51895-Case CX160 Crawler Excavator

Copyright ©
CX160 Crawler Excavators

Table of Contents
DIVISION/SECTION SECTION N° REFERENCE N°
1 GENERAL INFORMATION
Safety, general information and standard torque data .....................................1001 7-27690GB
General specifications and special torque setting............................................1002 7-27712GB
2 ENGINE
Removal and installation of the engine ............................................................2000 7-28220GB
Radiator and oil-cooler.....................................................................................2001 7-28040GB
Engine specifications ............................................................................................. *
Disassembly and assembly of the engine.............................................................. *
3 FUEL SYSTEM
Fuel tank ..........................................................................................................3001 7-27970GB
Fuel engine system................................................................................................ *
4 ELECTRICAL SYSTEM
Electrical system, electrical and electronic troubleshooting .............................4001 7-27721GB
Inspection and maintenance of batteries and connecting a booster battery ....4002 7-27921GB
Main and engine electronic control boxes........................................................4003 7-27931GB
5 UNDERCARRIAGE
Removal and installation of tracks ...................................................................5001 7-27750GB
Rollers..............................................................................................................5003 7-27770GB
Sprocket...........................................................................................................5004 7-27781GB
Idler wheel and tension shock absorber ..........................................................5005 7-27801GB
6 DRIVE TRAIN
Drive motor and final drive transmission removal and installation ...................6001 7-27841GB
Drive motor and final drive transmission disassembly and assembly ..............6002 7-29860GB
Swing reduction gear, removal and installation................................................6003 7-29900GB
Swing reduction gear, disassembly and assembly ..........................................6004 7-28370GB
7 UNDERCARRIAGE HYDRAULICS
8 UPPERSTRUCTURE HYDRAULICS
Depressurising and decontaminating the hydraulic system, use of the
vacuum pump and bleeding the components ..............................................8000 7-27951GB
Specifications, troubleshooting, checks and hydraulic pressure settings ........8001 7-27701GB
Hydraulic reservoir removal and installation ....................................................8002 7-27990GB
Main and pilot pumps, removal and installation ...............................................8003 7-27870GB
Main hydraulic control valve, removal and installation.....................................8004 7-27880GB
Attachment cylinders, removal and installation................................................8005 7-27791GB
Hydraulic swivel, removal and installation .......................................................8006 7-27811GB
Pilot blocs, removal and installation.................................................................8007 7-28100GB
Swing motor, removal and installation .............................................................8008 7-29890GB
Main hydraulic pump, disassembly and assembly...........................................8010 7-29770FR
Main hydraulic control valve, disassembly and assembly................................8011 7-28200FR
Attachment cylinders, disassembly and assembly...........................................8012 7-27900GB
Hand control levers, disassembly and assembly .............................................8013 7-28110GB
Foot control levers, disassembly and assembly ..............................................8014 7-28300FR
Six-solenoid valves, disassembly and assembly .............................................8015 7-27910GB
Caution valve, disassembly and assembly ......................................................8016 7-27940GB
Safety vave ......................................................................................................8017 7-29630GB
Hydraulic swivel, disassembly and assembly ..................................................8018 7-28080GB
Swing motor, disassembly and assembly ........................................................8019 7-28010GB
Hydraulic functions...........................................................................................8020 7-28480GB
Copyright  2001 Case France

Printed in France
Case Cre 7-29871GB December 2001
Copyright ©
DIVISION/SECTION SECTION N° REFERENCE N°
9 UPPERSTRUCTURE
Upperstructure, turntable and counterweight...................................................9002 7-27981GB
Boom, dipper and bucket .................................................................................9003 7-27961GB
Seat and seat belt ............................................................................................9004 7-28120GB
Cab and cab equipment...................................................................................9005 7-28021GB
Air conditioning troubleshooting.......................................................................9006 7-xxxxxFR
Air conditioning unit disassembly and assembly..............................................9007 7-29910GB
Air conditioning servicing .................................................................................9008 7-xxxxxFR
Air conditioning components............................................................................9009 7-xxxxxFR
Large format hydraulic and electrical schematics .........................................Pocket 7-27612
* Consult the Engine Service Manual

Sections to be distributed at a later date
NOTE: CASE Company reserves the right to make changes in the spec-
ification 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.
Cre 7-29871GB Edition 12-01

Copyright ©
1001
Section
1001
SAFETY, GENERAL INFORMATION

AND TORQUE SPECIFICATIONS

Printed in France
Case Cre 7-27690GB September 2000
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.
Cre 7-27690GB Issued 09-00

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

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

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

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

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

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

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

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

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

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

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

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

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

Copyright ©
1001-8

Copyright ©
1002
Section
1002
GENERAL SPECIFICATIONS
AND SPECIAL TORQUE SETTINGS
Copyright  2003 CNH France SA

Printed in France
CNH Cre 7-27714GB March 2003
Copyright ©
1002-2
TABLE OF CONTENTS
TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE ....................................................3
Machine.................................................................................................................................................................3
Engine ................................................................................................................................................................... 3
Component serial numbers ................................................................................................................................... 3
FLUIDS AND LUBRICANTS ..................................................................................................................................... 4
Hydraulic fluid....................................................................................................................................................... 4
Transmission component oil ................................................................................................................................ 4
Grease ................................................................................................................................................................. 4
Engine oil .............................................................................................................................................................. 5
Oil viscosity/Oil range............................................................................................................................................ 5
Fuel ...................................................................................................................................................................... 6
Anti-freeze/Anti-corrosion..................................................................................................................................... 6
Environment ......................................................................................................................................................... 6
Components made from plastic or resin .............................................................................................................. 6
SPECIFICATIONS..................................................................................................................................................... 7
Engine ................................................................................................................................................................... 7
Capacities ............................................................................................................................................................. 7
Electrical system ................................................................................................................................................... 7
Hydraulic system ................................................................................................................................................... 8
Cylinder .................................................................................................................................................................8
Control valve ......................................................................................................................................................... 9
Swing .................................................................................................................................................................... 9
Travel .................................................................................................................................................................... 9
Undercarriage ....................................................................................................................................................... 9
Attachment ..........................................................................................................................................................10
Weight of components ........................................................................................................................................10
DIMENSIONS AND LIMIT OF WEAR AND TEAR OF THE TRACKS SET ............................................................11
Toothed wheel.....................................................................................................................................................11
Idler wheel...........................................................................................................................................................12
Upper roller .........................................................................................................................................................13
Lower roller .........................................................................................................................................................14
Track ...................................................................................................................................................................15
DIMENSIONS AND LIMIT OF WEAR AND TEAR OF THE MOBILE JOINTS OF THE ATTACHMENT................16
1. Boom foot/Undercarriage ................................................................................................................................16
2. Boom cylinder foot/Undercarriage...................................................................................................................17
3. Boom cylinder head/Boom ..............................................................................................................................17
4. Dipper cylinder foot/Boom ...............................................................................................................................18
5. Boom/Dipper ...................................................................................................................................................18
6. Dipper cylinder head/Dipper............................................................................................................................18
7. Bucket cylinder foot/Dipper .............................................................................................................................19
8. Connecting rod/Dipper ....................................................................................................................................19
9. Compensator/Bucket.......................................................................................................................................19
10. Connecting rod/Compensator/Bucket cylinder head.....................................................................................20
11. Dipper/Bucket................................................................................................................................................20
SPECIAL TORQUE SETTINGS ..............................................................................................................................21
MACHINE OVERALL DIMENSIONS CX130 CX160...............................................................................................24
MACHINE OVERALL DIMENSIONS CX180...........................................................................................................25
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.

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

When placing a parts order or making a request for information or assistance, always give you CASE Dealer the
type and serial number of the machine concerned.
Enter the required information on the lines below: Type, serial number, year of manufacture of the machine and the
serial numbers of hydraulic and mechanical components.
Machine
1 3
2
CP98N006 CS01J532
(1) Type.............................................................................
(2) Serial number..............................................................
(3) Year of manufacture....................................................
Engine
Make and type .............................................................................................................................................................
Serial number ..............................................................................................................................................................
Component serial numbers

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

Copyright ©
1002-4
FLUIDS AND LUBRICANTS

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

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

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

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

Copyright ©
1002-7
SPECIFICATIONS
CX130 CX160 CX180
Engine
Make.............................................................................................. Isuzu ...............................← .................................... ←
Model.................................................................................... BB-4BG1TRA-01DD-4BG1TRA-02←
Type: Four stroke, water-cooled, overhead valve, direct injection (electronically controlled), in-line engine with
turbo-charger.
Number of cylinders.......................................................................... 4...................................← ................................ ←
Bore and stroke ....................................................................... 105x125mm .........................← .................................... ←
Displacement.............................................................................. 4329cm3............................← .................................... ←
Operating conditions
Idling ..........................................................................................1000 tr/mn ..........................← .................................... ←
Max speed .................................................................................2100 tr/mn ................ 2200 tr/mn ............................. ←
ECC 1289 power rating ......................................................... 66,2 KW (89cv) ..........75KW (101cv).......................... ←
Max torque at 1600 rpm .............................................................. 324 Nm .....................389 Nm ............................... ←
Capacities
Engine oil capacity.......................................................................... 15L ................................← .................................... ←
Engine cooling system.................................................................. 17.7 L ..............................← .................................... ←
Capacity of the radiator only............................................................ 6 L .................................← .................................... ←
Fuel tank........................................................................................ 250 L ...............................← .................................... ←
Hydraulic fluid reservoir capacity.................................................... 73 L ................................← .................................... ←
Total hydraulic system capacity ..................................................... 123 L ........................ 148 L ................................. ←
Capacity of the cooler only ..............................................................7 L .................................← .................................... ←
Travel reduction gear housing capacity ...........................................3 L .................................← .................................... ←
Swing drive housing capacity ........................................................ 2.2 L........................... 5 L ................................... ←
Idler wheel capacity ..................................................................... 160cm3 .....................180cm3 ............................... ←
Upper roller capacity................................................................ 35 to 40 cm3 .............50 to 55 cm3 ........................... ←
Lower roller capacity....................................................................190 cm3 .................... 210 cm3 ............................... ←
NOTE: These capacities are only provided in an indicative manner. To check fluid levels, always use the oil dipstick,
sight glasses or the filler cap.
Electrical system
Type of system ...................................................................................................24 volts negative earth
Alternator amperage......................................................................................................... 50 A
Battery
Number of batteries required .......................................................................................... 2
Voltage of each battery ..............................................................................................12 volts
Capacity ..................................................................................................................... 120 Ah
Reserve ......................................................................................................................160 min
Cold starting capacity at -17°C.................................................................................... 800 A
Load for load checking ................................................................................................ 400 A
Starter motor
Voltage .......................................................................................................................24 volts
Power ......................................................................................................................... 4.5 kW
Voltage regulator ..............................................................................................integrated, not adjustable

Copyright ©
1002-8
CX130 CX160 CX180
Hydraulic system
Main hydraulic pump
Double, axial piston, variable flow pump.
Max flow ................................................................................... 2x123 l/min ...............2x137 l/min ............................←
Displacement............................................................................ 2x57.6 cm3 ................ 2x64 cm3 ..............................←
Hydraulic pilot pump
Fixed flow pump.
Max flow ...................................................................................... 23 l/min .....................22 l/min ................................←
Displacement.............................................................................. 10.7 cm3 ........................... ←.....................................←
Pressure settings
Pilot circuit secondary relief valve ..............................................39 ±1 bar........................... ←.....................................←
Main relief valve (standard) ....................................................... 343±3 bar .......................... ←.....................................←
Main relief valve (higher pressure - 2-stage relief) .................... 363±5 bar .......................... ←.....................................←
Secondary relief valves (boom, dipper and bucket) .................. 383±5 bar .......................... ←.....................................←
Secondary relief valves (swing)................................................. 279±4 bar .......................... ←.....................................←
Secondary relief valves (travel) ................................................. 430±5 bar .................353±5 bar..............................←
Secondary relief valve (boom and dipper)................................. 383±5 bar .......................... ←.....................................←
Cylinder
Boom cylinder
Barrel diameter ............................................................................ 105 mm .....................115 mm................................←
Rod diameter ................................................................................ 70 mm ...................... 80 mm ................................←
Stroke .......................................................................................... 990 mm ....................1179 mm ..............................←
Dipper cylinder
Barrel diameter ............................................................................ 115 mm .................... 125 mm ...............................←
Stroke ......................................................................................... 1108 mm .................. 1253 mm ..............................←
Bucket cylinder
Barrel diameter ............................................................................. 95 mm ..................... 105 mm ...............................←
Stroke .......................................................................................... 881 mm .................... 985 mm ...............................←
Leaks on the cylinder - attachment lowering (without load)
Boom cylinders (rod retracting) ....................................................≤ 3 mm/5 min ............. ≤ 5 mm/5 min...........................←
Dipper cylinder (rod extension) .....................................................≤ 5 mm/5 min ............. ≤ 5 mm/5 min...........................←
Bucket cylinder (rod extension) .................................................... ≤ 7 mm/5 min ............. ≤ 7 mm/5 min...........................←
Full (at the end of the attachment) ............................................≤ 200 mm/10 min....... ≤ 200 mm/10 min .......................←
Cylinder speeds (in mode S)
Boom raising (open bucket on the floor)...................................3.6±0.6 sec. .............. 3.8±0.6 sec. ............................←
Boom lowering (open bucket)...................................................3.0±0.6 sec. .............. 3.6±0.6 sec. ............................←
Dipper extension.......................................................................2.6±0.6 sec. .............. 3.0±0.6 sec. ............................←
Dipper retraction .......................................................................3.2±0.6 sec. .............. 3.6±0.6 sec. ............................←
Bucket opening.........................................................................2.3±0.6 sec. .............. 2.4±0.6 sec. ............................←
Bucket closing ..........................................................................3.6±0.6 sec. .............. 4.2±0.6 sec. ............................←

Copyright ©
1002-9
Control valve
Five section control valve for dipper, boom acceleration, swing, option and RH travel.
Four section control valve for dipper acceleration, bucket, boom and LH travel.
Load holding valve for boom and dipper.
CX130 CX160 CX180
Swing
Fixed flow, axial piston motor.
Automatic disc brake.
Upperstructure swing speed....................................................... 13.4 rpm.................... 11.4 rpm .............................. ←
Displacement................................................................................65 cm3 ..................... 151 cm3 ............................... ←
Work output ................................................................................ 100 l/min ...................155 l/min .............................. ←
Reduction ratio .............................................................................. 17.03 ........................ 13.34 ................................. ←
Braking torque .....................................................................................≥ 294 Nm .................... ≥ 739 Nm.............................. ←
Minimum brake release pressure ................................................. 29 bar ..............................← .................................... ←
Acceptable hydraulic motor leakage............................................ xx l/min .............................← .................................... ←
Travel
Two-speed, axial piston motor.
Automatic disc brake.
Slow speed ................................................................................. 3.6 km/h.................... 3.2 km/h ................. 2,4 km/h
Fast speed.................................................................................. 5.5 km/h.................... 5,5 km/h .................... 4 km/h
Incline that can be overcome..................................................... 70% (35°) ...........................← .................................... ←
Tractive force ............................................................................ 11 000 daN ...............11 300 daN ........... 18340 daN
Displacement............................................................................52.7/34 cm3 ................87/49 cm3 ........... 162/95 cm3
Work output ................................................................................ 121 l/min ...................140 l/min................. 137 l/mn
Reduction ratio ................................................................................ 72............................ 57,5............................43,2
Braking torque (excluding reducer) ............................................. 145 Nm .....................135 Nm.................... 483Nm
Number of turns at the sprockets (10 turns)
Mode "S", fast speed ...............................................................13.4±0.6 sec. ............ 12.8±0.6 sec. ..... 19.6±0.6 sec.
Mode "S", slow speed..............................................................20.6±0.7 sec. ............ 21.9±0.7 sec. ..... 33.4±0.7 sec.
Permitted deviation in travel over a distance of 20 m
Mode "H", full speed ....................................................................... 1 m ................................← .................................... ←
Acceptable hydraulic motor leakage............................................ xx l/min .............................← .................................... ←
Undercarriage
One-piece undercarriage with welded components.
Lubricated rollers and idler wheels.
Grease type track tension.
Ground pressure
with 500 mm track pads...............................................................0.39 bar .................... 0.47 bar
with 600 mm track pads...............................................................0.33 bar .................... 0.40 bar ..................0,41 bar
with 700 mm track pads...............................................................0.29 bar .................... 0.33 bar ..................0,36 bar
With 800 mm track pads................................................................... X ...............................X ........................0,33 bar
with rubber track pads .................................................................0.40 bar ..........................X .................................. X
Tracks tension ........................................................................ 240 to 260mm .......... 260 to 280mm....280 to 300mm

Copyright ©
1002-10
CX130 CX160 CX180
Attachment
Break-out force ...........................................................................9740 daN.................11 790 daN ............................←
Penetration force
2.10 m dipper..............................................................................8020 daN
2.50 m dipper..............................................................................6740 daN
3.00 m dipper..............................................................................5610 daN
2.20 m dipper.................................................................................... X ........................ 9300 daN ..............................←
2.70 m dipper.................................................................................... X ........................ 8010 daN ..............................←
3.10 m dipper.................................................................................... X ........................ 7400 daN ..............................←
Weight of components
Engine .......................................................................................... 361 kg ............................. ←.....................................←
Hydraulic pump.............................................................................. 90 kg .............................. ←.....................................←
Attachment control valve .............................................................. 140 kg ............................. ←.....................................←
Swing motor/reduction gear assembly .......................................... 99 kg ........................221 kg .................................←
Travel motor/reduction gear assembly ......................................... 204 kg .......................247 kg...................... 308 kg
Boom cylinder............................................................................... 108 kg .......................157 kg.................................←
Dipper cylinder.............................................................................. 157 kg .......................210 kg.................................←
Bucket cylinder .............................................................................. 93 kg ........................117 kg .................................←
Counterweight ............................................................................. 2300 kg .....................3330 kg ...............................←
Cab ............................................................................................... 254 kg ............................. ←.....................................←
Turnable bearing .......................................................................... 188 kg .......................244 kg...................... 263 kg
Upperstructure............................................................................. 5820 kg .....................6780 kg.................... 7670kg
Hydraulic swivel............................................................................. 27 kg .............................. ← ........................... 31 kg
Undercarriage.............................................................................. 3880 kg .....................5760 kg................... 6570 kg
Machine without attachment........................................................ 9830 kg ....................12 540kg................ 14240 kg
Attachment .................................................................................. 2140 kg .....................3030 kg................... 3070 kg
Boom ........................................................................................... 1200 kg .....................1470 kg................... 1780 kg
Dipper ........................................................................................... 542 kg .......................729 kg...................... 805 kg
Radiator and cooler set ................................................................. 48 kg .............................. ←.....................................←
Fuel tank........................................................................................ 72 kg .............................. ←.....................................←
Hydraulic tank............................................................................... 106 kg ............................. ←.....................................←
Idler wheel ..................................................................................... 65 kg .........................82 kg ..................................←
Upper roller.................................................................................... 13 kg .........................17 kg ..................................←
Lower roller.................................................................................... 20 kg .........................36 kg ..................................←
Shock absorber ............................................................................. 63 kg .........................85 kg....................... 126 kg
Track 500 mm............................................................................... 728 kg ......................1016 kg
Track 600 mm............................................................................... 816 kg ......................1164 kg................... 1257 kg
Track 700 mm............................................................................... 970 kg ......................1374 kg................... 1460 kg
Track 800 mm................................................................................... X ...............................X........................ 1593 kg

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

Toothed wheel
Dimensions
a P
Ød
Øb Øc
CS01B512
Dimension (mm)
Marking
CX130 CX160 CX180
Standard 59 66
a
Limit 53 60
Standard 584.48 582.5
Øb
Limit 578.5 576.5
Standard 652 659
Øc
Limit 646 653
Standard 635.48 644.6
Ød
Limit --- ---
Standard 171.45 190
P
Limit --- ---
Gauge
CX130 CX160 CX180
A 200 220
A B 171.5 190
B C 60.48 69.58
C D D 31 35.61
E E 4.23 4.6
F
F --- 0.52
N G 17 21.46
G M H
I H 26.2 30.6
J I 60 70
Q
J 72.9 84.7
P K Ø 652 R329.5
L PDC 635.48 PDC 322.3
L O
K R M R4 R6
N R66 R76.5
O --- 12.7°
P R25.5 R29.6
Q --- R36
CS01D513
R 15.7° 17.1°

Copyright ©
1002-12
Idler wheel
Dimensions
Dimension (mm)
Marking CX160
CX130
CX180
Standard 510 494
Øa
Limit 506 490
b Standard 17.5 19
b
c Limit --- ---
Standard 68 84
c
Limit 64 80
Standard 55 65
Ø d (rod)
Limit 54.5 64.5
Øa Standard 55 65
Ø d (ring)
Limit 55.8 65.8
Standard 55 69
e
Limit 54.6 68.6
Standard 19.9 12.4
f
Limit 19.4 11.9
e f
Ød
CS01B514
Gauge
CX130 CX160 CX180
A 135 159
B 68 84
A C 10° 10°
D R37 R42
B
E 2-R4 2-R5
F 3.6 0.6
C G 4-R3 4-R3
H
K H 26.5 26
D E I I 17.5 19
J J 11 10
G K 55 55
F
L 160 180
L
CS01D514

Copyright ©
1002-13
Upper roller
Dimensions
Dimension (mm)
g e Marking CX160
CX130
CX180
Standard 120 120
Øa
Limit 112 112
Standard 10 10
b
Limit --- ---
Standard 68 85
c
Øa Ød Limit 62 79
Standard 40 46
Ø d (rod)
Limit 39.5 45.5
Standard 40 46
Ø d (ring)
Limit 40.8 46.8
b
Standard 63 83
e
Limit 62.6 82.6
f c Standard 5.5 5.5
f
Limit 5 5
CS01B516 Standard 22.5 22.5
g
Limit 22.5 22
Gauge
CX130 CX160 CX180
A 130 156
B 68 85
A C 64 78.6
D 56 68
B
E 20 24
C
F 10 16
G D G 11.3° 18°
E H 11° 11.5°
H F I 10 10
J 20.5 17.5
I L N K 6.5 5.5
P L R3 4-R3
M M R3 8-R3
K O
N 30 35
J O 5 10
Q
P 50.5 45
Q 150 175
CS01D515

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

Marking Marking
CX130 CX160 CX180 CX130 CX160 CX180
Standard 130 150 Standard 50 65
Øa Ø e (ring)
Limit 122 142 Limit 50.8 65.8
Standard 15 15 Standard 53 69
b f
Limit --- --- Limit 52.6 68.6
Standard 142 173 Standard 24.3 23.3
d g
Limit 148 179 Limit 23.8 22.8
Standard 50 65
Ø e (rod)
Limit 49.5 64.5
Gauge
CX130 CX160 CX180
A 191 221
B 175 215
C 150.6 184.7
D 142 173
A E 72 84
B F 26.1 29
C G 23 25.3
D
Q H 20 10
E P
I 14.1 13.8
I O J 15 15
K L RS T
FGH J K R10 R10
M L R15 2-R10
N U
V M 5° 5°
N 6R5 6-R5
O 1.5° 1.5°
P 17° 23°
Q 10° 10°
R 4-R5 ---
CS010D516 S 45 42
T 50 60
U 5 18
V 210 240

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

Marking Marking
CX130 CX160 CX180 CX130 CX160 CX180
Standard 28 34.5 Standard 50.6 58.72
a Ø e (ring)
Limit 18 21.5 Limit 49.5 57.5
Standard 89 106 Standard 34.1 37.3
b Ø f (ring)
Limit 84 101 Limit 35 38.3
Standard 17 37.985 Standard 33.25 36.3
c Ø g (rod)
Limit 15 36 Limit 32.5 35.5
Standard 10.7 17.95 Standard 171.45 190
d h
Limit 9 16 Limit 175 195

Copyright ©
1002-16
DIMENSIONS AND LIMIT OF WEAR AND TEAR OF THE MOBILE JOINTS OF

THE ATTACHMENT
3 4
1
5
6
2 11
10 8 7
CS01B521
1. Boom foot/Undercarriage
a c
b
Ød
CS01B522
Dimension (mm)
Marking
CX130 CX160 CX180
Standard 569 632
a
Limit 579 642
Standard 568.5 631
b
Limit 566.5 629
Standard 0.5 to 3 0.5 à 3
c (a - b)
Limit Shims Shims
Standard 75 80
Ø d (pin)
Limit 76.5 79
Standard 75 80
Ø d (ring)
Limit 74 81.5

Copyright ©
1002-17
2. Boom cylinder foot/Undercarriage

a c
b
Ød
CS01B523
Dimension (mm)
Marking
CX130 CX160 CX180
Standard 83.5 111
a
Limit 89.5 117
Standard 82.5 110
b
Limit 80.5 108
Standard 1 to 2.5 1 to 2.5
c (play)
Limit Shims Shims
Standard 70 70
Ø d (pin)
Limit 69 69
Standard 70 70
Ø d (ring)
Limit 71.5 71.5
3. Boom cylinder head/Boom
a b a c
Ød
CS01B524
Dimension (mm)
Marking
CX130 CX160 CX180
Standard 92 100
a
Limit 90 98
Standard 437 470
b
Limit 431 464
c (play)
Limit Shims Shims
Standard 70 80
Ø d (pin)
Limit 69 79
Standard 70 80
Ø d (ring)
Limit 71.5 81.5

Copyright ©
1002-18
4. Dipper cylinder foot/Boom

a c Dimension (mm)
Marking
CX130 CX160 CX180
b
Standard 99 111
a
Limit 105 117
Standard 98 110
b
Limit 96 108
Standard 0.5 to 2 0.5 to 2
Ød c (a - b)
Limit Shims Shims
Standard 70 80
Ø d (pin)
Limit 69 79
Standard 70 80
Ø d (ring)
Limit 71.5 81.5
CS01B525
5. Boom/Dipper
a b c Dimension (mm)
Marking
CX130 CX160 CX180
Standard 259 275
a
Limit 262 278
Standard 258.5 274.5
b
Limit 256.5 272.5
Standard 0.5 to 1.1 0.5 to 1.1
Ød c (play)
Limit Shims Shims
Standard 75 80
Ø d (pin)
Limit 74 79
CS01B526
Standard 75 80
Ø d (dipper)
Limit 76.5 81.5
Standard 75 80
Ø d (boom)
Limit 76.5 81.5
6. Dipper cylinder head/Dipper

Dimension (mm)
Marking
CX130 CX160 CX180
Standard 96.5 111
a
Limit 102.5 117
Standard 95.5 110
Ød b
Limit 92.5 108
c (a - b)
b Limit Shims Shims
a c Standard 70 80
Ø d (pin)
Limit 69 79
CS01B527 Standard 70 80
Ø d (ring)
Limit 71.5 81.5

Copyright ©
1002-19
7. Bucket cylinder foot/Dipper

a c Dimension (mm)
Marking
CX130 CX160 CX180
b
Standard 88 101
a
Limit 94 107
Ød Standard 87 100
b
Limit 85 98
c (a - b)
Limit Shims Shims
Standard 65 65
Ø d (pin)
Limit 64 64
CS01B528 Standard 65 65
Ø d (ring)
Limit 66.5 66.5
8. Connecting rod/Dipper
Dimension (mm)
Marking
CX130 CX160 CX180
c Standard 32 32
a
Limit 30 30
Standard 254 260
b
b Limit 252 258
c (play)
Limit Shims Shims
Standard 65 65
a Ø d (pin)
Limit 64 64
Ød Standard 65 65
Ø d (ring)
Limit 66.5 66.5
CS01B529
9. Compensator/Bucket
Ød Dimension (mm)
Marking
CX130 CX160 CX180
Standard 255 301
c a
Limit 261 317
Standard 254 300
b
Limit 252 298
b a Standard 1 to 3.5 1 to 3.5
c (play)
Limit Shims Shims
Standard 65 65
Ø d (pin)
Limit 64 64
Standard 65 65
Ø d (ring)
Limit 66.5 66.5
CS01B530

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

Dimension (mm)
Marking
CX130 CX160 CX180
a Standard 32 32
a
f Limit 30 30
Standard 254 260
b
b e d Limit 252 258
c (play)
Limit Shims Shims
c Standard 92 86
d
Limit 94 88
Øg Standard 91 85
e
Limit 93 83
CS01B531 Standard 0.5 to 2 0.5 to 2
f (d - e)
Limit Shims Shims
Standard 70 75
Ø g (pin)
Limit 69 74
Øg Standard 70 75
(compensator) Limit 71.5 76.5
Standard 70 75
Ø g (cylinder)
Limit 71.5 76.5
11. Dipper/Bucket
Dimension (mm)
Øe Marking
CX130 CX160 CX180
Standard 255 301
a
Limit 261 317
d Standard 255 301
b
Limit 253 299
a b c (a - b)
Limit Shims Shims
Standard 16 16
d
Limit 8 8
Standard 65 80
c Ø e (pin)
Limit 64 79
Standard 65 80
CS01B532
Ø e (dipper)
Limit 66.5 81.5
Standard 65 80
Ø e (bucket)
Limit 66.5 81.5

Copyright ©
1002-21
SPECIAL TORQUE SETTINGS

Screw Key Torque setting (Nm)
No. Component
(Ø) (mm) CX130 CX160 CX180
1* Travel motor/reduction gear assembly M16 24 267-312
2* Sprocket M16 24 267-312
3* Idler wheel M16 24 267-312
M16 24 267-312 ---
4* Upper roller
M20 30 --- 521-608
M16 24 267-312 ---
5* Lower roller
M18 27 --- 371-432
6* Chain guide M18 27 --- 380-443
M16 24 392-430 ---
7 Track pad
M20 30 --- 468-545
8 Counterweight M27 41 844-980 1058-1235
M16 24 280-322 ---
9 Turntable (undercarriage)
M20 30 --- 468-545
M16 24 280-322 ---
10 Turntable (upperstructure)
M20 30 --- 468-545
M16 24 280-322 ---
11 * Swing motor/reduction gear assembly
M20 30 --- 521-608
12 * Engine M16 24 265-313
13 * Engine support M10 17 64-73
14 Radiator M12 19 64-73
M10 17 63-72
15 * Hydraulic pump
M12 --- 88-111
16 * Hydraulic reservoir M16 24 206-247
17 * Fuel tank M16 24 206-247
M16 24 267-312
18 * Control valve
M12 19 88-107 ---
19 * Hydraulic swivel M12 19 109-127
20 Cab M16 24 78-80
21 Battery M10 17 20-29
NOTE: Use Loctite 262 or an equivalent on retaining screws of components marked with an asterisk (*).

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

Copyright ©
1002-23
11
13
12
9 9 10
CS00E512 CS00E513
15
CS00E516
14 CS00E515
18
CS00E520
16 CS00E518 17 CS00E519
18
18
19
21
20
CS00E524
CS00E522 CS00E523

Copyright ©
1002-24
MACHINE OVERALL DIMENSIONS CX130 CX160

E G
B A
F
M
K I
J H
L D
C
CS01B533
Only on CX130 machines with 3 m dipper Point A: Working position

Point B: Transport position
Point B C
Point A G IMPORTANT: For the transport of CX130 machines
with 3 m dipper, it is imperative that the dipper cylin-
der head/dipper linkage is positioned at point B.
NOTE: Never work with the pin in this position.
A A
WARNING: When the dipper cylinder is
F placed in position B (transport), take care not
I ! to damage the cab, there can be interference
H between the bucket and the cab.
N
C
CS00E527
CX130 CX160
Dippers Dippers
2.10 m 2.50 m 3.00 m (A) 3.00 m (B) 2.20 m 2.70 m 3.10 m
A.................................................... 2.74 m 2.74 m 3.26 m 2.78 m 2.92 m 3.09 m
B.................................................... 2.74 m 2.74 m 2.74 m 2.74 m 2.88 m 2.88 m 2.88 m
C.................................................... 7.49 m 7.49 m 7.38 m 7.54 m 8.40 m 8.44 m
D.................................................... 3.81 m 3.81 m 3.81 m 3.81 m 4.32 m 4.32 m 4.32 m
E.................................................... 2.52 m 2.52 m 2.52 m 2.52 m 2.54 m 2.54 m 2.54 m
F .................................................... 0.89 m 0.89 m 0.89 m 0.89 m 1.02 m 1.02 m 1.02 m
G ................................................... 2.05 m 2.05 m 2.05 m 2.05 m 2.37 m 2.37 m 2.37 m
H.................................................... 3.50 m 3.50 m 3.50 m 3.50 m 3.90 m 3.90 m 3.90 m
I ..................................................... 2.78 m 2.78 m 2.78 m 2.78 m 3.09 m 3.09 m 3.09 m
J .................................................... 1.99 m 1.99 m 1.99 m 1.99 m 1.99 m 1.99 m 1.99 m
K (standard track pads) .............. 0.60 m 0.60 m 0.60 m 0.60 m 0.60 m 0.60 m 0.60 m
L (with 500 mm track pads) ........ 2.49 m 2.49 m 2.49 m 2.49 m 2.49 m 2.49 m 2.49 m
M ................................................... 0.44 m 0.44 m 0.44 m 0.44 m 0.44 m 0.44 m 0.44 m
N.................................................... 5.44 m 5.44 m 5.34 m 5.50 m 6.03 m 6.07 m

Copyright ©
1002-25
MACHINE OVERALL DIMENSIONS CX180
E G
B A
F
M
K I
J H
L D
C
CS01B533
CX180
Dippers
2.20 m 2.70 m 3.05 m (A)
A ................................................... 2.53 m 2.92 m 3.09 m
B ................................................... 2.89 m 2.89 m 2.89 m
C ................................................... 8.41 m 8.39 m 8.44 m
D ................................................... 4.45 m 4.45 m 4.45 m
E ................................................... 2.54 m 2.54 m 2.54 m
F.................................................... 1.04 m 1.04 m 1.04 m
G ................................................... 2.37 m 2.37 m 2.37 m
H ................................................... 4.15 m 4.15 m 4.15 m
I ..................................................... 3.37 m 3.37 m 3.37 m
J.................................................... 2.20 m 2.20 m 2.20 m
K (standard track pads).............. 0.60 m 0.60 m 0.60 m
L (with 500 mm track pads)........ 2.80 m 2.80 m 2.80 m
M................................................... 0.46 m 0.46 m 0.46 m

Copyright ©
1002-26

Copyright ©
Section
2000
REMOVAL AND INSTALLATION OF THE ENGINE
2000

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

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

Copyright ©
2000-3
ENGINE
Removal and installation STEP 6
STEP 1
CD00J024
Remove the engine throttle control.
JS00163A
Park the machine on hard, flat ground. Lower the STEP 7
attachment to the ground.
STEP 2
Release pressure in the hydraulic system and in the
hydraulic reservoir (see Section 8000).
1
STEP 3
2
CD00J025
Disconnect the fuel supply pipe (1) and the fuel return
pipe (2) and plug them.
1 STEP 8
JD00375A
Remove the battery cover (1) and disconnect the
earth cable (-) (2) from the battery. 1
STEP 4 2
Refer to Section 8003 and remove the hydraulic
pump.
STEP 5
Refer to Section 2001 and remove the radiator and
oil-cleaner assembly.
CD00J026
Remove the hoses (1) and (2) from the heater system
and plug them.

Copyright ©
2000-4
STEP 9 STEP 12
1
CD00J027 CD00J030
Label and disconnect the electrical connection from Label and disconnect the electrical supply (1) to the
the water temperature sensor (1). pre-heating plugs.
STEP 10 STEP 13
CD00J028 CD00J031
Label and disconnect the electrical connection from Label and disconnect the starter motor electrical
the fuel temperature sensor (1). connections. Remove the earth braid cable (1) at the
engine end.
STEP 11
CD00J029
Label and disconnect the electrical connection from
the oil pressure detector (1) and the engine speed
detector (2).

Copyright ©
2000-5
STEP 14 STEP 16
CD00J032 CD00J035
Label and disconnect the connectors for the Label and disconnect the alternator electrical
electronic regulator and disconnect the fuel flow connections.
regulating resistance.
NOTE: If the machine is equipped with air
STEP 15 conditioning, remove the compressor retaining
hardware and move the compressor away from the
engine.
STEP 17
Remove all the clips, etc. which attach the electrical
harnesses to the engine and move them out of the
way.
STEP 18
CD00J033
Remove the hose which connects the turbo-charger
to the air filter.
CD00J036
Install a suitable lifting device on the engine lifting
rings (for the weight of the engine, see Section 1002).

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

Copyright ©
2001
Section
2001
RADIATOR AND OIL-COOLER

Printed in France
Copyright ©
2001-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 2
RADIATOR AND OIL-COOLER ............................................................................................................................... 3
Removing the radiator and oil-cooler assembly ................................................................................................... 3
Installation ............................................................................................................................................................ 4
CHANGING THE RADIATOR OR OIL-COOLER..................................................................................................... 5
Disassembly and assembly.................................................................................................................................. 5
! this symbol, carefully read the message which follows. Your safety depends on it.
SPECIFICATIONS
Coolant solution.............................................................................................................................. See Section 1002
Total capacity of coolant solution system .................................................................................................... 17.7 litres
Thermostat opening range
Starts to open..................................................................................................................................................82°C
Completely opened .........................................................................................................................................95°C
Hydraulic fluid ................................................................................................................................. See Section 1002

Copyright ©
2001-3
RADIATOR AND OIL-COOLER

Before performing any operation on the machine, carry out the following operations in the order shown:
- Park the machine on hard, flat ground.
- Lower the attachment to the ground.
- Shut down the engine.
- Remove the starter switch key.
- Make sure that all pressure in the hydraulic system has been released (see Operator’s Manual).
WARNING: The components of the engine and the hydraulic pump reach high temperatures when the
machine is operating. To avoid being burnt by hot metal or scalded by high temperature water or oil, allow the
! machine to cool down before starting any servicing operation.
Removing the radiator and oil- STEP 6

cooler assembly
3
STEP 1
Remove the engine lower cover plate.
STEP 2
1
2
1
2
3 CD00G022
Disconnect and plug the hoses (1) and (2) of the oil
cooler (3) and drain the oil cooler into a clean
receptacle.
5 STEP 7
4
CD00G021
Remove the engine upper hood (1), the upper grille
(2) and the air filter (3). Remove the air conditioning
2
(4) heat exchanger, without disconnecting it, and
place it on the battery hood (5).
STEP 3 1
Remove the expansion reservoir cap.
IMPORTANT: Do not remove the cap when the
engine is hot, since the system would still be under 4
pressure and you would run the risk of being scalded. 3
STEP 4 CD00G023
Disconnect the expansion reservoir hose (2) from the
Drain the cooling system (see Operator’s Manual). radiator (1). Disconnect the water pump return hose
(3) and inlet hose (4) from the engine.
STEP 5
Release pressure in the hydraulic reservoir to allow
installation of the vacuum pump (see Section 8000).

Copyright ©
2001-4
STEP 8 STEP 11
1
1
CD00G024
Remove the four lower retaining screws (1) from the
radiator and oil-cooler bracket (2).
STEP 9
CS00G513
2 Pass a suitable sling around the radiator and oil-
cooler assembly, then, using a suitable lifting device,
remove the radiator and oil-cooler assembly.
1
NOTE: During the lifting operation, push the radiator
and oil-cooler assembly back to avoid the engine
cooling fan.
3
Installation
When installing, proceed in the reverse order to that
of removal.
CD00G025
Disassemble the two retaining screws (1) and Before operating the machine:
remove the rear retaining tie-rod (2) from the radiator - Check the level of oil in the hydraulic reservoir. Top
and oil-cooler assembly bracket (3). up if necessary.
STEP 10 - Check the hydraulic circuit cooling system for
leaks.
- Fill and bleed the engine cooling system (see
Operator’s Manual).
- Check the engine cooling system for leaks.
2
3
CD00G026
Disassemble the two retaining screws (1) and
remove the front angle bracket (2) from the radiator
and oil-cooler assembly bracket (3).

Copyright ©
2001-5
CHANGING THE RADIATOR AND OIL-COOLER

Disassembly and assembly
NOTE: The parts are numbered in order of disassembly. Assembly is carried out in the reverse numerical order.
5 3 7 6
10
9
13
12
14
4 11
CI00G505
1 INTAKE SHROUD RETAINING SCREWS 8 FILTER MOUNTING
2 INTAKE SHROUD 9 FILTER
3 RADIATOR UPPER MOUNTING 10 OIL-COOLER UPPER MOUNTING
4 RADIATOR LOWER MOUNTING 11 OIL-COOLER LOWER MOUNTING
5 RADIATOR 12 OIL-COOLER
6 COVER MOUNTING 13 BRACKET
7 COVER 14 BRACKET

Copyright ©
2001-6

Copyright ©
3001
Section
3001
REMOVAL AND INSTALLATION

OF THE FUEL RESERVOIR

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

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

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

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

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

Copyright ©
4001
Section
4001
ELECTRICAL AND ELECTRONIC

CIRCUIT AND TROUBLESHOOTING

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

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

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

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

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

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

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

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

2 Multimeter CAS-1559

Copyright ©
4001-5
This page is intentionally left blank

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

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

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

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

CX210/CX240 Model
X2 E2 B45 B81
E1
E3
M4
X1
R5
B26
B22 B27
B41
G1
B21
F25
F24 M2
F23 52
F22 B42
K7
B44
S55
S52 Y7
B1 G2 Y8 R1 R2 A3 M1 B43 B2
CM02H002

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

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

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4001-11
CX210/CX240 Model
F23 F22 F24 F25
K7
CI00E502
1. Relay battery
2. Fuse 65 A: for F3 to F10 and F13 to F20A circuits
3. Fuse 20 A: for F11 and F12 circuits (before contact)
4. Fuse 20 A: for F1 circuits
5. Fuse 20 A: for F2 circuits
6. Battery cables

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

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

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

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

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

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

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

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

Copyright ©
4001-18
Work mode selection

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

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

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

Copyright ©
4001-20
H/S/L mode checking

Y7
A1 A2 1
Y5 A3
CS00F509
1 Engine A3 Electronic acceleration
A1 Computer Y5 Power-up solenoid valve (yellow band)
A2 Engine controller Y7 Main pump proportional solenoid
2) Fixed values for each model
CX160 Hydraulic
CX130 CX210 CX240
CX180 power boost
Engine rpm (Max) rpm 2150 2250 2000 2200
Automatic
H mode Current (variable (Max) mA 600 600 407 427
checking
current) (Min) mA 450 490 292 307
Engine rpm (Max -200) rpm 1950 2050 1800 2000
Automatic
S mode Fixed current intensity
mA 450 490 292 307 checking
(90% torque)
Engine rpm (Max -300) rpm 1850 1950 1700 1900
L mode Fixed current intensity Constant
mA < 100 < 280 < 50 < 50
(70% torque)
Eng. idling Engine rpm rpm 1000 1000 900 900 -----
Engine rpm at maximum torque rpm 1600 1600 1600 1800 -----
NOTE: The values listed above are those in normal conditions, the following are exceptions:
1. If the target engine rpm is less than the maximum 3. In "L" mode, if the hydraulic breaker or the grab is
torque rpm, the pump is controlled by the "L" mode used, the pump is controlled by the "S" mode
current value (same in H/S modes). current value.
2. In "L" mode, if only travel is selected, the pump is 4. If the engine coolant temperature is too low, or if the
controlled by the "S" mode current value. voltage coming in to the engine controller (A2) is too
low, the idle rpm increases to avoid over-cooling of
the engine or discharging of the battery.

Copyright ©
4001-21
Auto mode checking

B2
B42
B1
Y7
B44
A3
B43
Y5
B27
A1 A2 1
CS01N537
1 Engine B27 Travel pilot pressure switch
A1 Computer B42 Pump pressure sensor P1
A2 Engine controller B43 Pressure sensor (nega-cont)
A3 Electronic acceleration B44 Pump pressure sensor P2 (yellow band)
B1 Coolant temperature sensor Y5 Power-up solenoid valve (yellow band)
B2 Hydraulic oil temperature sensor Y7 Main pump proportional solenoid
2) Description
1. If the auto mode is selected, 2 modes, SA and LA,
are available. CX160
CX130
CX180
2. When the auto mode is selected, the LA mode is Engine rpm (MAX) rpm 1950 2050
engaged and then it automatically changes to SA or SA Current (equal to S mode
mA 490 530
LA mode depending on the work conditions. mode + 40 mA)
Hydraulic power boost --- Automatic Automatic
3. If the coolant temperature is less than 50°C or the oil Engine rpm (MAX) rpm 1850 1950
temperature is less than 25°C, auto mode checking LA
Current (equal to mode S) mA 450 490
mode
does not work and the LA mode is selected. When Hydraulic power boost --- Automatic Automatic
the coolant temperature is greater than 50°C and
the oil temperature is greater than 25°C, auto mode CX210 CX240
checking starts and continues to function even if the Engine rpm (MAX) rpm 1800 2000
coolant and oil temperatures reduce. SA Current (equal to S mode
mA 332 347
mode + 40 mA)
4. During auto mode checking, if the travel pilot
pressure switch (B27) is activated, the change of
Engine rpm (MAX) rpm 1700 1900
mode does not take place. (If the travel pilot LA
Current (equal to mode S) mA 292 307
pressure switch (B27) is activated in SA mode, the mode
SA mode remains, and if the travel pilot pressure
switch (B27) is activated in LA mode, the LA mode
remains).

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

Copyright ©
4001-23
Engine idle checking (automatic/manual)

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

Copyright ©
4001-24
Breaker mode checking

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

preset rpm

Copyright ©
4001-25
Automatic engine preheat

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

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

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

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

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

Copyright ©
4001-28
Auto engine warm-up

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

Copyright ©
4001-29
3) Timing diagram
Engine rpm Engine rpm

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

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

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

Copyright ©
4001-32
Engine emergency stop

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Copyright ©
4001-43
Supply cut-off delayed

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

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

Copyright ©
4001-44
Protection by power transistor

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

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

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

Copyright ©
4001-46
Hydraulic oil temperature indicator

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

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

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

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

Copyright ©
4001-48
Engine fuel injection pump electronic regulator

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

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

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

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

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

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

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

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

Copyright ©
4001-52
SW4 0 0 0 0 SW5 0 0 0 0 SW6 0 0 0 0

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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4001-64
EXCAVATOR MODEL SELECTION PROCEDURE

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

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

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

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

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

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

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4001-67
TROUBLESHOOTING
Prior inspections
Item Target Action

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

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4001-68
Reading the organisation charts

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

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

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

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

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

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

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

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

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

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4001-71
Add coolant solution

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

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

computer (A1) computer (A1)

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4001-72
Low engine oil pressure

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

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

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

computer (A1) computer (A1)

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

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4001-74

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

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

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

Copyright ©
4001-75
Overheating (continued)

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

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

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

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

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

Copyright ©
4001-77

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

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

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4001-78
Electrical system troubleshooting

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

Copyright ©
4001-79

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

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

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

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

Copyright ©
4001-81

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

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

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

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4001-83
ELECTRICAL INSPECTION OF COMPONENTS

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

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

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

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

Y6
Y3
M2 52
1
1
CS00E535
CD00F023
1. Disconnect the connector (1) from the engine
emergency stop motor (M2). Band
Mark Function
colour
2 4 3 Y1 Swing pilot shut-off solenoid valve Green

Y5 Power-up solenoid valve Yellow
Y4 2 stage travel solenoid valve Red
Y6 Cushion control solenoid valve Light green
Y3 Swing brake solenoid valve Pink
CS99A846 Y2 Pilot pressure solenoid valve Blue
to the connector at the main harness end (2) only.
3. Make sure that wire LR (blue/red) on the service
connector (4) is connected to wire LR on the main
harness (2) and install the meter (3).
NOTE: The + terminal on the meter must be
connected to wire LR (blue/red) on the service
connector and the - terminal to the machine earth.

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

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

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4001-88
Engine coolant and hydraulic oil

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

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

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

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

Copyright ©
4001-90

Copyright ©
4002
Section
4002
INSPECTION AND MAINTENANCE OF BATTERIES

AND CONNECTING A BOOSTER BATTERY

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

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

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

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

Copyright ©
4002-5
INSPECTING THE BATTERY

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

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

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

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

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

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4002-8
BATTERY CHARGING GUIDE

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

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

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

Copyright ©
4002-9
CONNECTING A BOOSTER BATTERY

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

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

earth, away from the battery.

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

Copyright ©
Section
4003
4003
MAIN ELECTRONIC CONTROL BOX
ENGINE ELECTRONIC CONTROL BOX

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

Copyright ©
4003-3
MAIN ELECTRONIC CONTROL BOX AND ENGINE ELECTRONIC

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

Copyright ©
4003-4
Main electronic control box Engine electronic control box

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

Copyright ©
5001
Section
5001

OF THE TRACKS SET

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

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

See Section 1002

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

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

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

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

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

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

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

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

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

Copyright ©
5001-10
Track tension adjustment STEP 4

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

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

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

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

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

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

Copyright ©
5001-12
Checking pin and bushing wear

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

the values with the specifications. Replace them if
necessary.

Copyright ©
Section
5003
5003
UPPER AND LOWER ROLLERS

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

Description ........................................................................................................................................................... 4
Removal ............................................................................................................................................................... 5
Reconditioning ..................................................................................................................................................... 6
Disassembly ......................................................................................................................................................... 6
Inspection ............................................................................................................................................................. 7
Assembly .............................................................................................................................................................. 7
Installation ............................................................................................................................................................ 9
UPPER ROLLER.................................................................................................................................................... 10
Description .........................................................................................................................................................10
Removal .............................................................................................................................................................11
Reconditioning ...................................................................................................................................................12
Disassembly .......................................................................................................................................................12
Inspection ...........................................................................................................................................................14
Assembly ............................................................................................................................................................15
Installation ..........................................................................................................................................................17
CHECKING FOR LEAKS ....................................................................................................................................... 18
! this symbol, read carefully the message that follows, as it indicates that there is a risk of serious injury.

Copyright ©
5003-3
SPECIFICATIONS
See Section 1002

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

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

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

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

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

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

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

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

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

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

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

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

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

or the retaining bracket.

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

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

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

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

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

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

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

Copyright ©
5003-18
CHECKING FOR LEAKS

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

Copyright ©
Section
5004
5004
SPROCKET

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

See Section 1002

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

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

Copyright ©
Section
5005
IDLER WHEEL AND TENSION SHOCK ABSORBER
5005

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

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

Description .........................................................................................................................................................14
Disassembly .......................................................................................................................................................15
Assembly ............................................................................................................................................................15
TRACK TENSION CYLINDER (CX130, CX160 AND CX210) ................................................................................16

Description .........................................................................................................................................................16
Removal .............................................................................................................................................................17
Disassembly .......................................................................................................................................................17
Inspection ...........................................................................................................................................................18
Assembly ............................................................................................................................................................18
Installation ..........................................................................................................................................................19
TRACK TENSION CYLINDER (CX210)..................................................................................................................20

Description .........................................................................................................................................................20
Removal .............................................................................................................................................................20
Disassembly .......................................................................................................................................................21
Inspection ...........................................................................................................................................................22
Assembly ............................................................................................................................................................22
Installation ..........................................................................................................................................................23
this symbol, read carefully the message that follows, as it indicates that there is a risk of serious injury.

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

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

Copyright ©
5005-4
REMOVAL AND INSTALLATION OF THE IDLER WHEEL

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

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

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

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

Copyright ©
5005-8
DISASSEMBLY AND ASSEMBLY OF THE IDLER WHEEL

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

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

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

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

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

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

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

Copyright ©
5005-13
Leakage test STEP 5

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

Copyright ©
5005-14
DISASSEMBLY AND ASSEMBLY OF THE TENSION SHOCK ABSORBER

Description
6
CS01B546
1 SHOCK ABSORBER SPRING 4 YOKE
2 ROLL PIN 5 SPRING GUIDE (CX210)
3 SLOTTED NUT 5 TENSION CYLINDER BARREL (CX130; CX160; CX240)
6 PRE-STRESS VALUE (SEE SPECIFICATIONS)

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

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

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

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

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

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

Copyright ©
5005-20
TRACK TENSION CYLINDER (CX210)

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

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

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

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

Copyright ©
5005-24

Copyright ©
6001
Section
6001
DRIVE MOTOR AND FINAL DRIVE TRANSMISSION


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

Copyright ©
6001-3
DRIVE MOTOR AND FINAL DRIVE TRANSMISSION

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

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

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

Copyright ©
6001-6
NOTES
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Copyright ©
6002
Section
6002
REMOVAL AND INSTALLATION OF THE TRAVEL

MOTOR AND REDUCTION GEAR ASSEMBLY

Printed in France
Case Cre 7-29860GB May 2001
Copyright ©
6002-2
TABLE OF CONTENTS
SPECIFICATIONS..................................................................................................................................................... 3
SPECIAL TORQUE SETTINGS ................................................................................................................................ 3
TRAVEL MOTOR AND REDUCTION GEAR ASSEMBLY........................................................................................ 4
Description ............................................................................................................................................................ 4
Disassembly ..........................................................................................................................................................7
Inspection............................................................................................................................................................22
Assembly.............................................................................................................................................................24
WARNING: This icon is employed in this manual to indicate important safety messages. Each time you
! come across this icon, read carefully what follows, as there is a risk of serious injury.

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6002-3
SPECIFICATIONS
See Section 1002.

Screw (1) ................................................................................................................................................. 24 to 33 Nm
Screw (5) ............................................................................................................................................. 138 to 187 Nm
Plug (9) ................................................................................................................................................ 390 to 467 Nm
Plug (14) .............................................................................................................................................. 153 to 191 Nm
Adaptor (18)........................................................................................................................................... 77 to 115 Nm
Plug (24) ................................................................................................................................................ 77 to 115 Nm
Plug (31) .................................................................................................................................................. 24 to 33 Nm
Plug (33) ................................................................................................................................................ 77 to 115 Nm
Plug (36) .................................................................................................................................................. 24 to 33 Nm
Safety valve (39).................................................................................................................................. 106 to 143 Nm
Cap (40)................................................................................................................................................... 57 to 95 Nm
Screw (83) ............................................................................................................................................. 84 to 115 Nm
Screw (100) ......................................................................................................................................... 286 to 391 Nm

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6002-4
TRAVEL MOTOR AND REDUCTION GEAR ASSEMBLY

Description
73
18 8 7
14 15 17 19 53 56 57
20
55 74 75 76
22 52
64
16 21 63
24 23 62 65
25 61
26 59 66
9 58
11
10 12 27
28 70
54 29 68
30
39 31 15
46 47 46 32 54
17
49 5 16 72
48 3 6 14 67
4 69 71 81
36 13 80
12
40 38 37 79
45 50 49 78
44 39 77
41 49
43 11
49 10
42 9
33 50
34 2 1 44
35 43 40
42 45
41
JS00940A

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6002-5
1. Screw 42. Sleeve
2. Washer 43. Spring
3. Safety valve block 44. Poppet
4. O-ring 45. O-ring
5. Screw 46. Thrust ring
6. Motor 47. O-ring
7. Spring 48. O-ring
8. Bearing 49. Thrust ring
9. Plug 50. O-ring
10. O-ring 51. O-ring (on next page)
11. Spring 52. Centring pin
12. Spring seat 53. Distribution plate
13. Spool 54. Centring pin
14. Plug 55. Piston
15. O-ring 56. Thrust ring
16. Spring 57. O-ring
17. Poppet 58. O-ring
18. Adaptor 59. Thrust ring
19. O-ring 60. O-ring (on next page)
20. Spool 61. Disk plate
21. Spring seat 62. Friction plate
22. Spring 63. Base plate
23. O-ring 64. Piston
24. Plug 65. Spherical bearing
25. O-ring 66. Thrust plate
26. Retaining ring 67. Connecting rods
27. Valve seat 68. Retaining ring
28. O-ring 69. Spring seat
29. Spring 70. Spring
30. Poppet 71. Spring seat
31. Plug 72. Cylinder block
32. Ball 73. Base plate
33. Plug 74. Swash plate
34. O-ring 75. Half-sphere
35. Piston 76. Stud
36. Plug 77. Piston
37. O-ring 78. Spring
38. Ball 79. Shaft
39. Safety valve 80. Bearing
40. Cap 81. Lip seal
41. Shim

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6002-6
106
107
108
101
60 104
96
93
109
102
95 113
84 83
51 100
82
94 103
105
99
87
92
114 85
110 86
112
98
111
89
91
97 88 89 90
91
JS00941A
82. Plug 100. Screw
83. Screw 101. Knuckle
84. Washer 102. Retaining ring
85. Cover 103. Retaining ring
86. Thrust shim 104. Crown wheel
87. Retainer pin 105. Spacer
88. Shaft 106. Floating seal
89. Shim 107. Metal ring
90. Planetary 108. O-ring
91. Needle roller bearing 109. Dowel pin
92. Satellite-carrier 110. Bearing
93. Sun gear 111. Metal ring
94. Coupling 112. O-ring
95. Retaining ring 113. Bearing
96. Ball 114. Hub
97. Thrust shim
98. Crown wheel
99. Dowel pin
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6002-7
Disassembly STEP 4
NOTE: The numbers in brackets refer to the
schematics on pages 4 and 6.
STEP 1
Clean around the outside of the motor and reduction
gear assembly to remove mud, impurities and other
foreign bodies.
STEP 2
2
5
JD00841A
Remove the screws (5).
1 STEP 5
6
54 7
JD00839A 54
Remove the screws (1) and the washers (2).
STEP 3
101
3 4 6
JD00842A
Attach a suitable lifting device to the motor (6). Use
the total movement of the lifting device. Slowly lift the
motor, while at the same applying leverage at the
centring lugs (54). Remove the motor (6) from the
knuckle (101). Take care not to drop the springs (7)
when removing the motor (6).
STEP 6
JD00840A 7
Remove the safety valve block (3) from the motor (6).
Remove and scrap the O-rings (4) from the motor (6).
JD00843A
Remove the springs (7).

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6002-8
STEP 7 STEP 10
13
JD00844A JD00938A
Remove the bearing (8) from the motor (6). If Remove the spool (13) from the motor bore (6).
necessary, use a small tool as a lever to extract the
bearing from its bore. STEP 11
STEP 8
12
9
15 14
JD00939A
11 10 Remove the two plugs (14). Remove and scrap the
JD00935A O-ring (15) from each plug.
Remove the plug (9). Remove and discard the O-ring
(10) from the cover. Remove the spring (11) and the STEP 12
spring seat (12).
6
STEP 9
Repeat step 8 to remove the other plug (9), O-ring
(10), spring (11), and spring seat (12).
17
16
JD00845A
Remove the springs (16) and the check valves (17)
from the motor bores (6).

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6002-9
STEP 13 STEP 16
25
19
18 24
JD00846A JD00849A
Remove the adaptor (18). Remove and scrap the Remove the plug (24). Remove and scrap the O-ring
O-ring (19) from the adaptor. (25) from the plug.
STEP 14 STEP 17
26
27
20
JD00847A JD00851A
Remove the spool (20) from the orifice.
STEP 15 A 26
22
23
21 27
A JD00850A
Turn the motor the other way up (6). Press on the
JD00848A valve seat (27) using an appropriate pointed tool.
Install a screw M5 (A) in the threaded central orifice Using the pointed end of the tool, press against that
of the spring seat (21). Remove the seat and the part of the snap ring (26) which has a notch (A), to
spring (22) from the orifice. Remove and scrap the deform the snap ring and extract it from the motor
O-ring (23) from the spring seat (21). groove. Remove and scrap the snap ring.

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6002-10
STEP 18 STEP 21
29
28 30 38
37 36
27
JD00852A JD00855A
Remove the valve seat (27) using a suitable tool. Remove the plugs (36). Turn the safety valve block
Remove the spring (29) and the check valve (30). the other way up (3) and remove the balls (38).
Remove and scrap the O-ring (28) from the valve Remove and scrap the O-ring (37) from each plug.
seat.
STEP 22
STEP 19
3 39
31
32 31 39
JD00856A
JD00853A Remove the safety valve (39) from the safety valve
Remove the plugs (31). Turn the motor the other way block (3).
up (6) and remove the balls (32).
STEP 20
34
35
33
JD00854A
Remove the plug (33) and the piston (35) from the
safety valve block (3). Remove and scrap the O-ring
(34) from the plug (33).

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6002-11
STEP 23 STEP 27
40 53
41
39
45
46
42
43
44
48 47
JD00857A JD00859A
Remove the cap (40), shims (41), sleeve (42), spring Remove the distribution plate (53).
(43), and the check valve (44). Remove and discard
the O-ring (45) from the cap. Remove and scrap the STEP 28
thrust rings (46) and the O-rings (47 and 48).
STEP 24 54
Insert a suitable tool into the bore of the housing from
which the safety valve was removed and remove the
thrust washers (49) and the O-ring (50).
STEP 25
Repeat steps 22 to 24 to remove the other safety
valve (39).
STEP 26
52 JD00860A
Remove the centring studs (54).
53
51
JD00858A
Remove and scrap the O-rings (51). Remove the
centring studs (52) from the distribution plate (53).

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6002-12
STEP 29
NOTE: If you use compressed air to remove the
piston, (55) cover the piston with a rag and hold it
firmly to prevent it from jumping out of the knuckle.
55 57 56
58
59
JD00863A
A If the inner ring of the bearing has stayed (8) on the
shaft (79), remove the bearing inner ring (8) using an
extractor (A) and a release tool (B).
JD00861A STEP 31
Remove the piston (55). Remove and scrap the
NOTE: In this step, hold the cylinder block (72) with
O-rings (57 and 58) and the thrust rings (56 and 59)
both hands and tilt it several times backwards and
from the piston. If the piston is difficult to remove,
forwards to separate the piston shoes (64) from the
apply 3 bar of compressed air to the parking brake
swash plate (74). If the piston shoes are stuck on the
passage (A) in the knuckle.
plate, the components (63 to 66) fitted on the cylinder
STEP 30 block will fall inside the knuckle.
61
62
8
B
72
JD00862A
JD00864A
Put the knuckle on its side, on top of a receptacle to
collect the hydraulic oil which will flow out of the
knuckle. Remove the cylinder block (72), the steel
discs (61) and the friction discs (62) from the knuckle.

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6002-13
STEP 32 STEP 35
62
71 63
64 61
JD00865A JD00868A
Remove the thrust plate (63) and the pistons (64) Turn the cylinder block the other way up (72).
from the cylinder block (72). Remove the steel discs (61) and the friction discs
(62) from the cylinder block (72).
STEP 33
STEP 36
A
64
63
68
JD00866A
Remove the pistons (64) from the thrust plate (63). JD00869A
Make marks on the pistons so that they can be re- Install the cylinder block (72) in a press. Apply a
installed in their original positions in the cylinder block suitable sleeve (A) to the spring seat (69) and
(72). compress the spring (70) using the press. Remove
the snap ring (68).
STEP 34
STEP 37
68
65 66
69
72
67
67 70
JD00867A
Remove the spherical bearing insert (65), the thrust JD00870A
plate (66) and the push-rods (67) from the cylinder Slowly release the pressure exerted on the spring
block (72). seat (69). Remove the spring seat (69), the spring
(70), and the spring seat (71) from the cylinder block
(72).

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6002-14
STEP 38 STEP 41
73
76
JD00871A JD00874A
Remove the thrust plate (73). Remove the studs (76).
STEP 39 STEP 42
74 77
JD00872A JD00875A
Remove the swash plate (74).
STEP 40
78
77
75
JD00876A
Remove the piston (77) and the spring (78).
JD00873A
Remove the half-spheres (75) from the knuckle.

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6002-15
STEP 43 STEP 45
80 79
JD00877A
Remove the shaft (79).
STEP 44
JS00879A
Install the shaft (79) in a sleeve (A) of suitable
diameter and length. Using a press (B), exert
pressure on the shaft (79) and remove the inner the
bearing ring (80).
NOTE: Do not remove the lip seal (81) for the
moment, since additional disassembly is necessary
when removing it.
STEP 46
JD00878A
Remove the outer ring from the bearing (80).
NOTE: Carry out step 45 only if the bearing (80) has
to be replaced.
JD00880A
Remove and scrap the O-ring (60) from the knuckle
(101).

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6002-16
STEP 47 STEP 50
JD00881A JD00884A
Make identification marks between the cover (85) Install an extractor on the satellite-carrier assembly
and the hub (114). Remove the screws (83) and the (92).
washers (84).
STEP 51
STEP 48
JD00885A
JD00882A Carefully lift the satellite-carrier assembly (92) and

Remove the plugs (82) and install a lifting eye (A) on remove the satellite-carrier from the hub (114).
the cover (85). Attach a suitable lifting device and
remove the cover (85) from the hub (114). STEP 52
STEP 49
JD00886A
Remove the pin (87) from the satellite-carrier
JD00883A assembly (92).
Remove the thrust shim (86).

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6002-17
STEP 53 STEP 56
Repeat steps 52 to 55 to remove the two other
planetaries from the satellite-carrier assembly (92).
STEP 57
96 93
94
JD00887A
Remove the shaft (88) from the satellite-carrier
97
assembly (92).
STEP 54
JD00890A
Remove the sun gear (93) and the coupling (94) from
the hub (114). Remove the ball (96) from the sun
gear (93) and remove the thrust shim (97) from the
hub (114).
89
STEP 58
95
JD00888A
Remove the planetary (90) and the shims (89) from
the satellite-carrier assembly (92).
STEP 55
JD00891A
Remove the snap ring (95) from the coupling (94)
only if they have been damaged.
JD00889A
Remove the needle roller bearings (91) from the
planetary (90).

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6002-18
STEP 59 STEP 61
100
JD00892A JD00894A
To facilitate re-assembly, make a mark between the To facilitate re-assemble, make a mark between the
hub (114) and the crown wheel (98). retaining crown (103) and the knuckle (101). Remove
the screws (100).
STEP 60
STEP 62
JD00893A
Using a suitable tool, remove the crown wheel (98) JD00895A
from the hub (114). Remove the centring studs (99). Install a suitable lifting device on the knuckle (101).
Make a mark between the knuckle (101) and the hub
(114). Carefully lift the hub/knuckle assembly about
76 mm.

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6002-19
STEP 63 STEP 64
WARNING: When the knuckle (101) is

disengaged from the hub (114), the crown
! wheel (104) and the retaining crown (103) will
fall onto the bench.
JD00898A
Remove the spacer (105) from the retaining crown
(103).
STEP 65
JD00896A
JD00899A
JD00897A
Disengage the knuckle (101) from the hub (114) by
levering with two screwdrivers between the knuckle
and the hub. Place the knuckle on the bench. Fasten
a suitable lifting device on the hub and move the hub
away from the crown wheel (104) and the retaining
crown (103).
JD00900A
Using a screwdriver, remove the snap ring (102).
Scrap the snap ring (102).

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6002-20
STEP 66 STEP 69
103
104
JD00901A JD00904A
Remove the retaining crown (103) from the crown Remove the metal ring (107) from the knuckle (101).
wheel (104). Scrap the metal ring.
STEP 67 STEP 70
106
JD00902A JD00905A
Remove the floating seal (106). Remove and scrap Remove the O-ring (108) from the knuckle (101).
the O-ring from the metal ring. Scrap the O-ring.
STEP 68 STEP 71
JD00903A JD00906A
Using a screwdriver, raise the metal ring (107). Using a screwdriver, remove the lip seal (81) from the
knuckle (101).

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6002-21
STEP 72 STEP 73
JD00907A JD00909A
114
113
JD00908A JS00911A
Using a hammer (A) and a suitable tool (B), remove
the bearing (113) from the hub (114).
B A
114
110
112
111
JS00910A
Using a hammer (A) and a suitable tool (B), remove
the bearing (110) and the metal ring (111) from the
hub (114). Remove the O-ring (112) from the hub
(114). Scrap the O-ring (112).

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6002-22
Inspection STEP 7
NOTE: The numbers in brackets refer to the Check for scratched or scored threads, deformation,
schematics on pages 4 and 6. wear or deep scratches on the screws (100). If any of
these conditions are seen, replace the component.
STEP 1
STEP 8
Check for any cracks, breakage, pitting, missing or
damaged teeth on the planetary assembly (90) and Check for cracks, breakage, pitting or other damage
the sun gear (93). If any of these conditions are seen, to the pistons (64). Check for scratches, scoring or
replace the component. Check for cracked, broken or roughness on the machined cylindrical surface. If any
corroded splines, on the sun gear (93). of these conditions are seen, replace the piston.
STEP 2 STEP 9
Turn the bearings (8, 80, 110 and 113) to make sure Check for cracks or breakage on the cylinder block
that they can be turned without difficulty. Check for (72). Check for cracks, pitting, scratches or
flattened areas and corrosion, chips, marked bearing roughness in the piston bores (64). If any of these
paths, scratches, corroded or cracked areas on the conditions are seen, replace the cylinder block.
bearings. If any of these conditions are seen, replace
STEP 10
the component.
Check for wear, cracks, pitting, deep scratches or
STEP 3 roughness on the distribution plate (53). If any of
Check for cracks or corroded, broken, cracked, worn these conditions are seen, replace the component.
or missing splines on the shaft (79). If any of these
STEP 11
conditions are seen or if lip seal path (81) in worn,
replace the component. Check for cracks, breakage or other damage to the
swash plate (74). Check for deep scratches or
STEP 4 roughness on the surface of the swash plate which is
Make sure that wear on the crown wheel teeth (103) in contact with the piston shoes (64). If any of these
and (104) is not irregular. conditions are seen, replace the component.
STEP 5 STEP 12
Check for deep scratches and wear on the metal Check for deep scratches or roughness on the
rings (111) and (107). If any of these conditions are machined surfaces of the spherical bearing insert
seen, replace the component. (65) and the thrust plate (66). Check for irregular
wear, cracks, breakage, deformation or other
STEP 6 damage to these components. If any of these
Check for cracks, breakage, pitting of deformed or conditions are seen, replace the component.
twisted assembly orifices on the knuckle (101) and STEP 13
the hub (114). If any of these conditions are seen,
replace the component. Check for scratched or Check for deep scratches or roughness and other
scored threads in the knuckle (101) internal orifices signs of wear or damage to the piston (77). If any of
and wear on the metal above the orifice. If any of these conditions are seen, replace the component.
these conditions are seen, replace the knuckle.

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6002-23
STEP 14
Check for deep scratches or roughness on the spools
(13 and 20), the check valve (44), and the pistons (35
and 55). If any of these conditions are seen, replace
the component.
STEP 15
Check for torsion, deformation, cracks or signs that
the springs are permanently locked in one position (7,
11, 16, 22, 29, 43, 70, and 78). If any of these
conditions are seen, replace the spring.
STEP 16
Check for irregular wear on both sides of the friction
discs (62) and steel discs (61) or signs of seizing due
to heat. If any of these conditions are seen, replace
the component.

Copyright ©
6002-24
Assembly STEP 2
NOTE: The numbers in brackets in the following
WARNING: Wear thermally insulated
steps refer to the schematics on pages 4 and 6. ! gloves when handling hot parts.
NOTE: When re-assembling, do not force the
components into the bores. The spools, check
valves, and valves are machined to very fine
tolerances and assembled in the same way. If you
force the components to install them, there is a risk
that you will damage the components. 113
STEP 1
110
JD00913A
Heat the hub (114) to a temperature of between 85
and 95°C. Position the hub (114) with the cover
contact surface (85) on the bench. Using a soft faced
hammer, install the bearing (110) in the hub (114)
until the outer race of the bearing touches the
shoulder in the hub. Turn the hub the other way up
JD00912A and install the bearing (113) in the hub in the same
Position the knuckle (101) on the bench with the manner.
motor contact surface (6) upwards. Apply lithium
grease to the lips of the new lip seal (81). Press the STEP 3
lips seal (81) into the knuckle bore (101) using a
suitable tool.
111
JD00907A
Install a new O-ring (112) in the hub groove (114).
Install the metal ring (111) in the hub (114), if
necessary, use a soft-faced hammer.

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6002-25
STEP 4 STEP 7
JD00905A JD00914A
Install an O-ring (108) in the knuckle (101). Install lifting eyes (A) on the hub (114).
STEP 5 STEP 8
JD00904A JD00915A
Install the metal ring (107) in the knuckle (101), if
necessary, use a soft-faced hammer.
STEP 6
106
JD00916A
NOTE: If the centring studs (109) were not

disassembled during the disassembly, remove and
JD00902A scrap the centring studs (109).
Apply a fine coating of lithium grease to the floating
seal O-ring (106). Install the metal ring, then the Using a suitable lifting device, position the hub (114)
floating seal O-ring (106) on the knuckle (101). above the knuckle (101). Lower the hub into the
knuckle. If the hub is difficult to install, tap gently on
the bearing race using a brass drift.

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6002-26
STEP 9 STEP 12
Degrease the threaded orifices of the screws (100)
and the centring stud orifices (109) in the knuckle
(101).
STEP 13
103
104
JD00901A
Install the retaining crown (103) in the crown wheel
(104).
STEP 10
JD00917A
JD00900A
Install a new snap ring (102) to retain the crown
wheel (104) on the retaining crown (103). JD00918A
Using a suitable lifting device, install the crown wheel
STEP 11 (104) / retaining crown (103) assembly in the hub.
Align the marks made during disassembly. Remove
the lifting device.
.
JD00898A
Apply lithium grease on the spacer (105). Install the
spacer (105) crown wheel (104) / retaining crown
(103) assembly.

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6002-27
STEP 14 STEP 16
109
JD00919A JD00878A
Check that the alignment marks are correctly aligned. Install the bearing outer race (80) in the knuckle bore
Apply Loctite 572 in the centring studs orifices (109). (101).
Install new centring studs (109) via the retaining
NOTE: Carry out step 17 only if the inner race of the
crown (103) and the knuckle. (101).
bearing (80) has been removed, otherwise pass on to
STEP 15 step 18.
STEP 17
79
80
JD00920A
Degrease the screws (100). Apply Loctite 262 to the
JS00921A
screw threads (100) and Loctite 767 under the screw
heads (100). Install the screws in the retaining crown
(103) and tighten the screws in the knuckle (101) to a WARNING: Use thermally insulated gloves
torque of between 286 and 391 Nm.
! when handling hot parts.
Heat the bearing inner race (80) to a temperature of

between 194 and 230°C. Using a suitable sleeve (A)
and a press (B), install the bearing inner race (80) on
the shaft shoulder (79).

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6002-28
STEP 18 STEP 20
76
JD00877A JD00874A
Install the shaft (79) in the knuckle (101). Install the studs (76) in the knuckle (101).
STEP 19 STEP 21
75
78
77
JD00876A JD00873A
Install the half-spheres (75) on the studs (76).
STEP 22
77
74
75
JD00875A
Install the spring (78) in the piston (77) and install the
assembly in the knuckle (101). JD0872A
Install the swash plate (74) on the shaft (79). Check
that the orifices (A) of the swash plate (74) are
aligned with the half-spheres (75).

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6002-29
STEP 23 STEP 26
62
61
JD00871A JD00868A
Install the thrust plate (73) in the knuckle (101). Remove the cylinder block (72) from the press. Orient
the cylinder block so that the snap ring (68) is facing
STEP 24 upwards and place the cylinder block on a bench.
Apply clean hydraulic oil to the friction discs (62).
69
Install a friction disc (62), a steel disc (61) and so on
for the other discs to be installed in the cylinder block
70 (72).
STEP 27
68
65
66
71
JD00870A
Place the cylinder block (72) in a press. Install the
spring seat (71), the spring (70), and the spring seat
(69) on the cylinder block (72). Install the snap ring
(68) on the spring seat (69). 67
STEP 25 JD00867A
Turn the cylinder block (72) the other way up. Install
the push-rods (67), the thrust plate (66) and the
A spherical bearing insert (65) in the cylinder block
(72).
69
JD00869A
Using a suitable sleeve (A), exert a pressure on the
spring seat (69) to compress the spring (70). Using
suitable pliers, install the snap ring (68) in the
cylinder block groove (72).

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6002-30
STEP 28 STEP 30
61
62
72
JD00866A JD00864A
Install the pistons (64) in their original orifices on the Install cylinder block (72) assembly in the knuckle
thrust plate (63). (101). Orient the knuckle/hub assembly so that the
motor mounting surface is facing upwards. Turn the
STEP 29 cylinder block (72) assembly by hand and check
there is no play. If there is play, disassemble the
cylinder block assembly again and correct the
assembly. Then repeat this step.
NOTE: Perform step 31 only if the bearing inner race
(8) has been removed, otherwise, pass on to step 32.
STEP 31
JD00865A
Install the piston (64) / thrust plate (63) assembly in
the original orifices in the cylinder block (72).
JD00863A
WARNING: Use thermally insulated gloves

! when handling hot parts.
Heat the bearing inner race (8) to a temperature of

between 90 and 110°C. Using a suitable sleeve,
install the bearing inner race (8) on the shaft (79).

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6002-31
STEP 32 STEP 34
55 57 56 40 41
58
59 39
45
46
42
43
44
60
48 47
JD00861A JD00857A
Apply clean lithium grease to new O-rings (57 and Apply lithium grease to the new O-rings (47 and 48).
58). Install the O-rings (57 and 58) and the new thrust Install the O-rings and the new thrust rings (46) on
rings (56 and 59) on the piston (55). Install a new the safety valve (39). Apply lithium grease to a new
O-ring (60) on the knuckle (101). Install the piston in O-ring (45) and install the O-ring on the cap (40).
the knuckle. Due to the resistance of the O-rings, it Install the check valve (44), the spring (43), the
may be difficult to install the piston in its bore in the sleeve (42), and the shims (41) in the safety valve.
knuckle. In this case, tap gently on the end of the Install and tighten the cap (40) to a torque of between
piston using a plastic-faced hammer to install the 57 and 95 Nm.
piston in the bore.
STEP 35
STEP 33
Apply lithium grease to a new O-ring (50). Install the
two new thrust rings (49) and the O-ring (50) in the
54 safety valve bore.
54
STEP 36
39
39
51
JD00860A
Install the centring studs (54). Apply clean lithium
grease to the new O-rings (51). Install the O-rings in
the knuckle orifices (101).
NOTE: For the following steps, apply clean hydraulic JD00856A
fluid to the components and make sure that they stay Install the safety valve (39) in the same orifice in the
wetted with that fluid. This is to prevent damage to safety block (3) from which it was disassembled.
the components during their re-assembly in their Tighten the safety valve to a torque of between 106
bores. and 143 Nm.
STEP 37
Repeat steps 34 to 36 to install the other safety valve
(39).

Copyright ©
6002-32
STEP 38 STEP 40
31
32 31
38
37 36
JD00855A JD00853A
Install the balls (38) in the safety valve block (3). Install the balls (32) in the motor bores (6). Install the
Apply lithium grease to the new O-rings (37). Install plugs (31) and then tighten them to a torque of
an O-ring (37) on each plug (36). Install and tighten between 24 and 33 Nm.
the plugs to a torque of between 24 and 33 Nm.
STEP 41
STEP 39
34
35
28
30
33
29
27
JD00852A
JD00854A Turn the motor (6) the other way up. Install the check
Install the piston (35) in the block. Apply lithium valve (30) and the spring (29) in the valve bore. Apply
grease to a new O-ring (34). Install the O-ring (34) on lithium grease to a new O-ring (28). Install the O-ring
the plug (33). Install and tighten the plug to a torque (28) on the valve seat (27) and install the valve seat.
of between 79 and 115 Nm.

Copyright ©
6002-33
STEP 42 STEP 44
26
22
23
A
21
A
27
JD00850A JD00848A
Slightly twist a new snap ring (26). Install the snap Apply lithium grease to a new O-ring (23). Install the
ring in the orifice where the valve seat (27) is O-ring (23) on the spring seat (21). To facilitate the
installed. Using a pointed tool, push the snap ring into assembly of the spring seat (21), install a screw M5
the orifice until it is seated in the motor (A) groove. (A) in the threaded orifice of the spring seat. Install
the spring (22) the spring seat (21) in the motor
STEP 43 orifice. Remove the screw (A) from the spring seat.
STEP 45
25
24
20
JD00849A
Turn the motor (6) the other way up. Apply lithium
grease to a new O-ring (25). Install the O-ring (25) on JD00847A
the plug (24). Install and tighten the plug to a torque Install the spool (20) in the opposite spring seat
of between 77 and 115 Nm. orifice (21).

Copyright ©
6002-34
STEP 46 STEP 49
Repeat steps 47 and 48 to install the other check
valve (17), spring (16), O-ring (15), and plug (14).
STEP 50
18
19
JD00846A
Apply lithium grease to a new O-ring (19) and install
the O-ring on the adaptor (18). Install the adaptor and
13
tighten it to a torque of between 77 and 115 Nm.
STEP 47 JD00938A
Install the spool (13) in the motor orifice (6).
STEP 51
12
9
17
16
JD00845A
Install the check valve (17) and the spring (16) in the 11 10
motor bore (6). JD00935A
STEP 48
the O-ring on the plug (9). Install the spring (11) and
the spring seat (12) in the plug. Install and tighten the
plug to a torque of between 390 and 467 Nm.
STEP 52
14 Repeat step 51 to install the other spring seat (12),
spring (11), O-ring (10) and plug (9).
15
JD00939A
the O-ring on the plug (14). Install the plug and then
tighten it to a torque of between 153 and 191 Nm.

Copyright ©
6002-35
STEP 53 STEP 56
JD00844A JD00924A
Turn the motor (6) the other way up on the bench. Apply lithium grease to the springs (7) to prevent
Install the bearing outer race (8) in the motor. them falling off the motor. Install the springs (7) in the
motor orifices.
STEP 54
STEP 57
52
JD00922A
Install the centring studs (52) on the motor. JD00925A
Carefully raise the motor and put it in position on the
STEP 55 knuckle (101). Check that the distribution plate (53)
and the springs (7) are still correctly installed in the
motor.
STEP 58
53
JD00923A
Apply lithium grease to the distribution plate (53) to
prevent it falling off the motor. Install the distribution
plate (53) on the motor. Check that the centring studs
(52) are correctly positioned in the orifices in the JD00841A
distribution plate. Install and tighten the screws (5) to a torque of
between 138 and 187 Nm.

Copyright ©
6002-36
STEP 59 STEP 62
4
JD00840A JD00891A
Apply lithium grease to the new O-rings (4) and install If removed, install new snap rings (95) in the coupling
them in the motor grooves. grooves (94).
STEP 60 STEP 63
JD00839A JD00927A
Install the safety valve block (3) on the motor. Install Apply lithium grease to the coupling splines (94) and
the screws (1) and the washers (2). Tighten the install the coupling (94) on the shaft (79).
screws to a torque of between 24 and 33 Nm.
STEP 64
STEP 61
JD00928A
JD00926A Install the ball (96) on the sun gear (93). Install the
Apply lithium grease to the thrust shim (97). Install sun gear (93) in the coupling (94).
the thrust shim (97) in the knuckle (101).

Copyright ©
6002-37
STEP 65 STEP 68
JD00889A JD00886A
Install two needle roller bearings (91) in one Fasten the shaft/planetary assembly on the satellite-
planetary (90). carrier (92) using a pin (87).
STEP 66 STEP 69
Repeat steps 65 to 68 to install the other planetaries
in the satellite-carrier.
STEP 70
A
92
JD00888A
Install the planetary/needle roller bearing assembly
and two shims (89) in the satellite-carrier (92).
STEP 67 90
JS00929A
Each planetary (90) has a stamped marking (A) 1.
Align the markings (A) as shown on the drawing
above to facilitate assembly in the hub (114).
JD00887A
Install a shaft (88) in the satellite-carrier (92).

Copyright ©
6002-38
STEP 71 STEP 73
JD00930A JD00932A
Using a suitable lifting device, position the satellite- Install a screw M24 on the hub (114) and a screw
carrier (92) above the hub (114). Slowly lower the M24 on the knuckle (101) as shown above. Using
satellite-carrier assembly (92) into the hub, engaging two wrenches, turn the hub until the alignment marks
the planetary teeth (90) with the teeth on the sun gear are aligned. Remove the screws.
(93) and the teeth in the crown wheel (104). Remove
the lifting device. STEP 74
STEP 72
99
JD00933A
Install the centring studs (99) in the crown wheel (98)
JD00931A and the hub (114).
Degrease the contact surfaces of the hub (114) and
the crown wheel (98). Apply Loctite 572 to the STEP 75
contact surfaces of the hub (114) and the crown Fill the hub with transmission oil.
wheel (98). Install the crown wheel (98) in the hub
(114), engaging the teeth of the crown wheel (98) in NOTE: For the quantity and specifications of the oil,
the teeth of the planetaries (90). Place the crown see Specifications.
wheel (98) so that the alignment marking made
during disassembly on the crown wheel (98) is to the
right of the alignment marking on the hub (114).

Copyright ©
6002-39
STEP 76
86
JD00934A
Apply lithium grease to the thrust shim (86). Install
the thrust shim (86) on the satellite-carrier (92).
STEP 77
JD00881A
Degrease the contact surface of the crown wheel (98)
and the contact surface of the cover (85). Apply
Loctite 572 to the contact surfaces of the crown
wheel (98) and the cover (85). Install the cover (85)
on the crown wheel (98). Apply Loctite 242 to the
screws (83) and install the screws (83) and the
washers (84). Tighten the screws (83) to a torque of
between 84 and 115 Nm.
STEP 78
If removed, install Teflon tape on the plugs (82) and
install the plugs (82) on the cover (85). Carefully
tighten the plugs.

Copyright ©
6002-40

Copyright ©
Section
6003
6003
OF THE SWING REDUCTION GEAR

Printed in France
Copyright ©
6003-2
TABLE OF CONTENTS
SPECIFICATIONS .................................................................................................................................................. 2
SPECIAL TORQUE SETTINGS ............................................................................................................................. 2
TOOLS REQUIRED ............................................................................................................................................... 2
SWING REDUCTION GEAR .................................................................................................................................. 3
Removal ............................................................................................................................................................... 3
Installation ............................................................................................................................................................ 4
SPECIFICATIONS
See Section 1002.

See Section 1002.
TOOLS REQUIRED
Hand pump CAS-10090

Copyright ©
6003-3
SWING REDUCTION GEAR

Removal STEP 4
STEP 1 Install the swing motor and reduction gear assembly
on suitable axle stands.
Carry out steps 1 to 13 to remove the swing motor
(See section 8008). NOTE: The axle stands must be sufficiently high so
that the pinion does not touch the ground.
STEP 2
STEP 5
2 1
1
JD00449A
Remove the retaining screws (1) which fasten the JD00386A
motor and reduction gear to the chassis. To facilitate re-installation, make an alignment mark
(1) between the motor and the reduction gear.
STEP 3 Remove the retaining screws (2) which fasten the
motor to the reduction gear.
STEP 6
Carefully lift the swing motor and move it away from
the reduction gear, then place it in a clean location.
JD00437A
Using an appropriate lifting device, carefully lift the
swing motor and reduction gear assembly and move
it away from the machine.

Copyright ©
6003-4
Installation STEP 5
STEP 1
Degrease the contact surfaces between the motor
and the reduction gear. Apply Loctite 504 to the
contact surface of the reduction gear.
B
STEP 2
JD00437A
Raise the swing motor and reduction gear assembly
off the ground and apply lithium grease around the
gear (A).
NOTE: Before re-installing the swing motor and
reduction gear assembly, make sure that the drain
hose (B) in installed on the swing motor and
JD00446A
reduction gear assembly.
Attach a suitable lifting device to the swing motor.
Position the swing rotation above the reduction gear. STEP 6
Carefully lower the motor onto the swing reduction
gear.
STEP 3
JD00385A
Lift the swing motor and reduction gear assembly and
position it above the machine contact surface.
JD00386A
Install the retaining screws (1) which fasten the motor
to the swing reduction gear. Tighten the screws to a
torque of 103 Nm.
STEP 4
Clean the surface around the swing motor and
reduction gear assembly on the machine.

Copyright ©
6003-5
STEP 7 STEP 11
A
1
JD00473A JD00449A
Connect a vacuum pump CAS 10090 to the swing Apply Loctite 262 to the screws (1) and tighten them
brake release orifice (A). to the torque specified in section 1002.
STEP 8 STEP 12
Check that the hand pump is full of hydraulic fluid and
that fluid temperature is between 21 and 27°C.
STEP 9
Operate the hand pump until the pressure gauge
shows 19.4 bar. The swing motor brake should now
be released, enabling the swing reduction gear A
output gear to be turned.
STEP 10
JD00473A
Release the pressure in the hand pump CAS 10090
and disconnect the hand pump from the swing motor
brake release orifice (A).
A B
JS00474A
Carefully lower the swing motor and reduction gear
assembly onto the contact surface of the
upperstructure. Check that the centring stud (A) is
correctly engaged in orifice (B) of the reduction gear.
NOTE: Make sure that the reduction gear output gear
is correctly engaged in the upperstructure crown
wheel.

Copyright ©
6003-6
STEP 13
2
1
JS00475A
Remove the purge plug (1) on the side of the swing
reduction gear. Inject lithium grease into the
reduction gear via grease fitting (2) until grease
comes out of the air purge orifice. Install the air purge
plug (1).
STEP 14
Carry out steps 4 to 14 to install the swing motor (See
section 8008).

Copyright ©
Section
6004
6004

Printed in France
Copyright ©
6004-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 3
SWING REDUCTION GEAR.................................................................................................................................... 4

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

Copyright ©
6004-3
SPECIFICATIONS
See Section 1002

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

Copyright ©
6004-4

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

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

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

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

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

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

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

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

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

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

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

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

Copyright ©
Section
8000
DEPRESSURISING AND DECONTAMINATING THE

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

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

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

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

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

Copyright ©
8000-4
RELEASING PRESSURE IN THE HYDRAULIC SYSTEM

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

Copyright ©
8000-5
BLEEDING AIR FROM THE MAIN HYDRAULIC SYSTEM COMPONENTS

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

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

Copyright ©
8000-7
CLEANING THE HYDRAULIC SYSTEM

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

Copyright ©
8000-8
Decontamination of the hydraulic STEP 7

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

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

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

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

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

Copyright ©
8001
Section
8001
SPECIFICATIONS, TROUBLESHOOTING, CHECKS

AND HYDRAULIC PRESSURE SETTINGS

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

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

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

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

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

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

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

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

Copyright ©
8001-6
IDENTIFICATION OF HYDRAULIC COMPONENTS

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

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

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

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

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

Copyright ©
8001-9

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

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

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

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

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

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

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

Copyright ©
8001-13
Installing the pilot pressure test Installing the flowmeter

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

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

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

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

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

Copyright ©
8001-16
CHECKING AND PRESSURE SETTING PROCEDURE

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

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

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

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

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

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

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

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

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

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

Copyright ©
8001-21
Dipper secondary relief valve (D1)

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

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

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

(27.9±0.4 MPa)
Function CX210 CX240

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

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

Copyright ©
8001-23
Checking the swing braking

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

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

tion and tighten the lock nut (1).
6. Check the pressure again. If the desired value is
not obtained, repeat steps 2 to 6.

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

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

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

Pressure 18 to 21 bar 16 to 20 bar

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

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

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

Copyright ©
8001-27
Checking the swing motor for leaks

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

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

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

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

Copyright ©
8001-30
Not possible to select 2nd travel speed

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

Copyright ©
8001-31
No swing or slow swing

(No problems with other functions)

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

Copyright ©
8001-32
No movement on any function

(Control cancellation lever in the low position)

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

(No problems with other movements)

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

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

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

(No problems with other movements)

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

Copyright ©
8001-34

Copyright ©
8002
Section
8002

OF THE FUEL RESERVOIR

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

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

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

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

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

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

Printed in France
Copyright ©
8003-2
TABLE OF CONTENTS
SPECIFICATIONS .................................................................................................................................................. 3
MAIN HYDRAULIC PUMP ..................................................................................................................................... 4
Removal and installation .................................................................................................................................... 4
PILOT PUMP .......................................................................................................................................................... 8
Removal and installation .................................................................................................................................... 8
HYDRAULIC PUMP COUPLING ............................................................................................................................ 9
Section ................................................................................................................................................................ 9
Removal .............................................................................................................................................................10
Inspection ...........................................................................................................................................................10
Installation ..........................................................................................................................................................10

Copyright ©
8003-3
SPECIFICATIONS
See Section 1002

Screw for fixing the main pump to the coupling flange .......................................................................... 88 to 111 Nm
Screw for fixing the grooved spacer to the coupling assembly........................................................... 206 to 226 Nm
Screw for fixing the coupling assembly to the engine hand-wheel ..................................................... 206 to 226 Nm
Nuts for fixing the silencer circlips to the bracket ............................................................................................ 39 Nm
Silencer bracket fastening screw............................................................................................................ 64 to 74 Nm
Screw for fixing the hydraulic reservoir lid ............................................................................................ 2.9 to 4.9 Nm
Screw for fixing the hydraulic pump coupling flange on the engine hand-wheel crankcase...........See Section 1002

Copyright ©
8003-4
MAIN HYDRAULIC PUMP

STEP 1
1
JS00163A
STEP 2
Release pressure in the hydraulic system and in the JS00015A
hydraulic reservoir (see Section 8000). Remove the access panel (1) below the hydraulic
reservoir.
STEP 3
STEP 5
Put an appropriate container under the hydraulic
reservoir. Open the drain cock and drain the hydraulic
fluid. Close the cock.
STEP 6
2
1
JD00375A
Remove the battery cover (1) and disconnect the
earth cable (-) (2) from the battery.
CD00F070
Unlock the two engine hood locking latches (1) and
raise the hood to the raised, locked position.

Copyright ©
8003-5
STEP 7 STEP 10
1 1
1
CD00F071 CD00F074
Remove the four screws (1) then remove the top Remove the two silencer circlips (1).
grille (2).
STEP 11
STEP 8
1
CD00F075
CD00F072
Remove the silencer assembly from the machine (1).
Loosen the circlip (1) fixing the silencer pipe to the
turbo-compressor. STEP 12
NOTE: Let the engine and the exhaust system cool
down before trying to remove the silencer.
STEP 9
1
CD00F076
Remove the three fastening screws (1) from the
silencer bracket.
1 NOTE: When installing, tighten the screws to the
CD00F073
torque specified on page 3.
Remove the four fastening nuts (1) from the silencer
circlips.
NOTE: When installing, tighten the nuts to the torque
specified on page 3.

Copyright ©
8003-6
STEP 13 STEP 16
Disconnect the pipes, the hydraulic lines and the
electrical connections. Seal all the hoses and unions
of the main pump as well as those of the pilot pump.
STEP 17
Install an appropriate lifting apparatus on the
hydraulic pump. Do not leave any slack so that the
pump can be supported once the fastening screws of
2 the pump are removed.
STEP 18
1
Remove the four fastening screws of the hydraulic
CD00F077 pump.
Label and disconnect the electrical connection (1).
Remove the screw that holds the hose (2) to the NOTE: When installing, tighten the screws to the
engine support. torque specified on page 3.
STEP 14 STEP 19
Remove and move the hydraulic pump away from the
engine and the machine. Place the hydraulic pump
on appropriate supports on a clean workbench.
NOTE: Carry out the following step only if a new
hydraulic pump is to be installed.
STEP 20
1
Remove the unions of the hydraulic pump that has
just been removed and install them on the new
hydraulic pump. Remove and install the unions one
after another to prevent any improper installation of
unions on the new hydraulic pump.
CD00F078 NOTE: When installing the hydraulic pump, proceed
Remove the two screws (1) then keep the engine and
in the reverse order to that of removal. Replace all
the bracket away from the hydraulic pump.
joints with new joints.
STEP 15
CD00F079
To make proper installation easier, put identification
tags on all hoses and electrical connections of the
main hydraulic pump and the pilot pump.

Copyright ©
8003-7
STEP 21 NOTE: Before working with the machine, operate the
swing, travel and attachment for five minutes with the
engine at idle. Ensure that there are no leaks in the
circuit, check the oil level in the hydraulic reservoir.
Top up if necessary. Carry out the hydraulic pump
setting, refer to section 8001.
2
CD00E176
Remove the four screws and the washers (1).
Remove the lid (2) and the O-ring from on top of the
hydraulic reservoir. Scrap the O-ring. Fill the
hydraulic reservoir with hydraulic fluid (see
section 1002) up to the level located in between the
"high" and "low" marks on the visual gauge. Install
the lid with a new O-ring, fasten it using four screws
and washers (1), tighten the screws to a torque of 2.9
to 4.9 Nm.
STEP 22
1
2
JD00375A
Connect the earth cable (-) of the battery (2) to the
battery and install the battery lid (1).
STEP 23
NOTE: Always drain the air from the hydraulic pump
before starting the engine. If the air is not drained out,
the pump could get damaged. For the procedure, see
section 8000.

Copyright ©
8003-8
PILOT PUMP
STEP 1 Remove the two fastening screws (and the flat
washers) from the pilot pump, then remove the pilot
Refer to "Removing the hydraulic pump" in this pump.
section and carry out steps 1 to 3.
STEP 6
STEP 2
Shut off the vacuum pump.
To prevent any hydraulic fluid leaks when
disconnecting hydraulic lines, connect a vacuum NOTE: When installing, proceed in the reverse order
pump to the hydraulic reservoir (see section 8000). to that of removal. Replace the O-rings with new
Start the vacuum pump. O-rings.
STEP 3 NOTE: Before working with the machine, operate the

engine at idle. Check that there are no leaks in the
system, check the level of oil in the hydraulic
reservoir, top up if necessary. Carry out the setting of
the hydraulic pump, refer to section 8001.
CD00F080
Place an appropriate container under the pilot pump
to recover the hydraulic fluid that could escape from
one of the disconnected hoses or from the hydraulic
pump when the pilot pump has been removed.
Disconnect the hoses from the upper union of the
pilot pump. Seal the union and the hoses.
STEP 4
CD00F081
Disconnect the hose from the lower union of the pilot
pump. Seal the union and the hose.

Copyright ©
8003-9
HYDRAULIC PUMP COUPLING

Section
9 1
7
4
2
5 3
CS00M502
1 HYDRAULIC PUMP 6 COUPLING ASSEMBLY
2 COUPLING FLANGE 7 ROLL PIN
3 SCREW 8 GROOVED SPACER
4 ENGINE HAND-WHEEL 9 SCREW FOR FIXING THE COUPLING ASSEMBLY ON THE
5 SCREW FOR FIXING THE COUPLING ASSEMBLY ON THE ENGINE HAND-WHEEL
GROOVED SPACER

Copyright ©
8003-10
Removal STEP 5
schematic on page 9. 6
STEP 1 9
Refer to the removal of the hydraulic pump in this
section and remove the hydraulic pump.
STEP 2
Remove the fastening screws (3) from the coupling
flange (2) then remove the coupling flange.
NOTE: When installing, tighten the screws to the
JD00953A
STEP 3 Remove the four screws (9) that fix the coupling
assembly (6) to the engine hand-wheel (4). Remove
5 the coupling assembly from the engine hand-wheel.
Inspection
STEP 1
Check for cracked, broken, burst or worn flutings on
8 the grooved spacer (8). Check that roll pins (7) are
6 not missing, damaged or worn out. If any one of the
above conditions exist, replace the grooved spacer.
JD00951A STEP 2
Remove the four screws (5) that are fastening the
Check for cracks, ruptures and other wear and tear
coupling assembly (6) to the grooved spacer (8).
on the coupling assembly (6). If any one of the above
NOTE: When installing, coat the screw threads with conditions exist, replace the coupling assembly.
Loctite 262, tighten the screws to the torque specified
on page 3. Installation
STEP 4 NOTE: When installing, proceed in the reverse order
to that of removal.
NOTE: Refer to the installation of the hydraulic pump
in this section and put the hydraulic pump back in
place.
JD00952A
Remove the grooved spacer (8) from the coupling
assembly.

Copyright ©
Section
8004
8004
OF THE MAIN HYDRAULIC CONTROL VALVE

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

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

For the hardware which fastens the control valve to the upperstructure frame.............................. See Section 1002
Retaining screws for central frame and the upper access panel........................................................... 88 to 107 Nm

Copyright ©
8004-3
MAIN HYDRAULIC CONTROL VALVE

STEP 1
1
CD00F061
Remove the retaining screws from the upper access
JS00163A panel (1) and remove the panel.
Park the machine on flat, hard ground. Lower the
attachment to the floor. NOTE: When installing, tighten the screws to a
torque of between 88 and 107 Nm (apply Loctite 262
STEP 2 to the threads).
Release pressure in the hydraulic system and STEP 6
release pressure in the hydraulic reservoir (see
Section 8000).
1
STEP 3
2
CD00F085
2 Remove the retaining screws (1) from the filter

bracket (2).
JD00375A
Remove the lid from the battery (1). Disconnect the
earth cable (-) (2) from the battery.
STEP 4
To prevent fluid loss when disconnecting hydraulic
lines, connect a vacuum pump to the hydraulic
reservoir (see Section 8000).

Copyright ©
8004-4
STEP 7 STEP 10
1
2
CD00F062 CD00F086
Remove the retaining screws from the central frame Attach an identification label and disconnect the two
(1) and remove the central frame. pipes (1) from the control valve. Remove the two
retaining screws and washers from the bracket (2).
NOTE: When installing, tighten the screws to a
Move the mounting bracket away from the control
torque of between 88 and 107 Nm (apply Loctite 262
valve with the two hoses still attached.
to the threads).
STEP 11
STEP 8
1
2
2 3
1
CD00F087
CD00F084
Remove the four hose clips (1) (2) and remove the
Remove the clamp (1) which fastens the two
hoses from the manifold (3).
hydraulic hoses (2) to the mounting bracket (3).
Remove the mounting bracket (3). STEP 12
STEP 9
CD00G183
Remove the two control valve supply hoses (1).

Copyright ©
8004-5
STEP 13 STEP 15
A
1
CD00F088 CD00G179
Attach identification labels to the hoses (1), (2) and Attach identification labels to all the control valve
(3), then disconnect and plug the hoses. Remove the hoses and pipes. Disconnect and plug the hoses and
four hose clips (A) and remove the hoses from the the pipes. Plug the control valve orifices. Identify and
manifold. disconnect the electrical connections.
STEP 14 NOTE: Plug the hoses with plugs and the adaptors
with caps to prevent any contamination of the
hydraulic system when disconnecting pipes and
2 hydraulic hoses.
STEP 16
1
CD00F089
Remove the four retaining screws (1) from the
flange (2).

Copyright ©
8004-6
STEP 17 STEP 20
Install lifting eyes in the threaded orifices on the top Carefully raise and guide the control valve off the
of the control valve. chassis. Move all the hoses and the pipes out of the
way. Remove the control valve from the machine and
STEP 18 place it on suitable stands.
Connect a suitable lifting device to the control valve. NOTE: Carry out the following step only if the control
See Section 1002 for the weight of the control valve. valve has to be changed.
STEP 19 STEP 21
Remove the unions and manifolds from the control
valve which has just been removed and fit them on
the new control valve. Remove and install the unions
and manifolds one after another so as to be sure that
you are installing them correctly on the new control
valve.
NOTE: When installing, use the same procedure in the
reverse order. Replace all O-rings by new O-rings.
NOTE: Before working with the machine, operate the
engine at idle. Check that there are no leaks in the
system, check the level of oil in the hydraulic
reservoir, top up if necessary. Adjust the valves in the
control valve (see Section 8001).
CS00E520
Remove the retaining screws (1) and washers from
the control valve.
torque specified in Section 1002.

Copyright ©
Section
8005

OF THE ATTACHMENT CYLINDERS
8005

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Copyright ©
Section
8006

OF THE HYDRAULIC SWIVEL
8006

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

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

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

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

Copyright ©
Section
8007

OF THE PILOT FUNCTION BLOCKS
8007

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

Control stick locknut of the control lever block ................................................................................................. 41 Nm

Copyright ©
8007-3
PILOT FUNCTION BLOCKS

Travel pedal block STEP 5
Removal and installation Attach identification tags to all hoses of the pedal
block.
STEP 1
STEP 6
STEP 7
Provide for a container to recover any possible leaks
of the hydraulic fluid.
STEP 8
JS00163A
Park the machine on hard and flat ground. Lower the
STEP 2
STEP 3
CD00G045
Remove and seal the hydraulic hoses (1). Remove
the junction joints (2), put plugs on the ports of the
control pedal, then discard the O-rings.
1 NOTE: When installing, replace all O-rings with new
O-rings.
2
STEP 9
JD00375A
Remove the battery cover (1). Disconnect the battery
ground (-) cable (2) from the battery.
STEP 4
To prevent any fluid leaks when disconnecting
hydraulic lines, connect a vacuum pump to the

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

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

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

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

Copyright ©
8007-8
RH control lever STEP 3

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

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

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

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8007-11
Swing shuttle block STEP 6

1
STEP 1
To make installation easier, attach identification tags
to all hydraulic hoses and electrical connections of
the shuttle block.
STEP 2
2
STEP 3
CD00G064
Provide for a container to recover any possible Remove the screws (1), then remove the shuttle
hydraulic fluid leaks. block (2) from its bracket.
STEP 4 NOTE: When installing, proceed in the reverse order
to that of removal. Start the engine, operate the
control levers, stop the engine, check the circuit for
up if necessary.
CD00G063
Remove and seal the hydraulic hoses, remove the
pressure detector, remove the junction unions, put
plugs on the ports of the shuttle block, then discard
the O-rings.
O-rings.
STEP 5

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8007-12
Cushion control valve STEP 5

Removal and installation Shut off the vacuum pump.
NOTE: Refer to page 3 and carry out steps 1 to 4. STEP 6

STEP 1 Loosen the retaining screws of the cushion control
valve behind the partition. Remove the cushion
Open the left-hand side doors. control valve (raise it until the screws and flat
STEP 2 washers are clear of the key hole slots in the bracket
then pull it from the bracket).
NOTE: When installing, proceed in the reverse order
up if necessary.
CD00F053
To aid installation, put identification tags on the
hydraulic hoses. Seal the ports of the cushion control
valve and the ends of the hydraulic hoses.
STEP 3
STEP 4
CD00F054
Disconnect the hydraulic hoses from the cushion
valve. Seal the hydraulic hoses and the ports of the
cushion control valve.

Copyright ©
8007-13
Servo control and return manifold STEP 6

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

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8007-14
6 solenoid valve block STEP 5

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

Copyright ©
Section
8008

OF THE SWING MOTOR
8008

Printed in France
Copyright ©
8008-2
TABLE OF CONTENTS
SPECIFICATIONS .................................................................................................................................................. 2
SWING MOTOR ..................................................................................................................................................... 3
Removal .............................................................................................................................................................. 3
Installation ........................................................................................................................................................... 5
SPECIFICATIONS
See Section 1002.

Motor retaining screws on the reduction gear ................................................................................................ 103 Nm

Copyright ©
8008-3
SWING MOTOR
Removal
STEP 1 STEP 5
JS00163A JD00377A
Park the machine on hard, flat ground. Lower the Remove the central frame (1).
STEP 6
STEP 2
STEP 3
To prevent any fluid leaks when disconnecting
hydraulic lines, connect a vacuum pump to the
hydraulic reservoir (see Section 8000). 2
1
STEP 4 3
1
JD00378A
Remove the flange (1) and remove the support (2).
Move the swing motor reduction gear (3) as far as
possible away from the machine.
STEP 7
Drain the swing reduction gear. See the operator’s
manual.
STEP 8
JS00376A To facilitate the installation, attach identification
Remove the upper panels (1) from the machine. labels to all the hoses and hydraulic unions which are
disconnected during disassembly.
STEP 9

Copyright ©
8008-4
STEP 10 STEP 14
Disconnect all the hoses connected to the swing
motor. Plug the hoses and unions to prevent any
contamination entering the hydraulic system.
STEP 11
1 A
JD00386A
To facilitate installation, make an alignment mark (A)
between the motor and the reduction gear. Remove
1 the retaining screws (1) which fasten the motor to the
swing reduction gear.
JD00384A STEP 15
Disconnect the hoses (1) above the bottom of the
boom. Plug the hoses and unions to prevent any Carefully lift the swing motor off the reduction gear.
contamination entering the hydraulic system. Move Place the motor on a clean bench.
the hoses (1) away from the swing motor.
STEP 16
STEP 12
To prevent any contamination of the swing reduction
Shut off the vacuum pump. gear, cover the reduction gear with a clean cloth or
other suitable protection.
STEP 13
JD00385A
Attach a suitable lifting device to the swing motor.

Copyright ©
8008-5
Installation
STEP 1 STEP 6
Remove the cloth or other suitable protection from
the reduction gear. Degrease the contact surfaces
between the motor and the swing reduction gear.
Apply Loctite 504 to the contact surface of the swing
reduction gear.
STEP 2
JD00384A
Remove the plugs. Connect the hoses (1) above the
bottom of the boom.
STEP 7
Stop the vacuum pump and remove the vacuum
pump from the machine (see Section 8000).
JD00446A
Attach a suitable lifting device to the swing reduction STEP 8
gear. Position the swing motor above the reduction
gear. Carefully lower the motor onto the reduction
gear. Remove the lifting device.
STEP 3
2
1
3
JD00378A
Install the bracket (2) on the control valve. Install the
hoses (3) on the bracket (2) by means of the flange
(1).
JD00386A
Install the retaining screws (1) which fasten the motor
to the swing reduction gear. Tighten the screws to a
torque of 103 Nm.
STEP 4
STEP 5
Remove the plugs. Connect all the hoses to the
swing motor.

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8008-6
STEP 9 STEP 14
1
JD00377A JS00376A
Install the central frame (1). Install the upper panel (1) on the machine.
STEP 10
Fill the swing reduction gear (see Operator’s
manual).
STEP 11
Remove a plug on top of the swing motor and fill with
clean hydraulic oil. Install the plug.
STEP 12
Carry out the purging of the swing motor (see
Section 8000).
STEP 13
If the swing motor safety valves have been removed,
the swing motor safety valves must be reset (see
Section 8001).

Copyright ©
Section
8010
MAIN HYDRAULIC PUMP
8010

Printed in France
Case Cre 7-29770GB December 2001
Copyright ©
8010-2
TABLE OF CONTENTS
SPECIFICATIONS..................................................................................................................................................... 2
SPECIAL TORQUE SETTINGS ................................................................................................................................ 3
TOOLS REQUIRED .................................................................................................................................................. 3

Tool to be manufactured locally ............................................................................................................................ 3
IDENTIFYING THE COMPONENTS......................................................................................................................... 4
IDENTIFYING THE PORTS ...................................................................................................................................... 5
REGULATING CONTROL......................................................................................................................................... 6
DISASSEMBLY ......................................................................................................................................................... 7
ASSEMBLY .............................................................................................................................................................14
SPECIFICATIONS
See section 1002.

Copyright ©
8010-3

Swash plate retaining screw.................................................................................................................. 6.9 to 8.3 Nm
HP pump housing retaining screw....................................................................................................... 230 to 270 Nm
LP pump housing retaining screw ........................................................................................................... 28 to 35 Nm
Balance valve retaining screw ................................................................................................................. 28 to 35 Nm
Retaining screw for the flange on LP pump............................................................................................. 28 to 35 Nm
Control block retaining screw .................................................................................................................. 28 to 35 Nm
Pressure setting valve ............................................................................................................................. 74 to 88 Nm
Pressure setting block screw................................................................................................................. 6.9 to 8.3 Nm
DRE4 K cover screw ............................................................................................................................... 12 to 15 Nm
LP pump retaining screw ......................................................................................................................... 28 to 35 Nm
Balance valve block retaining screw........................................................................................................ 28 to 35 Nm
Safety valve block screw ......................................................................................................................... 28 to 35 Nm
Flange retaining screw .......................................................................................................................... 98 to 123 Nm
TOOLS REQUIRED
Tool to be manufactured locally
Dia. 150
Dia. 50
65
CI01E530
Pump bracket (shaft side)

(Dimensions in mm)

Copyright ©
8010-4
IDENTIFYING THE COMPONENTS
16 10
1 18 10 14 17
4 8
6
9
15
3 12 10 11 7 13 10
CI01E516
1 REGULATOR BLOCK 11 CYLINDER BLOCK MACHINED PLATE
2 PRIMARY DRIVE SHAFT 12 SPRING
3 CYLINDER BLOCK 13 INTERMEDIATE PLATE
4 PISTON 14 PUMP HOUSING
5 RETAINING PLATE 15 MOTOR COUPLING FLANGE
6 SWASH PLATE 16 ELECTROMAGNETIC PRESSURE REDUCTION
7 LARGE DIAMETER CONTROL PISTON PROPORTIONING VALVE BLOCK
8 SMALL DIAMETER CONTROL PISTON 17 SECONDARY DRIVE SHAFT
9 GEAR PUMP 18 COUPLING
10 MIN-MAX FLOW ADJUSTING SCREW

Copyright ©
8010-5
IDENTIFYING THE PORTS
8
9
11 10 12 15
13
7
1 5 6 4 2 14
CI01E517
1 FRONT PUMP BODY 10 REGULATOR BLOCK
2 REAR PUMP BODY 11 ELECTROMAGNETIC PRESSURE REDUCTION
3 GEAR PUMP BODY PROPORTIONING VALVE
4 INTERMEDIATE PLATE 12 REAR PUMP PROPORTIONING VALVE CONTROL COVER
5 FRONT PUMP OUTPUT PORT 13 FRONT AND REAR PUMP BALANCE VALVE
6 REAR PUMP OUTPUT PORT 14 PILOT CIRCUIT VALVE
7 GEAR PUMP OUTPUT PORT 15 PUMP CONTROL PRESSURE INSPECTION PORT
8 MAIN PUMP SUCTION PORT
9 GEAR PUMP SUCTION PORT

Copyright ©
8010-6
REGULATING CONTROL
18
3
19
15
16
17
Pz
14
13
12
20 23 21 10 26
22 25
24 11 8
6 2 4
1
5
P1 P2
9 7
CI01E518
1 VARIABLE FLOW HYDRAULIC PUMP 14 SHAFT
2 GEAR PUMP 15 CONTROL SPOOL
3 PROPORTIONING VALVE 16 LINKAGE ROD
4 BALANCE VALVE 17 OUTLET ADJUSTMENT SPRING
5 PILOT CIRCUIT VALVE 18 PISTON
6 SWASH PLATE 19 SPRING
7 LARGE DIAMETER CONTROL PISTON 20 NEGATIVE PRESSURE SETTING BLOCK
8 SMALL DIAMETER CONTROL PISTON 21 PRESSURE SETTING BLOCK PISTON
9 LARGE DIAMETER PISTON ROD 22 CONTROL SPOOL
10 SMALL DIAMETER PISTON ROD 23 DRIVE ADJUSTMENT NEGATIVE SPRING
11 PISTON 24 BALANCE SPRING
12 ROLLER 25 SPRING SEAT
13 OSCILLATING DRIVE 26 GUIDE
P1-P2: Pump flow

Pz: Negative control pressure

Copyright ©
8010-7
DISASSEMBLY
STEP 1 STEP 3
NOTE: Always keep the components from different 1
pumps separate from one another. During
disassembly of the pump, place the components on a
2
rubber mat. Handle the components with care.
Always mark the position of the parts.
CD01F001
Remove the cover (1) of the DRE4 K. Remove the
proportioning valve electromagnetic block (2).
STEP 4
1
2 CD01F002
Remove the cover (1).
CI01E519
Remove the four screws (1) and remove the flange STEP 5
(2).
STEP 2
Remove the various hoses and connecting tube
(arrows).
1
CD01F003
Extract the spool (1) with a magnet or nose pliers and
remove the linkage rod from the end of the spool (1).

Copyright ©
8010-8
STEP 6 STEP 9
1
CD01F004 CD01F007
Remove the negative pressure setting block and Remove the control block (1) and discard the seals.
discard the seal.
STEP 10
STEP 7
1
1
CD01F008
CD01F005 Extract the piston (1) from the pump body (2).
Remove the jacket (1) and the spring from the valve
spool. Discard the seal. STEP 11
STEP 8
3
1 2
4 1
3
2
CD01F009
Remove the plug (1), take the spring out (2). Extract
CD01F006 the spool (3) from the cover (4).
Remove the adjusting cap (1) and discard the seal.
NOTE: Not required on model A20V064-999.
Remove the spring, the spring seat can remain in the
control block. Do not change the setting of the screw
(2) and the nut (3).

Copyright ©
8010-9
STEP 12 STEP 15
2 1
1
2
CD01F010 CD01F013
Remove the piston (1) and the spring (2) from the Remove the coupling flange (1) from the pilot pump.
guide (3). Remove the coupling piece (2).
STEP 13 STEP 16
1
1
CD01F011 CD01F015
Remove the safety valve block (1). Place the pump in a vertical position. Install an M10
lifting ring (1) on the shaft. Remove the retaining
STEP 14 screws (2). Draw reference marks on the housings.
Lift the front pump and the intermediate plate (3).
1
STEP 17
1
2
3
CD01F012
Remove the balance valve (1) from the front and rear
pumps.
CD01F016
Remove the small diameter piston (1) with its spring.
Remove the distribution plate (2) from the
intermediate plate (3).

Copyright ©
8010-10
STEP 18 STEP 21
CD01F017 CD01F020
Remove the large diameter piston (1) with its spring. Remove the stop screws (1). To avoid displacing
Remove the two push rods (2) from the small and them, measure the length of the screws in relation to
large diameter pistons. the supporting surface of the housing and loosen the
screw and the nut simultaneously.
STEP 19
STEP 22
2
2
1
CD01F018
Remove the retaining screws (1) from the two CD01F021
retaining plates (2). Remove the plates (2). Mark the position of the swash plate (2) in the
housing. Install two threaded rods (M5x140) (1) on
STEP 20 the swash plate (2). Remove the swash plate (2) with
the roller thrust bearings, retain the guides (3) and
the guide rods (4).
1
3
CD01F019
Remove the cylinder block (1) taking care not to let 4
the pistons fall.
CI01E521

Copyright ©
8010-11
STEP 23 STEP 26
1
2
CD01F022 CI01E522
Remove the outer rings (1) from the roller thrust Remove the snap ring (1) force the bearing out (2)
bearings. (arrows).
STEP 24 STEP 27
3
1
2
1
CD01F023 CD01F024
Remove the plug (1). Remove the shaft (2) (use a Dismantling the front pump body (1). Remove the
magnet) (four parts). four retaining screws (2) (M16x60). Install two lifting
rings (3) (M16x60). For disassembly of the front body
STEP 25 carry out steps 17 to 24.
STEP 28
4
3
CI01E524
Remove the snap ring (1). Remove and discard the
lip seal (2). Install the housing (3) under a press and CD01F025
force the shaft (4) out (boom). Mark the position of the pistons in the cylinder block.
Remove the pistons with the retaining plate.

Copyright ©
8010-12
STEP 29 STEP 32
1
1 2 3 2 4 2
CI01E526 CD01F027
Remove the spherical bushing (1), the shims (2) and Removing the dual pressure balance valve. Remove
the spring washers (3) from the cylinder block (4). the retaining screws (1) and remove the cover (2).
STEP 30 STEP 33
1 2
1
4
3
CD01F026 CD01F028
Identify and remove the pistons (1) from the retaining Remove the spool (1) from the body (2). Remove the
plate (2). piston (3) from the cover (4).
STEP 31 STEP 34
1 2
2 3
3
1
5
4
CD01E529 CD01F029
Remove the snap ring (1), remove the shim (2), the Removal of the gear pump. Remove the screws (1)
spring (3) and the shim (4) from the cylinder block (5). and separate the pump (2) from the flange (3).

Copyright ©
8010-13
STEP 35 STEP 37
1
1
3
CD01F030 CD01F032
Remove the snap ring (1), make an identification Remove the seal carrier plate (1). Remove the gears
mark between the body and the cover. (2) and (3) and discard the seals.
STEP 36
2
3
CD01F031
Remove the four retaining screws (1). Separate the
body (2) from the cover (3).

Copyright ©
8010-14
ASSEMBLY
STEP 1 STEP 3
1
2
CI01E523 CD01F022
Install the outer thrust bearings (1) in the housing.
WARNING: Wear insulating gloves when STEP 4
! handling hot parts.
1
Heat the bearing (1) in an oven to 80±5°C.
Install the bearing (1) on the shaft (2). 3
NOTE: Do not heat the bearing to a temperature
greater than 100°C.
Install the snap ring (3). 5
STEP 2 4 2
5 2
3
4 CD01F033
1 Degrease the swash plate (1) and specially the

tappings (M5) (coat the screws with Loctite). Apply
grease liberally to the bearing (2) and the roller thrust
bearings (3). Install the roller thrust bearings (3) on
the bearings (2). Install the guide rods (4) with the
guides (5) in the swash plate (1) and in the roller
thrust bearings (3) (four positions), turn the swash
plate over.
CI01E525
Install the housing (1) under a press and assemble
the shaft (2) complete with its bearing. Install the
snap ring (3). Install a new lip seal (4). Install the
snap ring (5).

Copyright ©
8010-15
STEP 5 STEP 7
2
3
CD01F021 CD01F020
Degrease the threaded rods (1) (M5x140) and screw Install the adjusting screws (1) equipped with nuts
them onto the swash plate (2). Install the swash plate (min/max flow), tighten the screw and nut
(2) in the housing, positioning the thickest portion of simultaneously. Check the dimension recorded during
the swash plate (2) on the central plug (3) side (mark disassembly.
made during disassembly).
STEP 8
STEP 6
6 7 4
3 2 1 5
CI01E526
CD01F034 Install the shim (1). Install the spring washers (2)
Position the swash plate so as to line up the roller opposite each other. Install the shim (3). Install the
bearing guide rods with the holes of the pivot bolt spherical bushing (4) on the cylinder block (5). Install
(arrow). Install the shaft in such a way that the guide the pistons (6) on the retaining plate (7). Oil and
rod fits into the shaft fork (use the screw driving install the pistons (6) in the cylinder block (5) (mark
recess on the shaft to rotate the shaft if necessary). made during disassembly).
Install and tighten the shaft plugs to a torque of 9.8 to
13 Nm.

Copyright ©
8010-16
STEP 9 STEP 11
1
2
1
2
3
4
CD01F035 CD01F037
Install the cylinder block (1) in the housing (2) by Install the large piston push rod (1). Install the small
engaging the splines of the cylinder block (1) on the piston push rod (2). Install a new seal (3). (4)
driving shaft (take care not to drop the pistons into reference mark of the plug in the position where the
the housing). rods have to be installed.
STEP 10 STEP 12
1
5
1 4
2
3
2
3
CD01F036 CD01F016
Coat the screws (1) with Loctite and install the two Install the small diameter piston (1) and the large
retaining plates (2) on the swash plate (3) (torque of diameter piston (2). Install the bearing (3) in the
6.9 to 8.3 Nm). intermediate plate (4). Coat the cylinder block
machined plate (5) with grease. Install the machined
plate (5) on the intermediate plate. Install two lifting
rings on the intermediate plate.

Copyright ©
8010-17
STEP 13 STEP 15
2
1
3
1
4
3
4
2
CD01F038 CD01F028
Lift and install the intermediate plate (1) on the pump
body (2). Take care to position the push rods in the
pistons (3). Take care to ensure that the cylinder
block machined plate does not fall during assembly. 4
Install and tighten the four retaining screws (M16x60)
(4) to a torque of 230 to 270 Nm.
STEP 14
5
2
CD01F027
Reassemble the balance valve. Install the spool (1) in
the body (2), the piston (3) in the cover (4), assemble
the body (2) and the cover (4), tightening the screws
1 (5) to a torque of 28 to 35 Nm.
CD01F015
Follow steps 1 to 13 to reassemble the other pump
body. Sling using a M10 lifting ring. Install the pump
shaft coupling. Install new seals. Install the assembly
by following the reference marks made during
disassembly. Position and guide the push rods in the
small and large diameter pistons. Install and tighten
the screws (M16x60) (1) to a torque of 230 to 270 Nm.

Copyright ©
8010-18
STEP 16 STEP 18
1 2
3 1
4 3
6
2
5
CD01F032 CD01F010
Install the spring (1) in the guide (2). Oil and install
the spool (3).
8
STEP 19
9 7
1
3
2 4
CD01F039
Install the gears (1) and (2). Install new seals (3) on
the seal carrier plate (4). Install the seal carrier plate
(4) in the pump body (5). Pressure outlet port (6). CD01F009
Install the cover (7) on the pump body (5). Install and Oil and install the piston (1) in the cover (2). Install
tighten the retaining screws to a torque of 28 to 35 Nm. the spring (3), install and tighten the plug (4) to a
Install a retaining ring (8). Install a new seal (9). torque of 31 to 41 Nm.
STEP 17 STEP 20
1 1
2
2
CD01F029 CD01F040
Install the pump (1) on the flange (2). Install and Install the piston (1) in the pump body (2).
tighten the screws (3) to a torque of 28 to 35 Nm.

Copyright ©
8010-19
STEP 21 STEP 24
1
CD01F007 CD01F041
Install new seals. Install the control block (1) and Install and tighten the control assembly (1) in the
tighten the screws to a torque of 28 to 35 Nm. control block (2) (torque of 74 to 88 Nm).
STEP 22 STEP 25
3
1
1
CI01E527 CD01F005
Push the control lever (1) (arrow) fully so as to make Install the spring (1), oil and install the sleeve (2)
the swash plate tip up. complete with its spool in the control block (3).
STEP 23 STEP 26
1 3
1
2
5 4
CI01E528 CD01F004
Install new seals (1). Do not change the setting of the Reassemble the negative pressure setting block (1).
adjusting screw (2), grease the spring (3) and the Tightening torque of 6.9 to 8.3 Nm.
guide (4) liberally and install them in the adjustment
cap (5).

Copyright ©
8010-20
STEP 27 STEP 29
2
2
1
1
CD01F003 CD01F001
Grease and install the linkage rod in the spool (1). Install the DRE4 K control block (1). Install the DRE4 K
Install the spool (1) in the control block (2) with the cover (2). Install the two plates on the A20V064-999
connecting rod in front. Install the spring on the model. Tighten the screws to a torque of 12 to 15 Nm.
A20V064-999 models.
STEP 30
STEP 28
3
1
2
CD01F013
CD01F002 Install the coupling (1) on the pump shaft. Install the
Install a new seal on the control block. Install the low-pressure pump (2) on the high-pressure pump
cover (1) equipped with the spring and the spool. (3). Tighten the screws to a torque of 28 to 35 Nm.
Tighten the screws to a torque of 6.9 to 8.3 Nm.
Install the two plates on the A20V064-999 model. STEP 31
CD01F012
Install the front and rear pump balance valve (1).
Tighten the screws to a torque of 28 to 35 Nm.

Copyright ©
8010-21
STEP 32 STEP 33
CD01F011
Install the safety valve block (1). Tighten the screws
to a torque of 28 to 35 Nm.
2
1
CI01E519
Install the hoses and the connecting tubes (arrows).
Install the flange (1) on the pump and tighten the
screws (2) to a torque of 98 to 123 Nm.

Copyright ©
8010-22
NOTES

Copyright ©
8011
Section
8011

OF THE CONTROL VALVE

Printed in France
Copyright ©
8011-2
TABLE OF CONTENTS
Torque setting ....................................................................................................................................................... 4
Description ........................................................................................................................................................... 6
CONTROL VALVE................................................................................................................................................... 7
Separating the sections ........................................................................................................................................ 8
Assembling the sections ...................................................................................................................................... 8
Removing the non-return check valves (13), (14), (15), (16), (17) .......................................................................9
Removing the options plate (27) .......................................................................................................................... 9
Removing the swing priority block (11) ...............................................................................................................10
Removing the plugs (34) ....................................................................................................................................10
Removing the cancellation valve (23) ................................................................................................................10
Removing the dipper extend and dipper retract safety valves (9) and (10) .......................................................10
Removing the dipper recyclable flow non-return check valve (28) .....................................................................10
Removing the boom pressure non-return check valve (29) ...............................................................................10
Removing the spools for dipper 1, option, boom 2, swing, RH travel (2a), (2b), (2c), (2d), (2e) ........................10
Removing the 39 bar supply block (30) .............................................................................................................. 11
Installing the spools for dipper 1, option, boom 2, swing, RH travel (2a), (2b), (2c), (2d), (2e) .......................... 11
Installing the boom pressure non-return check valve ......................................................................................... 11
Installing the dipper recyclable flow non-return check valve (28) ....................................................................... 11
Installing the dipper extend and dipper retract safety valves (9), (10) ............................................................... 11
Installing the 39 bar supply block (30) ................................................................................................................ 11
Installing the cancellation valve (23) .................................................................................................................. 11
Installing the plugs (34) ...................................................................................................................................... 11
Installing the swing priority block (11) ................................................................................................................. 11
Installing the option plate (27) ............................................................................................................................12
Installing the non-return check valves (13), (14), (15), (16), (17) .......................................................................12
Installing the dipper load holding block (3) .........................................................................................................12
Removing the section for dipper 2, bucket, boom 1, LH travel ........................................................................13
Removing the boom load holding block (4) ........................................................................................................13
Removing the non-return check valves (18), (19) (20), (21) ..............................................................................13
Removing the free passage locking (26) ............................................................................................................13
Removing the plugs (34) ....................................................................................................................................13
Removing the dipper semi-parallel valve block (12) ..........................................................................................13
Removing the cancellation valve (24) ................................................................................................................13
Removing the close bucket, boom lowering, open bucket, boom raising safety valves (5), (6), (7), (8) ............14
Removing the main relief valve (25) ...................................................................................................................14
Removing the non-return check valves from the relief valve (22) ......................................................................14
Removing the spools for dipper 2, bucket, boom 1, LH travel and straight-line travel (2a), (2b), (2c), (2d), (2e) .......14
Installation .............................................................................................................................................................14
Installing the section for dipper 2, bucket, boom 1, LH travel ............................................................................14
Installing the spools for dipper 2, bucket, boom 1, LH travel, and straight-line travel (2a), (2b), (2c), (2d), (2e) .........14
Installing the relief valve non-return check valves (22) ......................................................................................14
Installing the main relief valve (25) .....................................................................................................................14
Installing the safety valves for: close bucket, boom lowering, open bucket, boom raising (5), (6), (7), (8) ........15
Installing the cancellation valve (24) ..................................................................................................................15
Installing the dipper semi-parallel valve block (12) ............................................................................................15
Installing the plugs (34) ......................................................................................................................................15
Installing the free passage locking (26) ..............................................................................................................16
Installing the non-return check valves (18), (19), (20), (21) ...............................................................................16
Installing the boom (4) load holding block ..........................................................................................................16

Copyright ©
8011-3
DIPPER LOAD HOLDING BLOCK (3) .................................................................................................................. 17
Disassembly .......................................................................................................................................................17
Inspection ...........................................................................................................................................................17
Assembly ............................................................................................................................................................17
BOOM LOAD HOLDING BLOCK (4) .................................................................................................................... 18
Disassembly .......................................................................................................................................................18
Inspection ...........................................................................................................................................................18
Assembly ............................................................................................................................................................18
NON RETURN CHECK VALVE............................................................................................................................. 20
Disassembling the non-return check valve for dipper (13), bucket (19) and boom 1 (20) .............................20
Inspection ...........................................................................................................................................................20
Assembly ............................................................................................................................................................20
Disassembling the non-return check valves for option (14), boom 2 (15) and swing (16) ............................20
Inspection ...........................................................................................................................................................20
Assembly ............................................................................................................................................................20
Disassembling the non-return check valve for RH travel (17) and dipper (18) ...............................................21
Inspection ...........................................................................................................................................................21
Assembly ............................................................................................................................................................21
Disassembling the LH travel non-return check valve (21) ................................................................................21
Inspection ...........................................................................................................................................................21
Assembly ............................................................................................................................................................21
Boom non-return check valve (33) ......................................................................................................................22
Disassembly .......................................................................................................................................................22
Inspection ...........................................................................................................................................................22
Assembly ............................................................................................................................................................22
Main relief valve non-return check valve (22) ....................................................................................................22
Disassembly .......................................................................................................................................................22
Inspection ...........................................................................................................................................................22
Assembly ............................................................................................................................................................22
Boom pressure non-return check valve (29) .....................................................................................................23
Disassembly .......................................................................................................................................................23
Inspection ...........................................................................................................................................................23
Assembly ............................................................................................................................................................23
Dipper recyclable flow non-return check valve (28) ..........................................................................................23
Disassembly .......................................................................................................................................................23
Inspection ...........................................................................................................................................................23
Assembly ............................................................................................................................................................23
39 bar supply block (30) .......................................................................................................................................24
Disassembly .......................................................................................................................................................24
Inspection ...........................................................................................................................................................24
Assembly ............................................................................................................................................................24
Compensation valve (31) (32) ..............................................................................................................................24
Disassembly .......................................................................................................................................................24
Inspection ...........................................................................................................................................................24
Assembly ............................................................................................................................................................24
SWING PRIORITY BLOCK (11) ............................................................................................................................ 25
Disassembly .......................................................................................................................................................25
Inspection ...........................................................................................................................................................25
Assembly ............................................................................................................................................................25
SEMI-PARALLEL VALVE BLOCK (12) ............................................................................................................... 26
Disassembly .......................................................................................................................................................26
Inspection ...........................................................................................................................................................26
Assembly ............................................................................................................................................................27

Copyright ©
8011-4
CANCELLATION VALVE (23), (24) ...................................................................................................................... 28
Disassembly .......................................................................................................................................................28
Inspection ...........................................................................................................................................................28
Assembly ............................................................................................................................................................28
FREE PASSAGE LOCKING (26) .......................................................................................................................... 29
Disassembly .......................................................................................................................................................29
Inspection ...........................................................................................................................................................29
Assembly ............................................................................................................................................................29
Safety valve for close bucket (5), boom lowering (6), open bucket (7), boom raising (8),
dipper extend (9), dipper retract (10) ..............................................................................................................30
Disassembly .......................................................................................................................................................30
Inspection ...........................................................................................................................................................30
Assembly ............................................................................................................................................................30
Main relief valve (25) ............................................................................................................................................30
Disassembly .......................................................................................................................................................30
Inspection ...........................................................................................................................................................30
Assembly ............................................................................................................................................................30
Inspection ..............................................................................................................................................................31
Torque setting
Plug for dipper flow recyclable non-return check valve (28)............................................................................. 50 Nm
Non-return check valve with boom flow reducer (29) on the control valve ....................................................... 60 Nm
Adaptor on the body of the cancellation valve (23) and (24) ............................................................................ 59 Nm
Cancellation valve (23) and (24) on the control valve ...................................................................................... 59 Nm
Plug M5 on the swing priority plate (11) ........................................................................................................... 20 Nm
Plug M10 on the swing priority plate (11) ......................................................................................................... 59 Nm
Screw M6 retaining the swing priority plate (11) on the control valve............................................................... 30 Nm
Non-return check valve - RH travel (17), option (14), boom 2 (15), swing (16), dipper (13),
LH travel (21), dipper (18), bucket (19) ....................................................................................................... 98 Nm
Plug M5 on the load holding block (3) and (4).................................................................................................. 20 Nm
Plug M8 on the load holding block (3) and (4).................................................................................................. 49 Nm
Plug M10 on the load holding block (3) and (4)................................................................................................ 59 Nm
Screw retaining the load holding block (3) and (4) on the control valve ........................................................... 50 Nm
Cover for control valve spools .......................................................................................................................... 30 Nm
Safety valve on the control valve...................................................................................................................... 60 Nm
Plug for boom non-return check valve (33) ...................................................................................................... 30 Nm
Plug M10 on the dipper semi-parallel valve block (12)..................................................................................... 60 Nm
Plug M8 on the dipper semi-parallel valve block (12)....................................................................................... 50 Nm
Plug M27 on the dipper semi-parallel valve block (12)..................................................................................... 60 Nm
Screw retaining the semi-parallel valve block on the control valve .................................................................. 30 Nm
Free passage locking adaptor (26)................................................................................................................... 98 Nm
Plug on the non-return check valve - travel LH (21) ......................................................................................... 39 Nm

8011-5
Copyright ©

Copyright ©
8011-6
Description
31 32
34 11 1 12
2 28
1a 24 26 34
34 23
9 2a 18
10 1b 5
1c 19
13 7
14 3
27 2b
2c
15 4
8
2d
1d
16 20
2e 29
1e 6 21
17 30 30 34 33 25
22
34
CI00J501

Copyright ©
8011-7
CONTROL VALVE
Identifying the ports
Refer to section 8001
Description
1. Section for dipper 2, bucket, boom 1, LH travel, straight-line travel
1a: Dipper spool 2
1b: Bucket spool
1c: Boom spool 1
1d: LH travel spool
1e: Straight-line travel spool
2. Section for dipper 1, option, boom 2, swing, RH travel
2a: Dipper spool 1
2b: Option spool
2c: Boom spool 2
2d: Swing spool
2e: RH travel spool
3. Dipper load holding block
4. Boom load holding block
5. Close bucket safety valve
6. Boom lowering safety valve
7. Open bucket safety valve
8. Boom raising safety valve
9. Dipper extend safety valve
10. Dipper retract safety valve
11. Swing priority block
12. Semi-parallel valve
13. Dipper non-return check valve
14. Option non-return check valve
15. Boom 2 non-return check valve
16. Swing non-return check valve
17. RH travel non-return check valve
18. Dipper non-return check valve
19. Bucket non-return check valve
20. Boom 1 non-return check valve
21. LH travel non-return check valve
22. Main relief valve non-return check valve
23. Cancellation valve
24. Cancellation valve
25. Main relief valve
26. Free passage locking
27. Option plate
28. Dipper recyclable flow non-return check valve
29. Boom pressure non-return check valve
30. 39 bar supply block
31. Compensator valve
32. Compensator valve
33. Boom non-return check valve
34. Plug

Copyright ©
8011-8
Disassembling the control valve Re-assembling the control valve

Separating the sections Assembling the sections
STEP 1 STEP 1
Remove the control valve from the machine, See Install the O-rings (e, f, g, h and i).
section 8004.
STEP 2
STEP 2
Assemble and tighten the two sections together,
Clean the outside of the control valve with a suitable using the screws and (a and c) and washers (b and
cleaning solvent to eliminate all traces of impurities, d).
grease or other foreign bodies. Dry, using low
pressure compressed air. STEP 3
For the installation procedure, See section 8004.
STEP 3
a b c d
a b c d
CI00E506 CI00E504
Separate the two sections of the control valve by
removing the screws (a and c) and washers (b and
d).
STEP 4
e f
h
f
f
g
f
f e
CI00H500
Scrap the O-rings (e, f, g, h and i).

Copyright ©
8011-9
Removing the section for dipper 1, Removing the non-return check valves
option, boom 2, swing, RH travel (13), (14), (15), (16), (17)
The numbers in brackets refer to the drawing on STEP 1
page 6. Remove the dipper non-return check valve from the
control valve.
Removing the load holding block
for dipper (3) STEP 2
Remove the option non-return check valve from the
STEP 1
control valve.
STEP 3
Remove the boom 2 non-return check valve from the
control valve.
STEP 4
Remove the swing non-return check valve from the
control valve.
b STEP 5
a
c Remove the RH travel non-return check valve from
the control valve.
d
Removing the options plate (27)
STEP 1
Unscrew the screws and remove the option plate
CI00H501 from the control valve.
Unscrew the four screws and remove the dipper load
holding block. STEP 2
STEP 2 Scrap the O-ring.
Scrap the O-rings (a) and (b).

STEP 3
Remove the spring (c) and the non-return check
valve (d) from the control valve).

Copyright ©
8011-10
Removing the swing priority block (11) Removing the plugs (34)
STEP 1 Remove the plugs from the control valve. Scrap the
O-rings, and the back-up rings.
a
Removing the cancellation valve (23)
Remove the cancellation valve from the control valve.
Removing the dipper extend and dipper
retract safety valves (9) and (10)
STEP 1
Remove the dipper extend safety valve from the
control valve.
STEP 2
CI00H506
Remove the dipper retract safety valve from the
control valve.
NOTE: Do not touch the safety valve adjustments
during the disassembly, otherwise see section 8001
for the safety valve settings.
b
c Removing the dipper recyclable flow
e d non-return check valve (28)
f Remove the dipper recyclable flow non-return check
valve.
g
Removing the boom pressure non-return
check valve (29)
CI00H508 Remove the boom pressure non-return check valve.
Unscrew the screws (a) and remove the swing
priority block from the control valve. Removing the spools for dipper 1,
option, boom 2, swing, RH travel (2a),
STEP 2 (2b), (2c), (2d), (2e)
Scrap the O-rings (b), remove the seat (c), scrap the
O-ring (d) and the back-up ring (e). Remove the
STEP 1
check valve (f) and then the spring (g). Remove from the control valve: the covers of the
spools for dipper 1, option, boom 2, swing, RH travel.
Scrap the O-rings.
STEP 2
Use labels to identify the spools, then remove them
from the control valve.
NOTE: Do not remove the springs from the spools, if
a spring is damaged or broken, change the spool
assembly and check the condition of the spool
chamber. If it is scratched or marked, change the
complete section.

Copyright ©
8011-11
Removing the 39 bar supply block (30) Installing the 39 bar supply block (30)
Remove the supply block 39 bar from the control Install the 39 bar supply block on the control valve.
valve.
Installing the cancellation valve (23)
Installation Install the pump regulation check valve on the control
valve. Tighten to a torque of 59 Nm.
Installing the spools for dipper 1, option,
boom 2, swing, RH travel (2a), (2b), (2c), Installing the plugs (34)
(2d), (2e) Install new O-rings and back-up rings on the plugs.
STEP 1 Install and tighten the plugs on the control valve.
Install the spools in the control valve using the Installing the swing priority block (11)
identification labels affixed during disassembly.
STEP 1
STEP 2 b
Install on the control valve: new O-rings and then the
covers for the spools for dippers 1, option, boom 2, e d
swing, RH travel. Tighten to a torque of 30 Nm.
c
Installing the boom pressure non-return
f
check valve
Install the boom pressure non-return check valve on
the control valve. Tighten to a torque of 59 Nm. g
Installing the dipper recyclable flow non-
return check valve (28)
CI00H508
Install the dipper recyclable flow non-return check
Install the spring (g) on the control valve, and then
valve on the control valve. Tighten to a torque of
the check valve (f). Install (c) a new O-ring (d) and
59 Nm.
back-up ring (e) on the seat. Install the seat (c) in the
Installing the dipper extend and dipper control valve.
retract safety valves (9), (10) STEP 2
STEP 1
a
Install the dipper extend safety valve on the control
STEP 2
Install the dipper retract safety valve on the control
CI00H506
Install O-rings (b) on the swing priority block, install
the block on the control valve. Tighten the screws (a)
to a torque of 49 Nm.

Copyright ©
8011-12
Installing the option plate (27) Installing the dipper load holding block (3)
STEP 1 STEP 1
Install a new O-ring on the option plate.
STEP 2
Install the option plate on the control valve.
b
Installing the non-return check valves
(13), (14), (15), (16), (17)
a c
STEP 1
Install the non-return check valve for RH travel on the
control valve. Tighten to a torque of 98 Nm. d
STEP 2
CI00H501
Install the swing non-return check valve on the Install new O-rings (a) and (b) on the load holding
control valve. Tighten to a torque of 98 Nm. block.
STEP 3 STEP 2
Install the boom (2) non-return check valve on the Install, the non-return check valve (d) and then the
control valve. Tighten to a torque of 98 Nm. spring (c) on the control valve.
STEP 4 STEP 3
Install the option non-return check valve on the Install the load holding block dipper on the control
control valve. Tighten to a torque of 98 Nm. valve. Tighten to a torque of 50 Nm.
STEP 5
Install the dipper non-return check valve on the
control valve. Tighten to a torque of 98 Nm.

Copyright ©
8011-13
Removing the section for dipper 2, Removing the free passage locking (26)
bucket, boom 1, LH travel Remove the adaptor from the control valve. Remove
The numbers in brackets refer to the drawing on page 6. the spool and then the spring.
Removing the boom load holding block (4) Removing the plugs (34)
Remove the plugs from the control valve, scrap the
STEP 1
O-rings and the back-up rings.
Loosen and then remove the four screws. Remove
the boom load holding block. Scrap the O-rings (a) Removing the dipper semi-parallel valve
and (b). block (12)
STEP 1
a
a
b
c
d a
CI00H517
STEP 2 CI00H520
Loosen and then remove the screws (a) holding the
Remove the spring (c) and then the check valve (d) dipper semi-parallel valve block. Remove the block
from the control valve. from the control valve.
Removing the non-return check valves STEP 2
(18), (19) (20), (21)
b
STEP 1
Remove the dipper 2 non-return check valve from the
control valve. d e
c
STEP 2
Remove the bucket non-return check valve from the f g
control valve.
STEP 3
Remove the boom 1 non-return check valve from the
control valve. CI00H508
Scrap the O-rings (b), remove the seat (c), scrap the
STEP 4
O-ring (d) and the back-up ring (e). Remove the
Remove the LH travel non-return check valve from check valve (f) and then the spring (g).
the control valve.
Removing the cancellation valve (24)
Remove the pump cancellation valve from the control
valve.

Copyright ©
8011-14
Removing the close bucket, boom Removing the spools for dipper 2, bucket,
lowering, open bucket, boom raising boom 1, LH travel and straight-line travel
safety valves (5), (6), (7), (8) (2a), (2b), (2c), (2d), (2e)
STEP 1 STEP 1
Remove the close bucket safety valve from the Remove the spool covers from the control valve,
control valve. scrap the O-rings.
STEP 2 STEP 2
Remove the boom lowering safety valve from the Use labels to identify the spools and then remove
control valve. them from the control valve.
STEP 3 NOTE: Do not remove the springs from the spools, if
a spring is damaged or broken, change the spool
Remove the open bucket safety valve from the assembly and check the condition of the chamber. If
control valve. it is scratched or marked, change the complete
STEP 4 section.
Remove the boom raising safety valve from the Installation

control valve.
Installing the section for dipper 2,
NOTE: Do not touch the safety valve adjustments bucket, boom 1, LH travel
during disassembly, otherwise see section 8001 for
the safety valve settings. Installing the spools for dipper 2, bucket,
boom 1, LH travel, and straight-line travel
Removing the main relief valve (25)
(2a), (2b), (2c), (2d), (2e)
Remove the main relief valve from the control valve.
STEP 1
NOTE: Do not touch the main relief valve
adjustments during disassembly, otherwise see Install the spools in the control valve, using the
section 8001 for the main relief valve settings. identification labels.
Removing the non-return check valves STEP 2

from the relief valve (22) Install the O-rings and then the covers on the control
Remove the two relief valve non-return check valves valve. Tighten to a torque of 30 Nm.
from the control valve. Installing the relief valve non-return
check valves (22)
Install and tighten the 2 relief valve non-return check
valves on the control valve.
Installing the main relief valve (25)
Install and tighten the main relief valve on the control
valve.
NOTE: Do not touch the adjustments of the main
relief valve during disassembly, otherwise see
section 8001 for adjusting the main relief valve.

Copyright ©
8011-15
Installing the safety valves for: close Installing the dipper semi-parallel valve
bucket, boom lowering, open bucket, block (12)
boom raising (5), (6), (7), (8) STEP 1
NOTE: Do not touch the adjustments of the safety
valves during disassembly, otherwise see section
8001 for adjusting the safety valves. b
STEP 1
Install the boom raising safety valve on the control
c d e
STEP 2
Install the open bucket safety valve on the control
f g
STEP 3
CI00H508
Install the boom lowering safety valve on the control Install the spring (g) on the control valve. Then install
valve. Tighten to a torque of 59 Nm. the check valve (f). Install a new O-ring (d) and back-
STEP 4 up ring (e) on the seat (c). Install the seat (c) in the
control valve.
Install the close bucket safety valve on the control
valve. Tighten to a torque of 59 Nm. STEP 2
Installing the cancellation valve (24)
a
Install the pump cancellation valve on the control
CI00H520
Install O-rings (b) on the semi-parallel valve block.
Install the block on the control valve. Tighten the
screws (a) to a torque of 30 Nm.
Installing the plugs (34)
Install the plugs complete with a new O-ring and
back-up rings on the control valve and tighten them.

Copyright ©
8011-16
Installing the free passage locking (26) Installing the boom (4) load holding
Install the spring and then the spool on the control block
valve. Install a new O-ring on the plug. Install the plug STEP 1
on the control valve. Tighten to a torque of 98 Nm.
Installing the non-return check valves
(18), (19), (20), (21)
STEP 1
Install the LH travel non-return check valve on the
a
STEP 2 b
c
Install the boom 1 non-return check valve on the
d
STEP 3
CI00H517
Install the bucket non-return check valve on the Install the check valve (d) on the control valve, and
control valve. Tighten to a torque of 98 Nm. then the spring (c).
STEP 4 STEP 2
Install the dipper 2 non-return check valve on the Install new O-rings (b), (a) on the boom load holding
control valve. Tighten to a torque of 98 Nm. block.
STEP 3
Install the load holding block boom on the control

Copyright ©
8011-17
DIPPER LOAD HOLDING BLOCK (3)

Disassembly
STEP 1
A PLUG
B O-RING
l C PISTON
k D PLUG
c j g E O-RING
i h f F SPRING
G CHECK VALVE
H SLEEVE
I O-RING
b a d e J O-RING
K BACK-UP RING
L BACK-UP RING
M PLUG
n m N O-RING
r s O SPACER
o p g P SPRING
Q NON-RETURN CHECK VALVE
R O-RING
S BACK-UP RING
CI00J502
STEP 2
Remove the plug (a) and scrap the O-ring (b).
Install a new O-ring (n) on the plug (m). Install the
STEP 2 plug (m) on the load holding block. Tighten to a
Remove the piston (c) from the load holding block. torque of 20 Nm.
STEP 3 STEP 3
Remove the plug (d), scrap the O-rings (e), (r) and Install new O-rings (i) and (j), and new back-up rings
the back-up ring (s). (k) and (l) on the sleeve (h). Install the sleeve (h) on
the load holding block.
STEP 4
STEP 4
Remove the spring (f) and the check valve (g).
Install the check valve (g) and then the spring (f) in
STEP 5 the sleeve (h).
Remove the sleeve (h) from the block. Scrap the STEP 5
O-rings (i) and (j) and the back-up rings (k) and (l).
Install new O-rings (e), (r) and a back-up ring (s) on
STEP 6 the plug (d). Install the plug (d) on the load holding
block. Tighten to a torque of 49 Nm.
Remove the plug (m). Scrap the O-ring (n).
STEP 6
STEP 7
Install the piston (c) in the load holding block.
Remove the spacer (o), the spring (p) and the non-
return check valve (q). STEP 7
Inspection Install a new O-ring (b) on the plug (a). Install the
plug (a) on the load holding block. Tighten to a torque
See "Inspection" chapter page 31.
of 59 Nm.
Assembly
STEP 1
Install the non-return check valve (q), the spring (p)
and the spacer (o) in the load holding block.

Copyright ©
8011-18
BOOM LOAD HOLDING BLOCK (4)

Disassembly
STEP 1
A PLUG
B O-RING
C PISTON
s l D PLUG
f E O-RING
r h j F SPRING
G CHECK VALVE
H SLEEVE
a b I O-RING
e d J O-RING
K BACK-UP RING
L BACK-UP RING
M PLUG
g N O-RING
O SPACER
P SPRING
i k o
q p Q NON-RETURN CHECK VALVE
R O-RING
S BACK-UP RING
CI00J503
Inspection
Remove the plug (a) from the boom load holding
block, scrap the O-ring (b). See "Inspection" chapter page 31.
STEP 2 Assembly
Remove the piston (c) from the boom load holding STEP 1
block.
Install the non-return check valve (q), the spring (p)
STEP 3 and the spacer (o) on the load holding block.
Remove the plug (d) from the boom load holding STEP 2
block, scrap the O-rings (e), (r) and the back-up ring
Install a new O-ring (n) on the plug (m). Install the
(s).
plug (m) on the load holding block. Tighten to a
STEP 4 torque of 20 Nm.
Remove the spring (f) and the check valve (g) from STEP 3
the boom load holding block.
Install new O-rings (i) and (j) and back-up rings (k)
STEP 5 and (l) on the sleeve (h). Install the sleeve (h) on the
boom load holding block.
Remove the sleeve (h) from the boom load holding
block, scrap the O-rings (i) and (j) and the back-up STEP 4
rings (k) and (l).
Install the check valve (g) and the spring (f) in the
STEP 6 sleeve (h).
Remove the plug (m) from the boom load holding STEP 5
block, scrap the O-ring (n).
Install new O-rings (e), (r) and back-up rings (s) on
STEP 7 the plug (d). Install the plug (d) on the boom load
holding block. Tighten to a torque of 49 Nm.
Remove, the spacer (o), the spring (p) and the non-
return check valve (q) from the boom load holding
block.

Copyright ©
8011-19
STEP 6
Install the piston (c) on the boom load holding block.
STEP 7
Install a new O-ring (b) on the plug (a). Install the
plug (a) on the load holding block. Tighten to a torque
of 59 Nm.

Copyright ©
8011-20
NON RETURN CHECK VALVE

Disassembling the non-return Disassembling the non-return
check valve for dipper (13), bucket check valves for option (14), boom
(19) and boom 1 (20) 2 (15) and swing (16)
STEP 1 STEP 1
a a
f
b c
e
b c
e
d d
CI00H502 CI00H503
Scrap the O-ring (b) and the back-up ring (c) from the Scrap the O-ring (b) and the back-up ring (c) from the
body (a). body (a).
STEP 2 STEP 2
Remove the non-return check valve (d), the spring (e) Remove the non-return check valve (d) and the
and the check valve (f). spring (e) from the body (a).
Inspection Inspection
See "Inspection" chapter page 31. See "Inspection" chapter page 31.
Assembly Assembly
STEP 1 STEP 1
Install the check valve (f), the spring (e) and the non- Install the spring (e) and the non-return check valve
return check valve (d) on the body (a). (d) on the body (a).
STEP 2 STEP 2
Install a new O-ring (b) and a back-up ring (c) on the Install a new O-ring (b) and back-up ring (c) on the
body (a). Install the body (a) on the control valve. body (a). Install the body (a) on the control valve.
Tighten to a torque of 98 Nm. Tighten to a torque of 98 Nm.

Copyright ©
8011-21
Disassembling the non-return Disassembling the LH travel

check valve for RH travel (17) and non-return check valve (21)
dipper (18) STEP 1
STEP 1 e
a d
a
c b
b c
e
f
g
d
CI00H518
Scrap the O-ring (b) and the back-up ring (c) from the
CI00H504
Scrap the O-ring (b) and the back-up ring (c) from the body (a).
body (a). STEP 2
STEP 2 Remove the body of the non-return check valve (a)
Remove the non-return check valve (d) and the using a soft-jawed vice. Remove the plug (d) and
spring (e) from the body (a). scrap the O-ring (e).
Inspection STEP 3
See "Inspection" chapter page 31. Remove the spring (f) and the check valve (g) from
the body (a).
Assembly
Inspection
STEP 1
Install the spring (e) and the non-return check valve
(d) on the body (a). Assembly
STEP 2 STEP 1
Install a new O-ring (b) and a back-up ring (c) on the Install the check valve (g) and the spring (f) in the
body (a). Install the non-return check valve (a) on the body (a).
control valve. Tighten to a torque of 98 Nm. STEP 2
Install the body (a) in a soft-jawed vice. Install a new
O-ring (e) on the plug (d). Install the plug (d) on the
body (a). Tighten to a torque of 39 Nm.
STEP 3
Install a new O-ring (b) and back-up ring (c) on the
body (a). Install this non-return check valve assembly

Copyright ©
8011-22
Boom non-return check valve (33) Main relief valve non-return check
Disassembly valve (22)
STEP 1 Disassembly
STEP 1
c d a
e
b e
a
b
c
CI00H523
Remove the plug (a). Scrap the O-ring (b).
CI00H527
STEP 2 Scrap the O-ring (b) and the back-up ring (c) from the
body (a).
Remove the spacer (c), the spring (d) and the check
valve (e) from the control valve. STEP 2
Inspection Remove the non-return check valve (d) and the
spring (e).
Inspection
Assembly
STEP 1
Assembly
Install the check valve (e) the spring (d) and the
spacer (c) on the control valve. STEP 1
STEP 2 Install the spring (e) and the non-return check valve
(d) in the non-return check valve body (a).
Install the O-ring (b) on the plug (a). Install the plug
(a) on the control valve. Tighten to a torque of 30 Nm. STEP 2
Install a new O-ring (b) and back-up ring (c) on the
non-return check valve body (a). Install and tighten
the non-return check valve assemble on the control
valve.

Copyright ©
8011-23
Boom pressure non-return check Dipper recyclable flow non-return

valve (29) check valve (28)
Disassembly Disassembly
STEP 1 STEP 1
a b d b c d
f
e a
CI00H512 CI00H511
Remove the non-return check valve block (a) and Remove the plug (a), scrap the O-ring (b).
scrap the O-ring (b).
STEP 2
STEP 2
Remove the spring (c) and remove the non-return
Remove the check valve (d) and the spring (c). check valve (d).
STEP 3 Inspection
Place the non-return check valve block (a) in a soft- See "Inspection" chapter page 31.
jawed vice, unscrew the plug (e) and scrap the O-ring
(f). Assembly
Inspection STEP 1
See "Inspection" chapter page 31. Install the non-return check valve (d) and the spring
(c) on the control valve.
Assembly
STEP 2
STEP 1
Install a new O-ring (f) on the plug (e). Install the non- plug (a) on the control valve. Tighten to a torque of
return check valve block (a) in a soft-jawed vice and 50 Nm.
then install and tighten the plug (e) on the non-return
check valve block (a).
STEP 2
Install the spring (c) and the check valve (d) on the
control valve.
STEP 3
Install a new O-ring (b) on the non-return check valve
block (a). Install the non-return check valve block (a)

Copyright ©
8011-24
39 bar supply block (30) Compensation valve (31) (32)

Disassembly Disassembly
STEP 1 STEP 1
a
b c f
c b e
d e
a
d
g
f
CI00H505 CI00H514
Remove the union (a) and scrap the O-ring (b) from Remove the adaptor (a), scrap the O-ring (b).
the control valve.
STEP 2
STEP 2
Remove the spring (c), the sleeve (d), the spool (e)
Remove the spool (c). and the sleeve (f).
STEP 3 Inspection
Remove the plug (d) and scrap the O-ring (e). See "Inspection" chapter page 31.
STEP 4 Assembly
Remove the spring (f) and the non-return check valve STEP 1
(g).
Install the sleeve (f), the spool (e), the sleeve (d) and
Inspection the spring (c) in the control valve.
See "Inspection" chapter page 31. STEP 2
Assembly Install and tighten the adaptor (a) complete with a
new O-ring (b) on the control valve.
STEP 1
Install the non-return check valve (g) and the spring
(f) on the control valve.
STEP 2
Install and tighten the plug (d) complete with a new
O-ring (e) on the control valve.
STEP 3
Install the spool (c).
STEP 4
Install and tighten the union (a) complete with a new
O-ring (b) on the control valve.

Copyright ©
8011-25
SWING PRIORITY BLOCK (11)

Disassembly
STEP 1
A PLUG
B O-RING
C SPOOL
c D SPRING
d E PLUG
F O-RING
b f G PLUG
a e H O-RING
I SPRING
J SPOOL
K PLUG
L O-RING
g
k h
l
j i
CI00H507
Inspection
Remove the plug (a), scrap the O-ring (b).
STEP 2
Assembly
Remove the spool (c) and the spring (d) from the
swing priority block. STEP 1
STEP 3 Install a new O-ring (l) on the plug (k). Install the plug
(k) on the swing priority block. Tighten to a torque of
Remove the plug (e). Scrap the O-ring (f). 20 Nm.
STEP 4 STEP 2
Remove the plug (g) from the swing priority block. Install the spool (j) and then the spring (i) on the
Scrap the O-ring (h). swing priority block.
STEP 5 STEP 3
Remove the spring (i) and the spool (j). Install a new O-ring (h) on the plug (g). Install the
STEP 6 plug (g) on the swing priority block. Tighten to a
torque of 20 Nm.
Remove the plug (k) from the swing priority block.
Scrap the O-ring (l). STEP 4
Install a new O-ring (f) on the plug (e). Install the plug
(e) on the swing priority block. Tighten to a torque of
59 Nm.
STEP 5
Install the spring (d) on the control valve, then install
the spool (c).
STEP 6
plug (a) on the swing priority block. Tighten to a
torque of 59 Nm.

Copyright ©
8011-26
SEMI-PARALLEL VALVE BLOCK (12)

Disassembly
STEP 1
A PLUG
B O-RING
C O-RING
i h D BACK-UP RINGS
d c E PISTON
g F PLUG
b G O-RING
a f H SPRING
I SPOOL
J PLUG
e K O-RING
j k L SPOOL
M SPRING
n N PLUG
o O O-RING
l P PLUG
p q m Q O-RING
CI00H521
STEP 5
Remove the plug (a) from the dipper semi-parallel
valve block, scrap the O-rings (b) and (c) and the Remove the plug (j) from the dipper semi-parallel
back-up ring (d). valve block, scrap the O-ring (k).
STEP 2 STEP 6
Remove the piston (e) from the plug (a). Remove the spool (l) from the dipper semi-parallel
valve block, then remove the spring (m).
STEP 3
STEP 7
Remove the plug (f) from the dipper semi-parallel
valve block, scrap the O-ring (g). Remove the plug (n) from the dipper semi-parallel
valve block, scrap the O-ring (o).
STEP 4
STEP 8
Remove the spring (h) and the spool (i) from the
dipper semi-parallel valve block. Remove the plug (p) from the dipper semi-parallel
valve block, scrap the O-ring (q).
Inspection

Copyright ©
8011-27
Assembly STEP 6
STEP 1 Install a new O-ring (g) on the plug (f). Install the plug
on the semi-parallel valve block. Tighten to a torque
Install and tighten the plug (p) complete with a new of 60 Nm.
O-ring (q) on the dipper semi-parallel valve block.
STEP 7
STEP 2
Install the piston (e) on the plug (a).
Install and tighten the plug (n) complete with a new
O-ring (o) on the dipper semi-parallel valve block. STEP 8
STEP 3 Install new O-rings (b) and (c) and back-up ring (d) on
the plug (a). Install the plug (a) on the semi-parallel
Install the spring (m) on the dipper semi-parallel valve valve block. Tighten to a torque of 50 Nm.
block then install the spool (l).
STEP 4
Install a new O-ring (k) on the plug (j). Install the plug
(j) on the semi-parallel valve block. Tighten to a
torque of 60 Nm.
STEP 5
Install the spool (i) and the spring (h) on the dipper
semi-parallel valve block.

Copyright ©
8011-28
CANCELLATION VALVE (23), (24)

Disassembly Assembly
STEP 1 STEP 1
Install the spring (d) and install the shims (e) in the
a d e body of the cancellation valve (a) respecting the
number of shims specified during removal.
f
STEP 2
Install a new O-ring (g) on the adaptor (f). Place the
body of the cancellation valve (a) in a soft-jawed vice.
Install the adaptor (f) on the body of the cancellation
valve (a). Tighten to a torque of 59 Nm.
c STEP 3
g
Install a new O-ring (b) on the body of the
CI00H509 cancellation valve (a). Install this body assembly on
Scrap the O-ring (b) from the body of the cancellation the control valve. Tighten to a torque of 59 Nm.
valve (a).
STEP 2
Remove the check valve (c).
STEP 3
Place the body of the cancellation valve (a) in a soft-
jawed vice and unscrew and extract the adaptor (f).
Scrap the O-ring (g).
STEP 4
Remove the shims (e) and the spring (d).
NOTE: Respect the number of shims and the order
as specified when installing.
Inspection

Copyright ©
8011-29
FREE PASSAGE LOCKING (26)

Disassembly Inspection
STEP 1 See "Inspection" chapter page 31.
Assembly
a
STEP 1
Install the spring (d) and the spool (c) on the control
b valve.
d STEP 2
Install a new O-ring (b) on the adaptor (a). Install the
adaptor (a) on the control valve. Tighten to a torque
of 98 Nm.
c
CI00H519
Remove the plug (a) from the control valve and scrap
the O-ring (b).
STEP 2
Remove the spool (c) and the spring (d).

Copyright ©
8011-30
Safety valve for close bucket (5), Main relief valve (25)
boom lowering (6), open bucket (7), Disassembly
boom raising (8), dipper extend (9),
dipper retract (10)
Disassembly a
STEP 1
c a
b
CS00E551
Scrap the O-ring (a).
NOTE: Do not touch the adjustments of the main
relief valve during disassembly, otherwise, see
CI00E508
Section 8001 for the valve adjustments.
Scrap the O-rings (a) and (b) and the back-up ring (c)
from the body of the safety valve.
Inspection
NOTE: Do not touch the adjustments of the safety See "Inspection" chapter page 31.
valve during disassembly, otherwise see Assembly
Section 8001 for the valve adjustments.
Install the main relief valve complete with a new
Inspection O-ring (a) on the control valve. Tighten the valve.
See "Inspection" chapter page 31. NOTE: Do not touch the adjustments of the main
relief valve during assembly, otherwise, see
Assembly Section 8001 for the valve adjustments.
STEP 1
Install new O-rings (a) and (b) and back-up rings (c)
on the safety valve.
STEP 2
Install the safety valve on the control valve. Tighten
to a torque of 60 Nm.
NOTE: Do not touch the adjustments of the safety
valve during disassembly, otherwise see
Section 8001 for adjusting safety valves which are
out of adjustment.

Copyright ©
8011-31
Inspection
STEP 1
Clean all components with a suitable cleaning
solvent. Dry the components with low pressure
compressed air. If the components do not have to be
assembled immediately, coat the components
generously with hydraulic fluid to protect them
against corrosion. Cover the components with clean
cloths to prevent any contamination of the parts by
dust or impurities.
STEP 2
Check for damaged, deformed or scratched threads
on threaded components. Replace defective
components.
STEP 3
Check for wear, erosion, pitting, cracks, damage to
the finish, deformation or other damage to the control
valve pistons, spools, sleeves, spacers, rings and
check valves. Replace defective components.
STEP 4
Check for cracks, breakage or other damage to
covers or housings. Check for cracks, wear or
damage to internal threads, replace if necessary.
Check for foreign bodies in the bores and passages
in the housing, eliminate all foreign bodies.
STEP 5
Check for distortion, cracks or wear in the springs.
Replace all defective springs.

Copyright ©
8011-32

Copyright ©
8012
Section
8012
DISASSEMBLY AND ASSEMBLY

OF THE ATTACHMENT CYLINDERS

Printed in France
Copyright ©
8012-2
TABLE OF CONTENTS
SPECIFICATIONS ................................................................................................................................................... 2
SPECIAL TORQUE SETTINGS .............................................................................................................................. 3
SPECIAL TOOLS .................................................................................................................................................... 4
CYLINDERS ............................................................................................................................................................ 6
Boom cylinder description ................................................................................................................................... 6
Dipper cylinder description .................................................................................................................................. 8
Bucket cylinder description ................................................................................................................................10
Disassembly .......................................................................................................................................................12
Inspection ...........................................................................................................................................................20
Assembly ............................................................................................................................................................21
SPECIFICATIONS
See Section 1002.

Copyright ©
8012-3

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Copyright ©
Section
8013
8013
OF THE CONTROL LEVERS

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

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

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

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

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

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

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

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

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

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

Copyright ©
8013-12

Copyright ©
Section
8014
8014
OF THE CONTROL PEDALS

Printed in France
Copyright ©
8014-2
TABLE OF CONTENTS
TORQUE SETTINGS ............................................................................................................................................. 2
CONTROL PEDAL ................................................................................................................................................. 3
Description .......................................................................................................................................................... 3
Disassembly ........................................................................................................................................................ 4
Inspection ............................................................................................................................................................ 5
Assembly ............................................................................................................................................................. 5
TORQUE SETTINGS
Cover retaining screws ..................................................................................................................... 53.9 to 63.7 Nm
Cam articulation pin locking screw (Apply Loctite 241) .................................................................... 13.3 to 16.1 Nm
Cap screw............................................................................................................................................. 3.9 to 5.8 Nm

Copyright ©
8014-3
CONTROL PEDAL
Description
5 4 3
6
35
2
7 34 23 24
8
33
9
10 18 22 32
11 19 31
12 20 30
13 12 25 29
14
21
15
16 28 27 26
1
17
CI00K507
1 BODY 21 GUIDE
2 COVER 22 BALL
3 LOCKING SCREW 23 SHIM
4 CAM SHAFT 24 SHIM
5 GROMMET 25 O-RING
6 CAM 26 SHIM
7 BRACKET 27 SHIM
8 PISTON ASSEMBLY 28 SPRING SEAT
9 BUSHING 29 THRUST WASHER
10 BALL 30 O-RING
11 SPRING 31 GUIDE
12 BUSHING 32 O-RING
13 ROLL PIN 33 SPRING
14 FLANGE SCREW 34 U-SHAPED SEAL
15 SPRING 35 BALL
16 SPRING
17 SPOOL
18 SCREW
19 WASHER
20 SHIM

Copyright ©
8014-4
Disassembly STEP 7
Always handle high precision parts with the greatest Identify and remove the guide (31) and the piston
care to prevent them being damaged by being assembly (8).
knocked or dropped. The components of the control
lever may rust due to contamination and humidity if
STEP 8
they are left without protection after disassembly. If Identify and remove the ball (35), the bracket (7), the
work has to be stopped, the components must be shims (23) and (24) and the spring (33) from the
protected against contamination or corrosion. piston assembly (8).
NOTE: The numbers in brackets in the following NOTE: The ring (12), shim (20), spring (11) and ball
steps refer to the description on page 3. (10) are matched and press-fitted with the ring (9) in
NOTE: Clean around the foot control pedal and take the piston assembly (8) and cannot be disassembled.
care to prevent any foreign material entering the STEP 9
system.
Remove the O-ring (32) from the guide (31).
STEP 1
STEP 10
Tighten the control pedal in a vice with protective
jaws. Remove the bellows (5). Remove the U-shaped seal (34) from the cover (2).
STEP 2 STEP 11
Remove the locking screw (3) from the cam shaft. Remove the spool assembly (17) from the body (1).
STEP 3 STEP 12
Remove the cam shaft (4) using a suitable drift. Remove the thrust washer (29).
STEP 4 STEP 13
Identify the position of the cam (6) in relation to the Remove the spring (16), spring pin (13) and the
cover (2) and remove the cam. O-rings (25) and (30) from the body (1).
STEP 5 STEP 14
Remove the retaining screw (18) and washer (19). Fasten the spool (17) in a vice equipped with soft
jaws and unscrew the flange screw (14).
STEP 6
NOTE: Be careful not to damage the spool surface.
Identify and remove the cover assembly (2).
STEP 15
NOTE: Take care not to drop the springs (33).
Identify and remove in this order: the flange screw
NOTE: Repeat steps 1 to 6 for the other control pedal (14), guide (21), spring (15), shims (26) and (27) and
body. the spring seat (28).
NOTE: Repeat steps 7 to 15 for the three other ports
of the control pedal.

Copyright ©
8014-5
Inspection Assembly
STEP 1 NOTE: Immerse all parts in clean hydraulic fluid in
order to guarantee proper lubrication when installing
Check for cracks, distortion or blocking of the springs. and restarting operation.
If any one of the defects is found, replace the spring.
STEP 1
STEP 2
Fasten the spool (17) in a vice equipped with soft
Check the spools to ensure that their finish is not jaws. Install the following in the order shown: the
damaged, that they are not twisted, or chipped etc. spring seat (28), shims (26) and (27), spring (15),
Ensure that the spools slide smoothly in the bore of guide (21) and the flange screw (14). Tighten to the
the control pedal body. If defects are found, change torque shown on page 2.
the entire control pedal.
NOTE: If the installation is performed incorrectly, this
STEP 3 can cause a change in the secondary pressure.
Check the sleeves and the clips to ensure that their STEP 2
finish is not damaged, that they are not twisted,
cracked or chipped. If any one of the defects is found, Assemble the O-rings (25) and (30), the spring pin
replace the damaged part. (13) and the spring (16) in the body (1).
STEP 4 STEP 3
Check the bores for damage, internal damage of Carefully assemble the spool assemble (17) in the
housings, or signs of internal wear at the level of the body (1), install the thrust washer (29) in accordance
control pedal. If the control pedal is damaged, with the following illustration.
replace the entire assembly.
STEP 5
Discard all the O-rings and use new O-rings. 29
CS01D581
NOTE: Repeat the steps 1 to 3 for the three other

ports of the control pedal.

Copyright ©
8014-6
STEP 4 STEP 9
Assemble the U-shaped seal (34) in the cover (2) Assemble the cam (6) on the cover (2). Install the
orienting as per the following illustration; the seal lips cam shaft (4). The surface of the cam (6) must be
must be oriented downwards. parallel with the cover surface (2).
NOTE: Check that there is no play between the balls
and the cam. If any play is detected, repeat the
procedure as from step (7) and add shims.
STEP 10
Incline the cam and apply grease to the cam
articulation and to the steel ball.
STEP 11
34
Assemble and tighten the screws (3) to the torque
specified on page 2.
STEP 12
CS01D580
Assemble the upper portion of the grommet on the
STEP 5 cam, apply a humidity inhibitor in the groove of the
Assemble the piston assembly (8), with its spring cover in order to avoid oxidation, then assemble the
(33), in its original orifice in the cover (2). lower portion of the grommet on the cover.
STEP 6
Assemble the O-ring (32) on the guide (31) and then
install the guide in its original position in the cover (2).
STEP 7
Assemble the shims (23) and (24), the bracket (7)
and the ball (35).
NOTE: Repeat steps 4 to 7 for the three other ports
of the control pedal.
STEP 8
Assemble the cover assembly (2) on the body (1) in its
original position. Fasten it with the screw (18) and
washer (19). Tighten to the torque specified on page 2.
NOTE: Take care not to drop the spring (33).
NOTE: Repeat steps 4 to 8 for the other control pedal
body.

Copyright ©
Section
8015

OF THE SIX SOLENOID VALVES BLOCK
8015

Printed in France
Copyright ©
8015-2
TABLE OF CONTENTS
SIX SOLENOID VALVES BLOCK .......................................................................................................................... 3
Identifying the ports and the solenoid valves ...................................................................................................... 3
Section ................................................................................................................................................................ 4
Disassembly and assembly ................................................................................................................................. 5
Inspection ............................................................................................................................................................ 6

Copyright ©
8015-3
SIX SOLENOID VALVES BLOCK

Identifying the ports and the solenoid valves
C5 C3 C1
B T
S5 S3 S1
S4 S2 SP
C4 C2 P
CS01C519
C1 HIGH SPEED CONTROL S1 HIGH SPEED TRAVEL SOLENOID VALVE (RED RING)
C2 SWING BRAKE CONTROL S2 SWING BRAKE SOLENOID VALVE (PINK RING)
C3 POWER BOOST CONTROL S3 POWER BOOST SOLENOID VALVE (YELLOW RING)
C4 CUSHION CANCELLATION CONTROL S4 CUSHION CANCELLATION SOLENOID VALVE (LIGHT
C5 SWING CANCELLATION CONTROL GREEN RING)
P SIX SOLENOID VALVES BLOCK POWER SUPPLY S5 SWING CANCELLATION SOLENOID VALVE (GREEN
B MACHINE CONTROL POWER SUPPLY RING)
T RETURN TO THE RESERVOIR SP PILOT PRESSURE SOLENOID VALVE

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

Copyright ©
8015-5
Disassembly and assembly
4
2
3
6
CS01C522
NOTE: During disassembly, identify each part of STEP 5
every component in order to make assembly easier.
The spool of the component S2 is different from the Remove the spring (6) from the solenoid valve block
components S1, S3, S4, S5 and SP. housing.
STEP 1 STEP 6
Remove the connections of the solenoid valve block. Repeat steps 2 to 5 for the disassembly of the other
components.
STEP 2
STEP 7
Remove the retaining nut (1) from the coil (2) and
remove the coil from the core (3). Carry out inspection of the components.
NOTE: During assembly, tighten the nut (1) to a NOTE: During assembly, proceed in the reverse
torque of 4.9 Nm. order to that of disassembly.
STEP 3
Remove the core (3) from the solenoid valve housing.
Discard the O-ring (4).
NOTE: During assembly, install a new O-ring (4) on
the core (3), tighten the core (3) to a torque of 30 to
37 Nm.
STEP 4
Remove the spool (5) from the solenoid valve block
housing.

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

Copyright ©
Section
8016

OF THE CUSHION CONTROL VALVE
8016

Printed in France
Copyright ©
8016-2
TABLE OF CONTENTS
CUSHION CONTROL VALVE ................................................................................................................................. 2
Description .......................................................................................................................................................... 2
Disassembly ........................................................................................................................................................ 4
Inspection ............................................................................................................................................................ 6
Assembly ............................................................................................................................................................. 6
CUSHION CONTROL VALVE

Description
Identifying the ports
T G H R
E F
B
A
C D
CS01C518
A DIPPER RETRACTION (TOWARDS CONTROL LEVER) G BOOM LIFTING (TOWARDS CONTROL VALVE)
B DIPPER EXTENSION (TOWARDS CONTROL LEVER) H BOOM LOWERING (TOWARDS CONTROL VALVE)
C DIPPER RETRACTION (TOWARD CONTROL VALVE) R RETURN TO RESERVOIR
D DIPPER EXTENSION (TOWARDS CONTROL VALVE) S CUSHION FUNCTION CANCELLATION
E BOOM LIFTING (TOWARDS CONTROL LEVER) T LEAK RETURN
F BOOM LOWERING (TOWARDS CONTROL LEVER)

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

Copyright ©
8016-4
Disassembly STEP 3
STEP 1
7
7
JD00551A
Remove the spring (10) and the O-ring (9) of the
plug. Discard the O-ring.
STEP 4
JD00549A
If the cushion control valve has to be replaced,
remove the adaptors and elbow unions and install
them on the new control valve. Do not remove the
four flow restriction adapters (7) installed in the sides
of the valve.
NOTE: Mark parts to ensure correct assembly in
same valve bore as removed from.
STEP 2
JD00552A
Remove the spool (13) with the O-ring (12), the
spring guide (11) and the spring (10) of the control
valve.
STEP 5
JD00550A
Remove the plug (8) with the O-ring (9) and the
spring (10).
JD00553A
Put the spool (13) in a vice using wooden shims to
protect the spool. Remove the spring guide (11) from
the spool (13).

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

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

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

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

Copyright ©
Section
8017
RELIEF VALVES
8017

Printed in France
Copyright ©
8017-2
TABLE OF CONTENTS
TORQUE SETTINGS ............................................................................................................................................. 2
BOOM RELIEF VALVE .......................................................................................................................................... 3
Marking the ports ................................................................................................................................................ 3
Removal .............................................................................................................................................................. 3
Installation ........................................................................................................................................................... 3
Disassembly ........................................................................................................................................................ 4
Assembly ............................................................................................................................................................. 6
DIPPER RELIEF VALVE ........................................................................................................................................ 8
Marking the ports ................................................................................................................................................ 8
Removal .............................................................................................................................................................. 8
Installation ........................................................................................................................................................... 8
Disassembly ........................................................................................................................................................ 9
Assembly ........................................................................................................................................................... 11
TORQUE SETTINGS
Boom relief valve
CX130 CX160 CX210 CX240

Spool cap (3) 245.2 Nm +/- 10% 274.6 Nm +/- 10% 274.6 Nm +/- 10% 274.6 Nm +/- 10%
Spool stop cap (1) 9.8 Nm +/- 10% 78.5 Nm +/- 10% 78.5 Nm +/- 10% 78.5 Nm +/- 10%
Plug (11) 49 Nm +/- 10% 215.8 Nm +/- 10% 215.8 Nm +/- 10% 215.8 Nm +/- 10%
Plug (15) 9.8 Nm +/- 10% 78.5 Nm +/- 10% 78.5 Nm +/- 10% 78.5 Nm +/- 10%
Safety valve (10) 58.8 Nm +/- 10% 58.8 Nm +/- 10% 58.8 Nm +/- 10% 58.8 Nm +/- 10%
Dipper relief valve
CX130 CX160 CX210 CX240

Plug (1) and (5) 215.8 Nm +/- 10% 215.8 Nm +/- 10% 215.8 Nm +/- 10% 215.8 Nm +/- 10%
Spool cap (9) and (11) retaining
39.2 Nm +/- 10% 39.2 Nm +/- 10% 39.2 Nm +/- 10% 39.2 Nm +/- 10%
screws
Safety valve (18) 58.8 Nm +/- 10% 58.8 Nm +/- 10% 58.8 Nm +/- 10% 58.8 Nm +/- 10%

Copyright ©
8017-3
BOOM RELIEF VALVE

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

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

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

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

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

Copyright ©
8017-8
DIPPER RELIEF VALVE

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

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

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

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

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

Copyright ©
Section
8018

OF THE HYDRAULIC SWIVEL
8018

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

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

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

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

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

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

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

Copyright ©
8018-8

Copyright ©
Section
8019

OF THE HYDRAULIC SWING MOTOR
8019

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

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

Copyright ©
8019-4
HYDRAULIC SWING MOTOR

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Copyright ©
8019-24

Copyright ©
Section
8020
HYDRAULIC FUNCTIONS
8020

Printed in France
Copyright ©
8020-2
TABLE OF CONTENTS
HYDRAULIC FUNCTIONS........................................................................................................................................ 3
Function List..........................................................................................................................................................3
Controls in Neutral (Pump Uchida) (CX130/CX160) ............................................................................................. 6
Controls in Neutral (Pump Kawasaki) (CX130/CX160/CX180) ............................................................................. 8
High Speed Travel Circuit ...................................................................................................................................10
Low Speed Travel Circuit ....................................................................................................................................12
Straight Line Travel Circuit..................................................................................................................................14
Swing Circuit .......................................................................................................................................................16
Variable Priority Valve Circuit..............................................................................................................................18
Boom Raising Circuit...........................................................................................................................................20
Boom Lowering Circuit with Load Holding Valve ................................................................................................22
Boom Lowering Reinjection Circuit .....................................................................................................................22
Boom Lowering Anti-vibration Circuit ..................................................................................................................22
Dipper Extending Circuit .....................................................................................................................................24
Dipper Retracting Circuit .....................................................................................................................................26
Dipper Retracting Reinjection Circuit ..................................................................................................................26
Bucket Opening Circuit .......................................................................................................................................28
Bucket Closing Circuit .........................................................................................................................................29
Crusher Circuit ....................................................................................................................................................30
Breaker Circuit ....................................................................................................................................................32
NOTES ....................................................................................................................................................................34

Copyright ©
8020-3
HYDRAULIC FUNCTIONS
Function List
Description
Operation Description of function
of operation
Travel
High speed may be obtained by changing the displacement of the travel motors
from high to low.
When pressure becomes too high, the motors automatically change down to low
High speed speed. Page 10
When pressure drops, the motors automatically change up to high speed.
The machine returns to 1st speed when travel pressure drops to below
570 psi, to prevent snatching when turning on the spot in 2nd speed.
Low speed Low speed may be obtained by selecting high travel motor displacement. Page 12
Straight line If the attachment is used or swing operated during travel, the machine continues
Page 14
travel traveling in a straight line without hunting.
Swing
When the swing control is in neutral, swing is prevented by the motor reduction
gear brake.
When the swing control is operated, the moto-reduction gear brake is released.
If the boom, dipper or bucket are operated while the swing control is in neutral,
Braking the moto-reduction gear brake is released. Page 16
The brake will be applied once more within 5 seconds of returning the swing
control to neutral or of halting all attachment movement.
When the swing locking control is operated, the moto-reduction gear brake will
be applied.
Full swing power is maintained by a priority valve inside the control valve.
Priority Page 18
When digging trenches, the variable swing priority valve is actuated.
Anti-
This function allows the swing movement to come to a smooth halt.
shuddering
Attachment
Boom raising An internal spool makes two flows to the boom possible. Page 20
Boom
Boom can be lowered by releasing the load holding valve inside the control
lowering, Page 22
valve.
load holding
Boom By reinjecting hydraulic oil via the boom spool and maintaining permanent feed/
lowering return information feed back, higher speed and negative pressure prevention are Page 22
injection made possible.
Boom
lowering - Peak pressure is prevented by the bleed off circuit, thereby reducing extra
Page 22
vibration vibration.
prevention
Dipper
An internal spool makes two flows to the dipper possible. Page 24
extension
Dipper
Dipper retraction is made possible by releasing the load holding valve inside the
retraction - Page 26
control valve.
load holding
Dipper
retraction - The reinjection cancellation valve makes combined movements faster. Page 26
reinjection

Copyright ©
8020-4
Cushion The shocks encountered at the end of attachment movements are reduced by
valve the cushion valve, which has a built-in pilot heating circuit.
Attachment (continued)
An option section is included in the control valve and can be used for special
Option Page 30
attachments such as a crusher or breaker.
Other features
Auto When the engine is under heavy load, the control valve inlet limiter is subjected
boosting to forced feeding for 8 seconds.
Negative This is designed to reduce power consumption by reducing flow from the pumps
control when the machine is not under load.

Copyright ©
8020-5

Copyright ©
8020-6
Controls in Neutral (Pump Uchida) (CX130/CX160)

Pump minimum output mode
If the A1 flow from the P1 pump or the A2 flow from the P2 pump is not used then the pumps go into minimum
output mode to save energy.
When the controls are in neutral, with the engine running, a part of the flow coming from the low pressure pump
arrives at Ps1 and is divided by a battery of restrictors. Part of the flow goes through the travel control valves and
the other part goes to the remaining control valves before returning to the tank. When the spools are moved,
these circuits are closed, thereby closing the travel or upperstructure pressure switch contact points and
transmitting the electronic information.
The two flows from the HP pumps cross the control valve via the free passages. They are controlled by two
pressure limiters set at 370 psi for a flow of 13.2 gpm and two flow restrictors. Both pressures are sent to the PZ1
and PZ2 ports on the pumps to regulate them to deliver minimum flow.

Copyright ©
8020-7
P11 dr2 P13
P12 B
0.29 Mpa
42 psi
3V ø3 A 2.9 bar
R3 )/ dr1 )5 R4 R5 R2
R1
a
5B5
5A5
4b4
4a42
4a41
5a51 B T
5a52
5b52 C1
5b51
4A3
4B3
3
C3
5B4
5A4
4b3
4a3
C5
5a4
5b4
OPT
4A2
4B2
5a31
5a32
5b31
5b32
5B2
5A2
4b22
Ø2.5
4a2
5a2
4b21
5b2
Ø2.5
4A1
5B1
5A1 4B1 3
3 3
4b1 10µ
5a1 4a1
0.049 MPa
5b1 5.8 psi
0.4 bar
0.098 MPa
13 psi
0.9 bar
P2 3
3/ Px2
3V Px1
35 PY
G1 $ ; 3= G2 $ G3 ; 3= ; R1 R2 T1 T2 $
6 3.92 Mpa 6
565 psi
39 bar ;
* * ;
7 ;
G4 G5
CM00K031

Copyright ©
8020-8
Controls in Neutral (Pump Kawasaki) (CX130/CX160/CX180)

When the controls are in neutral, with the engine running, a part of the flow coming from the low pressure pump
arrives at Ps1 and is divided by a battery of restrictors. Part of the flow goes through the travel control valves and
the other part goes to the remaining control valves before returning to the tank. When the spools are moved,
these circuits are closed, thereby closing the travel or upperstructure pressure switch contact points and
transmitting the electronic information.
The two flows from the HP pumps cross the control valve via the free passages. They are controlled by two
pressure limiters set at 370 psi for a flow of 13.2 gpm and two flow restrictors. Both pressures are sent to the Pi1
and Pi2 ports on the pumps to regulate them to deliver minimum flow.

Copyright ©
8020-9
P11 dr2
P12 B
0.29 Mpa
3V
42 psi
ø3 A 2.9 bar
R3 )/ dr1 )5 R4 R5 R2
R1
5B5 a
5A5
4b4
4a42
4a41
5a51 B T
5a52
5b52 C1
5b51
4A3
4B3
3
C3
5B4
5A4
4b3
4a3
C5
5a4
5b4
OPT
4A2
4B2
5a31
5a32
5b31
5b32
5B2
5A2
4b22
Ø2.5
4a2
5a2
4b21
5b2
?
Ø2.5
4A1
5B1
5A1 4B1 3
3 3
4b1 10µ
5a1 4a1
0.049 MPa
5.8 psi
5b1 0.4 bar
0.098 MPa
13 psi
0.9 bar
P2 3
3/ Px2
3V Px1
35 PY
A1 a3 A2
Psv
a1 a2
(ARRIERE)
(AVANT)
Pi1 Pi2
3.92 MPa
568 psi
a3
39.2 bar
A3
Dr B1 B3
CM02M001

Copyright ©
8020-10
High Speed Travel Circuit

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

C3. Power boost (Yellow band)
C5. Swing shut off (Green band)
4a1/4A1. LH forward travel
4b1/4B1. LH reverse travel
5a1/5A1. RH forward travel
5b1/5B1. RH reverse travel
1. Travel speed switch
2. Controller
3. Work mode switch

Copyright ©
8020-11
C2 ' ' C2
% %
$ $
C1
&
$ '
)
& %
Pi1 dr2
Pi2 B
0.29 Mpa
42 psi
Ps2 ø3 A
R3 2.9 bar
FL dr1 FR R4 R5 R2
R1
a
5B5
5A5
4b4
4a42
4a41
5a51
5a52
5b52
5b51 B T
4A3
4B3
&
5B4
5A4 P
4b3
&
4a3
C2
5a4
5b4
OPT
4A2
5a31
4B2
& C4
5a32
5b31
5b32
5B2
5A2
4b22
4a2
5a2
Ø2.5
4b21
5b2
Ø2.5
% $
$ %
D E
E D
1
Px2 Ps1 Px1 PO PY
3/ 35
2
$ $
1 , 2
CM02M002

Copyright ©
8020-12
Low Speed Travel Circuit

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

4a1/4A1. LH forward travel
4b1/4B1. LH reverse travel
5a1/5A1. RH forward travel
5b1/5B1. RH reverse travel
2. Controller
3. Work mode switch

Copyright ©
8020-13
C2 ' ' C2
% %
$ $
& &
$ '
)
& %
Pi1 dr2
Pi2 B
0.29 Mpa
ø3 42 psi
Ps2 A
2.9 bar
R3 FL dr1 FR R4 R5 R2
R1
a
5B5
5A5
4b4
4a42
4a41
5a51
5a52
5b52
5b51 B T
4A3
4B3
&
5B4
5A4 P
4b3
&
4a3
C2
5a4
5b4
OPT
4A2
5a31
4B2
& C4
5a32
5b31
5b32
5B2
5A2
4b22
4a2
5a2
Ø2.5
4b21
5b2
Ø2.5
% $
$ %
4b1
5a1 4a1
5b1
1
Px2 Ps1 Px1 PO PY
3/ 35
2
$ $
1 , 2
CM02M003

Copyright ©
8020-14
Straight Line Travel Circuit

This chapter considers the situation whereby travel and boom raising operations are carried out at the same
time.
When boom spool 2 is piloted, the control circuit coming from Ps1 and going through all the attachment and
swing control valves is closed. The pressure in this circuit then rises to 565 psi and this pilots the straight line
travel valve. When this occurs, one pump supplies oil to both travel motors and the other pump supplies oil to the
attachment. As oil is supplied to both travel motors in parallel the pressure is equal and the machine travels in a
straight line. If all the flow to the attachment is not used, the surplus is sent to the travel function, thereby keeping
speed loss to a minimum.
If other functions than the boom are used at the same time as the travel function, the operating principle is the
same.
C1. 2 stage travel (Red band)

4a1/4A1. LH Forward travel
4b1/4A1. LH Reverse travel
5a1/5A1. RH Forward travel
5b1/5B1. RH Reverse travel
4a2/4A2. Boom down
4b22/4B2. Boom up
5a32. Boom spool 2
2. Controller
3. Work mode switch

Copyright ©
8020-15
C2 ' ' C2
% %
$ $
& &
$ '
)
& %
Pi1 dr2
Pi2 B
0.29 Mpa
3V
ø3
42 psi
A
2.9 bar
R1
a
5B5
5A5
4b4
4a42
4a41
5a51
5a52
5b52
5b51
4A3
4B3
5B4
5A4
4b3
4a3
5a4
5b4
OPT $
D %
D
E
E 5B2 E
5A2
5a2 D
E
Ø2.5
5b2
Ø2.5
% $
$ %
E B T
D D &
E
3
35
C3
3/
Px2 Px1 PO C2
PY
3V
C5 C4
$ $ 2
3
1 , 2
1
CM02M004

Copyright ©
8020-16
Swing Circuit
The swing function has one source of oil supply only.
When the engine is started and the swing control is in neutral, the swing brake electrovalve is powered and the
brake is applied.
When the swing function is operated, the swing pressure switch closes. Current to the swing brake electrovalve
is cut off and the brake is released. The upperstructure thereby becomes free to turn. When the swing control is
in neutral and the attachment is operated, lateral forces are exerted on the attachment. To prevent the swing
effect damaging the brake the swing brake is released.
When one of the HP pressure detectors situated on the pump outlets informs the calculator that pressure is
equal to or greater than 2132 psi, current to the swing brake electrovalve is cut off and the swing brake is
released.
When swing pressure switch or attachment pressure falls below 2932 psi, current flows to the swing brake
electrovalve after five seconds and the swing brake is applied.
If swing locking is solicited, even if the swing pressure is closed and pressure at both pumps is higher than
2132 psi, the swing brake will be applied. The swing spool is piloted on both sides. If the starter switch key is
turned to OFF position, the swing locking will be memorized and when the key is turned to ON position the swing
function will still be locked.
During travel, if pressure in one of the pumps rises to 2132 psi, the swing brake will be released for 5 seconds.
Outlet pressure on
Swing pressure Swing brake
Key switch A1 or A2 pump Swing brake
switch electrovalve
outlets
OFF OFF 0 OFF Applied
ON OFF 0 ON Applied
ON ON >0 OFF Released
ON OFF 2132 psi or more OFF Released
5a2/5A2. LH Swing
5b2/5B2. RH Swing
C2. Swing brake (Pink band)

Copyright ©
8020-17
Pi1 dr2
3 Pi2 B
0.29 Mpa
Ps2 ø3 42 psi
A
R3 FL 2.9 bar
dr1 FR R4 R5 R2
R1
Dr
5B5 a
5A5
4b4
4a42
4a41
GA GB
5a51
5a52
5b52
5b51
$ % 4A3
4B3
5B4
5A4
4b3
4a3
5a4
5b4
OPT
4A2
4B2
5a31
5a32
5b31
% 5b32
$ D Ø2.5

4b22
4a2
4b21
E Ø2.5
5B1 4A1
5A1 4B1
4b1
5a1 4a1
5b1
35
Px2 Ps1 Px1 PO PY
3/
$ $
G7 G6
6 B T
6 6 C1
6 6 3
3 3 10µ
3
6 C3
0.049 MPa
5.8 psi
& 0.4 bar
ON 5 bar 0.098 MPa

OFF 3 bar 13 psi
0.9 bar
& C4
P2 P1
3
T

2 4
CM02M005

Copyright ©
8020-18
Variable Priority Valve Circuit

After going through the selector the swing pilot pressure arrives at Pi2 and pilots the cancellation valve, there by
causing the variable priority valve to discharge oil. This makes it possible to have the maximum swing torque
with high swing pressure, even if the dipper is being used at the same time.
When the machine is digging, the boom raising pressure pilots the swing priority valve. Flow for the swing
function is then in parallel with the dipper via the priority valve and dipper speed is improved. Digging speed is
more constant, even if the free passage is closed by the boom (2) spool.
When the swing function and the dipper retracting or boom raising functions are operated simultaneously,
parallel working is reduced and swing pressure is maintained.
4a41/4b4. Dipper spool 2

5a2/5A2. LH swing
5b2/5B2. RH swing
5a52/5A5. Dipper out
5b52/5B5. Dipper in
5a32. Boom spool 2
Pi2. Priority to swing

Copyright ©
8020-19
Pi1
dr2
Dr
3L B
0.29 Mpa
ø3 A 42 psi
Ps2 2.9 bar
R1
GA GB
% a
MU $
$ % 4b4
4a42
4a41
5a51
5a52
5b52
5b51
4A3
4B3
5B4
5A4
4b3
4a3
5a4
5b4
OPT
4A2
4B2
5a31
D
5b31
% 5b32
4b22
$ Ø2.5
4a2
D 4b21
E Ø2.5
4A1
5B1 4B1
5A1
4b1
5a1 4a1
5b1
Ps1 PO PY
3/ 3[ 3[ 35
$ $
CM02M006

Copyright ©
8020-20
Boom Raising Circuit

Two supply flows are used to raise the boom.
The A1 pump flow goes through the straight line travel valve and them the left-hand travel spool, before going to
the boom (1) spool.
The A2 pump flow goes through the parallel working passage and then also through the straight travel valve and
the boom (1) spool before going to the boom (2) spool. The boom (2) spool in turn directs the flow to a location
between the boom (1) spool outlet and the load holding valve, where it combines with the flow from the other
pump.
4b22/4B2. Boom up
4a2/4A2. Boom down
Pa31. Boom spool 2

Copyright ©
8020-21
3L dr2
Pi2 B
0.29 Mpa
ø3 42 psi
Ps2 A
2.9 bar
R1
a
5B5
5A5
4b4
4a42
4a41
5a51
5a52
5b52
5b51
4A3
4B3
5B4
5A4
4b3
4a3
5a4
5b4
OPT $
D %
D 5b31
5b32
5B2
5A2
Ø2.5 E
5a2 4a2
5b2 E
Ø2.5
4A1
5B1
5A1 4B1
4b1
5a1 4a1
5b1
Px2 Ps1 Px1 PO PY
3/ 35
$ $
CM02M007

Copyright ©
8020-22
Boom Lowering Circuit with Load Holding Valve

A single supply flow is used to lower the boom.
When the boom lowering function is operated only the boom (1) spool is piloted.
At the same time, pilot pressure arrives at Ps2, flows through the boom spool and releases the load holding
valve. This allows the oil discharge from the boom cylinder large chambers to flow to the return circuit.
Boom Lowering Reinjection Circuit

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

Due to the constant loss of oil from the supply source to the free passage, via the orifice, peak pressures and
vibrations are avoided, even if the boom lowering control is operated roughly.
4b22/4B2. Boom up
4a2/4A2. Boom down

Copyright ©
8020-23
B
0.29 Mpa
42 psi
ø3 A 2.9 bar
Ps2
FR R4 R5 R2
4b4
4a42
4a41
4A3
4B3
4b3
4a3
$
%
4b22
4a2
4b21
4A1
$
4B1
4b1
4a1
%
PO
35
PY
$
D
3V 5
35
CM02M008

Copyright ©
8020-24
Dipper Extending Circuit

The dipper uses two supply flows.
When the dipper extends, pump A2 flow arrives at the dipper (1) spool, via the free passage.
Pump A1 flow arrives at the dipper (2) spool, via the free passage after passing through the straight line travel
valve. It merges with the other dipper (1) spool outlet flow before the load holding valve. The two flows supply oil
the dipper cylinder small chamber. Return to the large chamber is via the two dipper spools, thereby improving
efficiency.

5b51/5B5. Dipper in

Copyright ©
8020-25
Pi1 dr2 ø 1.2
Pi2
B
0.29 Mpa
ø3 42 psi
Ps2 A
2.9 bar
R4 FL dr1 FR R3 R5 R2 A
R1
% a
$
E
4a42
D
D
5a52
5b52
E 4A3
4B3
5B4
5A4
4b3
4a3
5a4
5b4
OPT
4A2
4B2
5a31
5a32
5b31
5b32
5B2
5A2
4b22
Ø2.5
4a2
5a2
5b2 4b21
Ø2.5
4A1
5B1
5A1 4B1
4b1
5a1 4a1
5b1
Px2 Ps1 Px1 PO PY

3/ 35
$ $
CM02M009

Copyright ©
8020-26
Dipper Retracting Circuit

The dipper uses two supply flows.
When the dipper retracts A2 pump flow arrives at the dipper (1) spool, via the free passage. At the same time,
the pressure arriving at Ps2 releases the load holding valve.
A1 pump flow arrives at the dipper (2) spool, via the free passage after passing through the straight line travel
valve. It merges with the other flow from the dipper (1) spool. These two flows supply oil dipper cylinder large
chamber. Return from the small chamber ensured by the dipper (1) spool.
Dipper Retracting Reinjection Circuit

Oil discharging from the small chamber is fed back into the large chamber. The feed back flow is controlled by
the reinjection cancellation valve.
When pressure in the large chamber increases, the cancellation valve is piloted by this pressure and reinjection
is progressively brought to a halt.

5b51/5B5. Dipper in

Copyright ©
8020-27
%
$
D
E
3V Pi1 dr2 ø 1.2
Pi2
B
3/ 0.29 Mpa
42 psi
Ps2 ø3 A
2.9 bar
$
R1
% a
$ E
D D
D
E
E 4A3
4B3
5B4
5A4
4b3
4a3
5a4
5b4
OPT 4A2
4B2
5a31
5a32
5b31
5b32
5B2
5A2 4b22
Ø2.5 4a2
5a2
4b21
5b2
Ø2.5
4A1
5B1
4B1
5A1
4b1
5a1 4a1
5b1
3/ 35
Px2 Ps1 Px1 PO PY
$ $
CM02M010

Copyright ©
8020-28
Bucket Opening Circuit

The bucket uses one supply flow which arrives from pump A1 via the parallel working passage.
4a3/4A3. Bucket closing

4b3/4B3. Bucket opening
B
0.29 Mpa
ø3 42 psi
Ps2 A
2.9 bar
FR R4 R5 R2
4b4
4a42
4a41
$
%
E
D
4A2
4B2
4b22
4a2
4b21
4A1
4B1
4b1
4a1
PO PY
35
$
CM02M011

Copyright ©
8020-29
Bucket Closing Circuit

The bucket uses one supply flow which arrives from pump A1 via the parallel working passage.
4a3/4A3. Bucket closing

4b3/4B3. Bucket opening
B
0.29 Mpa
ø3 42 psi
Ps2 A
2.9 bar
FR R4 R5 R2
4b4
4a42
4a41
$
%
E
D
4A2
4B2
4b22
4a2
4b21
4A1
4B1
4b1
4a1
PO
35
PY
$
CM02M012

Copyright ©
8020-30
Crusher Circuit
Two flows can be used to supply oil to the crusher circuit.
When the switch in the cab is tilted to crusher position, current flows to the second flow electrovalve.
When the option pedal is pressed. The pilot pressure goes through the selector and then on to the electrovalve.
The reinjection valve is released. The free passage closing value is piloted and the free passage is closed.
One flow supplies oil directly to the option. The other flow is forced towards the reinjection valve and combines
with the first flow at the option spool inlet.
5a4/5A4. Option circuit

5b4/5B4. Option circuit

Copyright ©
8020-31
Pi1 dr2
Pi2 B
0.29 Mpa
ø3 42 psi
Ps2 A
2.9 bar
R1
D
1
7 5B5
5A5
3
4b4
4a42
4a41
5a51
5a52
$6 $ 7 5b52
5b51
4A3
4B3
%
%6 %
$ 4b3
4a3
D
E
237 4A2
4B2
5a31
5a32
5b31
5b32
5B2
5A2
4b22
Ø2.5
4a2
5a2
4b21
5b2
Ø2.5
4A1
5B1
5A1 4B1
4b1
5a1 4a1
5b1
3/ Px2 Ps1 Px1

32 35 PY
3
$ $
$
CM02M013

Copyright ©
8020-32
Breaker Circuit
The breaker uses one supply flow.
When the switch in the cab is in breaker position and the option pedal toed forward, the pressure switch closes
and sends the information to the calculator, which sets the breaker running at the preselected speed.
The option spool is piloted and A2 pump flow supplies the breaker with oil.
5a4/5A4. Option circuit

5b4/5B4. Option circuit

Copyright ©
8020-33
% $
&
'
7 7
10µ
Pi1 dr2
Pi2 B
0.29 Mpa
ø3 42 psi
Ps2 A
2.9 bar
R1
1
7 5B5 a
5A5
3
4b4
4a42
4a41
5a51
5a52
$6 $ 3 7 5b52
5b51
4A3
4B3
%
%6 % $
$ 4b3
4a3
D
E
237 4A2
4B2
5a31
5a32
5b31
5b32
5B2
5A2
4b22
Ø2.5
4a2
5a2
4b21
5b2
Ø2.5
4A1
5B1
5A1 4B1
4b1
5a1 4a1
5b1
3/ Px2 Ps1 Px1

32 35 PY
7
3
$ $
$
CM02M014

Copyright ©
8020-34
NOTES
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.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................

Copyright ©
9002
Section
9002
UPPERSTRUCTURE, TURNTABLE
AND COUNTERWEIGHT

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

See Section 1002
SPECIFICATIONS
Weight ............................................................................................................................................See Section 1002
Quantity of grease to be applied
to the turntable........................................................... 190 cc (CX130); 400 cc (CX160, CXCX210); 500 cc CX240)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Copyright ©
Section
9003
9003
BOOM, DIPPER AND BUCKET

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

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

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

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

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

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

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

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

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

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

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

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

Copyright ©
Section
9004
9004
SEAT AND SAFETY BELT

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

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

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

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

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

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

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

Copyright ©
Section
9005
CAB AND CAB EQUIPMENT
9005

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

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

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

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

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

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

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

Copyright ©
9005-8
HEATING BLOCK/AIR-CONDITIONING BLOCK

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

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

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

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

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

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

Copyright ©
9005-12
STEP 9 STEP 14
Install the operator’s seat in the cab (see Add cooling fluid according to requirement in the
section 9004). expansion reservoir.
STEP 10
WARNING: Boiling cooling fluid can spurt out
Pour suitable cooling fluid in the radiator (see the when the radiator cap is removed. To remove
operator’s manual). the cap, proceed as follows: Wait until the
system has cooled down and then turn the
STEP 11 cap slightly and wait for all the pressure to be
(CX130/CX160)
! released. You can be seriously scalded if the
radiator cap or expansion reservoir cap is
removed too quickly. For checking and
1 maintenance of the cooling system, refer to
the maintenance instructions.
STEP 15
Start the engine and run it at maximum speed until it
reaches normal working temperature.
2
3 STEP 16
CD00F052
Open the left-hand side door. Connect the earth STEP 17
cable (1). Install the battery housing (2) using screws When the radiator feels cold, remove the caps from
(3) and washers. Tighten to a torque of between 20 the radiator and the expansion reservoir. Top up if
and 29 Nm. necessary.
STEP 12 STEP 18
(CX210CX240)
Close the left-hand side doors.
CD00G002
Open the left-hand side doors. Reconnect the earth
cable (1). Close the doors.
STEP 13
Start the engine and run it at idle speed for one
minute. Shut down the engine.

Copyright ©
9005-13
WINDSHIELD WIPER MOTOR

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

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

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

Copyright ©
9005-16
Installation STEP 8
NOTE: The numbers in brackets refer to the Turn back the flap (1) located on the lower portion of
schematic on page 13. the windshield wiper arm (2).
STEP 1 STEP 9
(CX130/CX160)
Place the windshield wiper motor (4) in position on
the cab bracket. Connect the windshield wiper motor
connector (4) to the electrical harness (10).
3
STEP 2
Install the windshield wiper motor (4) on the cab
pillar, using the screws (9) and (11).
STEP 3
2
1
CD00F052
Open the left-hand side door. Connect the earth
cable (1). Install the battery housing (2) using the
screws (3) and washers. Tighten the screws (3) to a
torque of 20 to 29 Nm.
STEP 9
(CX210/CX240)
CD00G134
Install the right-hand front trims in the cab using the
screws.
STEP 4
Install the support (8), washer (7) and the two nuts
(6). Tighten the nuts.
STEP 5
1
Install the rubber cap (5).
STEP 6
Install the windshield wiper arm (2) on the windshield
wiper motor shaft (4), positioning the windshield CD00G002
wiper arm (2) in the same position as was noted at Open the left-hand side doors. Connect the earth
disassembly. cable (1). Close the doors.
STEP 7 STEP 10
Install the nut (3) on the windshield wiper motor shaft. Switch on the windshield wiper motor and check that
Tighten the nut. everything is working correctly.

Copyright ©
107 28
107 * 83
22 C2 D D C2 ITEM DESCRIPTION PRESSURE SETTING ITEM DESCRIPTION
27 * 29 *B45 26 25 29 * A=
A=
MAIN RELIEF (STANDARD)
MAIN RELIEF (BOOST)

34.3 MPa / 343 bar / 4977 psi
36.3 MPa / 363 bar / 5267 psi

1.
2.
HYDRAULIC RESERVOIR
BREATHER
4. BY-PASS VALVE
30 *
B= BOOM RAISING PORT SECONDARY RELIEF 38.3 MPa / 383 bar / 5558 psi 5. SCREEN FILTER
6. RETURN FILTER
B1/B2 = RELIEF ON BOOM HBCV 38.3 MPa / 383 bar / 5558 psi
10. MAIN HYDRAULIC PUMP
P C= BOOM LOWERING PORT SECONDARY RELIEF 38.3 MPa / 383 bar / 5558 psi 15. MAIN CONTROL VALVE
16. HYDRAULIC SWIVEL
P2 P3 P3 P2 D= DIPPER OUT PORT SECONDARY RELIEF 38.3 MPa / 383 bar / 5558 psi 21. TRAVEL MOTOR
B B D1 = RELIEF ON DIPPER HBCV 38.3 MPa / 383 bar / 5558 psi
22. SWING MOTOR
23. TRAVEL MOTOR BRAKE
L1 K1 L2 K2
RED
RED
E= DIPPER IN PORT SECONDARY RELIEF 38.3 MPa / 383 bar / 5558 psi 25. RIGHT BOOM CYLINDER
A A F= BUCKET OPEN PORT SECONDARY RELIEF 38.3 MPa / 383 bar / 5558 psi
26. LEFT BOOM CYLINDER
Dr 27. DIPPER CYLINDER
T2 G= BUCKET CLOSE PORT SECONDARY RELIEF 38.3 MPa / 383 bar / 5558 psi 28. BUCKET CYLINDER
29. BOOM SAFETY VALVE
H= PILOT PRESSURE RELIEF 3.92 MPa / 39.2 bar / 568 psi
30. DIPPER SAFETY VALVE
Pi Pi I= RIGHT-HAND SWING PORT SECONDARY RELIEF 29.7 MPa / 279 bar / 4048 psi 31. DIPPER LOAD HOLDING VALVE
32. BOOM LOAD HOLDING VALVE
106
J= LEFT-HAND SWING PORT SECONDARY RELIEF 29.7 MPa / 279 bar / 4048 psi 41. FILTER (ULTRA-CLEAN)
K1/K2 = TRAVEL REVERSE PORT SECONDARY RELIEF 37.3 MPa / 373 bar / 5410 psi 42. OIL COOLER
43. RETURN MANIFOLD
L1/L2 = TRAVEL FORWARD PORT SECONDARY RELIEF 37.3 MPa / 373 bar / 5410 psi 44. OIL COOLER BY-PASS VALVE
T1 P1 Pi C1 C1 P1 T T P1 45. NON RETURN CHECK VALVE
N1/N2 = NEGATIVE CONTROL RELIEF 2.55 MPa / 25.5 bar / 370 psi
51. ACCUMULATOR
77 77 15 O/P = SECONDARY RELIEF (2eme OPTION) 23.5 MPa / 235 bar / 3410 psi 52. 6 SOLENOID VALVE BANK
T3 D1 T2 5b51 23 21 21 23 R= MAIN RELIEF (2eme OPTION) 20.6 MPa / 206 bar / 2989 psi
53. BOOM & BUCKET CONTROL LEVER
54. SWING & DIPPER CONTROL LEVER
1 77 51 = ACCUMULATOR PRECHARGE 1.5 MPa / 15 bar / 212 psi 55. TRAVEL CONTROL PEDAL
J I 16 4a2 B2 T1 B1 56. DIPPER CONTROL SHOCK ABSORBER

GA GB A 57. BOOM & DIPPER CONTROL SHOCK ABSORBER
C D LEGEND 58. PILOT AND RETURN SYSTEM MANIFOLD
B
* 73
E F 59. FILTER
60. PILOT SYSTEM MANIFOLD
R P1 PUMP 65. CALIBRATED ORIFICE
MU RH FORWARD LH FORWARD 71. SECOND OPTION PEDAL
RH REVERSE LH REVERSE 72. CONTROL PEDAL (OPTIONAL)
P2 PUMP 73. SECOND OPTION CONTROL VALVE
A B B1 A1
74. SWING PRIORITY BLOCK
RIGHT 75. FLOW RE-INJECTION BLOCK (OPTIONAL)
71 Pa1 PILOT SYSTEM PUMP
LEFT 76. 3-WAY SELECTOR (OPTIONAL)
2 77. SAFETY VALVE RETURN SYSTEM MANIFOLD (OPTIONAL)
RETURN TO RESERVOIR 78. RETURN FILTER (OPTIONAL)
79. CONTROL SHUTTLE BLOCK (OPTIONAL)
81. SWING SHUTTLE BLOCK
LEAK-OFF RETURN 82. PILOT CIRCUIT FILTER
78 83. SHUT-OFF VALVE (OPTIONAL)
T 56 P
85. HAND/FOOT CONTROL PILOT FILTER
SUPPLY CIRCUIT 86. PILOT FILTER BY-PASS VALVE
15 T
74 5b32 B
90.
92.
HYDRAULIC BREAKER VERSION PLUG
ORIFICE CALIBRE (CX160)
PILOT SYSTEM CIRCUIT 106. ANTI PENDULUM VALVE
Pi1 dr2
1.2
1 44 COMPONENT BOUNDARY
107.
108.
TWO STAGE TRAVEL VALVE
STRAIGHT TRAVEL VALVE
42 73 109. SWING PRIORITY VALVE
T 59 Pi2 B 71 Pb1
B22.
B23.
SWING PILOT PRESSURE SWITCH
BREAKER / CRUSHER PILOT PRESSURE SWITCH
HOSE
15 1 O B24.
B25.
SECOND OPTION PILOT CIRCUIT 2 PRESSURE SWITCH
BREAKER PILOT PRESSURE SWITCH
0.29 MPa
A 3 PIPING CONNECTION B26. UPPER PILOT PRESSURE SWITCH (YELLOW BAND)
42 psi
FL
109 A
2.9 bar
B27.
B28.
TRAVEL PILOT PRESSURE SWITCH
SECOND OPTION PILOT CIRCUIT 1 PRESSURE SWITCH
10µ dr1 Ps2 FR R4 R5 R2 A
31µ P PIPING CROSS-OVER B42.
B43.
PUMP PRESSURE SENSOR (P1)
PRESSURE SENSOR (NEGA-CONT)
E WITHOUT DUAL 41 COMPONENT ITEM NO.

B44.
B45.
PUMP PRESSURE SENSOR (P2) (YELLOW BAND)
OVERLOAD INDICATOR PRESSURE SWITCH
41 FLOW OPTION M3. PRESSURE TEST POINT
0.03 MPa 0.004 MPa COMPONENT NUMBER Y1. SWING PILOT SHUT-OFF SOLENOID VALVE (GREEN BAND)
4.35 psi 0.58 psi Y2. PILOT PRESSURE SOLENOID VALVE (BLUE BAND)
0.3 bar 0,04 bar 43 Y3. SWING BRAKE SOLENOID VALVE (PINK BAND)
D N1 N2 a
D7 9
Y4.
Y5.
2 STAGE TRAVEL SOLENOID VALVE (RED BAND)
POWER-UP SOLENOID VALVE (YELLOW BAND)
52 5B5 al1 Y6. CUSHION CONTROL SOLENOID VALVE (LIGHT GREEN BAND)
T Y7. MAIN PUMP PROPORTIONAL SOLENOID
2 B A D6
5A5
31 DIPPER (2) CONNECTION ITEM NO. Y9.
Y18.
CRUSHER/BREAKER OPTION TWO FLOW SOLENOID VALVE
FREE SWING SOLENOID VALVE
C T D1
D2
OUT 4b4
Y9
A
42
A * OPTIONAL ITEM NO.
D3
IN
0.098 MPa 10µ T1 4a41
13 psi DIPPER (1)
150 MESH 0.9 bar
43 D7 5a51
OUT
5a52
D 5b52
5b51 IN G
4A3
15 30 76 4B3 43
5 1 4 6 a Pi D D1
F 52
BUCKET 53 53
WITHOUT DUAL 76 5B4 3 1
30 FLOW OPTION A 5A4
T1
T4 OPEN
77 *
B T
T2 79 79 90 OPTION CLOSE
4b3
4a3
T3 B2 B1 HAMMER
C1
51 82 M3
ON
5a4 Y2
T1
C
HYDRAULIC / ELECTRIC SCHEMATIC

30 29 5b4 Y4 P3
CX130 - CX160 - CX180 EXCAVATOR

T2 T
OPT
32 B P P0
10 µ
P
4A2
15 15 4B2 0.049 MPa
T 4b21 C3 C2 5.8 psi
dr1
BOOM (2)
5a31
RAISE
Y3 0.4 bar
5a32
P 5b31
29 15 Y5
5b32 BOOM (1)
Pi 5a31 0.098 MPa
13 psi 86
5B2 0.9 bar
5A2 RAISE
* 75 A SWING 4b22 P2 P1
C5 C4
LOWER
0 2.5
5a2 LEFT
4a2 Y6
5b2 RIGHT 4b21 Y1 60
B
4A1
5B1 TRAVEL (LH)
TRAVEL (RH)
5A1 4B1
B A 15 REVERSE
4b1
5a4 FORWARD FORWARD
5a1 4a1
REVERSE
83 5b1
108 A 55 55
C D 15 2 1
55
* 78
5b4 55
4 3 B43 B42 A1
Px1 Px2
A2 B44
10
* 76 PL Px2 Ps1 Px1 PO ON 1.2 MPa OFF 0.9 MPa PR PY
a1 a2
T T 42
ON 2.0 MPa OFF 1.5 MPa B26 174 psi 130 psi
10µ A
290 psi
20 bar
218 psi
15 bar B27 12 bar 9 bar (FRONT) (REAR)
*
P4 P5 T4 T5
* 72
71
Pi1 Pi2
P3 P2 P1 T3 T2 T1
58 F
55 SECOND
OPTION OPTION
81 92 P1
RAISE TRAVEL (LEFT) TRAVEL (RIGHT)

1
H
85 P 54 85 P 53 2S 1S REVERSE FORWARD FORWARD REVERSE

3S a4
G
T T
LOWER
M
*
B23/B25
1 T 2 1 T 2
ISUZU
S2 S3 S1
E
4B61T H Y7
62,2 Kw
RIGHT LEFT
T R P 85 P 85 à 2100 tr/mn
A Dr A3
DIPPER SWING BOOM BUCKET ON 0.5 MPa B1

IN OUT LEFT RIGHT LOWER RAISE OPEN CLOSE
B22 72.5 psi
5 bar
3 1 3 1
ON 0.5 MPa
72.6 psi
5 bar
C OUT
1 2 4 T 3
OFF 0.3 MPa
43.5 psi
3 bar
*B28 *B24 A4 B3 a3
A1 S1 A2 P T
2 4 2 4 OFF 0.3 MPa
15 15 43.5 psi D IN
4b3 4a3 3 bar B2
85 P
ON 1.2 MPa ON 1.2 MPa
85 15 15
194 psi
12 bar
194 psi
15 15
*
12 bar
B 4b1 85 4a1 5a1 5b1 B1 S2 B2 A OFF 0.9 MPa OFF 0.9 MPa
79 130.5 psi 130.5 psi
S * 9 bar 9 bar
57 Y9
15 15 15 73
Pb1
73
Pa1
CX130 (DCH13B0544 ) - CX160 (DCH16B0199 )- CX180 EXCAVATOR
5a4 5b4 a
HYDRAULIC SCHEMATIC
Number 9-88380
Copyright ©
1
BR 207 BR 207 2 BR 207 F23 F24 F25
F21 1.25 YR 208
1.25 W 209 1 1 1
6
ITEM DESCRIPTION
CN 20
2
1
1
1.25 R 206
F22 2 2 2
2
1
1
CN 26
A1. COMPUTER
3 4
2 BR 207
CN C1 CN C3 CN C4 A2. ENGINE CONTROLLER
2
1
1.25 YR 208
2
A3. ELECTRONIC ACCELERATION
CN C2 1.25 WR 209
1
A4. WIPER CONTROLLER
F8 F16 F15 F18 F3 F13 F7 F9 F2 F1 F10 F19 F17 F14 F5 F6 F4 F20 F11 F12 1 BrR 544
9 10 11 12 13 14
6
K7
1.25 R 206 BR 203
B1. COOLANT TEMPERATURE SENSOR
X3 15A 15A 15A 15A 20A 20A 20A 30A 20A 20A 10A 10A 5A 15A 10A 10A 15A 10A 10A 2 BrW 545
5
CN 29 10A 206, 208, 209 1.25 LR 204 1.25 LR 204
3 B2. HYDRAULIC OIL TEMPERATURE SENSOR
4
1.25 RW 202
CN 22
1.25 GR 205 1.25 GR 205
4 B21. ENGINE OIL PRESSURE SWITCH
206, 208, 209

0.65 BrW 230
R 221
RW 220
0.85 LR 380
0.85 OR 375
0.85VR 370
0.85BrR 360
1.25 LgR 350
1.25 LW 340
1.25 GrR 330
2 WR 050
1.25 W 320
1.25 GR 310
GW290
VW 280
0.85 YW 270
0.85 YR 260
LR250
VR 240
OW 300
5 60 R 200 60 R 201 60 R 001
2 1 B22. SWING PILOT PRESSURE SWITCH
1.25 W 322
1
2
BrW 545
BrR 547
6 NB LgR 540
M10 M10 M10 M10 B23. BREAKER / CRUSHER PILOT PRESSURE SWITCH
3
1.25 GR 312
OW 303
0.65 GR 231
1.25 W 325
MB
B 703
GW 303
- + - +
0.85 OR 375
0.85 YR 260
8
B24. SECOND OPTION PILOT CIRCUIT 2 PRESSURE SWITCH
2
R 222
WR 541
0.85 LR 381
BrR 544
BrR 547
7
R 223
1
M4 B25. BREAKER PILOT PRESSURE SWITCH
60 B 799
BP 690
12V 12V B26. UPPER PILOT PRESSURE SWITCH (YELLOW BAND)
1.25 R 206 1 1.25 R 206
B27. TRAVEL PILOT PRESSURE SWITCH
G1 G1
LgR 540 2 LgR 540
WR 541 3 WR 541 B28. SECOND OPTION PILOT CIRCUIT 1 PRESSURE SWITCH
CN 13 1
1
GrR 010 4 GrR 010 M8 B41. ENGINE RPM SENSOR
1 2 3 4 5 6 7 8 9 BrR 543 5 BrR 543 CN C0 B42. PUMP PRESSURE SENSOR (P1)
B 779
2 BrR 547 P1 10 11 12 13 14 15 16 17 18 19 20
YR 630
VW 800
6
7
YR 630
VW 800
B43. PRESSURE SENSOR (NEGA-CONT)
B44. PUMP PRESSURE SENSOR (P2) (YELLOW BAND)
1 WR 548
VR 900 8 VR 900 BG 650 B45. OVERLOAD INDICATOR PRESSURE SWITCH
0.85 BG 660
9
BG 651 B61. SUNLOAD SENSOR
BG 641
BG 652
BG 640
OR 505 10 OR 505
B 779 B81. HORN
CN 5 CN 6 0.85 L 910 11 0.85 L 910
CN 32
2
2 BG 800 E1. WORKING LIGHT (UPPERSTRUCTURE)
IGN 0.85 LW 911 12 0.85 LW 911
IGN 1.25 W 1.25 W 1 1.25 W 322
1
1
P2 B+ 2 R B+ R 2 R 221
0.85 LY 912 13 0.85 LY 912 2 B 700
BP 690
E2. WORKING LIGHT (ATTACHMENT)
0.85 LR 380 14 0.85 LR 380 M8 E3. WORKING LIGHT (CAB)
1 2 3 4 5 6 7 8 17 18 19 20 21 22 23 24 25 26 S2 3 BrG BrG 3 BrG 441 GND
A1
B 779
2 BG 800
(GI)
2 B 700
9 10 11 12 13 14 15 16 27 28 29 30 31 32 33 34 35 36 S3 4 VY VY 4 VY 440 E4. CAB LIGHT
CN B4
S4 5 WG (OG) WG (OG) 5 WG 446
B 719 M5
24V 40A E51. CIGARETTE LIGHTER
E
1
2
VG VG 6 VG 534
M4
6 E52. AIR CONDITIONER
CN 5
S5 7 7
WV 930 1 F1. FUSE 20A; ENGINE CONTROLLER
S6 OG (GY) OG (GY) 8 OG 442 M
4
8
7 8
BW 630 2 F10. FUSE 10A; OPTION LINE AND LUBRICATOR CONNECTOR
CN 21
9 YG YG 9 YG 443
3
FILTER GND F11. FUSE 10A; BACK-UP
POWER 24V 10 1.25 LgR 351 RXD 10 PW RXD PW 10 PW 583
5 6
2
5V F12. FUSE 10A; KEY SWITCH
2 1.25 LgR 350 TXD 11 PL TXD PL 11 PL 584 24V
1
1.25 W 320
F13. FUSE 20A; HEATER / AIR CONDITIONER
CONTROL 24V 4 12 LY LY 12 LY 444
12 1.25 W 321 WR WR 13 WR 531 1.25 WR 209 1 1.25 WR 209 F14. FUSE 5A; AIR CONDITIONER COMPRESSOR
13 8 R 100 8 R 100 M5 B
GND 1 1.25 BG 600 14 BrR (BrY) BrR (BrY) 14 BrR 501 1.25 YR 208 2 1.25 YR 208 F15. FUSE 15A; WORKING LIGHT
WR 541
SG
LgR 540
2 LR 050 F16. FUSE 15A; WORKING LIGHT (NOT USED)
P3
GND 9 1.25 BG 501 15 GrR GrR 15 GrR 520 2 LR 060 3 2 LR 060
BrR 530
GND 3 16 LR 16 LR 521 1.25 GrR 330 4 1.25 GrR 330 BP 690 BrR 030 2 L F17. FUSE 10A; DC-DC (24V-12V) CONVERTER
GND 11
S7 YR 17 YR 522 1.25 GR 312 1.25 GR 312 010, 540, 541, 543 LgR 020 1 R
17 5 F18. FUSE 15A; WIPER AND WASHER
S8
CPU GND 5 18 LR VR 18 VR 523 BP 690 6 BP 690
140 F19. FUSE 10A; HORN
CN E0
S9
010, 543
GND 13 19 YR BrW (BrR) 19 BrW 545 1.25 B 700 7 2 B 700
CN C9
S10 F2. FUSE 20A; COMPUTER CONTROL INSTRUMENT PANEL AND DIAGNOSTIC TEST SOCKET
1
PWM 1 OUT 14 YR 940 20 VR GND 1.25 BG 20 1.25 BG 602 602, 603, 604 1.25 BG 600 8 2 BG 600
S11 YR 830
Y2 F20. FUSE 15A; CIGARETTE LIGHTER AND CAB SEAT COMPRESSOR ADJUSTMENT
2
PWM PWM 1 RET 6 BY 941 21 BrW (BrR) B 703 B 703 1
B 755
1.25 B 730
1.25 B 731
S12 B 760 2 F21. FUSE BOX
BG (B)
NOT USED 16 22 1.25 BG
603, 604
VR 524
B 760
PWM 2 OUT 15 GND F22. FUSE 20A; MAIN FUSE FOR F11 AND F12 CIRCUITS
CN P4
CN E2
D/A PWM F23. FUSE 65A; MAIN FUSE FOR F3 TO F10 AND F13 TO F20 CIRCUITS
G2
PWM 2 RET 7
2
1
E4
8 BIT
8 1.25 BG 602
2 STAGE RELIEF YW 802 F24. FUSE 20A; MAIN FUSE FOR F2 CIRCUIT
CN P0
BG 603 VW 800 1
Y3
3
6
6 60 R 001 M10 B F25. FUSE 20A; MAIN FUSE FOR F1 CIRCUITS
CN 9
0.85 BrR 0.85 BrR 360
PROTECT 1 BG 604 B 762 B 762 2 M
2
5
2 WR GrR 14 GrR 520 F3. FUSE 20A; COMPUTER POWER
1
4
24VB LR 12 LR 521 F4. FUSE 10A; HYDRAULIC FUNCTION CANCELLATION LEVER SWITCH
CN E1
11 12 13 14 15 16 17 18 19 20 21 22
9 10
P4 5V
4.7K 24V - 10W
YR 13 YR 522 F5. FUSE 15A; LUBRICATOR (NOT USED)
VR 3 VR 523 1 1.25 B 700
Y4
LW 801 1 F6. FUSE 10A; ROTARY LIGHT
8
SPARE 1 (PNP) FPC
17 B 710 0.85 GrR 010 S
S53 0.85 OR 11 0.85 OR 892 2
CN P8
B 702
1.25 B 701
B 761 B 761 2 F7. FUSE 20A; FUEL FILLER PUMP
7
H1
18
2
ROTARY LIGHT PW 819 VW 2 VW 525 3 B 711
19 F8. FUSE 15A; ENGINE STOP MOTOR
1
AUDIBLE ALARM WR 1 WR 390 4 B 713
CN E3
SPARE 2 (PNP) 21 0.85 BrR 543 R F9. FUSE 30A; GLOW PLUG
LW 7 LW 972 5 B 715
M1
1 VW 2 VW
3
8
6
SPARE 3 (PNP) 22 BL 8 BL 973 6 B 728 G1. BATTERY
Y5
2 BG (B) 1 BG (B) YW 802 1
2
7
CN P3
5
SWING BRAKE 27 VW 800 YW 9 YW 970 G2. ALTERNATOR
3 B 763 2
6
2 STAGE TRAVEL 28 LW 801
4
P5
BY 10 BY 971 2 LR 060 M4 H1. AUDIBLE WARNING DEVICE
E51
B 763
CUSHION CONTROL 29 LgW 803
3
WV 4 WV 730
CN E4
K1. RELAY-ENGINE EMERGENCY STOP
CN P9
719, 715, 728

4
NOT USED 30 BW BW 720
2
5
K2. RELAY-GLOW PLUG
R1
1.25 B 701
2
SWING SHUT OFF 31 BrW 804 0.85 BrW 230 B 715
710, 711
S54 Y6
WV 931
LgW 803 1 K3. RELAY-HORN
BW 721
B 702
NOT USED 32 WR 1 WR
BATT. RELAY B 764 B 764 2 K4. RELAY-WORKING LIGHT
20 WR 541 VW 2 VW
CN 14
9 10 11 12 13 14
6
NOT USED 23 WR 548 1 VR VR 3 VR K5. RELAY-ROTARY LIGHT
CN E5
CN D7
5
NOT USED 36 2 BG (B) 4 BG (B) K7. RELAY BATTERY
1
BG (B)
1.25 BG 800
4
CCW 24 3 BL (SPK: L-) 5 BL M1. STARTER MOTOR
2
Y1
BrW 804 1
U1
CW 26
CN 30
LW (SPK: L+) 6 LW
NOT USED 33 B 765 B 765 2 BG 640 1 B21 M2. ENGINE EMERGENCY STOP MOTOR
2
BY (SPK: R-) 7 BY
CN P7
LgY 438 2
M3. WIPER MOTOR
NOT USED 34
3
YW
3
YW (SPK: R+) 8
2
X5
M4. WASHER MOTOR
1
CN 27
GY 566
E3
A/C CONT. 25
3
1.25 W 325
X4
1
8
8
2
1
B 763
B 760
3
PROTECT
2 BG 600
M5. MOTOR (AIR CHANGING)
CN A5
2
5V NOT USED 35
2 B 700
2
2
CN 25
7
WR 571
2
1
7
1
24 V OR OR VW 280 1 VW 280 VW 280 6
B 779
24V M6. AIR VENT DIRECTION CONTROL MOTOR
3
LG 570 3
6
2
2 BG (B) R 223 R 223 R 223 2
CN D6
70W 2
M7. MOTOR ACT (AIR-MIX)
1
P 585
9 10 11 12 13
4
5
6
B 702 3 B 702 B 702 5 t C
0.85 BP 494 1
B1
OW 301
2
PG 586 5 M8. BLOWER MOTOR
1
CN 6
CN P10
4
5
BP 633 1 0.85 YR 281 1
0.85 PL 484 2
BP 587 6 P1. INSTRUMENT PANEL
4
2
2
1
CN P1
P 588 0.85 RW 282 3 0.85 L 913
VG 576 7 3 LW 801 1 LW 801 P2. SWITCH PANEL (LEFT-HAND)
BP 632 0.85 BY 729 4 0.85 B 751 2
YW 802 YW 802
M2
BG 620 8 2 P3. SWITCH PANEL (RIGHT-HAND)
2 3
7
LgW 803 3 LgW 803
1
A4
8
BY P4. MONITOR DISPLAY
R BrW 804 4 BrW 804
1
0.85 BrY 575
7
2 YW P5. HOURMETER
5 0.85 L 910 1 L
CN 1
P6. AIR CONDITIONER CONTROL PANEL

BrR 840 6 BrR 840 0.85 LW 911 2 LW
1K 100K 1K R1. GLOW PLUG
VR 841
CN P5
11 7
3
LR
7
5 LY
W1
0.85 LY 912
CN 70
4
1 2 3 M
CN A7
0.85 VG 469 0.85 BG 621 R2. FUEL FLOW ADJUSTMENT RESISTOR
2
1
VW 842 8
1
YR
2
12
X9
6
THERMO SENSOR (0) 6 0.85 OL 415 0.85 LR 380 4 LR
5 6 7 8 9 CN 11 WV 930 9 WV 930 R3. THROTTLE VOLUME
2
13 GrR 0.85 B 750
5
A GND 13 0.85 BO 425 6 B
2 WV BW 720 10 BW 720 R4. THERMISTOR
R2
1
4
FUEL SENSOR 14 0.85 GL 413 0.85 B 751 3 YL 488 1
0.85 GR 890 11 0.85 GR 890
CN 31
3 BW B 763 R5. FUEL SENSOR
1 BY 498
2
SPARE 11 (A/D) 15 BL 2
1 1 1 0.85 BrR 0.85 LgR 891 12 0.85 LgR 891
WR 391
S1. KEY SWITCH

YW 970
LW 972
L
BY 971
3 0.85 WY 400 2
S14
A VCC
BL 973
1
S13
1
LW
4
CN D6
R 222
LR 901 LR 901
B 710
2 3 2 3 10 1.25 B 13
CN 63 CN 62 S10. WORKING LIGHT SWITCH
CN A8
P1 SIG 1 0.85 WL 410
2
5
WR 980 14 WR 980
1
9
P2 SIG 9 0.85 YL 411 S11. WIPER SWITCH
3
6
GND
(G2)
OW 300 15 OW 300 B 760
2
7 VW WV 931 1
0.85 L 412
CN P6
N1 SIG 10
X8
WG 448 BrR 840 GrR 893 16 GrR 893 S12. WASHER SWITCH
8
3
9
4
6
2
1
7
5
8 VR BW 721 2 O 487 1
B41
2
1
A GND 2 0.85 BW 420 M6
B G 604 BP 690 YR 940 17 YR 940 S13. OVERLOAD SWITCH
4 W 497
A VCC 11 2
BrG 460 5 GW BY 941 18 BY 941 S14. BREAKER / CRUSHER SWITCH
X2
SPARE 9 (A/D) 4 GrR 893
6 GR S15. HORN SWITCH
PRESSURE SWITCH 5 B 755
S16. ONE TOUCH IDLE
9 10 11 12 13 14 15 16 17 18
8
A/O PRESSURE SENSOR (HBCV) 12 0.85 WG 417
LR 901
10 BIT KEY SW. 7 LgR 542 24V. 370 HZ. 111dB S2. TRAVEL MODE SWITCH
7
CN 53
1
CN 60
5 6
SPARE 12 (CMP) 16 1 2 3 4 S3. WORK MODE SWITCH
6
2
B81 B81
CN A2
6
M3
CN P2
2
BATT. CHARGE 8 BrR 543 LR 900 LR 901 S4. AUTO MODE SWITCH
5
1
5V
S51 S15
5
2
CN 23
7 8
3
5V 1 LW 532 B 753 B 754 S5. CUSHION CONTROL SWITCH
4
1
4
10V 2 B 713 3 GR S51. HYDRAULIC FUNCTION CANCELLATION LEVER SWITCH
1 VR 240
3 VW 842 M A3
1.25 BG 800
5V
4
2 YR 830 1 GW 24V. 370 HZ. 111dB 1.25 RG 950 1 VB S52. AIR CONDITIONING COMPRESSOR CLUTCH SWITCH
CN 2
R
4 B 714
3
1.25 B
2 BG 600
5 1.25 BrB 951 2 POWER GND S53. DOOR LIMIT SWITCH
2 B 700
VR
B 779
2
6 0.85 GR 954 3 PWM S54. FRONT WINDOW LIMIT SWITCH
E
CN B5
4 VW
1
0.85 WL 482 4 RACK 1ST
TXD SPARE 13 (CMP) 23 S55. RESERVE TANK LSW
1
2
SCI RXD RS 232 C
TX 27 P 585 R3 2
0.85 LgR 891
0.85 WY 472 5 VCC
D
S6. ROTARY LIGHT SWITCH
E1
1
X6
0.85 YG 508 6 PULL DOWN
B 710
RX 21 PG 586 24V S7. AUDIBLE ALARM CUT OUT SWITCH
0.85 B 741 2 Y 486
S1
CONNECTION 24V 7 TACHO SENSOR (SIG)
SG 20 BP 587 OFF ACC 70W S8. SWING BRAKE SWITCH
1 2 B G1 G2 Acc M ST L 496 8 TACHO SENSOR (GND)
SW. TO ACCESS 28 LG 570 HEAT ON 222, 391, 710, 970, 971, 972, 973 S9. ENGINE EMERGENCY STOP SWITCH
PROTECT 22 WR 571 ST HEAT
4
3
2
1
240, 448
1
2
CN 54 U1. DC-DC (24V-12V) CONVERTER
CN B2
TXD SERIAL OUTPUT 25 PW 583 OFF
1
SCI 830, 840, 842 W1. ANTENNA
WR 391
ACC
B 717
0.85 GR 291
0.85 L
0.85 B
0.85 Y
RXD SERIAL INPUT 19 PL 584 BrG 460
2
S16
1
4
CN A3
X1. FUEL FILLER PUMP CONNECTOR
5
ON
1
GROUND 26 1 2 3 4 BrG 461
2
5
START 0.85 GR 890 1 0.85 GR 890 1
6
VR 240 1 VR 240 2 X2. ROTARY LIGHT CONNECTOR
E2
TA INPUT 24 24V
CN 19
1/4 CN 53
3
COUNTER
6
1.25 B 740 2 0.85 B 740 2
GROUND 17 1 2 YR 830 2 YR 830 7 70W X3. OPTINAL POWER CONNECTOR
3 2 1 CN 55 8
2 B 700
TA GND 18 BrG 460 3 BrG 460 1.25 LG 952 1 VB X4. ENGINE TEST POINT CONNECTOR
B 753
B 754
1 G 450
3
10 9
1 2 3
3
2
1
BrR 840 4 BrR 840 X5. CONTROLLER TEST POINT CONNECTOR

CN 50 4 5 6 2 BG 603 1.25 B 740 1.25 B 740 1.25 GrB 953 4 POWER GND
4
GR 231 1
6
VW 642 5 VW 642
2
1
4
3 VR 841 2 X6. CAB SEATCOMPRESSOR MOTOR CONNECTOR

B 779
0.85 L 480
0.85 BL 490
0.85 LY 470
B 716 2 WG 448 6 WG 448

CN 52 0.85 BG 465 3 PWM X8. RADIO CONNETOR
WR 390
LgR 540
GrR 010
RW 220
4 B 711 1
YR 940 YR 940
CN 3
LW 532 7 LW 532
603, 604
0.85 BW 492 5 SIG GND
BY 941 BY 941 2 X9. ANTI-THEFT SYSTEM CONNETOR
B 713 B 713
Y7
8 0.85 WG 473 6 VCC
BP 690 9 BP 690 BP 690 Y1. SWING PILOT SHUT-OFF SOLENOID VALVE (GREEN BAND)
IMMOBILIZER
X1
CN D4
31 0.85 VG 469 BG 604 10 BG 604 BG 604 Y2. PILOT PRESSURE SOLENOID VALVE (BLUE BAND)
2 B 700
NOT USED 32
2 BG 600
1.25 GrR 330 Y3. SWING BRAKE SOLENOID VALVE (PINK BAND)
2
NOT USED 33 2 B 700 Y4. 2 STAGE TRAVEL SOLENOID VALVE (RED BAND)
NOT USED 34 E52 2 BG 600 1 Y5. POWER-UP SOLENOID VALVE (YELLOW BAND)
WR 391
PRESSURE SWITCH 35 G 464

2 Y6. CUSHION CONTROL SOLENOID VALVE (LIGHT GREEN BAND)
AUDIBLE ALARM CUT OUT 36 YG 443
WR 390
0.85 LG 507 3 LIMP HOME Y7. MAIN PUMP PROPORTIONAL SOLENOID

NOT USED 37 2
R4 1 G 465
RW 220 RW 220
LgR 542
LgR 540
BREAKER MODE BrG 460

Y8. AIR CONDITIONER MAGNET CLUTCH
38
WR 390 2 WR 390 BG 667 1
B28
GrR 010
Y9. CRUSHER/BREAKER OPTION TWO FLOW SOLENOID VALVE
1
TEST 41
CN A4
LgR 540 3 LgR 540
2
NOT USED 42
CN M1
GrR 010 4 GrR 010
3
NOT USED 43
1.25 BG 800
G 450 5 G 450
LgR 502
LgR 503
GrR 504
2
CUSHION CONTROL 44 WG 446 M10
VR 841 16 VR 841
LEGEND
P6
SWING BRAKE 45 LY 444
0.85 LY 470 6 0.85 LY 470 G 464 2
NOT USED 46
0.85 L 480 7 0.85 L 480 t C
BG 656 1
B24 0.85 BO 425
B2
NOT USED 47 1 2
0.85 BL 490 8 0.85 BL 490
NOT USED 48 0.85 OL 415
I/O 0.85 GR 231 15 0.85 GR 231 CONNECTED NOT CONNECTED
CN G2
CN M0
NOT USED 40
1
4 B 711 17 B 711
1
2
CN D3
CAN H 29
1
7 BG 603 18 BG 603
2
CAN CAN L 39 P 580
G 464
BG 656
8
2
YR 560 9 YR 560
CAN GROUND 30 PG 581
1 BY 561 10 BY 561 OW 300 1 OW 300 OW 300 1 BOOT GROUND CABLE GROUND
2 PL 562 11 PL 562 BrR 840 2 BrR 840 BrR 840 2 Y9
3
6
PW 563
WL 564
12
13
PW 563
WL 564
K1 K2 G 464 3 G 464 0.85 BG 660
R5
CN 4
CN G0
BrG 461 4 0.85 GL 413
1
5 BW 565 14 BW 565 LY 435 LY 435 SINGLE WIRE CONNECTOR HARNESS
5
2
BG 655 6 BG 655
CN B3
1
ENGINE OIL PRESSURE 49 LgY 436
3
8
11 12 13 14 15 16 17 18 19 20 21 22
9 10
18 17 16 15 14 13 12 11 10 9
2 1
2
SPARE 21 50
2
7
CN 51
1 2 LY 435 2 CONNECTOR (MALE) CONNECTOR (FEMALE)

B23
1
4
TRAVEL PILOT 51 YG 431
CN B1
1 2
6
1 2
3
8
BG 655 1
2
5
ROTARY LIGHT 52 VG 534 3 5 3 5
5
CN G2 0.85 WY 400 1
7
B61
3
4
2
2
4
4
3
5
1
5
1
3
6
L/M MODE 53
CN 10
1
4
B42
0.85 WL 410 2
CN G1
AUTO MODE 54 OG 442
1
CN 24
3
0.85 L 910
0.85 LR 381
BrR 530
0.85 LY 812
0.85 LW 811
2 WR 050
2 WR 051
OR 506
2 LR 060
CN 18 CN 15 0.85 BW 420
1
2
BREAKER PILOT 55 LY 435 OW 300 1
2
1 WL 564
5
WORK MODE 56 VY 440 BrR 840 2 INSULATION AGAINST MAGNETISM
BG 656
2 BW 565
6
CN D0
G 464 G 464
5
COOLANT 57 GrG 437 3
1
7
3
BrG 461 BrG 461
4
SPARE 22 58 4 INDICATES CONSTANT POWER
2
CN 12
LY 435 LY 435 LY 435
3
5
2
B25
WARNING CHG. 59 WG 448
060, 506, 910, 911, 912 BG 655 BG 655 BG 655 1
1
2
SPARE 23 60 6
050, 361, 530 INDICATES POWER WHEN KEY SWITCH IS ON
B44
1
SWING PILOT 61 BrY 432 0.85 Y 401 1
PW 563
CN C0
4
UPPER PILOT 62 LG 430 0.85 YL 411 2
1
ONE-TOUCH IDLE 63 G 450
5 PL 562
LG 430 1 LG 430 S52 0.85 BY 421 3 CN12 (R)
2
6 BY 561
TRAVEL MODE 64 BrG 441 YG 431 2 YG 431
I/O 7 YR 560
K4 K5 Y8
BrY 432 3 BrY 432
K3
CN C8
CN D1
16 VW 525 WR 980 2 CONNECTOR NUMBER
1
4 COLOR OF CONNECTOR
3
15 VR 524 W 981 1 (IN CAB) (IF NOT INDICATED COLOR IS WHITE)
2
LY 435 5 LY 435
14 GY 566
0.85 WY 400 6 0.85 WY 400
CONNECTOR
17 WR 590 W 981 1 LETTER LOCATED
0.85 WL 410 7 0.85 WL 410 BrY 432
3 0.85 GR 567 0.85 LY 402 1 (OUTSIDE CAB)
RAM - 2 K BYTE 9 1.25 LW 340
0.85 YL 411 8 0.85 YL 411
0.85 L 412 2
B43 60 B 001
0.85 L 412 9 0.85 L 412
8 0.85 YW 270 0.85 BL 422 3
1 2 1 2 1 2
0.85 W 420 10 0.85 W 420 LG 430 AREA CIRCUIT NUMBER
1 1.25 B 701 2
LgY 436 LgY 436 COLOR
430, 431, 432, 433, 435
436, 437, 440, 580, 581
11
641, 650, 651, 652

FLASH 2 3 5 3 5 3 5
EPROM BG 650 1
MEMORY GrG 437 GrG 437
3
12
2
2
4
CN D2
4
2
5
1
5
1
4 4
3
5
1
8 K BYTE TABLE OF COLOR SYMBOLS
1
2 M BYTE 10
BrG 461 13 BrG 461
3
LR 250
PW 819
B 728
GrR 893
11
GW 290
GW 291
LW 532
LR 900
0.85 VR 370
0.85 VR 371
WR 531
0.85 GR 890
2
CN 16 CN 17 CN 35 G 464 14 G 464
SYMBOL COLOR
0.85 OR892
12
CN C5
0.85 GL 413 15 0.85 GL 413 BrY 432 2
B26
1
0.85 GR 667
13
0.85 OL 415 16 0.85 OL 415 B BLACK
B22
250, 290, 370, 534
BG 652 1
2
0.85 LgR 891
18
CN 1 CN 2 CN 3 CN 4
LR 901 0.85 BO 425 17 0.85 BO 425 BG 641 1
S55 W WHITE
10 11 12 13 14 15 16 17 18
8 9
18 GrG 437 2
M PWM 0.85 PL 484 19 0.85 PL 484 Br BROWN
CN B0
7
0.85 WG 417 20 0.85 WG 417
CN B8
1 2 3 4 5 6 7 8 17 18 19 20 21 22 29 30 31 32 33 34 35 36 37 38 49 50 51 52 53 54 55 56 YG 431 P PINK
1
2
6
P 580 21 P 580
1.25 BG 600
1.25 BG 630
2
CN 2B
9 10 11 12 13 14 15 16 23 24 25 26 27 28 39 40 41 42 43 44 45 46 47 48 57 58 59 60 61 62 63 64
M8
2
M M M BG 651
5
PG 581 22 PG 581 1
V VIOLET
4
531, 532, 567, 890
650, 651, 652

G GREEN
CN C6
891, 892, 893, 900, 901
3
1.25 BG 800
M5
1
M6 M7
BG 652
2
BP 509
461, 470
480, 490
501, 502
503, 504
O ORANGE
2
BW 505 B27
1
0.85 PL 484 650, 651 650, 651, 652 0.85 LY 407 1 0.85 LY 407 1 B45 R RED
0.85 WG 417 2 0.85 WG 417 2
0.85 BG 427 3 0.85 BG 427 3 Y YELLOW
BY 500 Lg LIGHT GREEN
CN A0 CN A1 CN 7 CN 8 Sb SKY BLUE
1
CN R0
CN R1
L
1
BLUE
3
1 2 3 4 5 6 7 8 9 10 11 33 34 35 36 37 38 39 40 58 59 60 61 62 63 64 65 66 67 89 90 91 92 93
2
1.25 GrB 953
0.85 WG 473
0.85 BrY 575

1.25 BrB 951
0.85 WY 472
0.85 BW 492
1.25 GR 313
1.25 GR 312
1.25 RG 950
0.85 GR 954
0.85 GR 311
1.25 GR 310
0.85 YG 506
0.85 BG 955
0.85 BG 631
1.25 BG 630
1.25 LG 952
0.85 LG 507
0.85 BP 494
0.85 WL482
0.85 YL 465
0.85 LY 470
0.85 BL 490
0.85 PL 484
3
Gr GRAY
1.25 B 730
1.25 B 731
12 13 14 15 16 17 18 19 20 21 22 23 24 41 42 43 44 45 46 47 48 49 50 68 69 70 71 72 73 74 75 76 77 78 79 94 95 96 97 98 99 100
0.85 L 481
0.85 L 480
680
681
GrR 504
LgR 503
LgR 502
BrR 501
BW 505
OR 506
VG 576
PG 581
BP 509
BY 498
BY 500
BL 782
YL 488
25 26 27 28 29 30 31 30 51 52 53 54 55 56 57 80 81 82 83 84 85 86 87 88 101 102 103 104

W 497
O 487
Y 486
P 580
P 588
L 496
NOTE :
CN A0 CN A1 CN 7 CN 8 1. "BR" INDICATES BLACK CABLE WITH RED STRIPE.
89
94
90
91
92
93
95
96
97
98
99
100
101
102
103
104
2. WATERPROOF CONNECTORS USED OUTSIDE OF CAB.

2
3
6
7
8
12
13
14
16
18
19
21
23
24
25
26
28
29
1
4
15
30
5
17
31
9
10
11
20
22
27
32
39
42
33
51
54
52
34
36
45
43
53
35
44
38
48
55
37
46
40
41
47
49
50
55
57
88
63
64
66
69
71
72
75
77
78
79
84
85
87
59
67
82
80
60
61
65
62
73
74
83
86
70
81
68
75
58
A2
HEAT RELAY
TACHO SENSOR (SIG)
TACHO SENSOR (GND)
RPM SENSOR (SIG)
PULL DOWN (RED 4)

NV VB
TF SENSOR (SIG)
LIMP HOME (RED 4)
GND (TW & TF SENSOR)
PS (GE) PWR GND
GND (MV)
VBB (RED 4)
GND (RED 4)
SHLD (RED 4)
GND (RED 4)
VBB (RED 4)
5V (RED 4)
5V (RED 4)
SIG GND (RED 4)

PWM SOLL (RED 4)
PWM SOLL (RED 4)
CAN-H
CAN-L
CAN GND
Q ADJUST RES.
Q ADJUST RES.
RPM SENSOR (GND)
PS (GE) PWR VB
V 1ST (RED 4)
THROTTLE (GND)
ENGINE STOP MOTOR

ANTI-REVERSE SW
LIMP HOME SW.
MEMORY CLEAR
ENGINE STOP SIG IN
KEY SWITCH
KEY SWITCH
START SWITCH
ACCEL VOLUME (5V)
THROTTLE (SIG)
THROTTLE (SIG)
NAP SELECT-0
NAP SELECT-1
NAP SELECT-3
TW SENSOR (SIG)
CAN USE SELECTING SWITCH
TECH 2 (TXD)
TECH 2 (RXD)
MAIN POWER (VB)

MAIN POWER (VB)
CHECKER SELECT
GND
GND
NAP SELECT-2
5 B 796 CX 130 - CX 160 - CX 180 EXCAVATOR

M6 M8 ELECTRICAL SCHEMATIC
Part Number 9-88430

51895-Case CX160 Crawler Excavator

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Copyright ©

CX160 Crawler Excavators

Copyright  2001 Case France

* Consult the Engine Service Manual

Cre 7-29871GB Edition 12-01

SAFETY, GENERAL INFORMATION

Copyright  2000 Case France

Cre 7-27690GB Issued 09-00

Cre 7-27690GB Issued 09-00

To prevent injury always follow the Warning, Caution

WARNING: If you wear clothing that is too

WARNING: When working in the area of the

WARNING: When doing checks and tests

WARNING: When putting the hydraulic

Cre 7-27690GB Issued 09-00

WARNING: When the battery electrolyte is

WARNING: Use suitable floor (service)

Cre 7-27690GB Issued 09-00

STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS

Cre 7-27690GB Issued 09-00

Cre 7-27690GB Issued 09-00

Cre 7-27690GB Issued 09-00

Copyright  2003 CNH France SA

Cre 7-27714GB Issued 03-03

TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE

Component serial numbers

Cre 7-27714GB Issued 03-03

FLUIDS AND LUBRICANTS

Transmission component oil

Cre 7-27714GB Issued 03-03

Oil viscosity/Oil range

Cre 7-27714GB Issued 03-03

Cre 7-27714GB Issued 03-03

Cre 7-27714GB Issued 03-03

Cre 7-27714GB Issued 03-03

Cre 7-27714GB Issued 03-03

Cre 7-27714GB Issued 03-03

DIMENSIONS AND LIMIT OF WEAR AND TEAR OF THE TRACKS SET

Cre 7-27714GB Issued 03-03

Cre 7-27714GB Issued 03-03

Cre 7-27714GB Issued 03-03

Dimension (mm) Dimension (mm)

Cre 7-27714GB Issued 03-03

Dimension (mm) Dimension (mm)

Cre 7-27714GB Issued 03-03

DIMENSIONS AND LIMIT OF WEAR AND TEAR OF THE MOBILE JOINTS OF

Cre 7-27714GB Issued 03-03

2. Boom cylinder foot/Undercarriage

3. Boom cylinder head/Boom

Cre 7-27714GB Issued 03-03

4. Dipper cylinder foot/Boom

6. Dipper cylinder head/Dipper

Cre 7-27714GB Issued 03-03

7. Bucket cylinder foot/Dipper

Cre 7-27714GB Issued 03-03

10. Connecting rod/Compensator/Bucket cylinder head

Cre 7-27714GB Issued 03-03

SPECIAL TORQUE SETTINGS

Cre 7-27714GB Issued 03-03

Cre 7-27714GB Issued 03-03

Cre 7-27714GB Issued 03-03

MACHINE OVERALL DIMENSIONS CX130 CX160

Only on CX130 machines with 3 m dipper Point A: Working position