressure from rising. During the movement, the pressures in the chambers (r) and
(g) stay lower than the pressure in Port D through the effect of the orifice in valve (287).
At the same time, the valve (287) on the right-hand side stays open due to the difference in
pressures. The hydraulic oil flows into Port C from Port D. When the piston (286) reaches the
end of its stroke, the pressures in the chambers (g) and (f) rise and become equal to the
pressure in Port D. The valve (287) on the right-hand side then closes again. As the oil discharged from Port D loses its next flow passage, the pressure continues to rise.
The valve (287) on the left-hand side then opens and the hydraulic oil in Port D flows into Port
C. In time, the pressure in Port D decreases along with the decrease in inertial force, and
valve (287) on the left side closes again. The hydraulic motor will also stop its rotation.
In this manner, the hydraulic motor will be stopped smoothly by the brake through controlling
the pressure in Port D in two separate steps.
Issued 03-08
Copyright
8030-46
3) Anti-overrun features
When the hydraulic motor is forced to rotate by external forces during its normal operation, an
overrunning will occur. This occurs, for instance, when an excavator is traveling down a steep
slope at the same time as working the travel motor for a power shovel. The mechanism
against the overrun phenomenon is described below.
The hydraulic motor, during its normal operation, is forced to rotate by an external force. The
pressure of the hydraulic oil (supplied to Port A or Port B) decreases.
The spool (223) starts moving toward the center as the pressure reaches the level that
causes the motor to overrun. In conjunction with the movement of spool (223), the area of the
passage between Port D, which is at the outlet side of the hydraulic motor, and Port B
becomes smaller. The hydraulic oil flow discharged into Port B from Port D also becomes limited.
At the same time, the pressure on Port D (back pressure) also increases.
The overrunning will be prevented in this manner by controlling the oil flow/pressure at the
outlet port of the hydraulic motor.
Issued 03-08
Copyright
8030-47
3- High/low speed 2-step changing mechanism (during 2-speed manual switch)

1) Low-speed
At low speed, the pilot pressure is not supplied from Port P. At this time, the spool (271) is
pushed to the left by the force of spring (281) and the pressurized oil in Port F is being shut
off.
The hydraulic oil in chamber S is released into the drain (motor case) via spool (271). The
thrust of the piston (161) is small at this stage. The swash plate (103) is positioned along the
surface Y. The swash plate (103), then, reaches its maximum incline angle of 1.
In other words, the hydraulic motor reaches its maximum piston displacement and rotates at
low speeds.
Issued 03-08
Copyright
8030-48
2) High speed
At high speed, 3.92 MPa {568 psi} of pilot pressure is supplied from Port P. At this time, the
spool (271) is pushed to the right, overcoming the force of spring (281). The pressurized oil in
Port F is introduced into chamber S via spool (271).
The thrust of the piston (161) becomes stronger because of the pressurized oil in chamber S.
The piston (161) pushes the swash plate (103) until it hits the surface X, then holds the plate
there. The swash plate (103) is at its minimum incline angle of 2.
In other words, the hydraulic motor is at its minimum piston displacement and rotates at high
speeds.
Issued 03-08
Copyright
8030-49
4- Parking brake
1) During operation
The pressurized oil is supplied from the pump to Port A or Port B.
The spool (223) in the brake valve then moves towards the left or right. By the time the spool
has moved all the way, the Port E opens. The pressurized oil is thus introduced into the cylinder chamber (c) from Port E. When the oil pressure reaches 0.47 MPa {68 psi} or above, the
thrust of piston (112) becomes larger than the force of spring (113). The piston (112) moves
toward the rear flange (201). The force that has been pushing the counterpart plate (116) and
the friction plate (115) from the piston, therefore, ceases to exist, allowing the friction plate
(115) to rotate freely here.
Because the friction plate (115) engages with the cylinder block (104) in the hydraulic motor
section, the braking force on the cylinder block (104) will also be released, and the hydraulic
motor will also be free to rotate.
Issued 03-08
Copyright
8030-50
5- When applying the brake to stop

The supply of pressurized oil to Port A or Port B is stopped.
The spool (223) in the brake valve then moves to the neutral position. Port E shuts off. The
pressure in the cylinder chamber (c) decreases. When the pressure drops to 0.47 MPa {68 psi}
or below, the hydraulic force of piston (112) becomes smaller than the force of spring (113).
The piston pushes the counterpart plate (116) and the friction plate (115) with the force of the
spring (113). This pressing force generates a friction force, which will be used for braking.
The friction plate (115) engages with the cylinder block (104) in the hydraulic motor section.
The cylinder block (104) engages with the shaft (102) of the hydraulic motor section.
In this manner, the braking torque will be applied to the hydraulic motor at the time the machine
is stopped.
Issued 03-08
Copyright
8030-51
TRAVEL UNIT (CX80)

External Dimensional Drawing
Issued 03-08
Copyright
8030-52
Basic Structure and Drawings

1) Basic structure of GM motor
1st stage Reduction
2nd stage Reduction
High-Low 2-Speed
Switching Mechanism
Parking Brake
Brake Valve
Hydraulic Motor
Reduction Gear
AO13001 016
Issued 03-08
Copyright
AO13001-017
8030-53
Issued 03-08
Copyright
8030-54
2) Parts list
PART NAME
Hub
SYM
QTY
PART NAME
Mating plate
SYM
QTY
116
PART NAME
Plug
SYM
QTY
383
Spindle
Oil seal
132
O-ring
392
Carrier
O-ring
135
Name plate
399
Sun gear(1)
O-ring
139
Planetary gear(1)
Snap ring
145
Sun gear(2)
Ball bearing
149
Planetary gear(2)
Ball bearing
150
Thrust coller(1)
Roller
151
Thrust washer(1)
10
Piston
161
Thrust washer(2)
11
Shoe
162
Thrust washer(3)
12
Pivot
167
Cover
13
Parallel pin
171
Ring nut
22
Spring
190
Ball bearing
24
Valve seat
201
27
Valve
202
28
Sleeve
203
Inner ring
29
Coller
204
Inner ring
30
Plug
205
Floating seal
31
Spring
206
Plug
33
O-ring
207
O-ring
35
Backup ring
208
O-ring
37
O-ring
211
Plug
39
O-ring
212
Hex.head bolt
40
Shim
213
Steel ball
41
Piston
214
Parallel pin
42
O-ring
215
O-ring
43
Backup ring
216
O-ring
44
Rear flange
301
Ring
45
Plug
321
Hex.socket set screw
47
Spool
323
Retainning ring
50
Plug
324
Hex.head bolt
51
Spring retainer
325
Washer
52
Valve
327
Shaft
102
Spring
328
Swash plate
103
Spring
330
Cylinder block
104
O-ring
336
Piston
105
O-ring
338
Shoe
106
Pallalel pin
342
Retainning plate
107
Hex.socket bolt
345
Thrust ball
108
Hex.socket plug
352
Timing plate
109
Spool
363
Washer
110
Spring
366
Washer
111
Steel ball
368
Piston
112
Hex.socket plug
375
Spring
113
10
Filter
379
Spring
114
Orifice
380
Friction plate
115
Plug
382
Issued 03-08
Copyright
8030-55
1) Reduction gears
1] Functions
This reduction gear unit is composed of two stage planetary gear mechanism.
The reduction gear reduces the high seed of hydraulic motor and converts it low-speed, hightorque rotation.
2] Operational description
The rotation of hydraulic motor shaft is transmitted to sun gear [4] of the first stage which is linked
with shaft [102] in spline.
Sun gear [4] is meshed with three planetary gears [5], and three planetary gears [5] mesh with
hub [1] while rotating on their axis.
At that time, the hub is rotated by the rotation of the planetary gears [5].
The hub rotation is transmitted to carrier [3] which connected to planetary gears [5], and that
causes sun gear [6] rotation of the second stage.
The rotation of sun gear [6] is transmitted to the hub via four planetary gears [7] of the second
stage.
The generated rotation of reduction gear is output rotation.
Hub [1]
Planetary gear [7]

Planetary gear [5]
Spindle [2]
Shaft [102]
In put
Out put
Sun gear [6]
Sun gear [4]

Carrier [3]
AO13001-018
Issued 03-08
Copyright
8030-56
2) Hydraulic drive section

This section describes the hydraulic motor, brake valve, parking brake, and high-low 2-speed switching
mechanism of the hydraulic motor.
1] Functions
1- Hydraulic motor
Hydraulic motor is referred to as a swash plate type axial piston motor which converts the pressure oil power fed by pump into rotary motion.
2- Brake valve
1) Travel motor controls the force of rotational inertia of the body to brake and stop the rotation
smoothly.
2) Check valve function to prevent hydraulic motor from cavitation.
3) Open the port to release the parking brake force at travel motor operation, and close the port
at a standstill.
3- Relief valve
1) Softens the shock when starting the hydraulic motor, softens the shock when stopping the
hydraulic motor, and prevents cavitation through the relief operation (reduction of the stop
brake sound).
2) When sudden pressure operates on the hydraulic motor, the relief valve keeps the pressure to
a predetermined level or less to prevent damage to the hydraulic motor.
4- High-low 2-speed switching mechanism
Switches the hydraulic motor between high speed rotation with low torque, and low speed rotation with high torque.
5- Parking brake
The parking brake is used the prevent machine from running away or slipping while parking on
a slope using the friction plate type brake mechanism, and it installed on the hydraulic motor.
Issued 03-08
Copyright
8030-57
2] Principle and operational description
1- Hydraulic Motor
Hydraulic fluid fed by pump enters rear flange [301] of travel motor, and is led from timing plate
[109] to cylinder block [104] through brake valve mechanism. This pressure oil is led to only
the one side of (Y1)-(Y2) tied between top dead point and bottom dead point of piston [105]
stroke. And the pressure led to one side of cylinder block pushes 4 or 5 pistons [105], generating the power (F1 kgf = P kgf/cm2 x A cm2). This power enters on swash plate [103], but swash
plate is fixed having an angle (x) against axis of drive shaft [102], and divided into component
of force (F2, F3). And the radial component of force (F3) generated various torque (T= F3 x ri)
against line. The total torque T [= (F3 x ri)] is connected turning effort, and rotates cylinder
block [104] through piston [105].
The cylinder block [104] is connected with drive shaft [102] with spline, and rotates drive shaft
[102] to transmit torque.
301
104
105
109
102
103
Y1
F3
F2
F3
ri
F1
F3
F3
F3
x
Y2
AO13001-019
Issued 03-08
Copyright
8030-58
2- Brake valve
Port (A) and Port (B) are the input and output ports for the working fluid. The following
description assumes that the working fluid (hydraulic) is fed through port (A).
If the fluid is fed through port (B), the flow and motion are reversed. The direction of Rotation
of the motor is also reversed.
1) During normal operation
Hydraulic fluid is fed from the pump to port (A), causing the hydraulic motor to rotate. The
details are as follows.
First, the hydraulic fluid fed from the pump enters at port (A) and opens the valve [327].
The fluid oases through the valve [327], enters the hydraulic motor through port (C) and
applies rotary force to the hydraulic motor.
At the same time, hydraulic fluid enters at port (A) and passes through small holes in the
spool [323] and through channel (a) to chamber (b).
The hydraulic pressure in chamber (b) causes the spool [323] to move from the central position to the left. At this time a groove in the spool [323] forms a channel for hydraulic fluid to
pass between port (D) and port (B).
Hydraulic fluid ejected from the hydraulic motor flows from port (D) to port (B), and the
hydraulic motor rotates. The hydraulic fluid returns to the oil tank.
Also, as the spool [323] oscillates to the left, hydraulic fluid enters port (E). The hydraulic fluid
at port (E) flows to the parking brake and 2-speed switching valve.
Parking brake
E
323
323
327
328
B
A
AO13001-020
Issued 03-08
Copyright
8030-59
2) Stopping (by applying the brake)

If pressurized oil supply through the port (A) is suspended while traveling, the hydraulic force
to push up the spool is lost, and the spool [323] which is slid to left side, tries to return to the
neutral position through the spring retainer [325] due to the spring [328] force. At that time,
through the oil in the chamber (b) tries to flow out to the port (A) side through the passage (a)
in the spool [323], its flow is restricted and some back pressure is generated by the throttle
effect in the passage (a) controlling the return speed of the spool [323]. At the same time, the
hydraulic motor tries to rotate with its inertia force even though the pressurized oil is suspended, and the return oil from the hydraulic motor tries to return to the port (B) side from the
port (D) through the passages on spool groove and rear flange.
When the spool [323] entirely return to neutral position, the passage on the hydraulic motor of
the oil return side is completely closed by the spool [323], and the hydraulic motor ceases its
rotation. While machine working, the brake valve smoothly stops rotation of the hydraulic
motor which tries to rotate with its inertia force, by means of throttling the return side passage
of the hydraulic motor, generating back pressure due to shape of the spool groove and controlling the return speed of the spool [323].
On the other hand, when braking is operated, the hydraulic motor tries to rotate with its inertia
force and to intake oil with its pumping function.
However, because the intake side is closed its passage with the spool [323], the oil supply is
suspended. This causes cavitation in the hydraulic motor. To prevent the cavitation, the valve
[327] is operated by very slight negative pressure to open the passages of port (A) side and
intake port (C) of the hydraulic motor.
And when pressurized oil is supplied through the port (B), each motion of the mentioned
parts above becomes symmetrical right and left to stop the hydraulic motor.
Parking brake
301
323
a
325
323
327
328
B
AO13001-021
Issued 03-08
Copyright
8030-60
3) Anti-racing function
During normal operation, when a hydraulic motor is rotated by an outside force, a condition
called racing runaway can occur. For example when used as the drive motor for a excavator,
racing can occur when the vehicle moves down a steep slope.
This section describes the mechanism used to prevent this condition.
During normal operation, the hydraulic motor is rotated by an outside force. The pressure of
the hydraulic fluid feed (at port (A) or port (B)) falls.
As the pressure approaches the level at which racing begins, the spool [323] begins moving
to the center towards the central position. The movement of the spool [323] reduces the size
of the flow channel from port (D) to port (B) on the output side of the hydraulic motor. This
restricts the amount of hydraulic fluid ejected from port (D) to port (B). At the same time the
pressure at port (D) (back pressure) increases.
Thus racing is prevented by controlling the flow rate and pressure at the escape port from the
hydraulic motor.
Parking brake
301
323
a
323
327
328
B
AO13001-022
Issued 03-08
Copyright
8030-61
3- Operation description of relief valve

1) Starting
The pressurized oil supplied from the pump is led to port (C) from port (A). Port (C) is connected with the hydraulic pressure motor. Therefore, the hydraulic motor can give torque with
the pressurized oil led to port (C). At this time, the valve [202-a] of the relief valve(R/V) A is
not opened for the pressurized oil of port (C). The piston [214-a] moves to the stroke end of
the direction of an arrow with the pressurized oil. The oil of chamber (x) is led to port (D)
through the orifice (c) of the sleeve [203-a], the orifice (b) of the valve [202-a]. The pressurized oil of port (C) opens the valve [202-b] (b) of the relief valve B with set pressure, and
pressurized oil is led to port (D). The pressurized oil from port (C) is led to the chamber (y)
through the orifice (f) of the valve [202-b], the orifice (g) of the sleeve [203-b]. If the piston
[214-b] reaches the stroke end, the pressure between the orifice (f) of the valve [202-b] and
the orifice (g) of the sleeve [203-b] will rise. The cracking pressure of the valve [202-b] turns
into more than the system pressure of the excavator with the pressure during two orifices,
and the valve [202-b] is closed.
The pressure of port (C) rises by the operation of the relief valve (R/V) A and B, and the
hydraulic motor can obtain torque.
chamber(y)
a
214
orifice(f)
202
b
203
orifice(c)
R/V "B"
D
C
R/V "A"
203
orifice(g)
chamber(x)
214
202
B
orifice(b)
AO13001-023
Issued 03-08
Copyright
8030-62
Pressure
The pressure of the port (C) at starting is as follows.
Time
Relief valve "B" is opened

AO13001-024
Pressure
However, when the piston [214-b] position has reached the stroke end in the case of the last
stop, the valve [202-b] of the relief valve (R/V) B is not opened.
The pressure of the port (C) in this case is as follows.
Time
AO13001-025
The pressure of the port (C) at starting changes with the piston [214-b] positions.
NOTE: When the pressurized oil supplied from the pump is led to port (D) from port (B), operation explanation
becomes what replaced the relief valve (R/V) A and relief valve (R/V) B.
Issued 03-08
Copyright
8030-63
2) Stopping
If supply of pressurized oil in Port (A) is lost, the counter balance valve will return to neutrality.
Port (D) will be intercepted if the counter balance valve returns to neutrality.
However, since the hydraulic motor rotates according to inertia, the pressure is generated in
port (D).
The pressurized oil of port (D) is led to the chamber (x) through the orifice (b) of the valve
[202-a], the orifice (c) of the sleeve [203-a].
The piston [214-a] moves to the stroke end of the direction of an arrow with the pressurized
oil led to the chamber (x).
While the piston [214-a] is moving, the pressure in the chamber (x) does not rise.
The pressurized oil of port (D) opens the valve [202-a] of the relief valve (R/V) A with set
pressure, and pressurized oil flows into port (C). (Pressure under piston movement : Primary
relief pressure)
The pressure of port (D) is controlled by the operation of the relief valve (R/V) A, and the
cavitation is prevented by supplying oil to port (C).
If the piston [214-a] reaches the stroke end, the pressure of chamber (x) and the pressure
between the orifice (b) of the valve [202-a] and the orifice (c) of the sleeve [203-a] will rise,
and the valve [202-a] is closed.
At this time, the relief valve (R/V) A is relieved above the system pressure of the excavator,
and stops the hydraulic motor. (Pressure at the time of the completion of a piston move : Secondary relief pressure)
The piston [214-b] of the relief valve (R/V) B moves to the direction of an arrow with the
pressurized oil of port (D).
The oil of chamber (y) is led to port (C) through the orifice (g) of the sleeve [203-b], the orifice
(f) of the valve [202-b].
chamber(y)
214
orifice(f)
202 b
203 a
orifice(c)
R/V "B"
D
C
R/V "A"
203
orifice(g)
chamber(x)
B
214
202
orifice(b)
AO13001-026
Issued 03-08
Copyright
8030-64
Pressure
The pressure of the port (D) at stopping is as follows.
Time
Piston [214-a] is moving
Relief valve "A" is opened.

AO13001-027
Pressure under piston movement : Primary relief pressure

Pressure at the time of the completion of a piston move : Secondary relief pressure
Issued 03-08
Copyright
8030-65
4- High-low 2-speed switching mechanism

1) Low-speed
When the pilot pressure is shut off from port (P), the GM motor is low speed level.
At this time the spool [363] is pressed the left side by the force of the spring [366], the pressurized oil supply at port (F) is shut off.
The oil in chamber (S) is released into the motor case through the spool [363].
The force of the piston [161] is small. The swash plate [103] is parallel to side (Y).
At this time the swash plate [103] is tilted at a maximum angle (1). thus leading to lowspeed
operation.
363
161
chamber S
drain
F
366
fulcrum
A or
side Y
103
A
AO13001-028
Issued 03-08
Copyright
8030-66
2) High speed
When the pilot pressure supplied to port (P), the GM motor is high speed level. At this time
the pressure overcomes the force of the spring [366] and the spool [363] is pressed the right
side. The pressurized oil supply from port (F) is then introduced into chamber (S) through the
spool [363] . The force of the piston [161] is increased by the pressurized oil of chamber (S).
The piston [161] pushes the swashl plate [103] up until it touches side (X) and keeps it. At this
time the swash plate [103] is tilted at a minimum angle (2), thus leading io high-speed operation.
161
363
chamber S
366
F
fulcrum
or
side X
103
A
AO13001-029
Issued 03-08
Copyright
8030-67
3) Automatic switching from high speed to low speed

As the load on the hydraulic motor increases, the pressure at port (A) or (B) Increases. While
operating at the high speed level, when the pressure at port (A) or (B) reaches setting pressure, the spool [363] is pressed leftwards. From this point, the operation is as described for '
Low Speed Level '. The force of piston [161] is reduced, and the hydraulic fluid of chamber (S)
is opened to drain (motor case) through the spool [363]. The swash plate [103] is positioned
along side (Y).
At this time the swash plate [103] has its maximum angle (1). Thus in this state the hydraulic
motor has maximum displacement with low rotary speed.
363
161
chamber S
drain
F
366
fulcrum
A
or
side Y
103
A
AO13001-030
Issued 03-08
Copyright
8030-68
5- Parking brake
1) Travering
Hydraulic fluid is fed from the pump to port (A) or port (B), causing the brake valve spool [323]
to move to the left or right. The movement of the spool [323] opens port (E). The hydraulic oil
is fed from port (E) to cylinder chamber (c). When the hydraulic pressure reaches 0.63 MPa
(6.42 kgf/cm2), the force of the piston [112] exceeds the force of the spring [113]. The piston
[112] moves in the direction of the rear flange [301]. The pressure from the piston [112] on the
mating plates [116] and the friction plates [115] disappears, and the friction plates [115] is
able to rotate freely.
The friction plate [115] is locked to the cylinder block [104] of the hydraulic motor. Thus the
braking force of the cylinder block [104] is released, and the hydraulic motor is able to rotate
freely.
104
112
116
115
Parking brake
E
323
301
328
113
A
AO13001-031
Issued 03-08
Copyright
8030-69
2) Stopping
The supply of hydraulic fluid to port (A) or (B) is Stopped. The brake valve spool [323] moves
to the center position, shutting off port (E). The pressure in cylinder chamber (c) falls. When
this pressure falls below 0.63 MPa (6.42 kgf/cm2), the hydraulic force of the piston [112]
becomes less than the force of the spring [113]. The spring [113] causes the piston [112] to
press against the mating plates [116] and friction plates [115].
This pressure creates the friction that serves as the braking force. The friction plate [115] is
locked to the cylinder block [104] of the hydraulic motor.
The cylinder block [104] is Iocked with the shaft [102] of the hydraulic motor.
Thus brake torque is applied to the hydraulic motor while stopped.
104
112
116
115
102
301
113
AO13001-032
Issued 03-08
Copyright
8030-70
NOTES
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
....................................................................................................................................................................................
Issued 03-08
Copyright
Section
9007
9007
AIR CONDITIONING UNIT
CNH
Lep SM75SR9007-0EN

Printed in France
March 2008
Copyright
9007-2
TABLE OF CONTENTS
AIR CONDITIONER ................................................................................................................................................. 3
DISASSEMBLING THE CASE .................................................................................................................................... 3
Removing the switch box: ................................................................................................................................. 3
Removing the upper case: ................................................................................................................................ 3
REPLACING THE BLOWER MOTOR........................................................................................................................... 4
REPLACING THE EVAPORATOR ............................................................................................................................... 4
REPLACING THE EXPANSION VALVE........................................................................................................................ 5
REPLACING THE HEATER CORE .............................................................................................................................. 6
REPLACING THE MOTOR ACTUATOR ....................................................................................................................... 6
Lep SM75SR9007-0EN
Issued 08-2008
Copyright
9007-3
AIR CONDITIONER
1 Disassembling the case
Switch box
Top of case
Filter A
Heater core
Evaporator
To remove clamps
Retainers
Retainers
Filter C
Clamp
Blower motor
Filter B
Figure 2
Figure 1
MQ18001-001
1 Removing the switch box:

1.
Remove 6 screws (M4 x 10) and pull out the switch box.
2 Removing the upper case:

1.
Remove filter A.
2.
Remove filters B and C.
3.
Remove 3 screws (M5 x 12).
4.
Remove 11 clamps using a flathead screw driver.
MSM-17-18-001
Issued 08-2008
Copyright
9007-4
2 Replacing the blower motor

[1] When replacing the blower motor, refer to Figure 3 to
guide the power harness and position.
Blower motor
Power harness
Locations of cooling hose &
power harness for blower
motor installation
Bottom of case
Figure 3
MQ18001-003
[1] Install the blower motor after verifying the installation

position in Figures 4 and 5.
> or = 2 mm (both side)

Clearence between fan & case for
blower motor installation
Figure 4
MQ18001-004a
Blower motor
Unit case
Align centers of blower fan & unit case
Figure 5
MQ18001-004b
3 Replacing the evaporator

1.
Pull out the evaporator from under the unit case.
2.
Pull out the thermistor together with the sensor holder.
3.
Attach the sensor holder to the thermistor, then install the

thermistor on the new evaporator in the location shown in
Figure 6.
Second row of fins from bottom
Thermistor
Sensor holder
Figure 6
ASM-17-24-002
MQ18001-005
Issued 08-2008
Copyright
9007-5
4.
Position the thermistor cord as shown in Figure 7, then

install the evaporator at under the unit case.
Place thermistor cord

along groove
Figure 7
MQ18001-006
4 Replacing the expansion valve

1.
Remove the pipe at the expansion valve inlet and the nut at
the evaporator inlet.
2.
Peel off the insulation from the temperature sensor, remove

the sensing tube, then remove the expansion valve from the
evaporator.
3.
Install the new expansion valve on the evaporator to the

specified torque.
Tightening torque for the expansion valve inlet:
13.2 1.5 Nm.
Tightening torque for the evaporator inlet:
17.7 2.0 Nm.
Fan motor side
NOTE: When installing the expansion valve, be careful not to

put too much pressure on the O-ring.
After sensing tube is
installed
Evaporator side
Applying insulation to temperature sensor
Figure 8
MSM-17-18-001
MQ18001-007
Issued 08-2008
Copyright
9007-6
5 Replacing the heater core

1.
Pull the heater core out from the unit case.
2.
Remove the bolts (5x12) from the pipe retainer and install it on the new heater core.
Then install it under the unit case.
6 Replacing the motor actuator

1.
Push rod clamp A on the actuator lever in the direction of the

arrow to remove it from the lever.
2.
Remove the 4 screws that hold the actuator in place.
3.
Install the lever on the new actuator, insert the rod into rod
clamp and lock.
Figure 9
ASM-17-24-002
MQ18001-008
Issued 08-2008
Copyright
115
MULTI-PURPOSE + 3WAY VALVE
15
21
NOTES
72
1) UPPER VALUES IS MARK
, SHOW THE CONNECTIVE POINTS
AND LOWER VALUES SHOW THE ZONE NUMBER OF THIS DRAWING.
16
115
85
: OPTION PARTS
100
xx
114
For components description see section 8020
85
21
79
38
Y9
22
B32
75
B45
116
29
103
28
W1 W2
22
83
22
83
DOUBLE ACTING CIRCUIT
2
83
1
78
44
75
76
SECOND DOUBLE ACTING CIRCUIT
SINGLE ACTING CIRCUIT
B27
5
83
B26
MULTI-PURPOSE + 3WAY VALVE
78
97
102
51
104
60
95
85
55
10
85
99
94
85
93
Y26
Y25
96
53
96
B22
54
85
85
85
85
B22
CX80 TIER3 EXCAVATOR

HYDRAULIC SCHEMATIC
Pub. Number KAJ11600-E00 EN
Copyright
F34
K48
A11
F1
F3
F33
F27
K47
M20
G2
M10
E51
M1
P4
P5
K7
R1
G1
P10
Y2
K8
Y45
K34
S51
Y3
Y4
S1
Y22
H2
X2
B41
B81
K19
K18
K21
K4
K3
K20
K49
B47
E8
M4
Y25
B1
Y26
S16
P2
E3
E4
E2
B1
R3
S33
X8
S34
W1
B51
M14
P3
M3
S15
B21
B26
H4
R5
B27
NOTES
1) THE MARKS ARE INDICATED AS BELOW IN THIS DRAWING.
H5
S35
: OPTION PARTS
X15
U1
S6
: FOR CASE NORD AMERICA

: FOR CASE EUROPA
B22
S13
S28
: FOR LBX
B22
2) EARTH LINE SYMBOLS AND CROSS POINT OF LINES IN THIS DRAWING

SHOWS THE FOLLOWING.
B22
K5
H3
B22
A7
B2
CONNECTED
EACH OTHER
NOT CONNECTED
EACH OTHER
BODY EARTH
EARTH WITH CABLE
SINGLE WIRE CONNECTOR
HARNESS
3) THE SYMBOL AT EACH LINE SHOWS COLOR OF CABLE.
M7
M5
M6
THE FIGURE BEFORE THE SYMBOL SHOWS THE AREA OF CABLE.

THE AREA OF CABLE NOT INDICATED IS 0,5 mm
P6
K25
K24
K23
THE FIGURE AFTER THE SYMBOL SHOWS CIRCUIT N.
K22
B45
60 B 001
AREA
CIRCUIT NUMBER
COLOR
S52
4) THE SYMBOL OF CONNECTOR IN THIS DRAWING SHOS THE FOLLOWING:
CONNECTOR (FEMALE)
CONNECTOR (MALE)
Y8
CONNECTOR' S NAME
YAZAKI
SWP
(CN. xx)
E52
M8
R7
R4
A9
For components description see section 4020
CX80 TIER3 EXCAVATOR

ELECTRICAL SCHEMATIC
Pub. Number KAR11060-E00 EN
CONNECTOR. No

Case Crawler Excavator Cx75sr Cx80 Tier 3 Service Manual

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CRAWLER EXCAVATOR CX75SR/CX80 TIER 3

* Consult the Engine Service Manual

Copyright 2008 CNH France S.A.

Copyright 2006 CNH France S.A.

Clean all metal parts except bearings, in a suitable

Check all gears for wear and damage. Replace gears

Oil seals, O-rings and gaskets

This symbol means ATTENTION! BECOME ALERT! YOUR

To prevent injury always follow the Warning, Caution

WARNING: Before starting engine, study

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

WARNING: Read the operators manual to

WARNING: Operate the machine and

WARNING: This is a one man machine, no

WARNING: When servicing or repairing the

WARNING: Some components of this

WARNING: Engine exhaust fumes can

WARNING: When the battery electrolyte is

WARNING: Use insulated gloves or mittens

WARNING: Lower all attachments to the

WARNING: Pin sized and smaller streams

WARNING: When removing hardened pins

WARNING: When using a hammer to

WARNING: Use suitable floor (service)

STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS

Cap Screw Name Size (Size)

Copyright @ 2008 CNH France SA

TYPE, SERIAL NUMBER

TYPE, SERIAL NUMBER

(1) Type .......................................................................................................................................................................

Serial numbers of the components

FLUIDS AND LUBRICANTS

Transmission component oil

Oil viscosity / Oil range

1) With mineral base

Engine fuel, maintenance of fuel filters and fuel storage

JIS (Japanese Industrial Standard)

DIN (Deutsche Industrie Normen)

SAE (Society of Automotive Engineers)

Maintenance of fuel filters

Plastic and resin parts

Main body dimensions

Capacity of coolant and lubricants

Hydraulic oil filter

Engine oil pressure*

24V, 55W (x1)

24V, 70W (x1)

Offset boom spec.

Secondary pressure (MPa)

Secondary pressure (MPa)

Foot control valve (for travel)

Secondary pressure (MPa)

Operating torque (Nm) (lbf-ft)

Secondary pressure (MPa)

Foot control valve (for Dozer Blade)

Operating angle (deg.)

Push rod stroke (mm) (in)

Secondary pressure (MPa)

Operating torque (Nm) (lbf-ft)