SM CX330 Tier3 en

Copyright
CX330, CX330NLC and CX350 Tier 3 Crawler Excavators

Table of Contents
DIVISION/SECTION SECTION N REFERENCE N
1 GENERAL INFORMATION
Safety, general information and standard torque data .....................................1001 7-27691EN
General specifications and special torque setting............................................1002 9-94170EN
2 ENGINE
Radiator and engine, removal and installation .................................................2001 9-94830EN
Engine specifications ............................................................................................. *
Disassembly and assembly of the engine.............................................................. *
3 FUEL SYSTEM
Fuel tank ..........................................................................................................3001 9-43471EN
Fuel engine system................................................................................................ *
4 ELECTRICAL SYSTEM
Electrical system, electrical and electronic troubleshooting.............................4001 9-94180EN
Inspection and maintenance of batteries and connecting a booster battery....4002 9-43460EN
Main and engine electronic control boxes........................................................4003 9-43451EN
5 UNDERCARRIAGE
Removal and installation of tracks ...................................................................5001 9-42910EN
Rollers..............................................................................................................5003 9-42921EN
Sprocket ...........................................................................................................5004 9-36890EN
Idler wheel and tension shock absorber ..........................................................5005 9-94790EN
6 DRIVE TRAIN
Drive motor and final drive transmission removal and installation ...................6001 9-43141EN
Swing reduction gear, removal and installation................................................6003 9-43210EN
Swing reduction gear, disassembly and assembly...........................................6004 9-43221EN
Travel reduction gear disassembly and assembly ...........................................6005 9-43151EN
7 UNDERCARRIAGE HYDRAULICS
8 UPPERSTRUCTURE HYDRAULICS
Depressurising and decontaminating the hydraulic system, use of the
vacuum pump and bleeding the components ..............................................8000 9-43501EN
Specifications, troubleshooting, checks and hydraulic pressure settings.........8001 9-94190EN
Hydraulic reservoir removal and installation ....................................................8002 9-43230EN
Main and pilot pumps, removal and installation ...............................................8003 9-94840EN
Main hydraulic control valve, removal and installation .....................................8004 9-43261EN
Attachment cylinders, removal and installation ................................................8005 9-43251EN
Hydraulic swivel, removal and installation........................................................8006 9-43390EN
Pilot blocs, removal and installation .................................................................8007 9-43400EN
Swing motor, removal and installation..............................................................8008 9-43200EN
Main hydraulic pump, disassembly and assembly ...........................................8010 9-94850EN
Main hydraulic control valve, disassembly and assembly ................................8011 9-43551EN
Attachment cylinders, disassembly and assembly...........................................8012 9-94760EN
Hand control levers, disassembly and assembly .............................................8013 9-94630EN
Foot control levers, disassembly and assembly ...............................................8014 7-28301EN
Six-solenoid valves, disassembly and assembly..............................................8015 9-43361EN
Caution valve, disassembly and assembly.......................................................8016 9-94770EN
Hydraulic swivel, disassembly and assembly...................................................8018 9-43190EN
Swing motor, disassembly and assembly ........................................................8019 9-43441EN
Hydraulic functions...........................................................................................8020 9-94200EN
Travel hydraulic motor, disassembly and assembly..........................................8021 9-43161EN
Hydraulic component functions ........................................................................8030 9-94210EN
Copyright 2006 CNH France S.A.

Printed in France
CNH Lep 9-94900EN May 2006
Copyright
DIVISION/SECTION SECTION N REFERENCE N
9 UPPERSTRUCTURE
Upperstructure, turntable and counterweight...................................................9002 9-43411EN
Boom, dipper and bucket .................................................................................9003 9-43421EN
Seat and seat belt ............................................................................................9004 9-40960EN
Cab and cab equipment...................................................................................9005 9-94800EN
Air conditioning troubleshooting .......................................................................9006 7-xxxxxFR
Air conditioning unit disassembly and assembly..............................................9007 9-94640EN
Air conditioning servicing .................................................................................9008 7-xxxxxFR
Air conditioning components............................................................................9009 7-xxxxxFR
Large format hydraulic schematic ................................................................. Pocket 9-93960
Large format electrical schematic ................................................................ Pocket 9-93970
* Consult the Engine Service Manual

Sections to be distributed at a later date
NOTE: CNH Company reserves the right to make changes in the specifi-
cation and design of the machine without prior notice and without incur-
ring any obligation to modify units previously sold.
The description of the models shown in this manual has been made in
accordance with the technical specifications known as of the date of
design of this document.
Lep 9-94900EN Issued 05-06

1001
Section
Copyright
1001
SAFETY, GENERAL INFORMATION

AND TORQUE SPECIFICATIONS

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

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
Operators 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
Operators Manual safety messages. Read
Put the warning tag shown below on the key for the all safety signs on machine. Clear the area of
keyswitch when servicing or repairing the machine. other persons. Learn and practice safe use
One warning tag is supplied with each machine. of controls before operating.
Additional tags Part Number 331-4614 are available
from your service parts supplier
! It is your responsibility to understand and
f o l l o w m a n u f a c tu r e r s i n s tr u c t i o n s o n
. machine operation, service and to observe
pertinent laws and regulations. Operators
WARNING: Read the operators 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 operators
compartment and steps free of oil, water,
! grease, tools, etc. Use an oil absorbing
WARNING: Lower all attachments to the material and/or shop cloths as required. Use
ground or use stands to safely support the safe practices at all times.
! attachments before you do any maintenance
or service.
WARNING: Some components of this
machine are very heavy. Use suitable lifting
WARNING: Pin sized and smaller streams ! equipment or additional help as instructed in
of hydraulic oil under pressure can penetrate this Service Manual.
the skin and result in serious infection. If
hydraulic oil under pressure does penetrate
the skin, seek medical treatment
WARNING: Engine exhaust fumes can
immediately. Maintain all hoses and tubes in
! good condition. Make sure all connections
cause death. If it is necessary to start the
engine in a closed place, remove the exhaust
are tight. Make a replacement of any tube or
hose that is damaged or thought to be
! fumes from the area with an exhaust pipe
extension. Open the doors and get outside
damaged. DO NOT use your hand to check
air into the area.
for leaks, use a piece of cardboard or wood.
WARNING: When the battery electrolyte is

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

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

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

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

Copyright
1002
Section
1002
SPECIFICATIONS
AND SPECIAL TORQUE SETTINGS

Printed in France.
Copyright
1002-2
TABLE OF CONTENTS
WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see
! this symbol, carefully read the message which follows. Your safety depends on it.
TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE .................................................... 3
FLUIDS AND LUBRICANTS ..................................................................................................................................... 4
SPECIFICATIONS..................................................................................................................................................... 8
COMPONENT WEIGHT.......................................................................................................................................... 16
DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY ........................................................................... 18
DIMENSIONS AND WEAR LIMITS OF ATTACHMENT LINKAGES ...................................................................... 23
SHIMS FOR ADJUSTING ATTACHMENT GAPS................................................................................................... 28
SPECIAL TORQUE SETTINGS .............................................................................................................................. 30
MACHINE OVERALL DIMENSIONS....................................................................................................................... 33

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

For all part orders, request for information or assistance, always specify the type and the serial number of the
machine to your Case dealer.
Fill in the following lines with the required information: Type, serial number, year of manufacture of the machine and
the serial numbers of the hydraulic and mechanical components.
Machine
CP98N006 CT04A171A
(1) Type .............................................................................
(2) Serial number..............................................................
(3) Year of manufacture ....................................................
Engine
Make and type .............................................................................................................................................................
Serial number ..............................................................................................................................................................
Serial numbers of the components

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

Copyright
1002-4
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
CASE/AKCELA hydraulic fluid is specially designed for high pressure applications and for the CASE hydraulic sys-
tem. The type of fluid to be used depends on the ambient temperature.
Temperate climates: -20C to +40C (-4 to 104 F)
CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID (MS 1230. ISO VG 46. DIN 51524 PART 2 HV)
Hot climates: 0C to +50C (32 to 122 F)
CASE/AKCELA: AW HYDRAULIC FLUID 68 HV (MS 1216. ISO VG 68. DIN 51524 PART 3 CATEGORY HVLP)
Cold climates: -25C to +20C (-13 to 68 F)
CASE/AKCELA: AW HYDRAULIC FLUID 32 (MS 1216. ISO VG 32. DIN 51524 PART 2)
Biodegradable fluid: -30C to +40C (-22 to 104 F)
This yellow-colored fluid is miscible with standard fluid. If used to change standard fluid, it is advised to drain the cir-
cuit completely before refilling with this fluid.
CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID BIO (MS 1230. ISO VG 46. DIN 51524 PART 2 HV)
Transmission component oil

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

Copyright
1002-5
Engine Oil
THE CASE/AKCELA No. 1 engine oil is recom-
mended for your engine. This oil ensures proper
lubrication of your engine for all operating conditions.
If you are unable to procure the CASE No. 1 Multiper-
formance or Performance engine oil, use the corre-
sponding oil from the API/CG/CF category.
NOTE: Do not put any Performance Additives or any
other additives in the engine housing. The oil
changing intervals are indicated in the Operators
manual based on tests carried out on CASE
CP02N001
lubricants.
Oil viscosity / Oil range
1
2
2
3
3
CT02M001
1) With mineral base

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

Copyright
1002-6
Fuel
Use fuel which is to ASTM (American Society for Testing and Materials) D975 standard.
Use grade No. 2-D fuel. The use of other types of fuel can result in a loss of power of the engine and may cause
high fuel consumption.
In cold weather (below -7C), it is provisionally approved to use a mixture of fuels No. 1-D and No. 2-D.
If the temperature falls below the fuel cloud point (point at which wax begins to form) the wax crystals will cause
power loss or will prevent the engine from starting.
Required conditions for diesel fuel
The following specific conditions are required for diesel fuel:
- Must be free from minute dust particles.
- Must have adequate viscosity.
- Must have high cetane value.
- Must have high fluidity at low temperature.
- Must have low sulphur content.
- Must have little residual carbon.
Diesel fuel recommendation
- JIS (Japanese Industrial Standard) : No. 2
- DIN (Deutsche Industrie Normen) : DIN 51601
- SAE (Society of Automotive Engineers) Based on SAE-J-313C: No. 2-D
- BS (British Standard) Based on BS/2869-1970: Class A-1
IMPORTANT : If fuel other than the specified one is used, engine operation will be impaired.
Using fuels other than those recommended can damage the fuel injection pump, the injector and other parts of the
fuel supply system and the engine. CASE disowns any responsibility concerning this kind of damage, which
is not covered by the guarantee. To avoid any damage to the engine fuel supply system, you are recommended
to take the following safety messages into account:
Some fuel suppliers mix used engine oil with diesel fuel. Certain manufacturers of large engines allow them to do
this. However, for your engine, do not use diesel fuel contaminated by engine oil. In addition to damaging the
engine, this fuel can actually adversely affect the correct purification of exhaust gases. Before using any diesel fuel,
ask the supplier if this fuel has been mixed with engine oil.
IMPORTANT : For use of the correct fuel additives, consult your oil or lubrication supplier. Do not inject fuel oil or
gasoline, both fuels can damage the engine.
IMPORTANT : In cold weather, fill the fuel tank at the end of the day's work, in order to prevent the formation of con-
densation.
Fuel storage
Long storage can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can often be
traced to the presence of water in the fuel.
The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain
off water and impurities regularly.

Copyright
1002-7
Anti-freeze/Anti-corrosion
Use anti-freeze in all seasons to protect the cooling system from corrosion and all risk of freezing.
CASE/AKCELA: PREMIUM ANTI-FREEZE (MS 1710)
For areas where the temperature goes down to -38C, mix 50/50 with water.
IMPORTANT : Do not mix products of a different origin or brand. The same product must be used when topping up
the system.
Environment
Before carrying out any maintenance operation on this machine and before disposing of used fluids or lubricants,
always think of the environment. Never throw oil or fluid on the ground and never place it in leaking receptacles.
Contact your local ecological recycling centre to obtain information on the correct method of disposing of these
lubricants.
Plastic and resin parts

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

Copyright
1002-8
SPECIFICATIONS
Main data
Model name..................................................................................................................... CX330 Hydraulic Excavator
.................................................................................................................................. CX330NLC Hydraulic Excavator
......................................................................................................................................... CX350 Hydraulic Excavator
Operating weight .......................................................................... CX330 ................................. 34100 kg (75178 lbs)
.................................................................................................. CX330NLC ............................. 34000 kg (74957 lbs)
...................................................................................................... CX350 .................................. 36100kg (79587 lbs)
Engine output ............................................................................................................................... 202 kW / 2000 rpm
Performance
Standard weight.............................................................................................................................. 18.0 kN (4047 lbf)
Swing speed ...............................................................................................................................................9.6 Tr/min.
Travel speed...............................................................................................................Low Speed 3.2 km/h (1.9 mph)
................................................................................................................................... High Speed 5.5 km/h (3.4 mph)
Maximum drawbar pull .................................................................................................................. 278 kN (62497 lbf)
Grade ability ................................................................................................................................................70% (35)
Ground pressure.......................................................................................... 64 kPa (600 mm (23.6 in) grouser shoe)
Complete machine dimensions

CX330, CX330NLC
Standard arm Super short arm Short arm Long arm
3.25 m (10 ft 8 in) (2.21m) (7 ft 3 in) (2.63 m) (8 ft 8 in) (4.04 m) (13 ft 3 in)
Length 11050 mm (36 ft 3 in) 11250 mm (36 ft 11 in) 11130 mm (36 ft 6 in) 11090 mm ( 36 ft 3 in)
CX330 = 3200 mm (10 ft 6 in)
Width
CX330NLC = 3040 mm (10 ft 0 in)
Height 3290 mm (10 ft 9in) 3600 mm (11 ft 9 in) 3530 mm (11 ft 7 in) 3510 mm ( 11 ft 6 in)
CX350
HD Standard arm HD Super short arm HD Short arm
(3.25 m) (10 ft 8 in) (2.21m) (7 ft 3 in) (2.63 m) (8 ft 8 in)
Length 11050 mm (36 ft 3 in) 11250 mm (36 ft 11 in) 11130 mm (36 ft 6 in)
Width 3200 mm (10 ft 6 in)
Height 3290 mm (10 ft 9 in) 3570 mm (11ft 8 in) 3530 mm (11 ft 7 in)
Main body dimensions

Main body length .........................................................................................................................5910 mm (19 ft 5 in)
Main body width...........................................................................................................................3200 mm (10 ft 6 in)
Upper swing body width ..............................................................................................................3040 mm (10 ft 0 in)
Cab width......................................................................................................................................1000 mm (39.36 in)
Main body height .......................................................................................................................3130 mm (10 ft 26 in)
Tail swing radius ..........................................................................................................................3450 mm (11 ft 2 in)
Distance of rear swing body .....................................................................................................3420 mm (11 ft 2.5 in)
Ground clearance for upperstructure..........................................................................................1210 mm (4 ft 0.5 in)
Center-to-center of wheels ..........................................................................................................4040 mm (13 ft 3 in)
Overall track length...................................................................................................................4980 mm (16 ft 2.5 in)
Maximum track width ............................................................. CX330, CX350 ............................3200 mm (10 ft 6 in)
.................................................................................................. CX330NLC .................................2990 mm (9 ft 9 in)
Center-to-center for track....................................................... CX330, CX350...............................2600 mm (8 ft 6 in)
.................................................................................................. CX330NLC ..............................2390 mm (7 ft 9.5 in)

Copyright
1002-9
Width of track shoe ...........................................................................................................................600 mm (23.6 in)
Minimum ground clearance ......................................................................480 mm (19 in) (To bottom of lower frame)
Engine
Name ..................................................................................................................................... ISUZU, AH-6HK1XYSS
Type: 4-cycle, water-cooled, overhead camshaft, common rail injection (electric control),
with air-cooling type inter-cooler turbo with air-cooling.
No. of cylinders - bore x stroke ................................................................... 6-dia. 115 mm x 125 mm (4.53 x 4.92 in)
Displacement................................................................................................................................ 7790 cc (475 cu.in)
Compression ratio ................................................................................................................................................17.5
Rated output ....................................................................................................................... 202 3.0 kW / 2000 min-1
Maximum torque....................................................................................................... 1080Nm (797 lb-ft) / 1500 min-1
Engine dimensions (LxWxH) ..................................................... 1357 x 995.4 x1141 mm ( 53.42 x 39.19 x 44.92 in)
Oil pan ............................................................................................................................... All direction 35, inclinable
Starter, reduction type ................................................................................................................................24 V, 5 kW
Alternator, AC type ..................................................................................................................................... 24 V, 50 A
Battery .................................................................................................................................. 2x 12V/24V,128 Ah/5 Hr
Cooling system
Fan type..................................................................... diameter 850 mm (33.5 in), suction type-6blades resin & steel
Pulley ratio .............................................................................................................................................80 (reduction)
Direction of rotation ............................................................................... Right (viewed from fan side); compliant with
Radiator capacity............................................................................................................................................96.0 kW
Fin type ...........................................................................................................................................................wavy
Fin space.......................................................................................................................................2.0 mm (0.08 in)
Oil cooler capacity ..........................................................................................................................................66.6 kW
Fin type .......................................................................................................................................................... Wavy
Fin space.....................................................................................................................................1.75 mm (0.07 in)
Inter-cooler capacity .......................................................................................................................................29.9 kW
Fin type ....................................................................................................................................... triangular straight
Fin space.......................................................................................................................................2.0 mm (0.08 in)
Fuel cooler capacity..........................................................................................................................................1.7 kW
Fin type ...........................................................................................................................................................wavy
Fin space.......................................................................................................................................2.0 mm (0.08 in)
Capacity of coolant and lubricants

Coolant .................................................................................................................................................30 L (7.92 gal)
Fuel......................................................................................................................................................580 L (153 gal)
Lubricant for engine .................................................................................................................................38 L (10 gal)
Lubricant for travel reduction gear (per side) .........................................................................................9.5 L (2.5 gal)
Lubricant for swing reduction gear (per side) .........................................................................................6 L (1.59 gal)
Hydraulic oil ........................................................................................................................................350 L (92.5 gal)
Capacity of hydraulic oil tank ..............................................................................................................175 L (46.2 gal)
Hydraulic oil filter

Suction filter (inside tank) ............................................................................................................................ 150 mesh
Return filter (inside tank) ..................................................................................................................................10 m
Nephron filter (inside housing)............................................................................................................................1 m
Pilot line filter (inside housing)..........................................................................................................................10 m

Copyright
1002-10
Operating devices
Operator's seat
Location; left side
Structure; low frequency air suspension with helical springs and double acting hydraulic damper.
Cab
Smooth and round shape design cab, fabricated by press work Safety glass for all windows.
Levers and pedals
For travel use; levers and pedals (hydraulic pilot type) (2)
For operating machine use; levers (hydraulic pilot type) (2)
Instruments and switches
Work mode switchover; 4 modes (heavy digging, standard, finishing and auto)
Travel speed switchover; Low Speed / High Speed panel switch
One-touch idle; Knob switch type
Monitor device
Machine status display (full-dot liquid crystal)
Travel speed selection status; Low Speed / High Speed
Work mode selection status; H/S/L/A
Auto idle selection status; ON/OFF
Instruments (full-dot liquid crystal, except for hour meter)
Fuel gauge; bar graph indicator
Engine coolant temperature gauge; bar graph indicator
Hydraulic oil temperature gauge; bar graph indicator
Hour meter; digital type
Machine Status and Warning Alarms (full-dot liquid crystal and warning tone) *Items have a warning alarm
Over heat* Battery charge* Faulty electrical system*

Refill fuel* Engine oil pressure* Refill coolant*
Engine preheat Auto warm-up Air cleaner*
Idling Service interval
Lighting
Working light Upper: 24V, 70W (1)

Boom: 24V, 70W (1)
Cab: 24V, 70W (1)
Interior light 24V, 10W (1)
Horn; electric horn (2)

Other
Wiper with intermittent function (1)
Window washer fluid (1)
Air conditioner (1)
Rear view mirror (right-hand side) (1)

Copyright
1002-11
Hydraulic system
Hydraulic pump drive system, directly coupled to the engine (no transmission)
Main pump
Manufacturer ........................................................................................................................................Kawasaki
Pump type .......................................................................................double variable displacement piston pump
Displacement ........................................................................................................ 140 cm3 (8.54 cu in) X 2 /rev
Rated operating pressure ...................................................................................................34.3 MPa (4975 psi)
Maximum operating pressure .............................................................................................37.3 MPa (5410 psi)
Input revolution speed.......................................................................................................................2030 min-1
Maximum flow .........................................................................................284 L/min (75 gpm) x 2 at 2030 min-1
Input horsepower .................................................................................................................................171.7 kW
Shaft input horsepower .................................................................................................174.7 kW at 2030 min-1
Shaft input torque......................................................................................821.8 Nm (1085 lb-ft) at 2030 min-1
Pilot pump
Pump type ........................................................................................................................................Gear pump
Displacement ..................................................................................................................15 cm3 (0.91 cu in)/rev
Operating pressure ............................................................................................3.9 to 4.1 MPa (565 to 595 psi)
Maximum flow ................................................................................................30.5 L/min (8 gpm) at 2030 min-1
Input horsepower .....................................................................................................................................3.0 kW
Control characteristics; simultaneous output control of overall, negative control, electric horse power control
Control Valve
Model; 4-spool section: integrated (1) or 5-spool section: integrated (1)
Operation method; hydraulic pilot method: travel, swing and operating machine
Maximum flow ........................................................................................................................284 L / min (75 gpm)
Set pressure of main relief valve ......................standard; 34.3 MPa (4975 psi), power boost 37.3 MPa (5410 psi)
Set pressure of overload relief valve ....................................when boom down; 27.4 MPa (3974 psi) at 20 L / min
................................................................................................................ other: 39.2 MPa (5685 psi) at 20 L / min
Set pressure of foot relief valve ............................................................................2.89 MPa (420 psi) at 53 L / min
Functions
Straight travel circuit
Boom UP / 2-speed internal confluence for Arm
Boom/arm load holding circuit
Boom down regenerative circuit
Arm IN forced regenerative circuit
Variable throtlle valve in parallel circuit arm
Swing priority variable throttle valve
Preliminary 2-speed confluence
Hydraulic Cylinders
Boom cylinder (2)
Inner diameter of tube x rod diameter x stroke .................................................................... 145x100x1495 mm
Arm (dipper) cylinder
Bucket cylinder

Copyright
1002-12
Rotating Joint
Operating pressure
High pressure passage (ABCD)......................................................................................... 34.3 MPa (4975 psi)
Drain port (T) ..........................................................................................................................1.0 MPa (145 psi)
Pilot port (P .............................................................................................................................3.9 MPa (566 psi)
Hydrostatic test pressure
High pressure passage (ABCD)......................................................................................... 51.5 MPa (7470 psi)
Drain port (T) ......................................................................................................................... 2.0 MPa (290 psi)
Pilot port (P) .......................................................................................................................... 5.9 MPa (856 psi)
Flow
High pressure passage (ABCD)...........................................................................................360 L/min (95 gpm)
Drain port (T) ......................................................................................................................40 L/min (10.6 gpm)
Pilot port (P)..........................................................................................................................31 L/min (8.2 gpm)
Number of revolutions ............................................................................................................................... 15 min-1
Torque, when pressurizing 2 ports ............................................................................................. 196 Nm (145 lb-ft)
Port A; forward right ............................................................................................................................. G1-A Class
Port B; forward left................................................................................................................................ G1-A Class
Port C; backward right.......................................................................................................................... G1-A Class
Port D; backward left ............................................................................................................................ G1-A Class
Port T; drain port .............................................................................................................................. G1/2-A Class
Port P; pilot port ............................................................................................................................... G1/4-A Class
Solenoid Valve
Maximum flow .............................................................. P -> B: 20 L / min (5.28 gpm) Other: 5 L / min (1.32 gpm)
Rated pressure..........................................................................................................................4.41 MPa (640 psi)
Operating voltage ............................................................................................................................. DC 20 to 32 V
Current ............................................................................................................................... 13.0 W (at 24 V, 20 C)
Hand control valve
Manufacturer ............................................................................................................................................Kawasaki
Operating pressure ...................................................................................................................3.92 MPa (569 psi)
Secondary pressure, primary short type ..................................................................0.64 0.1 to 2.45 0.14 MPa
Operating angle
Ports 1, 3.............................................................................................................................................. 19 1.9
Ports 2, 4.............................................................................................................................................. 25 2.5
Operating torque
Port 1 ........................................................................................................... 1.18 to 2.67 Nm (0.87 to 1.97 lb-ft)
Port 3 ........................................................................................................... 0.94 to 2.38 Nm (0.70 to 1.76 lb-ft)
Ports 2, 4...................................................................................................... 1.37 to 3.19 Nm (1.01 to 2.35 lb-ft)
Foot control valve
Manufacturer ...............................................................................................................................................Nishina
Operating pressure ...................................................................................................................3.92 MPa (569 psi)
Secondary pressure; primary short type....................................................................0.64 0.1 to 2.45: 0.14 MPa
Operating angle..................................................................................................................................... 12.4 0.3
Operating torque
Valve ............................................................................................................ 4.16 to 10.6 Nm (3.06 to 7.81 lb-ft)
Damper .................................................................................... 4.90 0.98 Nm (3.61 0.72 Ib-ft) at 0.0275 m/s

Copyright
1002-13
Digging force (New JIS)

Bucket digging force
Standard pressure..................................................................................................................... 229 kN (51481 lbf)
Power boost pressure................................................................................................................ 248 kN (55753 lbf)
Arm (dipper) digging force
Standard pressure
3.25 m arm ........................................................................................................................... 164 kN (36869 lbf)
2.21m arm ............................................................................................................................ 227 kN (51031 lbf)
2.63 m arm ........................................................................................................................... 195 kN (43838 lbf)
4.04 m arm ........................................................................................................................... 140 kN (31473 lbf)
Power boost pressure
3.25 m arm ........................................................................................................................... 178 kN (40016 lbf)
2.21m arm ............................................................................................................................ 246 kN (55303 lbf)
2.63 m arm ........................................................................................................................... 211 kN (47435 lbf)
4.04 m arm ........................................................................................................................... 153 kN (34396 lbf)
Swing unit
Swing circle; swing bearing type (with internal gears)
Swing hydraulic motor (1); fixed displacement piston motor with parking brake and reversal prevention valve
Displacement ...............................................................................................................186.7 cm3 (11.39 cu in)/rev
Operating pressure..................................................................................................................29.4 MPa (4264 psi)
Operating flow ..........................................................................................................................284 L/min (75 gpm)
Brake torque...........................................................................................................961.6 Nm (709.24 lb-ft) or over
Brake off pressure ....................................................................................................... 2.9 MPa (421 psi) less than
Relief set pressure .................................................... 28.9 to 29.7 MPa (4192 to 4308 psi) at 100 L/min (26 gpm)
Reduction gears, planetary gear 2-stage reduction system
Reduction ratio .............................................................................................................................................27.143
Swing parking brake; mechanical lock (operational lever linkage type)
Swing lock; mechanical lock (swing lock switch linkage type)
Travel lower body

Travel hydraulic motor (2); variable displacement piston motor, automatic 2-speed switch-over with parking brake
Displacement .........................................................................................290.7 / 170.1 cm3 (17.74/10.38 cu in)/rev
Operating pressure..................................................................................................................34.3 MPa (4975 psi)
Operating flow .......................................................................................................................284.2 L/min (75 gpm)
Brake torque.................................................................... 4738 Nm (3495 Ib-ft) or over (excluding reduction gear)
Relief set pressure .............................................................................. 35.8 MPa (5112 psi) at 5 L/min (1.32 gpm)
2-speed control pressure ................................................................................................. 26.5 1 MPa (3443 psi)
Reduction gears; planetary gear 2-stage reduction system
Reduction ratio .............................................................................................................................................40.467
Travel brake; hydraulic lock
Parking brake; mechanical lock (travel lever linkage type)
Track shoe
Model; assembly-type double grouser shoe
Number of shoes (per side).................................................................................................................................48
Shoe width
standard ...................................................................................................................................600 mm (23.6 in)
optional CX330 .................................................................700, 800, 850, 900 mm (26.56, 31.5, 33.5, 35.43 in)
optional CX330NLC, CX350 .................................................................................700, 800 mm (33.5, 35.43 in)
Grouser height ...............................................................................................................................36 mm (1.42 in)
Link pitch ........................................................................................................................................216 mm (8.5 in)
Roller
Number of upper rollers (per side) .......................................................................................................................2
Number of lower rollers (per side) ........................................................................................................................8
Track belt tension adjuster; grease cylinder type (with cushion spring)
mounting length of spring...........................................................................................................779 mm (30.67 in)

Copyright
1002-14
Work Unit
Model; backhoe attachment
Capacity / dimensions / working dimensions
Boom length ............................................................................................................................................. 6450 mm
Standard arm Super short arm Short arm Super long

(3.25 m) (2.21 m) (2.63 m) arm (4.04 m)
Arm length 3250 mm 2210 mm 2630 mm 4040 mm
Bucket radius 1680 mm 1680 mm 1680 mm 1680 mm
Bucket wrist angle 173 173 173 173
Maximum digging radius 11170 mm 10200 mm 10670 mm 11900 mm
Maximum digging radius at ground line 10980 mm 9990 mm 10470 mm 11720 mm
Maximum digging depth 7340 mm 6300 mm 6730 mm 8140 mm
Maximum vertical straight wall digging depth 6350 mm 5080 mm 5970 mm 7150 mm
Maximum reach height 10370 mm 9850 mm 10320 mm 10670 mm
Maximum dump height 7230 mm 6770 mm 7140 mm 7540 mm
Minimum swing radius at front 4500 mm 4660 mm 4630 mm 4560 mm
Overall height with minimum swing radius at 8480 mm 8650 mm 8540 mm 8490 mm
front

Copyright
1002-15
Reference Values
Numerical values for performance may change without notice due to product improvement.
Reference values
Items CX330 Conditions
CX350
CX330NLC
Idling 900 20 900 20
1 Engine speed (min-1) Mode: H
Maximum without load 1950 10 1950 10
Standard 34.3 2.0 34.3 2.0
Main Relief
Boosting 37.3 2.0 37.3 2.0
2 Pressure of each part (MPa) Mode: S
Swing relief Vertical 31.5 2.0 31.5 2.0
Pilot relief 3.9 0.1 3.9 0.1
Boom cylinder 10 or below 10 or below
Arm cylinder 15 or below 15 or below No load for 10
Natural lowering level of each minutes
3 Bucket cylinder (when
cylinder (mm) 20 or below 20 or below
open)
No load for 10
Overall 250 or below 250 or below
minutes
Up 4.5 0.6 4.8 0.6
Boom
Down 3.3 0.6 3.1 0.6
Operational speed of each cyl- Open 3.8 0.6 3.9 0.6

4 Arm Mode: S
inder (sec) Close 4.9 0.8 4.8 0.8
Open 3.1 0.6 3.1 0.6
Bucket
Close 5.3 0.3 5.4 0.3
5 Swing speed (sec/1 revolution) 6.8 0.6 6.8 0.6 Mode: S
6 Swing angle 180, neutral brake flow angle (degrees) 40 or below 40 or below Mode: S
7 Travel speed (sec/6 m) High 4.3 0.6 4.3 0.6 Mode: S
Number of drive sprocket revolutions High 16.5 1.5 16.5 1.5

8 Mode: S
(sec/10 revolutions) Low 27.6 1.8 27.6 1.8
Horizontal 6.5 or below 6.5 or below
9 Amount of turntable bearing shift (mm) Mode: S
Vertical 2.0 or below 2.0 or below
Amount of shoe tension ranging from the side frame bot-
10 340 to 460 340 to 460
tom to shoe surface (mm)

Copyright
1002-16
COMPONENT WEIGHT
Major component weight
330-3-01-00-46A
Item Component Name CX330 CX330NLC CX350

A Overhall machinet 34100 kg (75178 lbs) 34000 kg (74957 lbs 36100 kg (79587 lbs)
Upper structure (including coun-
B 14720 kg (32472 lbs) 15700 kg (34612 lbs)
terweight and turntable bearings)
C Counterweight 6410 kg (14132 lbs) 7410 kg (16336 lbs)
Bottom structure (with grouser
D 12240 kg (26985 lbs) 12150 kg (26786 lbs) 12490 kg (27536 lbs)
shoe)
E Machine without attachement 26960 kg (59437 lbs) 26850 kg (59194 lbs) 28200 kg (62170 lbs)
F Attachments 7030 kg (15498 lbs) 7840 kg (17284 lbs)
G Boom (including cylinder) 3960 kg (8730 lbs) 4250 kg (9370 lbs)
Arm (including cylinder and link-
H 1890 kg (4167 lbs) 2090 kg (4608 lbs)
age)
Weight information is approximate

Copyright
1002-17
Other component weight

Engine ..................................................................................................................... Approximately 640 kg (1410 lbs)
Air cleaner .......................................................................................................................................... 13.6 kg (30 lbs)
Hydraulic pump.................................................................................................................................. 130 kg (287 lbs)
Control valve...................................................................................................................................... 192 kg (432 lbs)
Swing motor and reduction gear assembly ....................................................................................... 435 kg (959 lbs)
Travel motor and reduction gear assembly (2)................................................................................... 399 kg (880 lbs)
Rotary joint .......................................................................................................................................... 56 kg (123 lbs)
6 solenoid valve bank ........................................................................................................................... 6 kg (13.2 lbs)
Hand control valve .................................................................................................................................. 1.8 kg (4 lbs)
Foot control valve ............................................................................................................................... 10.5 kg (23 lbs)
Cab .................................................................................................................................................... 255 kg (562 lbs)
Muffler.................................................................................................................................................... 20 kg (44 lbs)
Radiator total weight........................................................................................................................... 140 kg (309 lbs
Oil cooler ........................................................................................................................................... 34 kg (75 lbs)
Radiator.......................................................................................................................................... 21.1 kg (47 lbs)
Air cooler ........................................................................................................................................ 19.9 kg (44 lbs)
Fuel cooler .................................................................................................................................... 1.2 kg (2.65 lbs)
Idler wheel ......................................................................................................................................... 165 kg (364 lbs)
Upper roller............................................................................................................................................ 43 kg (95 lbs)
Lower roller .......................................................................................................................................... 60 kg (132 lbs)
Tension damper assembly ................................................................................................................. 254 kg (560 lbs)
Recoil spring assembly .............................................................................................................. 119.4 kg (263 lbs)
Grease cylinder assembly .............................................................................................................. 41.3 kg (91 lbs)
Yoke................................................................................................................................................ 39.8 kg (88 lbs)
Threaded rod .................................................................................................................................... 50.3 kg (111 lbs)
Track chains
600 mm (23.62 in) (48 shoe) ..................................................................................................... 2217 kg (4888 lbs)
700 mm (26.56 in) (48 shoe) .................................................................................................... 2473 kg (5452 lbs)
800 mm (31.5 in) (48 shoe) ...................................................................................................... 2618 kg (5772 lbs)
850 mm (33.5 in) (48 shoe) ....................................................................................................... 2735 kg (6030 lbs)
900 mm (35.5 in) (48 shoe) ...................................................................................................... 2817 kg (6210 lbs)
Boom (without cylinders)
CX330, CX330NLC ................................................................................................................... 2417 kg (5329 lbs)
CX350 ....................................................................................................................................... 2709 kg (5972 lbs)
Arm (without cylinders)
CX330, CX330NLC
3.25 m Standard arm ........................................................................................................... 1102 kg (2429 lbs)
2.21 m Super short arm ......................................................................................................... 967 kg (2132 lbs)
2.63 m Short arm ................................................................................................................. 1038 kg (2288 lbs)
4.04 m Long arm .................................................................................................................. 1434 kg (3161 lbs)
CX350
3.25 m HD Standard arm ..................................................................................................... 1297 kg (2859 lbs)
2.21 m HD Super short arm ................................................................................................. 1006 kg (2216 lbs)
2.63 m HD Short arm ........................................................................................................... 1076 kg (2372 lbs)
Boom cylinder.................................................................................................................................... 279 kg (615 lbs)
Arm (dipper) cylinder ....................................................................................................................... 462 kg (1019 lbs)
Bucket cylinder .................................................................................................................................. 276 kg (608 lbs)

Copyright
1002-18
DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY

Sprocket
Dimensions
a P
d
b c
CS01B512
Dimension
Mark
mm in
Standard 83 3.26
a
Limit 73 2.87
Standard 660.7 26
b
Limit 649.2 25.5
Standard 748 29.4
c
Limit 738 29
Standard 732.5 28.8
d
Limit --- ---
Standard 216 8.5
P
Limit --- ---
Gauge
unit in mm
300
215.9
43.3
5.1 5.1
84.5
40.7

.6
90
(117.8)
49
37.2
26.1
100
R
93
3-
R
R.9
35
12
R
.7
R3
R3
66.
74
CI01N501

Copyright
1002-19
Idler wheel
Dimensions
c Dimension
Mark
mm in
b
Standard 560 22.04

a
Limit 550 21.6
Standard 22.5 0.88
b
Limit --- ---
Standard 102 4.01
c
Limit 92 3.62
Standard 85 3.34
d (shaft)
Limit 84 3.30
a
Standard 85 3.34
d (bushing)
Limit 86 3.38
Standard 82 3.22
e f e (bushing)
Limit 81 3.18
Standard 19 0.74
f
Limit 18.6 0.73
d
000-6-10-00-08B
Gauge
Unit in mm
250
204
102
37.5

10
75
(15) 22.5
R5
R50
R3
R3
0.2
CI01N502

Copyright
1002-20
Upper roller
Dimensions
Dimension
Mark
mm in
c
Standard 150 5.9
b
a
Limit 140 5.5
Standard 15 0.59
b
Limit --- ---
Standard 104 4.09
c
d
a
Limit --- ---

Standard 65 2.55
d (shaft
Limit 64 2.51
Standard 65 2.55
d (bushing)
Limit 66 2.59
g e Standard 69 2.71
f e (bushing)
Limit 68 2.67
Standard 9 0.35
f
Limit 8.5 0.33
000-6-10-00-8C
Standard 30 1.18
g
Limit --- ---
Gauge
Unit in mm
210
104
97

.1
13
35
65
15
R3
R3
R3
R3
15
R3
125 120
245
CI01N503

Copyright
1002-21
Lower roller
Dimensions
d
f g
a
e
b
000-6-10-00-08D
Dimension Dimension
Mark Mark
mm in mm in
Standard 180 7.08 Standard 75 2.95
a e (bushing)
Limit 170 6.69 Limit 76 2.99
Standard 25 0.98 Standard 82 3.22
b f
Limit 20 0.78 Limit 81 3.18
Standard 216 8.50 Standard 17.5 0.68
d g
Limit 224 8.81 Limit 17 0.66
Standard 75 2.95
e (Pin)
Limit 74 2.91
Gauge
Unit in mm
300-6-10-03-08D

Copyright
1002-22
Track
d
e e
f f
g g
h h
CS01B520
Dimension Dimension
Mark Mark
mm in mm in
a h
Limit 34 1.33 Limit --- ---
b e (bushing)
Limit 124 4.88 Limit 67 2.63
c f (bushing)
Limit 41 1.61 Limit 50.9 1.99
Standard 28.4 1.11 Standard 47.6 1.87
d g (Pin)
Limit 27 1.06 Limit 45 1.77
Standard 71.35 2.80
e (ring)
Limit 67 2.63
Standard 47.9 1.88
f (ring)
Limit 50.4 1.98
Standard 47.3 1.85
g (Pin)
Limit 45 1.77

Copyright
1002-23
DIMENSIONS AND WEAR LIMITS OF ATTACHMENT LINKAGES
3 4
1
5
6
2 11
10 8 7
CS01B521
1. Boom foot/Frame
a c
b
CS01B522
Dimension
Mark
mm (in)
Standard 860 33.8
a
Limit 868 34.1
Standard 859 33.8
b
Limit 857 33.7
Standard 1.5 to 4 0.05 to 0.15
c (a - b)
Limit Shims adjustment
Standard 110 4.33
d (pin)
Limit 109 4.29
Standard 110 4.33
d (bushing)
Limit 111.5 4.38

Copyright
1002-24
2. Boom cylinder foot/Frame

a c
b
CS01B523
Dimension
Mark
mm in
Standard 131 5.15
a
Limit 137 5.39
Standard 130 5.11
b
Limit 127 4.99
Standard 1 to 3.5 0.039 to 0.13
c (clearance)
Limit Shim adjustment
Standard 90 3.54
d (pin)
Limit 89 3.50
Standard 90 3.54
d (bushing)
Limit 91.5 3.60
3. Boom cylinder head/Boom
a b a c
CS01B524
Dimension
Mark
mm in
Standard 123 4.84
a
Limit 120 4.72
Standard 669 26.3
b
Limit 665 26.1
Standard 1.5 to 3 0.05 to 0.11
c (clearance)
Standard 110 4.33
d (Pin)
Limit 109 4.29
Standard 110 4.33
d (bushing)
Limit 111.5 4.38

Copyright
1002-25
4. Arm cylinder foot/Boom

a c Dimension
Mark
mm in
b
Standard 146 5.74
a
Limit 152 5.98
Standard 145 5.70
b
Limit 143 5.62
Standard 1 to 3.5 0.039 to 0.13
d c (a - b)
Standard 100 3.93
d (Pin)
Limit 99 3.89
Standard 100 3.93
d (bushing)
Limit 101.5 3.99
CS01B525
5. Boom/Arm
a b c Dimension
Mark
mm in
Standard 89 3.50
a
Limit 87 3.42
Standard 392 15.4
b (boom)
Limit 395 15.5
Standard 391.5 15.4
d b (arm)
Limit 389 15.3
Standard 0.5 to 2 0.019 to 0.07
c (clearance)
CS01B526
Standard 115 4.52
d (Pin)
Limit 114 4.48
Standard 115 4.52
d (arm)
Limit 116.5 4.58
Standard 115 4.52
d (boom)
Limit 116.5 4.58
6. Arm cylinder head/Arm

Dimension
Mark
mm in
Standard 146 5.74
a
Limit 151 5.94
Standard 145 5.70
d b
Limit 143 5.62
Standard 0.5 to 3 0.019 to 0.11
c (a - b)
b Limit Shim adjustment
a c Standard 100 3.93
d (Pin)
Limit 99 3.89
CS01B527
Standard 100 3.93
d (bushing)
Limit 101.5 3.99

Copyright
1002-26
7. Bucket cylinder foot/Arm

a c Dimension
Mark
b mm in
Standard 146 5.74
a
Limit 152 5.98
d Standard 145 5.70
b
Limit 143 5.62
Standard 1 to 3.5 0.039 to 0.13
c (a - b)
Standard 95 3.74
d (Pin)
Limit 94 3.70
CS01B528
Standard 95 3.74
d (bushing)
Limit 96.5 3.79
8. Connecting rod/Arm
Dimension
Mark
mm in
c Standard 50 1.96
a
Limit 47 1.85
Standard 375 14.7
b
b Limit 371 14.6
Standard 1 to 2 0.039 to
c (clearance) 0.078
a
Standard 85 3.34
d (Pin)
d Limit 84 3.30
Standard 85 3.34
d (bushing)
CS01B529 Limit 86.5 3.40
9. Compensator/Bucket
d Dimension
Mark
mm in
Standard 401 15.7
c a
Limit 406 15.9
Standard 400 15.7
b
Limit 397 15.6
b a Standard 1 to 4 0.039 to 0.15
c (clearance)
Standard 90 3.54
d (Pin)
Limit 89 3.50
Standard 90 3.54
d (bushing)
Limit 91.5 3.60
CS01B530

Copyright
1002-27
10. Connecting rod/Compensator/Bucket cylinder head

Dimension
Mark
mm (in)
a Standard 50 1.96
a
f Limit 48 1.88
Standard 376 14.8
b b
e d Limit 371 14.6
Standard 1.5 to 2.5 0.05 to 0.09
c (clearance)
c Standard 106 4.17
d
Limit 109 4.29
g Standard 105 4.13
e
Limit 102 4.01
CS01B531 Standard 1.5 to 2.5 0.05 to 0.09
f (d - e)
Standard 105 4.13
g (Pin)
Limit 104 4.09
g Standard 105 4.13
(compensator) Limit 106.5 4.19
Standard 105 4.13
g (cylinder)
Limit 106.5 4.19
11. Arm/Bucket
e Dimension
Mark
mm (in)
Standard 401 15.7
a
Limit 406 15.9
d
Standard 400 15.7
b
Limit 397 15.6
Standard 1 to 4 0.039 to 0.15
a b c (a - b)
Standard 16 0.62
d
Limit 10 0.39
c Standard 90 3.54
e (Pin)
Limit 89 3.50
Standard 90 3.54
CS01B532
e (arm)
Limit 91.5 3.60
Standard 90 3.54
e (bucket)
Limit 91.5 3.60

Copyright
1002-28
SHIMS FOR ADJUSTING ATTACHMENT GAPS

For boom foot
R
O.D I.D H
000-6-10-02-02A
Part No. I.D. O.D. R H Shim Material

Thickness
KNV1132 76 160 100 30 1.2 SPHC
KRV2390 91 190 115 30 1.2 SPHC
KBV1441 101 220 130 30 1.2 SPHC
KBV1748 101 230 135 30 1.2 SPHC
KSV1805 111 240 140 30 1.2 SPHC
R
O.D I.D H
000-6-10-02-02B
Part No. I.D. O.D. R H Shim Material

Thickness
KSV1930 111 240 140 30 1.0 Urethone
KSV11380 111 240 140 30 2.0 Urethone
KSV1931 116 240 140 30 1.0 Urethone
KSV11390 116 240 140 30 2.0 Urethone

Copyright
1002-29
NOTES
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Copyright
1002-30
SPECIAL TORQUE SETTINGS

Screw Wrench Torque setting
No. Component
() (mm) lb-ft
1* Travel motor and reduction gear assembly M24 36 900-1051 664-775
2* Sprocket M20 30 521-608 384-448
3* Idler wheel M16 24 267-312 197-230
4* Upper roller M20 30 521-608 384-448
5* Lower roller M24 36 902-1049 665-774
6* Chain guide M24 36 902-1049 665-774
7 Track pad M24 36 1236-1510 912-1114
8 Counterweight M33 50 1685-1960 1243-1446
9 Turntable (frame) M24 36 900-1050 664-774
10 Turntable (upperstructure) M24 36 900-1050 664-774
11 * Swing motor and reduction gear assembly M24 36 900-1050 664-774
12 * Engine M20 30 289-337 213-248
13 * Engine bracket M12 19 109-127 80-93
14 Radiator M16 24 147-176 108-130
M10 17 64-73 47-54
15 * Hydraulic pump
M20 Hex. Socket 367-496 270-496
16 * Hydraulic reservoir M16 24 233-276 171-203
17 * Fuel reservoir M16 24 233-276 171-203
18 * Control valve M16 24 267-312 197-230
19 * Hydraulic swivel M16 24 267-312 197-230
20 Cab M16 24 78-80 57-59
21 Battery M10 17 20-29 15-21
NOTE: Use Loctite 262 or an equivalent on retaining screws of those components marked with an asterisk (*).

Copyright
1002-31
18 15
16
11 12 13
17
8
14
21
19 7
1 2
9 10 5
20 6
4
3
330-5-05-01-17C_1
1 6
2 CS01N969
CS01N968
4
CS01N971
5
8
3 CS01N970

Copyright
1002-32
11
13
10 12
9 9
CS01N972
330-5-05-01-17D
15 330-5-05-01-17D4
330-5-05-01-17D3
14
18 CS01N978
16 CS01N976 17 CS01N977
19
20 21
CS01N979 CS01N980 CS01N981

Copyright
1002-33
MACHINE OVERALL DIMENSIONS
CS00K520
(CX330LC)
Arms (dippers) 2.20 m 2.60 m 3.25 m 4.00 m
(A) .................................................................3.60 m .................. 3.53 m ................ 3.29 m ................. 3.51 m
(B) .................................................................3.13 m .................. 3.13 m ................ 3.13 m ................. 3.13 m
(C) ...............................................................11.25 m ................ 11.13 m .............. 11.05 m ............... 11.09 m
(D) .................................................................5.91 m .................. 5.91 m ................ 5.91 m ................. 5.91 m
(E) .................................................................3.04 m .................. 3.04 m ................ 3.04 m ................. 3.04 m
(F)..................................................................1.21 m .................. 1.21 m ................ 1.21 m ................. 1.21 m
(G) .................................................................3.42 m .................. 3.42 m ................ 3.42 m ................. 3.42 m
(H) .................................................................4.98 m .................. 4.98 m ................ 4.98 m ................. 4.98 m
(I) ...................................................................4.04 m .................. 4.04 m ................ 4.04 m ................. 4.04 m
(J) ..................................................................2.60 m .................. 2.60 m ................ 2.60 m ................. 2.60 m
(K) (standard pads) .......................................0.60 m .................. 0.60 m ................ 0.60 m ................. 0.60 m
(L) (with 600 mm track pads).........................3.20 m .................. 3.20 m ................ 3.20 m ................. 3.20 m
(M) .................................................................0.48 m .................. 0.48 m ................ 0.48 m ................. 0.48 m
(CX330NLC)
Arms (dippers) 2.20 m 2.60 m 3.25 m 4.00 m
(A) .................................................................3.57 m .................. 3.53 m ................ 3.29 m ................. 3.51 m
(B) .................................................................3.13 m .................. 3.13 m ................ 3.13 m ................. 3.13 m
(C) ...............................................................11.25 m ................ 11.13 m .............. 11.05 m ............... 11.09 m
(D) .................................................................5.91 m .................. 5.91 m ................ 5.91 m ................. 5.91 m
(E) .................................................................3.04 m .................. 3.04 m ................ 3.04 m ................. 3.04 m
(F)..................................................................1.21 m .................. 1.21 m ................ 1.21 m ................. 1.21 m
(G) .................................................................3.42 m .................. 3.42 m ................ 3.42 m ................. 3.42 m
(H) .................................................................4.98 m .................. 4.98 m ................ 4.98 m ................. 4.98 m
(I) ...................................................................4.04 m .................. 4.04 m ................ 4.04 m ................. 4.04 m
(J) ..................................................................2.39 m .................. 2.39 m ................ 2.39 m ................. 2.39 m
(K) (standard pads) .......................................0.60 m .................. 0.60 m ................ 0.60 m ................. 0.60 m
(L) (with 800 mm pads) .................................3.19 m .................. 3.19 m ................ 3.19 m ................. 3.19 m
(M) .................................................................0.48 m .................. 0.48 m ................ 0.48 m ................. 0.48 m

Copyright
1002-34
CS00K520
(CX350)
Arms (dippers) 2.20 m 2.60 m 3.25 m
(A) ............................................................................ .................. 3.57 m ................ 3.53 m ................. 3.29 m
(B) ............................................................................ .................. 3.13 m ................ 3.13 m ................. 3.13 m
(C) ............................................................................ ................ 11.25 m .............. 11.13 m ............... 11.05 m
(D) ............................................................................ .................. 5.91 m ................ 5.91 m ................. 5.91 m
(E) ............................................................................ .................. 3.04 m ................ 3.04 m ................. 3.04 m
(F)............................................................................. .................. 1.21 m ................ 1.21 m ................. 1.21 m
(G) ............................................................................ .................. 3.42 m ................ 3.42 m ................. 3.42 m
(H) ............................................................................ .................. 4.98 m ................ 4.98 m ................. 4.98 m
(I).............................................................................. .................. 4.04 m ................ 4.04 m ................. 4.04 m
(J) ............................................................................. .................. 2.60 m ................ 2.60 m ................. 2.60 m
(K) (standard pads) .................................................. .................. 0.60 m ................ 0.60 m ................. 0.60 m
(L) (with 600 mm track pads).................................... .................. 3.20 m ................ 3.20 m ................. 3.20 m
(L) (with 700 mm track pads).................................... .................. 3.30 m ................ 3.30 m ................. 3.30 m
(L) (with 800 mm pads) ............................................ .................. 3.40 m ................ 3.40 m ................. 3.40 m

2001
Section Copyright
2001
RADIATOR, OIL-COOLER, INTER COOLER, FUEL

COOLER AND ENGINE
REMOVAL AND INSTALLATION

Printed in France
Copyright
2001-2
TABLE OF CONTENTS
SPECIFICATIONS .................................................................................................................................................. 2
RADIATOR, OIL-COOLER, INTER COOLER AND FUEL COOLER ..................................................................... 3
Removal .............................................................................................................................................................. 3
Installation ........................................................................................................................................................... 3
ENGINE .................................................................................................................................................................. 4
Removal .............................................................................................................................................................. 4
Installation ........................................................................................................................................................... 4
ENGINE AND RADIATOR - FIGURE 1 .................................................................................................................. 6
SPECIFICATIONS
See Section 1002

Copyright
2001-3
RADIATOR, OIL-COOLER, INTER COOLER AND FUEL COOLER

Before carrying out any operation on the machine, perform the following operations in the order shown:
- Park the machine on hard, flat ground.
- Lower the attachment to the ground.
- Shut down the engine.
- Remove the starter switch key.
- Make sure that pressure in the hydraulic system has been completely released (see Operators Manual).
WARNING: When the machine is working, the engine components and the hydraulic pump reach a high
temperature. To avoid being burnt by hot metal or scalded by high temperature water or oil, allow the
! machine to cool down before starting any servicing operation.
Removal Installation
NOTE: For the removal refer to the figure 1, page 6. NOTE: For the installation refer to the figure 1, page
6, proceed in the reverse order from that of removal.
STEP 1
1) Coat the thread of reference (40) and (51) with loc-
Drain the cooling system (see Operators Manual). tite or equivalent after removing any oil film and fas-
STEP 2 ten by tightening torque .
Release pressure in the hydraulic reservoir to allow 2) Apply packing liquid (38) to the connection of radi-
the vacuum pump to be mounted (see Section 8000). ator hose after removing any oil film and fasten by
tightening torque.
3) Tighten up the hose band from the direction
schown on the D.W.G.
Before operating the machine:
- Check the oil level in the hydraulic reservoir. Top up
if necessary.
- Check the hydraulic fluid cooling circuit for leaks.
- Fill and bleed the engine cooling system (see Oper-
ators Manual).
- Check the engine cooling system for leaks.

Copyright
2001-4
ENGINE
Removal STEP 7
NOTE: For the removal refer to the figure 1, page 6. Remove the engine retaining hardware.
NOTE: When installing, make a visual inspection of
STEP 1
the condition of the rubber flexible mountings and
change them if necessary. Tighten the engine retain-
ing screws to the torque specified in Section 1002.
STEP 8
When there is nothing interfering with the removal of
the engine, raise the engine carefully and install it on
a suitable repair bench.
STEP 9
Refer to Section 8003 and remove the hydraulic
pump.
JS00163A
Installation
Park the machine on hard, flat ground. Lower the
attachment to the ground. NOTE: For the installation refer to the figure 1, page
6, proceed in the reverse order from that of removal.
STEP 2 1) Coat the thread of reference (1), (4), (63) and (74)
Release pressure in the hydraulic system and in the with loctite or equivalent after removing any oil film
hydraulic reservoir (see Section 8000). and fasten by tightening torque .
STEP 3 2) The elastic rubbers of reference (49) and (72)

should be assembled after confirming the discrimina-
tion color.
1 Before operating the machine, carry out the following
operations:
- Bleed and prime the fuel system (see Operators
Manual).
- Fill and bleed the engine cooling system (see Oper-
ators Manual).
- Check the hydraulic, fuel and cooling systems for
leaks.
- Check the oil level in the hydraulic reservoir. Top up
if necessary.
CT05L063
Disconnect the earth cable (-) (1) from the battery.
STEP 4
Label and disconnect all the electrical connections
from the engine.
STEP 5
NOTE: For the removal refer to the figure 1, page 6.
Remove all the clips, etc. which attach the electrical
harnesses to the engine and move out of the way.
STEP 6
Install a suitable lifting device on the engine lifting
rings (for the weight of the engine, see Section 1002).

Copyright
2001-5
NOTES
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Copyright
2001-6
ENGINE AND RADIATOR - FIGURE 1
330-5-02-02-24

Copyright
2001-7
1 - BOLT; HIGH STRENGTH 44 - JOINT; SPL
2 - WASHER; HIGH STRENGHT 45 - BAND; HOSE
3 - BOND 46 - HOSU; RUBBER
4 - BOLT; HIGH STRENGTH 47 - BAND; HOSE
5 - WASHER; HIGH STRENGHT 48 - TUBE
6 - HOSE; AIR 49 - RUBBER; ELASTIC
7 - BRACKET 50 - HOSE; RADIATOR
8 - CLAMP; SPL 51 - BOLT; HIGH STRENGTH
9 - PIPE; EXHAUST 52 - WASHER; HIGH STRENGHT
10 - MISSING NUMBER 53 - HOSE; VINYL
11 - NUT; SPL 54 - TANK; RESERVE
12 - CLIP; JUBILEE 55 - HOLDER
13 - HOSE; AIR 56 - BOLT; SEMS
14 - CLAMP; HOSE 57 - MISSING NUMBER
15 - HOSE; AIR 58 - MUFFLER
16 - CLIP; JUBILEE 59 - BOLT; U
17 - MISSING NUMBER 60 - NUT; FLANGED
18 - MISSING NUMBER 61 - SUPT; ENGINE
19 - CLIP; JUBILEE 62 - BRACKET; MUFFLER
20 - BOLT; SPL 63 - BOLT; HIGH STRENGTH
21 - MISSING NUMBER 64 - SUPT; ENGINE
22 - MISSING NUMBER 65 - BOLT; HIGH STRENGTH
23 - MISSING NUMBER 66 - BOLT; HIGH STRENGTH
24 - RADIATOR (STD) ASSY 67 - BRACKET
25 - LABEL; SPL 69 - CONT; SPL
26 - ELBOW 70 - NUT; SPL
27 - STUD 71 - SUPT; ENGINE
28 - MISSING NUMBER 72 - RUBBER; ELASTIC
29 - WASHER; HIGH STRENGHT 73 - PLATE
30 - CLAMP; HOSE 74 - BOLT; HIGH STRENGTH
31 - CLAMP 75 - WASHER; HIGH STRENGHT
32 - MISSING NUMBER 76 - HOSE; RADIATOR
33 - MISSING NUMBER 77 - CLAMP; HOSE
34 - ENGINE; DIESEL 78 - BRACKET
35 - CLAMP; HOSE 79 - BOLT; SEMS
36 - HOSU; AIR 80 - ELBOW
37 - CLAMP; HOSE 81 - BOLT; SEMS
38 - PACKING; LIQUID 82 - CLEANER; AIR
39 - STAY; RADIATOR 83 - SUPI; ENGINE
40 - BOLT; SEMS 84 - CONT; SPL
41 - ELBOW 89 - WASHER; HIGH STRENGHT
42 - NUT; HIGH STRENGTH 90 - HOSE; SPL
43 - SENSOR; VACUUM 91 - ENGINE; DIESEL

Copyright
2001-8
NOTES
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3001
Section Copyright
3001

OF THE FUEL TANK

Printed in France
Copyright
3001-2
TABLE OF CONTENTS
SPECIFICATIONS .................................................................................................................................................. 2
FUEL TANK ............................................................................................................................................................ 3
Removal .............................................................................................................................................................. 3
Installation ........................................................................................................................................................... 4
Description .......................................................................................................................................................... 5
SPECIFICATIONS
See Section 1002.

Copyright
3001-3
FUEL TANK
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 under 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
Attach labels on the two hoses and remove them.
JS00163A
Park the machine on hard, flat ground. Lower the STEP 12
attachment to the ground. Shift the plastic protection (13) from the fuel sensor
STEP 2 (14). Remove the retaining screws (15) then the fuel
sensor (14) as well as the seal (16).
Reduce the engine speed to idle for 30 seconds, then
shut down the engine. STEP 13
STEP 3 Remove the screws (17) from the fuel tank (1), and
the shims (18).
Turn the ignition key to "ON" without starting the
engine. STEP 14
STEP 4 Remove the fuel tank (1) using a hoist.
Attach a "DO NOT OPERATE" tag to the ignition key STEP 15

in the cab. See the operator's manual for removing the fuel filter.
STEP 5
NOTE: The numbers within brackets refer to the fig-
ures on pages 5 and 6.
Remove the access panel under the fuel reservoir (1).
STEP 6
Open the filling plug (2) of the tank (1). Bleed the
remaining fuel using the valve (3) then remove the
latter. Remove the filter (19) and the fuel gauge (20).
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).

Copyright
3001-4
Installation
NOTE: The numbers within brackets refer to the fig- STEP 7
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 (18) as well as the six screws (17),
tighten the screws to a torque of 232.4 to 276 Nm. 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 (16), then the fuel probe (14) using
the five screws (15), reposition the plastic protection Reinstall the protective plate on top of the machine.
correctly (13).
STEP 4
Install the two hoses by taking help of the labels
attached during removal. Tighten using retaining
clips.
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 reser-
voir (1). Tighten the screws (8).

Copyright
3001-5
Description
Location
7 6 9
11 8
6
5
8
12
11 10
CS02B557 CS02B556
4 SCREW
5 ACCESS RAMP
6 SCREW
7 PROTECTIVE HOUSING
8 SCREW
9 SKID PLATE
10 SCREW
11 SCREW
12 SKID PLATE

Copyright
3001-6
Fuel tank
2
20
19
1
14
13
16
15
18
17
CS02C553
1 FUEL RESERVOIR 15 SCREW
2 PLUG 16 SEAL
3 VALVE 17 SCREW
13 PLASTIC PROTECTION 18 SHIM
14 FUEL PROBE 19 FILTER

4001
Section Copyright
4001
ELECTRICAL AND ELECTRONIC

CIRCUIT AND TROUBLESHOOTING

Printed in France
Copyright
4001-2
TABLE OF CONTENTS
ELECTRIC CIRCUITS OPERATION EXPLANATION ............................................................................................. 4
System Chart of Function ..................................................................................................................................... 4
ENGINE CONTROL ................................................................................................................................................. 7

Fuel Injection Control (Common rail type) ............................................................................................................ 7
GENERAL LOCATION OF THE COMPONENTS (INSIDE THE CAB) .................................................................. 12
RELAYS AND MAIN FUSES (battery compartment) ............................................................................................. 13
FUSE BOX ............................................................................................................................................................. 14
WORK MODE SELECTION ................................................................................................................................... 15
THROTTLE CONTROL .......................................................................................................................................... 22
IDLING CONTROL (AUTO/ONE-TOUCH)............................................................................................................. 25
BREAKER MODE................................................................................................................................................... 27
AUTO PREHEAD (GLOW CONTROL) .................................................................................................................. 28
AUTO WARM UP ................................................................................................................................................... 31
OVERHEAT PROTECTION ................................................................................................................................... 32
ATMOSPHERIC PRESSURE COMPENSATION .................................................................................................. 33
CONTROL WHEN STARTING ENGINE ................................................................................................................ 34
CONTROL WHEN STOPPING ENGINE................................................................................................................ 35
EMERGENCY STOP OF THE ENGINE................................................................................................................. 35
FUNCTION LOCKING............................................................................................................................................ 36
POWER BOOST .................................................................................................................................................... 37
SWING BRAKE ...................................................................................................................................................... 38
TRAVEL MODE...................................................................................................................................................... 40
POWER SHUT-OFF DELAY .................................................................................................................................. 42
FUEL SUPPLY PUMP CONTROL (AUTOMATIC STOP) OPTION ....................................................................... 43
POWER TRANSISTOR PROTECTION ................................................................................................................. 45
MONITOR DISPLAY .............................................................................................................................................. 46

Normal Display ................................................................................................................................................... 46
Message Display ................................................................................................................................................ 49
ACCESS AND CONTENTS OF MONITOR DISPLAYS (Diagnostic mode)........................................................... 50

Access to monitor displays ................................................................................................................................. 50
Copyright
4001-3
Machine condition ..............................................................................................................................................51
Diagnostic code ..................................................................................................................................................54
Machine history ..................................................................................................................................................59
Resetting ............................................................................................................................................................62
EXCAVATOR MODEL SELECTION PROCEDURE .............................................................................................. 66

Changing the language code .............................................................................................................................68
TROUBLESHOOTING ........................................................................................................................................... 69
Prior inspections .................................................................................................................................................69
Reading the organisation charts ........................................................................................................................70
Procedures .........................................................................................................................................................71
Fuel ....................................................................................................................................................................72
Add coolant solution ...........................................................................................................................................73
Low engine oil pressure .....................................................................................................................................74
Overheating ........................................................................................................................................................75
Defective battery charge circuit ..........................................................................................................................78
Electrical system troubleshooting .......................................................................................................................80
ELECTRICAL INSPECTION OF COMPONENTS.................................................................................................. 82

Main pump proportional solenoid .......................................................................................................................83
6 solenoid valve bank .........................................................................................................................................84
Hydraulic oil temperature sensor .......................................................................................................................84
Pressure sensor .................................................................................................................................................85

Copyright
4001-4
ELECTRIC CIRCUITS OPERATION EXPLANATION

System Chart of Function
ITEM FUNCTION METHOD
1 Engine control Electronic control (common-rail)
2 Work mode selection a) H/S/L mode Maximum engine speed, pump current,
and pressurizing solenoid valve are con-
Machine setting can be selected accord-
trolled according to the selected work
ing to conditions such as of workload or
mode.
fuel efficiency preference, and lifting oper-
ation.
b) Auto-mode Selection of auto-mode allows the load to
be calculated with pressure of negative
Suitable work mode is automatically
control P1 and P2 which in turn work
selected.
mode is switched.
c) Load prefectch control Pump current and engine controller are
controlled by signal from pressure switch.
Pump current is kept at 0 mA while
machine is not being operated.
3 Throttle control Engine can be controlled continuously Engine speed is adjusted by control of
from idling to high idling speed by opera- throttle valve.
tor's instruction.
4 Idling control Engine speed can be switched to/form Pushing knob of switch on the right allows
idling by control of onetouch switch. the engine to run idle and pushing it again
to return it as it was.
It makes engine to run idle while machine Selection of auto-idle allows the engine to
is not being operated. run at idling speed automatically in 5 min-
utes after he lever is shifted to its neutral.
Shifting lever makes the engine to return
to its normal speed automatically.
5 Breaker mode Pressing the breaker pedal allows the Turning ON the pressure switch in breaker
engine to run at the set speed automati- pilot line allows the engine to run at previ-
cally and boosting pressure will be cut. ously set speed. Also, pump current will
be set as that in S-mode and boosting
pressure is to be cut.
6 Auto preheat It helps the engine to start easily at a low Depending on cooling water temperature
temperature. Also, it stabilizes engine at the time when the key switch is turned
speed immediately after start of the ON, the glow plug is energized for a
engine to reduce exhausting smoke. period of time being set. It is to be ener-
gized for a certain period of set time after
the engine has been started to reduce
exhausting smoke.
7 Auto warm-up When coolant temperature is low, it allows In case where no operation of the
the engine to start warming up automati- machine after the engine has been started
cally after it has been started. is carried out when coolant temperature is
low, it automatically increases engine
speed gradually to warm it up.
8 Overheat protection When engine coolant temperature has When coolant temperature goes over
been increased, reduce injection quantity 108C, reduce fuel injection quantity.
to protect engine. Coolant temperature sensor to ECM.

Copyright
4001-5

9 Correction of atmos- It prevents black smoke and engine dam- Fuel is to be restricted by an atmospheric
pheric pressure age when intake air quantity is decreased sensor when altitude is over 2000 meters.
such as operating in highland.
10 Control on engine It increases fuel injection according to It monitors coolant temperature when it is
start coolant temperature to improve starting under 0C. It watches a lapse of time after
performance.It improves starting perform- cranking has been started.
ance when sufficient fuel fails to be
injected due to wear in the machine as it
has been operated for a long time.
11 Engine stop control Engine controller (ECM) recognizes It stops fuel injection from injector.It
engine key OFF by turning key switch insructs pressure control valve to opened
OFF fully. It makes EGR valve to be fully open.
12 Emergency engine Emergency stop switch is set up with no Signal of emergency stop switch is trans-
stop engine stop by key switch in mind. ferred to engine controller (ECM) to per-
form engine stop control.
13 Lever lock It allows the machine not to be operated When the lever is raised by control of the
by control of levers while cab is being gate lever on the left console, the lever
moved Up/Down or when the machine will lock solenoid turns OFF which in turn pilot
not be needed for operation. pressure is cut off.
14 Auto boost control Boost control Whether boost of pressure is needed or
not is judged by the input data on load fac-
It increases main relief pressure by
tor of the engine and on pump discharge
approx. 10%.
pressure. (Boosting for 8 seconds.)
Boost -cut control Boosting will not function when travelling
and reserve pressure switches are turned
It does not allow boosting according to a
OFF.
certain condition to protect machine and
equipment.
15 Swing lock It disables swing even when the swing Turning ON the swing lock switch allows
lever is mistakenly controlled. the swing brake solenoid to be energized
to actuate mechanical brake.
16 Swing brake control When swing lock is OFF, in order to pro- It controls swing brake solenoid valve by
tect swing device, it controls swing the data obtained from switches of swing,
mechanical brake ON/OFF automatically attachments, and travel pressure, and
according to operating conditions. also from pump discharge pressure.
17 Travel speed switch- It allows travel speed to switch to either It controls solenoid valve by the travel
ing-over one of 2 levels. mode switch to switch over tilt angle of
swash plate in the traction motor.
18 Travel alarm Alarm buzzer functions when travelling. Travel pressure switch controls the
buzzer.
19 Power shut-off delay This ensures power supply for engine stop It allows a time-lag until main relay shuts
function. off after key switch has been turned OFF.
20 (Option) It makes an automatic stop when fuel tank Enter signal of fuel sensor to turn OFF
becomes full on refueling. switch.
Fuel supply pump
control

Copyright
4001-6

21 Power transistor pro- It protects controller in case where a cir- Over-current detection shuts off transistor
tection cuit connected to transistor output is short- output.
circuited.
22 Travel speed switch- a) Normal display Temperature of hydraulic oil and of coolant
ing-over temperature, and fuel level are displayed
It displays current status of the machine.
in bar graphs on LCD monitor and work/
travel mode is also displayed.
b) Message display Each information is to be displayed by let-
ters on LCD monitor.
Warning.
Functioning operation.
When to service the machine

Copyright
4001-7
ENGINE CONTROL
Fuel Injection Control (Common rail type)
1. Process to determine quantity of fuel injection
1) System diagram
Engine control module (ECM)
INPUT Standard fuel injection

CAN communication Machine
Boost sensor control unit
CKP sensor
G sensor
Correction of:
-Engine coolant temperature
-Atmospheric pressure
-Fuel temperature boost
pressure
-Between cylinders
-Q adjustment
-QR
Correction
Decision of
Open/Close Decision of timing for
timing of SCV energizing injector coil
Common rail
pressure sensor
Common rail Injector coil
SCV
Supply pump
Injector
Fuel tank
700-1-04-01-23ADA

Copyright
4001-8
2) Operation
Engine controller (ECM) gets information (signal from mounted sensors) such as engine speed and engine load.
Based on the information, ECM sends electric signals to supply pump and to injector to make a proper control of
fuel injection quantity and injection timing for each cylinder.
1) Injection quantity control
Based mainly on engine speed and load given to actual machine, Injection rate control is carried out for optimum
injection by controlling fuel injector.
2) Injection pressure control
Injection pressure is controlled by control of fuel pressure in the common-rail.
The right pressure in the common-rail is calculated by using engine speed and fuel injection quantity.
The supply pump and the pressure control valve are controlled according to the calculated pressure so that it
can discharge proper quantity of fuel to pressure-feed into the common-rail for control.
3) Injection timing control
The control substitutes timer function and an appropriate fuel injection timing is calculated by mainly using
engine speed and fuel injection quantity to control the injector.
4) Injection rate control
In order to improve fuel consumption in the cylinder, a small amount of fuel is injected (pre injection) for ignition at
first, then 2nd time injection (main injection) into the ignited cylinder is carried out.
In this control, the injection quantity control in section 1) and the injection timing control in section 3) are carried
out by controlling injector.

Copyright
4001-9
2. Mounting position of accessories related to engine

Engine
B3 B50 B51 B47 harness
connector B1
B49
B6
B48
S62
R5
A2
EST
connector
ECM memory
clear
330.1.04.01.24AE2
A2 Engine controller B50 Camshaft position sensor (or G sensor: cylinder
B1 Coolant temperature sensor recognition sensor (detects rotation of cam
B3 Fuel temperature sensor shaft))
B6 Air intake temperature sensor B51 Boost temperature sensor
B47 Boost pressure sensor R5 Fuel sensor
B48 Atmospheric pressure sensor S62 Air cleaner sensor
B49 Crankshaft position sensor (or engine speed
sensor (flywheel mounted))

Copyright
4001-10
3. Appearances of accessories related to the Tier 3 emission control regula-

tion
A2. Engine controller (ECM)
700-1-04-01-23AF
Controller for the engine meeting Tier 3 emission control regulation (hardware is common to the vehicle).
Quantity of pin is 121 as against 104 for the engine meeting Tier 2 emission control regulation.
In area indicated by an arrow, ISUZU part number and TRANSTRON part number, and serial number are
recorded.
B1. Coolant temperature sensor B3. Fuel temperature sensor
330.1.04.01.24AI
700.1.04.01.23AG
1 Power, positive (+) B6. Intake air temperature sensor
2 Power, negative (-)
3 For water temperature indicator (not in use)
700.1.04.01.23AH

Copyright
4001-11
B47. Boost pressure sensor B50. Camshaft position sensor (or G sen-
sor)
330.1.04.01.24AM
B51. Boost temperature sensor
700.1.04.01.23AK
B48. Atmospheric pressure sensor
700.1.04.01.23AH
R5. Fuel level sensor
700.1.04.01.23AJ
1 Power, positive (+)
2 Power, negative (-)
3 Output
B49. Crankshaft position sensor 700.1.04.01.23AO
S62. Vacuum sensor

Operating negative pressure: 6.27 0.29kPa.
700.1.04.01.23AN
700.1.04.01.23AL

Copyright
4001-12
GENERAL LOCATION OF THE COMPONENTS (INSIDE THE CAB)
M3 A4
S54
S15 S16
S51
P1
S63 S14
S17 R3
S53 S1
S64 P6
S13 E4
E52 E51
F21
X8
A1
A2 B61
K5 K6 K4 K3 K2 K33 U1
CS02M538B
A1 Computer A4 Wiper controller
A2 Engine controller B61 Sunload sensor

Copyright
4001-13
E4 Cab light R3 Throttle volume
E51 Cigarette lighter S1 Key switch
E52 Air conditioner S13 Overload switch
F21 Fuse box S14 Breaker/crusher switch
K2 Relay-glow plug S15 Horn switch
K3 Relay-horn S16 One touch idle
K4 Relay working light S17 Boom raising priority switch
K5 Relay-rotary light S51 Hydraulic function cancellation lever switch
K6 Relay-air conditioner condenser fan S53 Door limit switch
K33 Main relay S54 Front window limit switch
M3 Wiper motor S64 Cooling hydraulic motor switch
P1 Instrument panel U1 DC-DC (24 V-12 V) converter
P6 Air conditioner control panel X8 Radio connector
RELAYS AND MAIN FUSES (BATTERY COMPARTMENT)
F23 F24 F25 F22
K7
K8
700.1.04.07.20A2
1 Battery cable
F22 Fuse 20 A; main fuse for F11 and F12 circuits
F23 Fuse 65 A; main fuse for F3 to F10 and F13 to
F20 circuits
F24 Fuse 20 A; main fuse for F2 circuit
F25 Fuse 20 A; main fuse for F1 circuit
K7 Relay battery
K8 Relay safety

Copyright
4001-14
FUSE BOX
CM00E005
F1 Fuse 20 A: Engine controller

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

Copyright
4001-15
WORK MODE SELECTION

1) Circuit configuration
Y7
S3 1
S4
3
P4 2 A1 A2
P1
700-1-04-01-23AP
1 Engine P1 Instrument panel
2 SERIAL communication P4 Monitor display
3 CAN communication S3 Work mode switch
A1 Computer S4 Auto mode switch
A2 Engine controller Y7 Main pump proportional solenoid
2) Timing diagram
S3
S4
700-1-04-01-23 AQ
S3 Work mode switch
S4 Auto mode switch

Copyright
4001-16
3) Mode selection switch 4) Operation
1. If the machine was in H/S/L mode and was turned 1. Pushing the mode switch on the monitor display will
off by the key switch, it will restart in S-Mode send a signal to the controller. The controller then
when it is turned on through the key switch again. switches modes according to the signal it received.
(The previous data is reset.) 2. The controller signals the currently selected mode to
2. By pressing the work mode switch (S3), the modes the monitor via serial communication. The LCD
alternate as follows: SHLSH. screen switches according to the data sent.
3. No matter what mode is selected (S4) to start with, 3. The controller transmits the current mode to the
pushing the auto-mode switch (S4) once will switch engine controller via CAN communication. The
the mode to auto. Pushing the switch again will engine controller regulates the engine governor
switch the auto-mode to S-mode, regardless of the according to the data.
mode that was selected prior to auto-mode. 4. Also, the engine controller transmits via CAN com-
4. During the auto-mode operation, the work mode munication the data on current mode and the actual
switch stays deactivated. The switch will not work to engine speed.
change modes. 5. The controller determines the pump current based
5. After the machine has been turned off with auto- on the following data: current mode, actual engine
mode selected, it will restart in the auto-mode even speed, target engine speed. The controller then
when the key switch is turned on. (Previous data is transmits the result to the pump.
retained.) 6. The LCD on the monitor switches, reflecting the
transmission received from controller via serial com-
munication.

Copyright
4001-17
5) Switches and LCD
P4 S2 S3 S4 S7 S8 S9 P5
H1 S5 S22 S10 S11 S12
CD00E007A
H1 Audible warning device

P4 Monitor display 1 2 3 P4
P5 Hourmeter
S2 Travel mode switch
S3 Work mode switch
S4 Auto mode switch
S5 Cushion control switch
S7 Audible alarm cut out switch
S8 Swing brake switch
S9 Emergency engine stop switch
S10Working light switch
S11Wiper switch
S12Washer switch 4 5 6
S22Rotary light switch (Europe only)
CS00F521
S22Free swing switch (North America only) 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
4001-18
A) Auto Modes
1) Alteration
The current value of I min in mode H is set up between mode S and mode L.
The engine speed sensing control is carried out even in mode S and I maxi is set to the current value equivalent
in mode S and I min to the same as I min of mode H.
The engine speed sensing control is carried out even in auto mode and control it within the range from I maxi to
the current value I min to the same as I min of mode H for both Sa and La.
2) Purpose
It lowers pump output automatically to cope with drop of engine power due to use of poor quality fuel and operation
in highland.
It applies optimum load with fuel cost and cycle time in mind when operated in automatic mode.
Y7
P1 A1 A2 1
700-1-04-01-23AP
1 Engine
A1 Computer
A2 Engine controller
P1 Instrument panel
Y7 Main pump proportional solenoid

Copyright
4001-19
Max.torque point = X engine speed
H mode
A
S mode Torque
A mode
Target speed (min-1)
B
L mode H mode
Engine horsepower
C
S mode
Horsepower
L mode
900
0 0.5 4.5 5.0

Trottle volume (V)
900 C B A
HImax ((1) mA)
Engine speed (min-1)
Quantity of flow (Q)
SImax ((2) mA) H mode
S mode
Imin=L mode ((3) mA)
Pressure (P)
P-Q chart of pump
700.1.04.01.23AT2
Mode H: 4) Operation in mode H, S, and L
When engine speed is between A rotation and X 1. When the target speed of the engine is lower than
rotation at maximum torque point, it controls current the speed at maximum torque, the pump current
value range from HI maxi ((1) mA) to I min ((3) mA). comes to the current value in mode L even if it is
Mode S:
operated in mode H or S. (To prevent engine stop).
When engine speed is between B rotation and X
rotation at maximum torque point, it controls current 2. When operating travel alone even it is operated in
value range from SI maxi ((2) mA) to I min ((3) mA) mode L, the current value in mode S is to be taken
Mode L: (to prevent endless travelling).
When engine speed is C rotation, current value is of 3. When using a backup line (breaker, crusher etc.),
mode L ((3) mA). the current value in mode S is to be taken.
Auto mode:
Sa: 4. Even if it applies to the section 2) or 3) above, the
When engine speed is between B rotation and X current value in mode L is to be taken in the case of
rotation at maximum torque point, it controls current section 1). (To prevent engine stop.)
value range from ((1) mA) to l min ((3) mA). 5. When in auto idling, put the idling engine speed at
La: 1200 min-1. (For measures against black smoke
When engine speed is between C rotation and X generated when restoring engine speed by manual
rotation at maximum torque point, it controls current control of lever).
value range from HI maxi ((1) mA) to I min ((3) mA).

Copyright
4001-20
6. When temperature of engine cooling water is too mode has been selected and the mode is fixed to La
low or when power-supply voltage applied to the selected on starting.
engine controller is too low, increase the idling 4. Once water temperature reaches more than 50C
speed to prevent over-cooling and/or running out of (122F) and oil temperature more than 25C (77F)
battery. however, control in auto mode starts and continues
5. Operation in auto mode operating in this mode if water and/or oil tempera-
ture is dropped again.
1. When auto mode has been selected, start the
machine with mode La first then select mode 5. If travel pressure switch is turned ON during control
Sa according to working conditions. in auto mode, work mode will not be changed over
while it is being turned ON.
2. In addition, the mode can be changed automatically
from Sa to La. 6. (If travel pressure switch is turned ON during con-
trol in mode Sa, mode Sa is to be held, and simi-
3. When water temperature is less than 50C (122F)
larly if the switch is turned ON during control in
and oil temperature is less than 25C (77F), control
mode La, this mode is to be held).
in auto mode will not be carried out even if the auto
Set value in each mode
Mode Designation Unit Set value

-1
(MAX) min 1950
Engine speed
(When travelling) min-1 2050
H (I MAX) mA 470
Pump current (I MIN) mA 250
(When in no control) mA < 50
Engine speed (MAX) min-1 1850
(I MAX) mA 410
S
L (STD) mA < 50
Pump current
Mode Sa (I MAX) mA 470
Pump current
(I MIN) mA 250
-1
Engine speed (MAX) min 1750
(I MAX) mA 470
Mode La
Engine speed in idling min-1 900
-1
Engine speed in auto idling min 1200
Engine speed at maximum torque min-1 1500

Copyright
4001-21
B) Load pre-fetch control
1) Purpose
Pump current is controlled as measures against black smoke.
Y7
B26
A2
B27
A1
700.1.04.01.23AU
1 Engine B26 Upper pilot pressure switch (yellow band)
A1 Computer/Controller B27 Travel pilot pressure switch
3) Operation
1. When no operation is carried out (attachment and
travel pressure switches OFF), the pump current
is always 0 mA regardless of operation mode and
engine speed.
2. When attachment or travel pressure switch is
turned ON, the controller provides pump current
so that it can get to the set current for the work
mode being selected after 0.8 second.
* No control for decreasing transient load has been
employed for machines above current model of
CX330.
Control for decreasing transient load is illustrated
below:
Since engine response (or returning property) has
been improved (or no difference between target
speed and actual speed), if an abrupt engagement
of the lever from inching operation is carried out,
and when difference between target speed and
actual speed reaches within 150 min-1, pump cur-
rent of 0 mA is to be applied to ease the engine
load.
This is for the purpose of taking measures against
black smoke and of prevention from engine stop.

Copyright
4001-22
THROTTLE CONTROL
The analog voltage signal from throttle potentiometer is provided to the controller in the machine to transfer it to the
engine controller (ECU) via CAN communication circuit together with work mode.
1) Purpose
Engine speed can be set by no dependence of the engine controllers on ISUZU side.
TARGET SPEED ENGINE SPEED
5V
THROTTLE VOLUME SIG CAN-H 1

A1 A2
GND CAN-L
ENGINE
CONTROLLER ENGINE CONTROLLER H mode
5.0
S mode
A
L mode
B
C
Input voltage (V)
A mode
900
0 100 0 0.5 4.5 5.0
Throttle Volume Position (%) Input voltage (V)
700.1.04.01.23AV
1 Engine A2 Engine controller
A1 Computer/Controller
3) Operation
1. The controller determines the target speed from the 4. When CAN communication linking between the
position of throttle potentiometer and the work mode controller and the engine controller (ECM) is
currently being entered to transfer the data to the stopped, the engine speed is fixed to a certain
engine controller (ECM) via CAN communication specified speed and the throttle potentiometer
circuit. specifying engine speed will not be functioning.
2. ECM determines fuel injection quantity from the cal- (Specified speed: 1350min-1).
culated target speed and the data obtained from The specified speed, for the purpose of emer-
each sensor (such as actual engine speed, fuel tem- gency escape, has been set as the engine speed
perature, and boost temperature) to transfer it to the which will not damage the breaker while the
supply pump and to the injector for engine control. engine is running.
3. When the engine is rotated at a speed less than that

at the maximum torque by controlling throttle poten-
tiometer, the pump current becomes that of mode L
even if work mode is selected either to mode S or to
mode H.

1
ENGINE
K7
S1
EGR MOTOR
R3
3LR GLOW PLUG
BATTERY RELAY U
KEY SWITCH V M
Lep 9-94180EN
THROTTLE
CN.A6
B G1 G2 ACC M ST W
VOLUME
M15
R1
HEAT EGR POSITION
1.25LgR 0.75WB 8
OFF 0.75GB 7 SENSOR
ACC 1.25RW 1 1.25RW 0.75YB 6
WR
ON 0.75WG 4
U
1.25LgR 3 1.25LgR 0.75G 3
ST V
0.85GrR 4 0.85GrR 0.75YG 2
W
1
0.85LY 6 0.85LY 1.25LgR 2 1.25LgR
1
2
3
3
6
1
2
5
0.85L 7 0.85LG WR 3 WR SAFETY RELAY COMMONRAIL PRESS. SENSOR
CN.A4
0.85BL 8 0.85BL
CN.50 CN.52
0.85GrR 5 0.85GrR 0.85GrR 3
0.85L
0.85LY
0.85BL
1.25RW 4
CN.19
1.25LgR
0.85GrR
LgR
GrR
K8
CN.22
CN.T3
0.85LgR
CRANK ANGLE (MPU) SENSOR
0.75R 12
0.75W 13
-
CONTROLLER MAIN RELAY GLOW RELAY 0.75G 14 +
0.75G 1
24VB 0.75L 2 CAM ANGLE SENSOR
CN.6
BW 3
ENGINE STOP 21 WR 0.75L 5
BL 6
K2
0.75WR 7
K33
0.75WL 15 WATER TEMP. SENSOR
0.75RG 8
3
4
5
1
2
5
1
3
4
0.75GR 16
CN.1
0.75BR 17
BG
BrR
2LR
YR
LgR
2LR
2WR
0.75RY 9
1.25GR
0.75YB 10 BOOST TEMP. SENSOR
5V THROTTLE 11 0.85LY 0.75BY 11
SIG THROTTLE VOL. 4 0.85LG
WR
A GND 5 0.85BL
A1
CN.A2
4) Throttle Control Relation Electric Circuit Diagram
BOOST PRESS. SENSOR
S9
CN.3
MONITOR SWITCH
ENGINE STOP 43 BrR ENGINE STOP

OIL PRESS. SENSOR
CAN H 29 0.85P
39 0.85PL 2LR 3 3LR
CAN L
1.25GR 5 1.25GR
FUEL LEAKAGE
CN.21
TEMP. SENSOR
B6
AIR INTAKE
WR 16 WR TEMP. SENSOR
CN.A7
0.85LgR 17 0.85LgR 0.75Y 1

GrR 18 GrR 0.85BO 1 0.75P 2
BrR 19 BrR 0.75OL 2 0.75W 3 SCV
YR 20 YR 4
0.85P 21 P 5
0.85PL 22 PL 6
B53 B52 B49 B50 B1 B51 B47 B21 B3 Y35
BARO SENSOR
CN.A8
CN.A5
CN.23
0.85Y 1
0.85YL 3
0.85BY 2
B48
1.25RG 1
1.25RW 2
No.1 CYLINDER
0.75GW 5
0.75WL 6
No.6 CYLINDER
0.75GB 7
0.75G 8
0.75WB 9 No.5 CYLINDER
0.75WR 10
No.3 CYLINDER
A2
CN.A3
CN.A0 CN.A1 No.2 CYLINDER

0.75Y
0.75W
0.75G
0.75P
0.75WR
0.75G
1.25RG
0.75WR
0.75W
0.75RG
0.75W
0.75GR
0.75YG
0.75G
0.75WG
0.75R
0.75W
0.75L
0.75P
0.75G
0.75L
0.85BW
0.75BR
0.75YB
0.75WB
0.75WB
1.25RW
0.75WL
0.75GW
0.75GB
1.25B
0.85BG
0.85BG
BrR
YR
0.85LgR
0.75L
1.25B
1.25B
0.85BG
1.25GR
1.25GR
P
PL
YR
BL
GrR
WR
0.85BY
0.85Y
BL
BL
0.85YL
0.75OL
2
5
1
80 0.75YR
3
46
63
67
4
21
60
61
71
79 0.75BY
97
81
24
40
41
47
64
74 0.75WL
84
89
95
91
92
93
87
82
90
98
62
18
37
72
83
94
43
10
121
107
113
117
101
103 0.75GB
109
111
114
100 0.85BL
105
106
108
110
115
116
119
120
118
No.4 CYLINDER
ENGINE CONTROLLER (ECM)

Copyright
330-1-04-01-24aw
Issued 02-06
4001-23
Copyright
4001-24
1 Engine
A1 Computer
B1 Coolant temperature sensor
B3 Fuel temperature sensor
B6 Air intake temperature sensor
B21 Engine oil pressure switch
B47 Boost pressure sensor
B48 Ambient air (barometric) pressure sensor
B49 Crankshaft position sensor
B50 Camshaft position sensor
B51 Boost temperature sensor
B52 Common rail pressure sensor
B53 Exhaust gas recirculation valve position sensor
K2 Relay-glow plug
K7 Relay battery
K8 Relay safety
K33 Main relay
M15 Exhaust gas recirculation motor
R1 Glow plug
R3 Throttle volume
S1 Key switch
S9 Engine emergency stop switch
Y35 Suction control valve

Copyright
4001-25
IDLING CONTROL (AUTO/ONE-TOUCH)

P1 B26
H1
B27
S16
B25
P4 A1 B22 A2 1
700.1.04.01.1.23AX
1 Engine B27 Travel pilot pressure switch
A1 Computer/Controller H1 Audible warning device
A2 Engine controller P1 Instrument panel
B22 Swing pilot pressure switch P4 Monitor display
B25 Breaker pilot pressure switch S16 One touch idle
B26 Upper pilot pressure switch (yellow band)
2) Switching between auto idle and one- the machine was manoeuvred though the lever.
touch idle 8. LCD displays IDLING on the monitor during idling
control.
1. Pushing the knob switch (IN1) down and holding it
for 3 seconds will trigger the modes to toggle 3) Switching between auto idle and one-
between auto and one-touch. When the mode touch idle
switches, the ON/OFF display on the auto idle
1. When setting idling revolutions based on condi-
section of the LCD also switches, and the buzzer
tions described in 2). Switching between auto idle
buzzes for 3 seconds.
and one-touch idle, the controller transmits an
2. At the time of auto idle/one-touch idle selection, the
idling signal to the engine controller via CAN com-
previous setting will still prevail even after the key
munication. Also, a signal is sent to the monitor
switch was turned ON. (Previous data is retained.)
display via serial communication to display
3. The LCD will display ON/OFF status of auto idle. ON
IDLING on the screen.
on the display indicates the auto idle, OFF indicates
2. The engine controller, upon receiving the signal,
one-touch idle.
selects idling mode and adjusts engine speed to
4. If there occurs no handling through the lever for 5 that of the idling state.
seconds with auto idle turned ON (both attachment 3. The monitor displays IDLING on the LCD accord-
pressure switch and travel pressure switches are ing to the signal sent.
OFF), the engine speed automatically goes back to 4. When recovering from idle control based on the con-
the idling state. (For 5 seconds, the initial setting ditions described in 2). Circuit configuration, the
prevails. Programming is possible through adjusting controller transmits a signal to the engine controller
settings on the back panel for the duration between via CAN communication conveying the previous
1 and 30 seconds.) engine mode selection. Also, the serial transmission
5. During auto idle, if operated via lever while engine is that has been sent to the monitor for displaying
idling (either attachment pressure switch or travel IDLING on the screen will be terminated.
pressure switch is on), the engine speed automati- 5. The engine controller, depending on the mode sig-
cally goes back to the previous rate. nal received, switches the idling mode back to the
6. Even during auto idle, idling/recovery operation is previous mode and adjusts the engine speed.
attained by pressing the knob switch (one-touch 6. The monitor recognizes the termination of the idling
switch). signal transmission and stops the IDLING display
7. When auto idle is OFF (i.e. during one-touch idle), on LCD.
idling/recovery is attained by simply operating the
knob switch (one-touch idle switch), whether or not
Copyright
4001-26
4) Timing diagram
1) Timing diagram for auto idle ON/OFF selection
POWER 24V
0V
IN1 OFF (5V)

(KNOB SW) ON (0V)
AUTO IDLE
700-1-04-01-23 AY2
2) Timing diagram when auto idle is ON
IN1 OFF (5V)

(KNOB SW) ON (0V)
IN3 OFF (5V)

PRESSURE SW
(TRAVEL) ON (0V)
ENGINE SPEED
IDLE
700-1-04-01-23 AZ2
3) Timing diagram when auto idle is OFF
IN1 OFF (5V)

(KNOB SW) ON (0V)
IN2 OR IN3 OFF (5V)

ON (0V)
ENGINE SPEED
IDLE
700-1-04-01-23 BA2

Copyright
4001-27
BREAKER MODE
1. Alteration 2. Purpose
Optimization of pump current in mode S and in mode Although in the breaker mode up to now, pump cur-
L at the engine speed with the breaker being used. rent in mode S is to be applied at engine speed of
Pump current at engine speed of between 1200 and more than 1500 min-1, It spreads the speed range in
1500min-1 is applied from that in mode L to that in mode S so that the machine can be operated in less
mode S. than that of the flow-rate.
S14 Y7 R3
B25
A2
A1
700.1.04.01.23BB
1 Engine R3 Throttle volume
A1 Computer/Controller S14 Breaker/crusher switch
B25 Breaker pilot pressure switch
4) Operation
1. When the breaker mode switch is turned ON by
locker switch on the console (left side) and the
pressure switch in backup line is turned ON, it
controls to rotation of the breaker.
2. When the engine is rotated at a speed less than that
set for the breaker by controlling the throttle potenti-
ometer, engine speed will not be increased to the
speed set for the breaker even if the breaker is oper-
ated.
3. If the pressure switch in backup line is turned ON
regardless of breaker mode switch input, the pump
current is to be at the current value in mode S irre-
spective of operation of at that time. (However,
when the engine speed is less than 1200min-1,
pump current becomes that in mode L).

Copyright
4001-28
AUTO PREHEAD (GLOW CONTROL)

1) Alteration temperature, at the same time when the key switch
Only the circuit structure and the pre-glow control are is turned ON.
different. (Refer to time chart attached) It is the
same that the pre-glow starts, according to water
ENGINE CONTROLLER CONTROLLER ENGINE

KEY SWITCH
S1 B M ST
A2 GLOW
OFF PLUG
ON
ST
A1
1
ENGINE START
TO BATTERY RELAY KEY ON
CAN-H
GLOW RELAY
TO STARTER RELAY CAN-L

K2
GLOW RELAY
700.1.04.01.23BC
1 Engine K2 Relay-glow plug
A1 Computer/Controller S1 Key switch
3) Operation
1. When the key switch is turned ON, the engine seconds (below -5C) (23F).
controller (ECM) calculates pre-glow time from *The glow lamp time map is added from the engines
engine cooling water by using the attached map. meeting the emission control regulation of 3rd-
2. ECM turns ON the glow relay output during calcu- stage.
lated pre-glow time to transfer the glow lamp signal *Refer to attached sheets for the glow control time
through CAN communication circuit to the controller according to water temperature and for the time
displaying ENGPREHEAT on the monitor. chart.
3. The glow relay output continues regardless of ON/
OFF of the glow lamp signal.
4. After the engine has been started, it turns ON the
glow relay output again only when cranking the
engine. The glow lamp signal will not be trans-
ferred at this time.
5. When the key switch returns to ON from the start
(when cranking is completed), it calculates after-
glow time by using the attached map. The glow
lamp signal will not fee transferred at this time.
6. Since the control mentioned above starts immedi-
ately after the key switch has been turned ON,
ENG PREHEAT will not be displayed on the mon-
itor unless the pre-glow time passes more than 3

Copyright
4001-29
4) Water temperature control map
1) Glow lamp time (it transmits by CAN communication)
GLOW LAMP TIME (sec)
C
-4 14 32 50 68 86 104 F
ENGINE COOLANT TEMPERATURE
700-1-04-01-23 BD2
2) Pre-glow time
PRE GLOW TIME (sec)
C
-4 14 32 50 68 86 104 F
700-1-04-01-23 BE2
3) After glow time

AFTER GLOW TIME (sec)
C
-4 14 32 50 68 86 104 F
700-1-04-01-23 BF2

Copyright
4001-30
5) Timing chart
1) When in normal operation
START
KEY ON
SWITCH
OFF
ON
GLOW
LAMP OFF
ON
GLOW OFF
RELAY
GLOW LAMP TIME PRE GLOW TIME AFTER GLOW TIME
700-1-04-01-23 BG2
2) When the engine has been started after pre-glow is completed
START
ON
KEY
SWITCH OFF
ON
GLOW OFF
LAMP
ON
OFF
GLOW
RELAY
GLOW LAMP TIME PRE GLOW TIME CRANKING AFTER GLOW TIME
GLOW TIME
700-1-04-01-23 BH
3) When the engine has been started before glow lamp goes off
START
KEY ON
SWITCH
OFF
GLOW ON
LAMP
OFF
GLOW
ON
RELAY
OFF
GLOW LAMP TIME CRANKING AFTER GLOW TIME

PRE GLOW TIME GLOW TIME
700-1-04-01-23 BI2
Copyright
4001-31
AUTO WARM UP
S16 B26 R3
H1
A2 1
P4 A1
700.1.04.01.23BB
1 Engine H1 Audible warning device
A1 Computer/Controller P4 Monitor display
A2 Engine controller R3 Throttle volume
B26 Upper pilot pressure switch (yellow band) S16 One touch idle
2) Operation
1. A coolant temperature sensor is installed inside 5. Once auto warm-up control is cancelled, the control-
the engine. The signal from this sensor goes out ler does not initiate auto warm-up control again
to the engine controller and is converted into a unless key switch is turned from OFF to ON.
temperature value. The engine controller then 6. While controller is executing the auto warm-up con-
transmits the coolant temperature data to the control, an AUTO WARM UP message is displayed on
troller via CAN communication. the monitor's LCD.
2. If the coolant temperature is below 50C (122F)
after engine starts, the controller transmits the auto
warm-up signal to the engine controller via CAN
communication.
3. The engine controller executes the auto warm-up
control upon receiving the signal transmission from
the controller.
4. The controller terminates the auto warm-up con-
trol on the following conditions. The engine con-
troller terminates the auto warm-up control once
the command is cancelled.
*When one of the following switches turns on: attach-
ment pressure switch, travel pressure switch, and
knob switch (one-touch idle switch).
*When throttle volume is changed.
*When engine speed stays above 1800 min-1 for 3
minutes.

Copyright
4001-32
3) Auto warm-up control
AUTO WARM-UP AUTO WARM-UP
COMPLETE COMPLETE
ENGINE SPEED (MIN -1)
ENGINE SPEED (MIN -1)

TIME TIME
THROTTLE DURATION OF OPERATION THROTTLE DURATION OF OPERATION
POSITION POSITION
700-1-04-01-23-BK2
OVERHEAT PROTECTION
1) Purpose water temperature exceeds 100C (212 F).
It is the function protecting the engine by restriction of * Waning OVER HEAT is to be displayed on the
fuel injection quantity which in turn reduces engine monitor in actual machine when temperature
out put forcibly when water temperature has kept on exceeds 105C (221 F).
rising.
The control starts functioning at the moment when
2) Water temperature-fuel injection quantity
Q RESTRICTION BY OVERHEAT PROTECTION (6HK1)
120
100
Q RESTRICTION RATE (%)
80
60
40
20
0
90 100 110 120 130 140 C
194 212 230 248 266 284 F
330.1.04.01.24BL2

Copyright
4001-33
ATMOSPHERIC PRESSURE COMPENSATION

1) Purpose to prevent the engine from being damaged (preven-
Purpose is to prevent black smoke from increasing tion of over-revolution of turbo) due to temperature
because an excessive fuel is fed in the combustion rise of exhaust gas.
chamber of the engine due to lack of intake air and
2) Map
ALTITUDE _ TORQUE
OUTPUT DROP DUE TO OUTPUT DROP DUE TO

(lbf-ft) (N-m) CHANGE IN ENVIRONMENT FUEL COMPENSATION
737
700
663
TORQUE
626
590
553
516
479
442
405
368
(m)
1640 3280 4921 6561 8202 9842 11482 13123 (ft)
ALTITUDE
330.1.04.01.24BM2

Copyright
4001-34
CONTROL WHEN STARTING ENGINE

1) Starting control (by monitoring water
temperature
1. Purpose
When water temperature is below 0C (32F), Pur-
pose is to ensure starting performance of the engine
in cold temperature by making fuel injection accord-
ing to water temperature.
2) Long cranking control
1. Purpose
While aiming at reduction of black smoke when start-
ing engine, the purpose is to improve starting per-
formance by increasing starting Q (fuel injection) by
fixed quantity, as a backup when sufficient starting Q
(fuel injection) will not be injected in such case
where an injector is worn out, after the specified-
time has passed from the time when cranking was
started.
2. Time chart
START
KEY ON
SWITCH 1.5 sec
OFF
ENGINE IDLING
SPEED CRANKING
0
UP-Q
STARTING Q ST-Q
NL-Q
0
ST-Q: Standard starting Q, UP-Q: Starting Q after increase of quantity, NL-Q: Q in no lord
700.1.04.01.23BN2
3) Starting control when number of effective cylinders is reduced

1. Purpose 2. Operation
Purpose is to correct fuel injection quantity to assure
1. Fuel quantity to be injected by faulty injectors is
starting performance of the engine with a view to
allotted to other normal injectors (total quantity is to
escaping in an emergency when a certain number
be the same).
of stopped injectors are detected by trouble diagno-
sis. 2. In case where number of faulty cylinders is over half
of the total numbers, increase of fuel injection quan-
tity will not be performed (to prevent the engine from
being damaged by forcible starting.
3. Number of cylinders-Correction factor
Number of effective cylinders 6 5 4 3 2 1 0

Correction factor 1.0 1.2 1.5 2.0 1.0 1.0 1.0

Copyright
4001-35
CONTROL WHEN STOPPING ENGINE

1. Operation
1) Turn OFF the key switch. 5) EGR valve is instructed so that it is fully closed
2) When the engine controller recognizes that the and its initial point is corrected.
key is turned OFF, steps 3) through 5) below 6) After steps 3) through 5) have been completed,
are carried out simultaneously. information such as history failure is written in
3) Fuel injection quantity stops to be calculated. EPROM in the ECM.
4) Suction control valve (SCV) is instructed so that 7) Turn OFF the main relay and turn OFF the
it is fully closed. power supplied to ECM.
EMERGENCY STOP OF THE ENGINE

1. Alteration
In current type 3 (engine meeting emission control regulation of 2nd-stage), depression of the emergency stop
switch allows the engine stop motor to rotate to the stop position by way of the relay and allows the engine gov-
ernor to control for stopping engine by the engine stop signal from the engine controller (ECU).
In the next type (engine meeting emission control regulation of 3rd-stage), depression of the emergency stop
switch allows the controller to transfer engine stop signal to ECM controlling the engine to be stopped.
2. Circuit configuration
MONITOR DISPLAY
24V-OUTPUT ENGINE STOP

P4 CN6-21(PNP)
WR501
1
BrR530
CN3-43
S9 A1 A2 ENGINE
SWITCH CONTROLLER ENGINE CONTROLLER

(EMERGENCY STOP)
700.1.04.01.23BO
1 Engine P4 Monitor display
A1 Computer/Controller S9 Engine emergency stop switch
3. Operation
1) Depression of emergency stop switch on the
monitor display allows the output signal from
transistor in the controller to be turned ON and
at the same time, the engine stop signal is
transferred from the controller to the engine
controller (ECM)
2) ECM performs stopping control for the engine.

Copyright
4001-36
FUNCTION LOCKING
F21
K7
F4
F23
Y2
G1 S51
700.1.04.01.23BP
F4 Fuse 10 A; hydraulic function cancellation lever G1 Battery
switch K7 Relay battery
F21 Fuse box S51 Hydraulic function cancellation lever switch
F23 Fuse 65 A; main fuse for F3 to F10 and F13 to Y2 Pilot pressure solenoid valve (blue band)
F20 circuits
2) Timing diagram
KEY
SWITCH
POWER
GATE BAR RUN

POSITION STOP
LEVER LOCK
SOLENOID VALVE
OPERATION ENABLE
DISABLE
700-1-04-01-23 BQ2
3) Operation
1) By positioning the gate lever on cab console (left) 3) By positioning the gate lever toward entering/leav-
toward operation (gate lever sticks out when this is ing cab (gate lever stays housed), the limit switch
done) while the machine is powered on, the limit will be turned OFF (open) and the lever lock sole-
switch will be turned ON (closed) and the lever lock noid valve turns OFF.
solenoid valve will be ON. 4) When the lever lock solenoid valve turns off, pres-
2) When the lever lock solenoid valve is ON, pressure cannot reach the pilot line. Thus the operation
sure can reach the pilot line, enabling the machine of the machine will be disabled.
to operate.
Copyright
4001-37
POWER BOOST
A2
B42
A
B44
B27
Y5
B25
A1
700.1.04.01.23BR
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
Automatic power boost (*)

Mode Auto
(34.3 37.3 MPa) (4974 5410 psi)
H mode Automatic power boost (*)
(Pressure) (34.3 37.3 MPa) (4974 5410 psi)
S mode Automatic power boost (*)
(Pressure) (34.3 37.3 MPa) (4974 5410 psi)
L mode Constant power boost (*)
(Pressure) (34.3 37.3 MPa) (4974 5410 psi)
* When the travel pilot pressure switch (B27) or the optional breaker pilot pressure switch (B25) is activated, power
boost is deactivated.
3) Operation If the pump pressure (P1) or (P2) is greater than 300
bar (4351 psi) and the load ratio is within a range of
When operating in H or S mode, the computer (A1)
5% for 2 seconds, the computer (1) activates the
records the ratio between:
power-up solenoid valve (yellow band) (Y5) for 8 sec-
- The engine load transmitted by the engine con-
onds, which increases the main pressure.
troller (A2).
- The hydraulic circuit load transmitted by the When the travel pilot pressure switch (B27) or the
pump pressure sensors (P1) (B42) and (P2) optional pilot pressure switch (B25) is activated, the
(B44). computer (A1) deactivates the power-up solenoid
valve (yellow band)(Y5).

Copyright
4001-38
SWING BRAKE
S8
B22
B26
S1 B27
B42 1
B44
P1 Y3
A1
700.1.04.01.23BS
1 Swing brake B44Pump pressure sensor (P2) (yellow band)
A1 Computer P1 Instrument panel
B22Swing pilot pressure switch S1 Key switch
B26Upper pilot pressure switch (yellow band) S8 Swing brake switch
B27Travel pilot pressure switch Y3 Swing brake solenoid valve (pink band)
B42Pump pressure sensor (P1)
2) Operation of the swing brake control
1) Overview
1. Pressing the swing lock switch on monitor display will turn on the red LED, activating the swing lock con-
trol. Pressing the swing lock switch again will turn off the LED, and the swing lock is deactivated.
2. During swing lock control, controller's transistor output turns on and the mechanical brake that is built in
the swing motor turns on.
3. The ON/OFF state of the swing lock holds when turning the key switch from OFF to ON.

Copyright
4001-39
2) Timing diagram
KEY SWITCH
POWER
SWING LOCK
SWITCH
OUT
(IN1)
SWING
PRESSURE
SWITCH (IN3)
SWING LOCK
LED
700-1-04-01-23 BT2
3) Swing brake auto control

1) Overview
The auto control of the swing brake takes place when the swing lock is OFF.
The auto control also releases the mechanical brake automatically during a digging operation as well as during
swing operation. If the operation is halted, the auto control turns on the mechanical brake automatically.
The detailed conditioning for ON/OFF of the swing mechanical brake is shown below.
The swing brake will be turned OFF based on the following conditions.
1. Pressure switch (swing) is ON
2. P1>15 MPa (2175 psi) or P2>15 MPa (2175 psi)
The swing brake will be turned ON based on the following conditions.
1. Pressure switch (attachment) stays OFF for 5 seconds
2. Key switch is OFF
The swing mechanical brake will be deactivated once when the pump delivery pressure (P1 or P2) grows over
15 MPa (2175 psi) during travel. However, it will take effect in 5 seconds.

Copyright
4001-40
TRAVEL MODE
P1
A1
B42
B44
S2 B43
B27
Y4
P4
700.1.04.01.23BU
A1 Computer P1 Instrument panel
B27Travel pilot pressure switch P4 Monitor display
B42Pump pressure sensor (P1) S2 Travel mode switch
B43Pressure sensor (nega-cont.) Y4 2 stage travel solenoid valve (red band)
B44 Pump pressure sensor (P2) (yellow 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
700-1-04-01-23 BV

Copyright
4001-41
3) Operation Travel speed II selected
When the starter motor switch is positioned in the 1. When the pressure of the pumps P1 or P2 is less
ON position, the 1st speed is selected by default. than 40 bar (580 psi), the output from the compu-
ter (OUT)(A1) of the 2 stage travel solenoid valve
Every time the travel mode switch is pressed (S2),
(Y4) is deactivated (1st speed).
the computer (A1) registers a signal (IN1: 0 volts).
2. When the pressure of the pumps P1 or P2 is greater
The computer (A1) changes the travel speed in the than 40 bar (580 psi), the output from the computer
following way I-> II, II -> I and transmits the modifica- (OUT)(A1) of the 2 stage travel solenoid valve
tions to the monitor display (P4). (Y4) is activated (2nd speed).
When the attachment controls are operated, the out-
Travel speed I selected
put from the computer (OUT)(A1) of the 2 stage
The output from the computer (OUT)(A1) of the 2 travel solenoid valve (Y4) cannot be activated or
stage travel solenoid valve (Y4) is deactivated (1st deactivated.
speed). 3. When the travel pressure is greater than 260 bar
(3771 psi), the travel motor displacement change
spool is pushed back and the swash plate angle is
in high displacement (1st speed).
4. Travel speed II may still be selected if necessary, for
example for cleaning tracks.

Copyright
4001-42
POWER SHUT-OFF DELAY

1) Alteration
Power being supplied to the engine controller is shut off via main relay and at the same time, the battery relay
stops to be energized shutting off the power to the machine.
Delayed operation time is 4 seconds (immediately after 0 min-1 of engine speed) from the key is turned ON to
OFF, and approximately 7 seconds after starting to stopping the engine.
BATTERY RELAY
KEY
SWITCH KEY
S1 SWITCH
B M ST
A1 CONTROLLER OFF - + - + K7
ON
ST
IS-IGKEY
IS-START
OS-MAINR
OS-MAINR
MAIN
K33 RELAY
PS-+B
PS-+B
A2 ENGINE CONTROLLER
700.1.04.01.23BY
A1 Computer/Controller K33 Main relay
A2 Engine controller S1 Key switch
K7 Relay battery
3) Timing diagram
ON
KEY SWITCH S1
OFF
ENGINE SPEED 0
7 sec.
MAIN RELAY ON
K33 OFF
4 sec. 4 sec.
ON
BATTERY RELAY K7
OFF
700-1-04-01-23BZ

Copyright
4001-43
FUEL SUPPLY PUMP CONTROL (AUTOMATIC STOP) OPTION

1) Control outline
The controller detects fuel quantity by fuel sensor allowing the fuel supply pump to make an automatic stop when
the fuel tank is filled up.
Fuel tank Fuel sensor Battery relay
Fuse 20A
Battery
Rf
Controller
R5
SIG K7
GND
G1
A1
Re
S61
Main relay
(for fuel supply pump) (Manual) (Automatic)
3-position roker
switch
(*1)
Fuel supply K30
pump)
K31 CN6-17(PNP)
Motor
P BZ
M14 GND
(*2)
Switch
Relay
(automatic)
(*1) Fuel supply pump: Made by JABSCO (manufacturer in UK).

(*2) Buzzer: Same buzzer used as travelling alarm to MSR.
700-1-04-01-23CK3
*All components other than controller, battery, and fuel level sensor are stored in the tool box (in house in front-
right).
A1 Computer/controller
G1 Battery
K7 Relay battery
K30 Refuel pump relay
K31 Refuel pump stop relay
M14 Fuel feed pump motor
R5 Fuel sensor
S61 Refuel pump switch
Copyright
4001-44
3) Operation
1) Automatic stop
1. Assemble it with the switch built-in the fuel supply pump turned ON. (No control is required for customers.)
2. Put the 3-position rocker switch to Automatic side after the key switch has been turned ON. (Center: OFF,
Automatic Alternate: ON, Manual: Momentary ON.)
3. This operation allows electric power to be supplied to the fuel supply pump by way of both relays of auto
and main so that fuel is pumped up into the fuel tank out of an fuel drum.
4. The controller is always monitoring quantity of fuel remained in the tank by using fuel sensor.
5. When the fuel sensor comes to the full level (Rf) position or above, the controller gives output signal to
the relay (auto). (NPN output.)
6. The relay (auto) is switched over by the output signal allowing the power supplied to the fuel pump to be
shut off.
7. At the same time, the buzzer sounds to inform that refueling has been made an automatic stop.
8. When the 3-position rocker switch is turned OFF, the buzzer stops sounding and automatic refueling
mode is released.
9. Even if the automatic refueling mode has been released, the controller keeps on sending output signal to
the relay (auto) if the position of fuel sensor is at the full level (Rf) or above.
10. The controller stops giving the output signal to the relay (auto) when the fuel sensor comes down below
the full level (Rf) position.
2) Manual refueling
1. In case where automatic refueling fails functioning due to troubles such as in the fuel sensor, the control-
ler, and the relay (auto).
2. In case where a machine cannot fill up the fuel to its full by automatic refueling.
3. Supply fuel while monitoring fuel gauge with the 3-position rocker switch turned to manual side (momen-
tary).
4. Power is supplied to the fuel supply pump via the relay (main) from the manual switch so that fuel can be
supplied to the tank.

Copyright
4001-45
POWER TRANSISTOR PROTECTION

CONTROLLER
24V (PNP)
17 FUEL SUPPLY PUMP
18 FEEL SWING (NA) BEACON (EU)
19 TRAVEL ALARM
21 ENGINE STOP (EMERGENCY STOP)
22
27 SWING BRAKE
28 2-SPEED TRAVEL
2-
2
29 CUSHION
30
31 SWING SHUT-OFF
32 BACKUP 1
20 BACKUP 2
700-1-04-01-23 CL
In the event that a solenoid valve or a relay develops a short circuit, the power transistor output will be shut off in
order to protect the controller. A ELEC PROBLEM message will be displayed during the failure. Perform the
service support check to have the location of failure pinpointed and displayed.
Then follow the display result and inspect the wire or the equipment that seems to be experiencing the failure.

Copyright
4001-46
MONITOR DISPLAY
3 2 1
CD00E007A2
1. Fuel level indicator 3. Coolant temperature indicatora2
2. Hydraulic oil temperature indicator
Normal Display
1.Radiator coolant temperature
A1
A2
B1
P4
SCALE
C
104 122 140 158 176 194 212 230 F
COOLANT TEMPERATURE
700-1-04-01-23CN2
A1 Computer/controller B1 Coolant temperature sensor
A2 Engine controller P4 Monitor display
2) Operation
1. Coolant temperature sensor is installed inside the engine. The signal from this sensor (Vtw) will be trans-
mitted to engine controller as an analog signal (voltage).
2. The engine controller converts the transmitted signal into a temperature value. It then transmits this cool-
ant temperature data to the controller via CAN communication.
3. When the controller receives the signal, it uses to the graph shown above to determine the bar graph dis-
play level for the signal level. The controller then transmits the data to monitor display via serial commu-
nication.
4. When the monitor display receives transmission, it reflects the data received as a bar graph on the dis-
play.
5. OVER HEAT will be displayed when level 8 lights up on the scale. (The engine does not stop.)

Copyright
4001-47
2. Hydraulic oil temperature
P4
B2
A1
SCALE
68 86 104 122 140 158 176 194 212 F
OIL TEMPERATURE
700-1-04-01-23CO
A1 Computer/controller P4 Monitor display
B2 Hydraulic oil temperature sensor
2) Operation
1. Hydraulic oil temperature sensor is installed inside the suction piping. The signal from this sensor (Vto)
will be transmitted to controller as an analog signal (voltage).
2. When the controller receives the signal, it first converts it into a temperature value. The controller then
uses to the graph shown above to determine the bar graph display level for the signal level. The controller
then transmits the data to monitor display via serial communication.
play.
4. OVER HEAT will be displayed when level 8 lights up on the scale.

Copyright
4001-48
3. Fuel level
P4
B3
A1
700-1-04-01-23 CP2
A1 Computer/controller P4 Monitor display
B3 Fuel temperature sensor
Fuel sensor Input voltage

Remaining fuel (L) Bar graph
resistance (W) Vfl (V)
437 < 10 to 18 0.283 to 0.802 8
379 to 436 18 to 24 0.802 to 1.321 7
325 to 378 24 to 30 1.321 to 1.698 6
266 to 324 30 to 37 1.698 to 2.123 5
192 to 265 37 to 46 2.123 to 2.594 4
106 to 191 46 to 61 2.594 to 3.208 3
53 to 105 61 to 75 3.208 to 3.774 2
< 52 75 to 80 3.774 < 1 (Refill fuel)
2) Operation
1. Fuel sensor is installed inside the fuel tank. The signal from this sensor (Vfl) will be transmitted to the con-
troller as an analog signal (voltage).
2. When the controller receives the signal, it uses to the graph shown above to determine the bar graph dis-
play level for the signal level. The controller then transmits the data to monitor display via serial commu-
nication.
play.

Copyright
4001-49
Message Display
START MESSAGES DISPLAYED
KEY SWITCH ON KEY SWITCH AND ENGINE RUNNING
ELEC PROBLEM
LOW FUEL ALTERNATOR
LOW OIL PRESS
LOW COOLANT
AIR FILTER
YES
WARNING OVER HEAT
ENG PRE HEAT ENG IDLING

NO SERVICE DUE AUTO WARMUP
POWER UP
MODE DISPLAYS TRAVEL MODE DISPLAT

I : LOW-SPEED TRAVEL
H : SUPER HEAVY MODE
II : HIGH-SPEED TRAVEL
S : REGULAR MODE
AUTO IDLE DISPLAYS
L : FINISHING MODE
ON : AUTO IDLE
AUTO : AUTO MODE
OFF : ONE-OUCH IDLE
700-1-04-01-23 CQ
Buzzer Message Display Meaning and Measures to be Taken

ENG PRE HEAT Engine warm up (glow) is indicated.
AUTO WARN UP Indicates automatic warming of the engine. The automatic warming is re-
leased by moving the throttle volume or operation levers.
ENG IDLING Indicates the engine is running at low idling.
POWER UP Indicates the system is in automatic digging power up.
SERVICE DUE At the time of every 500 hour service intervals, one minute indication ap-
pears for 5 times when the engine starts.
Sounds LOW FUEL Indicates the fuel level is very low. Add fuel.
Sounds LOW COOLANT Indicates the coolant water level is low. Add coolant water.
Sounds LOW OIL PRESS Indicates the engine oil pressure is abnormally low. Stop the engine, check
engine oil level and add oil.
Sounds OVER HEAT Indicates the engine coolant temperature or hydraulic oil temperature abnor-
mally rises. Put the engine in low idling and reduce water or oil temperatures.
Check the radiator & oil cooler.
Sounds ALTERNATOR Indicates problems in battery charging system. Check the electric circuit.
Sounds ELEC PROB- Indicates electric problems (short circuit or disconnection) in the electric sys-
LEM tem.
Check the electric circuit.
Sounds AIR FILTER Indicates the air filter clogged.
Air filter are cleaned or exchanged promptly.

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

Access to monitor displays
Normal A Service support

display display
B
Status B Diagnostic B Usage B

Reset
(a) display trouble history
D E
(b) C
CHK1 DIAG1 HR 12 HR 1 RST1
C C C C
F
CHK5 CHK2 DIAG2 D HR 11 HR 2
G C C C C
CHK6 CHK3 DIAG3 D HR 10 HR 3
C C C C
CHK4 DIAG4 HR 9 HR 4
C C C C
CHK5 DIAG5 D HR 8 HR 5
C C C C
DIAG6 D HR 7 HR 6
C C
700-1-04-04-07 AA2
a) Bar graph (oil temperature, coolant temperature, fuel amount)
b) Mode (Travel, work, idle)
Operating Switches
A. Switched when the travel & work mode switch is G. Short circuit automatic detection display (buzzer)
ON for more than 3 seconds when the travel mode switch is ON for more
B. Switched when the auto mode switch is ON than10 seconds
C. Switched when the buzzer stop switch is ON
D. Data cleared when the work mode switch is ON
for more than 10 seconds (When the data is
cleared, the buzzer buzzes.).
E. With the buzzer stop switch ON, reset function
selection; with the travel mode switch ON, reset;
with the work mode switch ON for more than 10
seconds, data reset (When the data is reset, the
buzzer buzzes.)
F. Output check when the protection circuit is trig-
gered with the travel mode switch ON

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Machine condition
1. Machine condition CHK1
MODE: Travel - work
CHK MODE II H ENG 2000 rpm
P1: Main pump (P1) pressure
1
P2: Main pump (P2) pressure
P1 030.0 MPa I 0300 mA
N: Negative pressure (N)
ENG: Engine rpm
P2 030.0 MPa WT 0080 C
I Pump control current value
Fan motor current value (when Travel
N 03.00 MPa OT 0055 C Mode switch ON))
WT: Radiator coolant temperature
Hydraulic oil temperature
OT: Intake air temperature (only when Travel
Mode switch ON))

R: Engine load ratio
CHK MODE II H TR1 0000
FT: Fuel temperature
2
R 0080 % TR2 0000 Boost temperature (only when Travel
Mode switch ON)
FT 0000 C TR3 0000 TV: Throttle volume degree of opening
TR1 Controller transistor output
TV 0100 % TR4 0000 TR2 Controller transistor output
Transistor output: 0 = OFF; 1 = ON
TR1 0 0 0 0 TR2 0 0 0 0 TR3 0 0 0 0

Swing brake Battery relay Free swing (NA)
2-speed travel Soft/hard (EU,NA) Engine stop
Hyd Fan
Travel alarm Swing shutoff reverse(CX460to800)
Boosting High dump(CX700/800) X
TR4 0 0 0 0
Fuel supply pump
(EU)(NA=NON)
X
X
X
X: Not used

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4001-52
SW1 to SW3 Controller switch input (sensor
CHK MODE II H SW4 0000 switch)
3 SW4 to SW7 Controller switch input (operation
SW1 0000 SW5 0000 switch)
SW2 0000 SW6 0000
SW3 0100 SW7 0000
Pressure switch electronic control box switch inputs: 0 = OFF; 1 = ON
SW1 0 0 0 0 SW2 0 0 0 0 SW3 0 0 0 0

Attachment press. SW Air cleaner Battery charge
Travel press. SW Coolant SW Engine stop
Swing press. SW 2nd auxiliary press. SW X
Auxiliary pressure SW Boom up press. SW X
SW4 0 0 0 0 SW5 0 0 0 0 SW6 0 0 0 0

Soft/hard (EU, NA) Swing lock Windshield washer
Travel alarm change
Free swing (NA) Emergency stop (EU, NA)

High dump Working lamp Breaker mode
One-touch idle Wiper L/M mode
SW7 0 0 0 0
Anti-theft protection
Key switch
Fan reverse(CX460 to
800)
X
X = Not used
FS: Fuel surface sensor resistance (W)
CHK MODE I H TG 0000 rpm
AC: A/C control temperature
4
TR5: Engine oil pressure (kPa)
FS 0080 () BP 0000 MPa TG: Target engine speed (min-1)
BP: Boom bottom pressure (MPa)(Europe only)
AC 0005 SP1 0000 Overload alarm pressure display (only when
beacon switch ON)
TR5 0010 SP2 0000 SP1 Atmospheric pressure (kPa)
SP2 Boost pressure (kPa)
AC 0 0 0 4
1: below 30C
2: between 30C and 45C

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R Engine load ratio

FT Fuel temperature
5
TV Throttle volume degree of opening
R 0080 % TR2 0001 TR1 Transistor output status when over-current
detected
FT 0000 C TR3 0000 TR2 Transistor output status when over-current
detected
TV 0100 % TR4 0000 TR3 Transistor output status when over-current
detected
1. While the travel mode switch is ON on the TR4 Transistor output status when over-current
CHK2 screen, the output status when over-cur- detected
rent has been detected in the past is displayed.
2. Data is cleared by resetting the trouble code on
the trouble diagnosis screen.
3. The example in the figure above shows that a
travel alarm, swing braking, and battery relay out-
put were being carried out when over-current was
detected.
R Engine load ratio

FT Fuel temperature
6
TV Throttle volume degree of opening
R 0080 % TR2 0000 TR1 Results of automatic short detection
TR2 Results of automatic short detection
FT 0040 C TR3 0000 TR3 Results of automatic short detection
TR4 Results of automatic short detection
TV 0100 % TR4 0000
1. Shorts are automatically detected if the key

switch is switched ON while the one-touch idle
switch is ON.(* The engine must not be running.)
2. If you switch to the CHK2 screen and switch
the travel mode switch ON for 10 seconds, the
automatic detection results are displayed.
3. The example in the figure above shows that the 2-
speed travel line is currently shorted.
4. This data is cleared when the key switch is
switched OFF.
* For CHK1 to 6, the units can be switched with
the work lamp switch. Status held as is when key
OFF

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4001-54
Diagnostic code
2. Detection of engine failures DIAG1 to 6
1) Trouble diagnosis (DIAG1), Engine system current trouble status (trouble code)
E: Engine system trouble code

DIAG MODE II H E 0000 For the engine error code list, refer to
1 Page 57
E 0118 E 0000 Example Water temperature sensor abnormality
E 0000 E 0000
E 0000 E 0000
2) Trouble diagnosis (DIAG2), Engine system past trouble status (trouble code)
E: Engine system trouble code

DIAG MODE II H E 0000
Example CAN time-out abnormality
2
E 2106 E 0000
E 0000 E 0000
E 0000 E 0000
3) Trouble diagnosis (DIAG2), Engine system past trouble status (time of trouble: controller hour meter
value)
E: Engine system trouble code trouble

DIAG MODE II H E 0000 code.
3 Example CAN time-out abnormality: Abnormality
E 0200 E 0000 occurred at 200 hours
1. Switching the work mode switch ON for longer

E 0000 E 0000 than 10 seconds clears the data on past trouble
codes and their times of occurrence.
E 0000 E 0000
2. The time displayed with DIAG3 is the time at
which the first trouble code occurred after the data
was cleared. (The times for the second and sub-
sequent trouble codes are not recorded.)
3. When the data is cleared, the DIAG2 and
DIAG3 data is stored into EEPROM.

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4) Trouble diagnosis (DIAG5), Machine main unit system Current trouble status (trouble code)
M: Machine main unit system trouble code

DIAG MODE II H M 0000
Example Oil temperature sensor abnormality
4
M 0020 M 0000
M 0000 M 0000
M 0000 M 0000
M0000: No defect
M0010: Transistor output short
M0020: Oil temperature sensor
M0030: Fuel surface sensor
M0040: Pressure sensor (P1)
M0050: Pressure sensor (P2)
M0060: Pressure sensor (N)
M0070: Key switch
M0080: Pressure switch (attachments or travel)
M0090: CAN communications error
M00A0: Controller reset
M00B0: Engine controller mismatch
M00C0: Boom pressure sensor (Europe)

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5) Trouble diagnosis (DIAG5), Machine main unit system Past trouble status (trouble code)

Example Oil temperature sensor abnormality, fuel
5 sensor abnormality
M 0020 M 0000
Fuel sensor abnormality: abnormality
M 0030 M 0000 occurred at 1000 hours
M 0000 M 0000
6) Trouble diagnosis (DIAG6), Machine main unit system Past trouble status (time of trouble: controller
hour meter value)

Example Oil temperature sensor abnormality:
6 Abnormality occurred at 2000 hours
M 2000 M 0000 Fuel sensor abnormality: Abnormality
occurred at 1000 hours
M 1000 M 0000 1. Switching the work mode switch ON for longer
than 10 seconds clears the data on past trouble
M 0000 M 0000 codes and their times of occurrence.
2. The time displayed with DIAG6 is the time at
which the first trouble code occurred after the
datawas cleared. (The times for the second and
subsequent trouble codes are not recorded.)
3. When the data is cleared, the DIAG5 and
DIAG6 data is stored into EEPROM.

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4001-57
7) Engine error code list
Engine Type Restora-

Trouble
Trouble contents 6S/ Monitor display tion from
code 4H BH
6W troubles
0087 No pump pressure send (fuel leak) O O O ELEC PROBLEM 1

0088 Common rail pressure abnormality O O O ELEC PROBLEM 1
(1st stage. 2nd stage)
0089 Common rail pressure abnormality O O O ELEC PROBLEM 1
(pump overpressure send)
0090 SCV drive system cut line, +B short, ground O O O ELEC PROBLEM 2
short
PCV1 drive system cut line or ground snort
0092 PCV1 drive system +B short -- -- O ELEC PROBLEM 1
0107 Atmospheric pressure sensor abnormality O O O ELEC PROBLEM 2
(low voltage abnormality)
0108 Atmospheric pressure sensor abnormality O O O ELEC PROBLEM 2
(high voltage abnormality)
0112* Intake air temperature sensor abnormality O O O ELEC PROBLEM 2
0113* Intake air temperature sensor abnormality O O O ELEC PROBLEM 2
0117* Water temperature sensor abnormality O O O ELEC PROBLEM 2
0118* Water temperature sensor abnormality O O O ELEC PROBLEM 2
0182* Fuel temperature sensor abnormality O O O -- 2
0183* Fuel temperature sensor abnormality O O O -- 2
0192 Common rail pressure sensor abnormality O O O ELEC PROBLEM 2
0193 Common rail sensor abnormality O O O ELEC PROBLEM 2
0201 Injection nozzle #1 drive system open line O O O ELEC PROBLEM 1
0205 Injection nozzle #5 drive system open line -- O O ELEC PROBLEM 1
0206 Injection nozzle #6 drive system open line -- O O ELEC PROBLEM 1
0219 Overrun O O O ELEC PROBLEM 2
0237 Boost pressure sensor abnormality O O O ELEC PROBLEM 2
0238 Boost pressure sensor abnormality O O O ELEC PROBLEM 2
(nigh voltage abnormality)
0335/ Crank sensor abnormality O O O ELEC PROBLEM 1
0336 (no signal, abnormal signal)
0340/ Cam (G) sensor abnormality O O O ELEC PROBLEM 1
0341 (no signal, abnormal signal)

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Engine Type Restora-

Trouble
Trouble contents 6S/ Monitor display tion from
code 4H BH
6W troubles
0380 Glow relay abnormality O O O ELEC PROBLEM 1

0487 EGR position sensor abnormality O O O ELEC PROBLEM 1
0488 EGR valve control abnormality O O O ELEC PROBLEM 2
0522 Engine oil pressure sensor abnormality O O O ELEC PROBLEM 1
0523 Engine oil pressure sensor abnormality O O O ELEC PROBLEM 2
0601 ROM abnormality O O O ELEC PROBLEM 2
0603 EEPROM abnormality O O O ELEC PROBLEM 2
0606 CPU abnormality O O O ELEC PROBLEM 2
0611 Charge circuit 1 abnormality O O O ELEC PROBLEM 2
0612 Charge circuit 2 abnormality O O O ELEC PROBLEM 2
1093 No pump pressure send (2nd stage) -- -- O ELEC PROBLEM 1
1095 Pressure limiter open O O O ELEC PROBLEM 1
1112* Boost temperature sensor abnormality O O O -- 2
1113* Boost temperature sensor abnormality O O O -- 2
1173 Overheating O O O -- 2
1261 Injection nozzle common 1 drive system O O O ELEC PROBLEM 1
abnormality
1262 Injection nozzle common 2 drive system O O O ELEC PROBLEM 1
abnormality
1291 PCV2 drive system cut line or ground short -- -- O ELEC PROBLEM 2
1292 PCV2 drive system +B short -- -- O ELEC PROBLEM 1
1345 Cam (G) sensor out of phase O O O ELEC PROBLEM 1
1625 Main relay system abnormality O O O ELEC PROBLEM 2
1630 A/D conversion abnormality O O O ELEC PROBLEM 2
1631 5V power supply 1 voltage abnormality O O O -- 2
1632 5V power supply 2 voltage abnormality O O O ELEC PROBLEM 2
2104 CAN bus abnormality O O O ELEC PROBLEM 2
2106 CAN time-out abnormality O O O ELEC PROBLEM 2
1 Item marked with O in the table means that it can be applied.
2 Restoration from troubles.
There are 2 ways as illustrated below to restore it from troubles.
In order to clear an error code depending on circumstances, control of main switch is necessary as follows:
1) Turn ON the key switch to start the engine, hold the switch for 10 second as it is turned ON, and then turn it
OFF to restore it to be normal.
2) Turn ON the key switch, hold the switch for 10 second as it is, and then turn it OFF to restore it to be normal
3 For temperature sensors marked with * in the table however, hold the key switch for 3 minutes after it has
been turned ON, then turned it OFF.

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Machine history
1. Screen HR1
ENG : Hour meter (alternator generation time)
WRK : Machine operation time (attachment ON or travel
ON)
U : Attachment operation time
T : Travel operation time
S : Swing operation time
PU : Boost time
BRK : Breaker usage time
2. Screen HR2
H : H mode usage time
S : S mode usage time
L : L mode usage time
A : A mode usage time
WT : Maximum coolant temperature
OT : Maximum oil temperature
FT : Maximum fuel temperature
3. Screen HR3
1 : Controller power supply ON time
2 : 1-speed mode usage time
3 : 2-speed mode usage time
4 : Travel only time
5 : Maintenance time
(Overseas: Reset with Buzzer Stop switch)
6 : *****
7 : *****
4. Screen HR4
[P1 pressure distribution]
1 : Time P1 10 MPa or less
2 : Time P1 10 to 15 MPa
7 : Time P1 35 MPa

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5. Screen HR5
[P2 pressure distribution]
1 : Time P2 10 MPa or less
7 : Time P2-35 MPa
6. Screen HR6
[Engine speed distribution]
1 : Time N 1175 min-1 or less
2 : Time N 1175 to 1375 min-1
3 : Time N 1375 to 1575 min-1
4 : Time N 1575 to 1775 min-1
5 : Time N 1775 to 1975 min-1
6 : Time N 1975 to 2175 min-1
7 : Time N 2175 min-1 or more
7. Screen HR7
[Coolant temperature distribution]
1 : Time TW 77C or less (Marks 1 and 2 on the bar
graph)
2 : Time TW 77 to 82C (Mark 3 on the bar graph)
7 : Time TW 105C or more (Mark 8 on the bar graph)
8. Screen HR8
[Oil temperature distribution]
1 : Time TO 45C or less (Marks 1 and 2 on the bar
graph)
2 : Time TO 45 to 60C (Mark 3 on the bar graph)
7 : Time TO 98C or more (Mark 8 on the bar graph)

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9. Screen HR9
[Fuel temperature distribution]
1 : Time TF 30C or less
2 : Time TF 30 to 40C
7 : Time TF 80C or more
10. Screen HR10
[Load ratio distribution]
1 : Time R 30% or less
2 : Time R 30 to 40%
3 : Time R 40 to 50%
4 : Time R 50 to 60%
5 : Time R 60 to 70%
6 : Time R 70 to 80%
7 : Time R 80% or more
11. Screen HR11
[H mode high idle load ratio distribution]
2 : Time R 30 to 40%
3 : Time R 40 to 50%
4 : Time R 50 to 60%
5 : Time R 60 to 70%
6 : Time R 70 to 80%
12. Screen HR12
[S mode high idle load ratio distribution]
2 : Time R 30 to 40%
3 : Time R 40 to 50%
4 : Time R 50 to 60%
5 : Time R 60 to 70%
6 : Time R 70 to 80%
Switching any of the work mode switches for the HR1 to 12 display ON for longer than 10 seconds clears
all the usage history data.

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Resetting
Resetting (RST1)
MODE : Travel mode, work mode

BRK : Breaker engine speed set
L/M : Lifting magnet engine speed set
AI : Auto idle time set (1 to 30 sec.)
PA : Pump output adjustment
AU : Automatic pressure rise (0 = ON, 1 = OFF)
HLD : Previous data hold set (0 = OFF, 1 = ON)
OUT : Oil pressure drive fan inspection mode
1) Breaker speed set
1 Select the breaker speed set (BRK) with the Buzzer Stop switch. (The selected item switches from light-on-
dark display to dark-on-light display.)
2 Now, set the breaker speed (BRK) to 1800 min-1. Start the engine and while watching the monitor, adjust the
engine speed with the throttle volume. When the adjustment is complete, switch the work mode switch ON for
10 seconds. The buzzer buzzes to announce that the storing the setting into memory is complete.
3 Switch OFF the key switch.
4 To check, see the CHK1 engine speed.
2) Lifting magnet speed set
1 Select the lifting magnet speed set (L/M) with the buzzer stop switch. (The selected item switches from light-
on-dark display to dark-on-light display.)
2 Now, set the lifting magnet speed (BRK) to 2000 min-1. Start the engine and while watching the monitor, adjust
the engine speed with the throttle volume. When the adjustment is complete, switch the work mode switch ON
for 10 seconds. The buzzer buzzes to announce that the storing the setting into memory is complete.
4 To check, see the CHK1 engine speed.

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4001-63
3) Auto idle time change
1 Select the auto idle time change (AI) with the buzzer stop switch. (The selected item switches from light-on-
2 Now, set the auto idle time to 10 seconds. Switch the travel mode switch ON until the number reaches 10. The
number increases each time you switch ON the switch and can be set from 1 to 30. When the setting is com-
plete, switch the work mode switch ON for 10 seconds. The buzzer buzzes to announce that the storing the
setting into memory is complete.
4) Pump output change
PA=0 : Normal output mode
PA=1 : Low output mode 1 (-100 mA)
1 Select the pump output adjustment (PA) with the buzzer stop switch. (The selected item switches from light-
on-dark display to dark-on-light display.)
2 Now, set the pump output to low-output mode. Switch the travel mode switch ON so that the number reaches
1, 2, or 3. Each time you switch ON the switch, the number moves to the next step in the sequence 0, 1, 2, 3,
When the setting is complete, switch the work mode switch ON for 10 seconds. The buzzer buzzes to
announce that the storing the setting into memory is complete.
3 Switch OFF the Key switch.
5) Automatic pressure rise release setting
1 Select the auto boost rise release (AU) with the buzzer stop switch. (The selected item switches from light-on-
2 Now, set the automatic boost rise to none. Switch the travel mode switch ON so that the number reaches 1.
Each time you switch ON the switch, the number toggles between 0 and 1. When the setting is complete,
switch the work mode switch ON for 10 seconds. The buzzer buzzes to announce that the storing the setting
into memory is complete.

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4001-64
6) Previous data hold condition change
Auto mode (0 = default setting, 1 = previous data held)

Work mode (0 = default setting, 1 = previous data held)
Travel mode (0 = default setting, 1 = previous data held)
*****
1 Select the previous data hold (HLD) with the buzzer stop switch. (The selected item switches from light-on-
2 Now, set the work mode to previous data hold.
Switch the travel mode switch ON so that the number reaches 1.
Each time the switch is switched ON, the number displayed moves to the next step in the sequence:
0000 0001 0010 0011 0100 0101 0110 0111 1000 1001 1010 1011 1100 1101 1110 1111
700-1-04-04-07BJ2
When the setting is complete, switch the work mode switch ON for 10 seconds. The buzzer buzzes to
announce that the storing the setting into memory is complete.
7) Hydraulic drive fan inspection mode (only for specifications with hydraulic drive fan)
1 Select the previous data hold (OUT) with the buzzer stop switch. (The selected item switches from light-on-
2 The number displayed shows the command current value. The display immediately after the selection is the
command current value. When the travel mode switch is switched ON once, the display becomes 0100 and
each time the switch is switched ON, the value displayed moves to the next step in the sequence:
->0100->0110->0120->0130->0140->0150->->0160->0170->0180->0190->0480->0490->0500-> Current value at present ->
3 For the noise test mode, the previous time's data is reset. In other words, even if the key switch is switched
OFF with some current value set, the next time the Key switch is switched ON, the mode is normal mode.

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4001-65
8) Maintenance time setting
1 Move to RST2 with the buzzer stop switch and select (2). (The selected item switches from light-on-dark dis-
play to dark-on-light display.)
2 The number displayed shows the time for displaying Maintenance time. The display immediately after the
selection is the default maintenance time. Each time the travel mode switch is switched ON, the number dis-
played moves one step through the cycle 50->250-> 500-> 1000-> 2000-> 5000-> 50-> 250.
When the setting is complete, switch the work mode switch ON for 10 seconds. The buzzer to announce that
the storing the setting into memory is complete
* If the buzzer stop switch is held ON for 20 seconds, the time until maintenance display (1) is re-
set.
9) Injector test mode
1 Move to RST2 with the buzzer stop switch and select (3). (The selected item switches from light-on-dark dis-
play to dark-on-light display.)
2 Now, set the automatic boost to none. Switch the travel mode switch ON so that the number reaches 1. The
number toggles between 0 and 1 each time you switch ON the switch.
When the number reaches 1, the engine speed is fixed at 500 min-1.
3 For the injector test mode, the previous time's data is reset. In other words, even if the key switch is switched
OFF with a value set, the next time the Key switch is switched ON, the mode is normal mode.

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EXCAVATOR MODEL SELECTION PROCEDURE

The excavator model is selected after re initialising 4. Press the travel mode switch until the required
the machine code or replacing an electronic control destination code is displayed.
box.
1. Key switch ON, the screen below appears and Destination Pressure
Destination T unit
? for machine is selected: code unit
3 EUROPE MPa C
4 Rest of world KgF C
MACHINE: SH ? -4
5. Press the work mode switch. The screen below
TERRITORY:? LANGUAGE:? appears and ? for language is selected.
CONT. P / N KHR3320
MACHINE: SH0300- 4
2. Press the travel mode switch until the required TERRITORY: 3 LANGUAGE: ?
machine code is displayed.
CONT. P / N KHR3320
MACHINE CODE MACHINE MODEL
SH0120 CX130
6. Press the travel mode switch to display the
SH0150 CX160 required language code:
SH0180 Not used 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
SH0700 CX700 8 = Portuguese
9 = Dutch
SH0800 CX800
10 = Danish
11 = Norwegian
12 = Swedish
MACHINE: SH0300- 4 13 = Finnish
14 = Icons
TERRITORY:? LANGUAGE:?
CONT. P / N KHR3320 MACHINE: SH0300- 4
TERRITORY: 3 LANGUAGE: 5
3. Press the work mode switch. The screen below
appears and ? for territory is selected.
CONT. P / N KHR3320
MACHINE: SH0300- 4 Example:

The screen above corresponds to a CX330 model
TERRITORY: ? LANGUAGE:?
excavator for Europe in French.
CONT. P / N KHR3320

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4001-67
7. After selecting the machine code, the destination 10. To confirm the excavator model selection, press
code and the language code, press the auto mode the auto mode switch for 10 seconds:
switch and the screen below will appear: The screen below will appear
MACHINE: SH0300- 4
CONT. P / N KHR3320
11. Press the auto mode switch again and the work
CS00F533 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: SH0300- 4 again from the beginning.
MACHINE: SH ? -4
CONT. P / N KHR3320
TERRITORY:? LANGUAGE:?
E. CONT. ERROR
CONT. P / N KHR3320
9. Check that the machine code corresponds to the

engine controller installed on the excavator.
- If the machine code is wrong, start the procedure
again from the beginning.
- If the engine controller installed is not correct,
change it.

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4001-68
Changing the language code

Display the excavator model confirmation screen
(press the auto mode switch for 10 seconds).
To change the language code, press the travel
mode 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.
MACHINE: SH0300- 4
CONT. P / N KHR3320
Example:
In the screen opposite, the language code has
changed from 5 (French) to 1 (English).

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TROUBLESHOOTING
Prior inspections
Item Value 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
-
Electrical equipment
8. Check the battery terminals and wiring for tightness and corrosion --- Tighten or replace
9. Check the alternator terminals and wiring for tightness and corrosion --- Tighten or replace
10. Check the starter motor terminals and wiring for tightness and --- Tighten or replace
corrosion
OTHER POINTS TO CHECK
Hydraulic system - Mechanical equipment
11. Abnormal noise or smell --- Repair
12. Check for oil leaks --- Repair
13. Air in the system --- Bleed the air
Electrical system - Electrical equipment
14. Check the battery voltage (with the engine shut down) 23-26 V Replace
15. Check the quantity of fluid in the battery --- Add or replace
16. Make sure that the cables are not discoloured, burnt or stripped --- Replace
17. Check for missing or loose cable retaining clips --- Repair
18. Check for damp on cables (especially on connectors and terminals) --- Disconnect and dry if
damp
19. Check fuses for condition and corrosion --- Replace
20. 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)
21. Noise from relay battery (with starter motor ON or OFF) --- Replace

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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 fol-
lowing 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
NO and pass on to the next step. Symbol Colour Symbol Colour
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 descrip- Br Brown Lg Light green
tion of the cause and carry out the repair procedures
P Pink Sb Sky blue
described on the right-hand side.
V Violet L Blue
The inspection methods/measurements are
described in one step. YES should be chosen if the G Green Gr Grey
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 con-
should be carefully read before starting the inspec-
nector, always turn the key switch OFF.
tion and the measurements and the procedures
should be followed, starting with step (1) since negli-
gent preparation work or incorrect operating methods
can cause damage to the machine.

Copyright
4001-71
Procedures
1. This is how one has to proceed to detect defects when the message is still displayed after all necessary meas-
ures have been taken to correct the error.
Message displayed Description of the problem Problem No.

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
Overheating The message is still displayed even when the hydraulic oil tem- 4
perature is 84C (183 F) or less and the engine coolant temper-
ature is 92C (197 F) or less.
Alternator The message is still displayed. 5
Elect. 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

Copyright
4001-72
Fuel
Description of problem No. 1
- The message is still displayed even after refilling the fuel tank.
R5
CN1 CN23 CNB3 FUEL SENSOR
A1 CONTROLLER
14 GL413 9 GL413
BG660
KEY SWITCH OFF
700.1.04.06.11E
A1 Computer/Controller R5 Fuel sensor
Troubleshooting Cause Action

Key switch ON
Measure the fuel sen-
sor resistance (R5) YES Replace the
Computer/con-
using maintenance computer/
troller (A1)
support CHK4. (Refer controller
defective
to the table below for (A1)
the resistance).
Key switch OFF
Disconnect the fuel sen-
sor connector (R5) to
NO measure the resistance NO Replace or
Fuel sensor
on the connector at the check the fuel
(R5) defective
fuel sensor end. (Refer sensor (R5)
to the table below for
the resistance).
Disconnect the CN23
connector to measure
the resistance between NO Bad connec- Clean the
YES
GL female and the GND tion on fuel connection
earth. (Refer to the sensor (R5) terminal
table below for the
resistance).
Disconnect connector
CN1 to measure the
resistance between GL NO Clean CN23
Bad connec-
YES female and GND earth. connection
tion on CN23
(Refer to the table terminal
below for the resist-
ance).
Replace the
computer/
Defective com-
controller
puter (A1) or
YES (A1) or clean
incorrect CN1
the CN1 con-
connection
nection termi-
nal
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 68-80 55-68 45-55 36-45 28-36 17-28 6-17

Copyright
4001-73
Add coolant solution

- The message is still displayed even after adding coolant solution.
RESERVOIR 2
CNB8 LEVEL SWITCH
GrG438
BG642
S56
RESERVOIR 1
CN4 CN23 CNB8 LEVEL SWITCH
CONTROLLER 57 GrG437 6 GrG437
BG641 S55
A1
700.1.04.06.11F2
A1 Computer/Controller S56 Reservoir tank low switch
S55 Reservoir tank low switch

Key switch ON
Replace the
Disconnect the minimum cool- YES Defective mini-
minimum cool-
ant solution level switch con- mum coolant
ant solution
nector (S55) to see if the solution level
level switch
message disappears switch (S55)
(S55)
Short-circuit on
wire GrG
YES between the min-
NO Disconnect connector CN23 to Repair wire
imum coolant
see if the message disappears GrG
solution level
switch (S55) and
CN23
Short-circuit on
NO YES
Disconnect connector CN4 to wire GrG Repair wire
see if the message disappears between CN23 GrG
and CN4
NO Defective com- Replace the

puter/controller computer/con-
(A1) troller (A1)

Copyright
4001-74
Low engine oil pressure

- The message is still displayed even when the engine oil level is satisfactory.
OIL PRESSURE
CNA0 CNA2 SENSOR
ENGINE 80 RY478 9
A2 CONTROLLER 67 YB488 10
B21
79 BY498 11
700.1.04.06.11G
A2 Engine controller B21 Engine oil pressure switch

Check the following points during the 12 seconds following starting the engine
Replace the
Disconnect the engine oil pres- YES Oil pressure
engine oil
sure switch connector (B21) to switch (B21)
pressure
see if the message disappears defective
switch (B21)
YES Short-circuit on
NO Disconnect connector CNAO
wire between
to see if the message disap- Repair wire
CNAO and
pears
CNA2
NO Replace
Defective engine
engine control-
controller (A2)
ler (A2)

Copyright
4001-75
Overheating
- The message is still displayed even when the actual temperature is lower than the following:
Hydraulic oil temperature 98C (208F), engine coolant temperature 105C (221F).
Prior check:
1. Make sure that 8 bars are displayed on the hydraulic oil and engine coolant temperature gauge bar-graphs.
ENGINE CONTROLLER
CNA1
84
A2
CNA0
79
THERMO-SENSOR
CNA2 (COOLANT)
WR484 7
CONTROLLER
B1
BY498 11
CN1 THERMO-SENSOR
A1 CN23 CND3 (OIL)
6 10 OL415
B2
13 11 BO425
700.1.04.06.11H
A1 Computer/controller B1 Coolant temperature sensor
A2 Engine controller B2 Hydraulic oil temperature sensor

Copyright
4001-76

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 mainte-
nance assistance CHK1 YES
(comparison between
the actual temperature
and the indicated tem-
perature).
See coolant tempera-
ture in CHK1 WT.
Measure the actual
temperature
Check problem code
E0015 for the coolant
temperature sensor
(B1) with the mainte-
nance diagnostic (DIAG
1)
YES
NO Defective Replace the
CNA2 on the coolant
coolant tem- coolant tem-
temperature sensor
perature sen- perature sen-
(B1) to measure the
sor (B1) sor (B1)
resistance
Disconnect the connec-
Bad connec- Clean the
tors CNA1 and CNAO
NO tion on the coolant tem-
to measure the resist-
coolant temperature sen-
YES ance between the male
perature sensor
terminals. (Refer to the
sor connector connecting
table below for the
(B1) terminal (B1)
resistance).
Replace con-
Bad connec-
troller or
tions on
YES clean CNAO,
CNAO, CNA1
CNA1 con-
or defective
nector termi-
controller
nal
Note: In the event of a short-circuit, the bar-graph goes off completely.

Copyright
4001-77
Overheating (continued)

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

perature sensor (B2)
temperature is abnor-
mal compared to main-
tenance assistance YES
CHK1 (comparison
between the actual tem-
perature and that indi-
cated).
See hydraulic oil tem-
perature in CHK1 OT.
Measure the actual
temperature
See problem code
M0020 for the oil tem-
perature sensor (B2)
using maintenance
diagnostic (DIAG 4)
YES
CND3 on the hydraulic
Defective Replace the
oil temperature sensor NO
hydraulic oil hydraulic oil
(B2) to measure the
temperature temperature
resistance. (Refer to the
sensor (B2) sensor (B2)
table below for the
resistance).
Disconnect the CN23
Bad connec- Clean the
connector to measure
NO tion on the hydraulic oil
the resistance between
hydraulic oil temperature
YES the male terminals OL
temperature sensor con-
and BO. (Refer to the
sensor connecting termi-
table below for the
nector (B2) nal (B2)
resistance).
CN1 to measure the
Clean the
resistance between the NO Bad connec-
connecting
OUI female terminals OL tions on
terminal on
and BO. (Refer to the CN23
CN23
table below for the
resistance).
Replace the
Defective
computer/
computer/
controller
controller
YES (A1) or clean
(A1) or bad
the connect-
connection
ing terminals
on CN1
on CN1
Note: In the event of a short-circuit, the bar-graph goes off completely.

Copyright
4001-78
Coolant and hydraulic oil temperature sensor resistance
NOTE: The resistance varies with temperature.
Coolant or hydraulic oil Hydraulic oil temperature

Coolant temperature sensor (B1)
temperature sensor (B2)
20C (68F) 2.50 k 2.45 k
30C (86F) 1.73 k 1.66 k
40C (104F) 1.20 k 1.45 k
50C (122F) 0.84 k 0.81 k
60C (140F) 0.61 k 0.51 k
70C (158F) 0.45 k 0.43 k
80C (176F) 0.31 k 0.32 k
Defective battery charge circuit

- The message is still displayed.
CN13
S1
19 K7 G2
P5 KEY SWITCH
BATTERY RELAY ALTERNATOR
E
LgR540
LgR540
HOUR METER
B
CN22 CNC9
2 LgR540 G020 R SG
A1 CN26
L
CN1 1 BrR544 4
7 LgR542 ENGINE
CONTROLLER
CONTROLLER 2 BrW545
A2 BrR030
M1
BrR543 STARTER
700.1.04.06.11J2
A1 Computer/controller M1 Starter motor
A2 Engine controller P5 Hourmeter
G2 Alternator S1 Key switch
K7 Relay battery

Copyright
4001-79

NO CN1 to measure the volt- NO
The hour meter (P5) Break in wire between
age between the female Repair wire
does not work CN1 and CN22
terminal on wire WR and
YES Ground. 10V or above.
YES
Clean CN1 connector
Bad connection on CN1
terminal or replace con-
or defective controller
troller
Disconnect the connector CNC9 on alternator R ter-

Replace the alternator
minal to measure the voltage between alternator NO Defective alternator (G2)
(G2)
side and ground. 10 V or above.
YES
Break in wire between
CN22 to measure the
CN22 and alternator or Repair wire between
voltage between the NO
bad connection on alter- CN22 and alternator or
male terminal on wire
nator connector terminal clean the connector
LgR and ground. 10 V or
of alternator
above
YES

Copyright
4001-80
Electrical system troubleshooting

- The message is still displayed
K5
BEACON RELAY
TRAVEL ARARM
W 2
0.85B 1
H2
S51
A1
4
5
2
3
PW
GrR
LR
B
LIMIT SWITCH
CONTROLLER (GATE) BEACON
GrR
CN.5
1 VR 1 VR B GW 1
2 YR B 2
FREE SWING
SOLENOID Y18
CN.19
2 STAGE RELIEF 8 YW
CN22
24VB SOLENOID VALVE
Y2
PW
YR 6 0.85GR 0.85GR 1 LEVER LOCK

REFUEL PUMP 17 OW OW 8 OW 0.85B 2
FREE SWINGBEACON 18 GW VW 9 0.85VW (BLUE TAPE)
19 W W 7 W
WARNING BUZZER
ENGINE STOP 21 WR 0.85VW
0.85B
1
2
SWING BRAKE Y3
SWING BRAKE 27 VW (PINK TAPE)
2 SPEED TRAVEL 28 LW LW 1 0.85LW
LgW LgW 0.85LgW 0.85LW
CUSHION
SWING SHUT-OFF
29
31 BrW BrW
3
4 0.85BrW
0.85B
1
2
2 SPEED TRAVEL
Y4
(RED TAPE)
SPARE 1 (PNP) 32 WL GW 5 GW
SPARE 2 (PNP) 20 WV YW 2 0.85YW 0.85YW 1
2 STAGE RELEF
2
VARIABLE ISC 23
1
2
0.85B
(YELLOW TAPE) Y5
CN24
CN.6
0.85LgW 1
0.85B 2 SOFTHARD SELECT
WR
CN.23
(LIGHT GREEN TAPE)
Y6
16
0.85BrW 1
CONNECTOR SWING SHUT-OFF
0.85B 2
(OPTION)
(GREEN TAPE)
Y1
WR
CN.A0
47
STOP SWITCH
IS-ENGINE
A2
ENGINE CONTROLLER (ECM)
OPTION (REFUEL PUMP)

REFUEL PUMP PUMP STOP
RELAY
S61
RELAY
K31 AUTOMANUAL
SELECT SWITCH
K30 VR
GW
1
2
L 3
1
5
3
2GrR 4
2LR 5
3
2
VR 1
B 2
VR
0.85BrR
OW
B
L
AUTO STOP
0.85BrR
ALARM
B82
0.85B
M14 REFUEL PUMP
1 2GrR
OW 3 OW 2LR 1 2R
2 2B 2B 2 2B M
330.1.04.06.12K
A1 Computer Y1 Swing pilot shut-off solenoid valve (green band)
A2 Engine controller Y2 Pilot pressure solenoid valve (blue band)
B82 Refuel pump stop alarm Y3 Swing brake solenoid valve (pink band)
H2 Travel alarm (North America) Y4 2 stage travel solenoid valve (red band)
K5 Relay-rotary light Y5 Power-up solenoid valve
K30 Refuel pump relay Y6 Cushion control solenoid valve (light green band)
K31 Refuel pump stop relay Y18 Free swing solenoid valve (North America)
M14 Fuel feed pump motor
S51 Hydraulic function cancellation lever switch
S61 Refuel pump switch
Copyright
4001-81

Troubleshooting using the diagnostic system
Key switch ON
Refer to the
Failure code displayed in DIAG 1 YES engine trouble-
shooting manual
NO
Find troubled location by DIAG4
M0020
YES
appears
To CHK2
With automatic detection for short-circuit

YES
The failure code disappears after disconnecting the solenoid valve Defective (Yn) solenoid Replace the solenoid
YES
connector valve valve (Yn)
NO
The failure code disappears when either one of connectors CN21,
YES Short-circuit on wire Repair the wiring
CN22, CN23 in short-circuit line is disconnected
NO
The failure code disappears after disconnecting connector CN6
YES
NO
Defective controller Replace controller

Copyright
4001-82
ELECTRICAL INSPECTION OF COMPONENTS

Details of service connector kit
0.85 0.85
02A 01A 200 0.85BW
WY BW 50 50
01A
BrG 0.85
03A 50
WL
100
50
0.85WY
50
BrG BrG
100 150 02A
50
100 101 0.85
BW
0.85
WY 01B 02B
150 BrG 0.85
WL 03B 03A
100 0.85WL
700.1.04.02.14AH
700.1.04.02.14AA
1. For solenoid valve and fuel sensor 8. For pressure sensor (3P)
200 0.85YL
BrB 50 50
01A
01A 02A 03A
50
102
BrB BrG
100 150 0.85 0.85 0.85
50
50
50 YL BY Y
102 103 0.85BY
02A
150 BrG
103 03B 02B 01B
03A
700.1.04.02.14AB 0.85 0.85 0.85
Y BY YL 0.85Y
2. For electromagnetic proportional valve of hydrau-
700.1.04.02.14AI
lic pump
9. For atmospheric pressure sensor
BrG
104 0.85BO
BrG BrB
100 150 01A
50
104 105 50
150 BrB 50
300
01A 02A
50
105 0.85BO 0.85OL
700.1.04.02.14AC 02A
3. For electromagnetic proportional valve of hydrau- 0.85OL
lic pump 700.1.04.02.14AJ

10. For intake air temperature sensor
L
106
L BY 3B
100 150
50 01A
106 107 6
150 BY 50
107 50 200
3B 01A
50
700.1.04.02.14AD
50
6
4. For pressure switch 02A
3LR 02A 3LR
BY 700.1.04.02.14AM
108
BY L
150
11. For glow (1P)
50 100
108 109
150 L
109
700.1.04.02.14AE
5. For the harness side of pressure switch
C
814
C C
100 150
50
814 850
150 C
450
700.1.04.02.14AF 700.1.04.02.14AN
6. For receiver dryer (2P) 12. For fuel pump (6P)
0.85BP
01A
0.85PL 0.85BP 50
50 150
02A 01A
50
02A
0.85PL
700.1.04.02.14AG
7. For oil temperature sensor
Copyright
4001-83
Main pump proportional solenoid
1 Y7
700.1.04.02.14AO
13. EGR (8P)
330.1.04.02.15AP2
1. Disconnect connector (1) from the main pump
hydraulic solenoid (Y7).
2 3
700.1.04.02.14AP
14. For injector (12P)
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 voltmeter (5).
NOTE: The + terminal of the voltmeter 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 con-
700.1.04.02.14AQ nector coming from the hydraulic pump.
15. For sensor (20P) 3. When the connections have been made, start the
engine and check the current on the voltmeter (5) in
each work mode, at maximum speed.
Current in mA
H S Auto
L
Maxi Min Maxi Min S L
50 or
470 250 410 250 470 470
below

Copyright
4001-84
6 solenoid valve bank

1. Disconnect connector (A) from one of the sole-
2
noids on the 6 solenoid valve bank (B) Yn
Y1 Y5 Y4
3
1
Y6 CS99A843
2. Connect the appropriate service connector (2P)(3)
to the connector on the disconnected solenoid (1)
only (Yn) and install the voltmeter (2).
Y3 Y2 B 3. When the connection has been made, the solenoid

resistance reading on the voltmeter (2) should be 45
at 20C (68 F).
NOTE: The resistance value varies with temperature.
A
Hydraulic oil temperature sensor
CD01M010A
Marking Function
Y1 Swing pilot shut-off solenoid valve (green band)
B2
Y2 Pilot pressure solenoid valve (blue band)
Y3 Swing brake solenoid valve (pink band)
Y4 2 stage travel solenoid valve (red band)
Y5 Power-up solenoid valve (yellow band)
Y6 Cushion control solenoid valve (light green band)
330.1.04.02.15AW2
B2 Hydraulic oil temperature sensor

Copyright
4001-85
1. Remove the oil temperature sensor (B2) from the Pressure sensor
machine.
3
4 B44
9
5
6
7
B42
8
330.1.04.02.15AY2
CS99A851
3 Service connector (2P)
4 Thermometer
5 Beaker
6 Temperature sensor (B2)
7 Tripod
8 Spirit lamp
9 Voltmeter
2. Connect the appropriate service connector (2P) (3)
to the temperature sensor (B2) connector (1) or (2)
and install the voltmeter (9).
3. When the connection has been made, place the B43
temperature sensor (B2) in the beaker (5) contain-
ing water. Place the beaker (5) on the tripod (7). 330.104.02.15AY3
Using the spirit lamp (8) gradually increase the

B42 Pressure sensor P1
water temperature in the beaker (5). Using the volt-
B43 Pressure sensor (nega-cont.) (N)
meter (9), check the resistance value in function of
B44 Pressure sensor P2
the temperature read on the thermometer (4) (see
table below). 1. Disconnect the connector from the main hydraulic
pump pressure sensor.
Oil Temperature Oil temperature sensor
20C (68F) 2.45 k
30C (86F) 1.66 k
40C (104F) 1.15 k
50C (122F) 0.81 k
60C (140F) 0.58 k
70C (158F) 0.43 k
80C (176F) 0.32 k

Copyright
4001-86
B42
1 2 3
4
B43
B44
CS00E541
2. Connect the appropriate service connector (3P)(4)
between sensor (B42), (B43) or (B44) and the corre-
sponding connector (1), (2) or (3) of the main har-
ness (5) and install the voltmeter (6).
NOTE: The + terminal on the voltmeter should be
connected to wire YL (yellow/blue) on the service
connector and the - terminal to the machine earth.
3. When the connection has been made, start the
engine and check the voltage read on the voltmeter
(6) in accordance with the pressures indicated in the
table below.
Pump pressure sensor (B42) and (B44)
Pressure (MPa) Voltage (V)

50 (7252 psi) 4.5
43.7 (6338 psi) 4
37.5 (5439 psi) 3
25 (3626 psi) 2
17.5 (2538 psi) 1
0 0.5
Pressure sensor (nega-cont.) (B43)
Pressure (MPa) Voltage (V)

5 (725 psi) 4.5
4.37(634 psi) 4
3.75 (544 psi) 3
2.50 (362 psi) 2
1.25 (181 psi) 1
0 0.5

Copyright
4002
Section
4002
INSPECTION AND MAINTENANCE OF BATTERIES

AND CONNECTING A BOOSTER BATTERY
Copyright 2002 Case France

Printed in France
Case Cre 9-43460GB March 2002
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 inspection .................................................................................................................................................. 5
Check 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
Cre 9-43460GB Issued 03-02

Copyright
4002-3
SAFETY INSTRUCTIONS
WARNING: Never try to charge a battery WARNING: The acid from the battery can
! which has frozen electrolyte. cause very serious burns. Batteries contain
sulphuric acid. Avoid all contact with skin,
eyes or clothes.
Antidote:
WARNING: Never cause sparks or smoke
EXTERNAL - Rinse copiously with plenty of
close to batteries being charged or those
! recently charged.
water.
INTERNAL - Drink large quantities of water or
milk. Follow up with hydrated magnesia,
beaten egg or vegetable oil.
WARNING: When disconnecting the battery Consult a doctor immediately.
cables, always disconnect the earth cable
! EYES - Rinse copiously with water for 15 min-
! first. When reconnecting the battery cables, utes and seek medical attention immediately.
always reconnect the earth cable last. Batteries produce explosive gases. Keep
them away from sparks, flames and ciga-
rettes. If you use or charge a battery in a con-
fined space, make sure that the space is well
WARNING: Some batteries are equipped
ventilated. Always protect your eyes when
with an aerator pipe. If the aerator pipe con-
working close to batteries.
tains acid from the battery, it could spill out
Keep batteries and the acid they contain out
when the battery is turned over. When you
of the reach of children.
! turn the battery over, always keep the end of
the aerator pipe away from yourself and peo-
ple around you. The acid from the battery can
cause serious burns.
SPECIFICATIONS
See Section 1002.

Copyright
4002-4
MAINTENANCE
Electrolyte level If the battery needs to be cleaned, remove the battery
from its bracket and clean the battery, the cable ter-
If the battery is a maintenance-free battery, check the minals as well as the battery bracket. If possible, use
electrolyte level every 1000 hours of use or every six CASE Battery Saver and Cleaner, following the
months, whichever comes first. For all other batteries, instructions on the cartridge. CASE Battery Saver
check the electrolyte level every 250 hours of use. and Cleaner also fights corrosion. If CASE Battery
Saver and Cleaner is not available, use bicarbonate
Inspecting and cleaning the battery of soda and water. MAKE SURE that the cleaning
If the battery is damaged and leaks, it must be agent does not enter the battery components.
replaced. Check the battery regularly for contamina-
tion, corrosion and damage. If the top covering of the WARNING: When disconnecting the battery
battery is contaminated by impurities or the electro- cables, always disconnect the earth cable
lyte, the battery can get discharged since the current ! first. When reconnecting the battery cables,
can pass. always reconnect the earth cable last.
WARNING: When disconnecting the battery Assemble the battery on the machine and check that
cables, always disconnect the earth cable the straps are tightened properly. Apply CASE Bat-
! first. When reconnecting the battery cables, tery Saver and Cleaner or a urethane based sealant
always reconnect the earth cable last. on the battery terminals to prevent corrosion. Refer to
the Parts Catalogue. Do not use grease.

Copyright
4002-5
INSPECTING THE BATTERY

NOTE: For a proper inspection of the battery, carry 2. Read the float.
out each part of the inspection until the actual state of
3. Read the thermometer, if the reading is greater than
the battery is known.
26.7C, add specific gravity points to the reading to
Visual inspection get the specific gravity. If the reading is less than
26.7C, deduct specific gravity points from the read-
- Check that the cable connections are clean and ing to get the specific gravity. See the illustration
tightened properly. Remove all foreign bodies from below and add or deduct specific gravity points
the top of the battery. depending on the situation.
- Check the box, the terminals and the battery cables
for damage.
- Check the electrolyte level, see page 4.
- If you have added water to the battery, charge the
battery for 15 minutes at 15 to 25 amperes to allow
the water to mix correctly with the electrolyte.
Check the specific gravity

Use a battery hydrometer to check the specific gravity
of the electrolyte. The specific gravity indicates the
charge level in each cell.
Battery hydrometers are designed to indicate the cor-
JS00532A
rect specific gravity when the electrolyte is at a tem-
4. Record the corrected specific gravity for each cell.
perature of 26.7C.
5. If the difference between the high and low readings
Before checking the specific gravity, check the elec-
is 0.050 minimum, charge the battery and check the
trolyte temperature. If the hydrometer is not equipped
specific gravity again. If after charging the difference
with a thermometer, use a thermometer to measure
is still 0.050 minimum, install a new battery.
the electrolyte temperature. The thermometer has to
be calibrated at least up to 52C. NOTE: When the battery is replaced, do not use a
used battery with a new one. The life of the new bat-
1. Remove sufficient electrolyte from a cell so that
tery will be reduced.
the float moves freely in the tube.
NOTE: If it is not possible to check the specific gravity
without first adding water to the cell, charge the bat-
tery for 15 minutes at 15 to 25 amperes to allow the
water to mix correctly with the electrolyte. Then,
check the specific gravity.

Copyright
4002-6
6. The corrected specific gravity indicates the charge Charge test
level in each cell. The charge level of each cell
should be 75% minimum. For maintenance-free bat- For this test, use a variable charge controller such as
teries, the charge level is 75% minimum when the a Sun Electric VAT-33 or an equivalent device. Con-
corrected specific gravity is 1.240 minimum. For all nect the controller in accordance with the instructions
other batteries the charge level is 75% minimum of the device manufacturer.
when the corrected specific gravity is 1.230 mini- 1. The charge level should be at least 75%. Check
mum. the specific gravity in this section.
7. If the difference between the high and low readings 2. Prepare the controller for the tests (the diagram
is less than 0.050 and the charge level is 75% mini- shows a Sun Electric VAT-33).
mum in each of the cells, carry out the charge test.
A. Set the voltmeter range to between 1 and 18 volts.
8. If the difference between the high and low readings
is less than 0.050 but the charge level is less than B. Check that the charge control knob is in the OFF
75% in one of the cells, change the battery and position.
check the specific gravity again. If after charging: C. Set the ammeter range to between 0 and
A. The charge level is less than 75% in one of the 1000 amperes.
cells, replace the battery. D. Turn the voltmeter switch to the INT position.
B. The charge level is 75% minimum in each of the E.
cells, carry out the charge test.
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 sec-

onds. 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 15 sec- 8. Compare the reading and the electrolyte tempera-
onds. Wait at least 3 minutes before continuing the ture with the values below.
test.
Electrolyte temperature Minimum voltage
4. Measure and note down the electrolyte tempera-
21C minimum 9.6
ture.
16C 9.5
5. Refer to the specifications for the correct charge 10C 9.4
required for this test. 4C 9.3
6. The correct charge corresponds to half the value of -1C 9.1
the cold starting current (-17C). -7C 8.9
-12C 8.7
7. Turn the charge control knob until the ammeter
-18C 8.5
shows the current required. Maintain the charge for
15 seconds and read the voltmeter. Turn the charge A. If the test result is greater or equal to the indi-
control knob to OFF. cated voltage, the battery is in good condition.
B. If the test result is less than the voltage indicated,
replace the battery.
CHARGING THE BATTERY

Refer to the Specifications on page 3 for the reserve
WARNING: Never try to charge a battery charge of the battery of this machine.
! which has frozen electrolyte. Reduce the charging rate if:
1. The electrolyte is spilling out of the cells as these
Before charging the battery, check the electrolyte
contain too much gas.
level.
2. The electrolyte temperature exceeds 52C.
It is difficult to state an exact charging rate since the
following conditions are variable: (1) electrolyte tem- NOTE: For optimal charging, select slow charging
perature, (2) charge level, and (3) condition of the rates. The battery is fully charged when after having
battery. Refer to the Charging Guide for correct charged it slowly for 3 hours, no cell emits too much
charging time. gas and the specific gravity remains unchanged.

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4002-8
BATTERY CHARGING GUIDE

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

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

Copyright
4002-9
CONNECTING A BOOSTER BATTERY

NOTE: The photos below do not correspond to the
WARNING: When a battery is frozen it may machine model, but the procedure is the same.
explode if (1) you try to charge it or (2) you try 1. Open the RH access door.
to start the engine using jump leads. To pre-
vent the electrolyte from freezing, always
! keep the battery fully charged. Failure to com-
ply with these instructions can be detrimental
to your safety as well as the safety of those
around.
WARNING: Batteries contain acid and explo-

sive gases. A spark, flame or incorrect cable
connection can cause the battery to explode.
The correct procedure for connecting jump
! leads to the machine battery is explained on
this page. Non-observance of these instruc- CD01M005
tions may lead to serious or fatal injury.
2. From the operators seat, ask your assistant to make
the connections. Check that the voltage of the
booster batteries is indeed 24 volts.
WARNING: Batteries produce explosive
3. If the connections are made from another machine,
gases. Keep all cigarettes, sparks and flames
check that the two machines are not touching each
away from the area. If you charge or use a
other.
! battery in a confined space, make sure that it
is well ventilated. Always protect your eyes 4. Connect the positive (+) (1) booster cable to the
when working close to batteries. positive (+) terminal of the battery.
WARNING: When connecting booster cables,

prevent the positive (+) and negative (-) termi-
! nals from touching each other.
2 1
WARNING: Improper connection of the
booster cables may lead to an accident.
! Always proceed with great care.
CD01M006
5. Connect the negative (-) (2) booster cable to a clean

earth away from the battery.

Copyright
4002-10
6. If the connections are made from another machine,
start the machine and run it at half the maximum
engine speed.
7. Start the engine of the machine that has broken
down and ask your assistant to disconnect first the
negative (-) booster cable and last the positive (+)
booster cable.
8. Put back the battery cover and close the LH 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 .................................................................................................................................. 3
Engine electronic control box ............................................................................................................................... 4
Installation ............................................................................................................................................................ 4

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4003-3
MAIN ELECTRONIC CONTROL BOX AND ENGINE ELECTRONIC

CONTROL BOX
Removal STEP 4
STEP 1
B
A C
CD00F011
Remove the panel (A) located behind the operators
JS00001A seat, taking care to disconnect the connector from
Park the machine on hard, flat ground. Lower the the cigarette lighter (B) and the solar radiation
attachment to the ground. detector (C).
STEP 2 Main electronic control box
Shut down the engine and position the starter switch
on OFF.
STEP 5
STEP 3
B
CD00F047
Disconnect the connectors CN1 to CN6 from the
main electronic control box (B).
STEP 6
CT05L063
Remove the 4 retaining screws (A) from the main
Disconnect the main earth cable (-) (A) from the
electronic control box (B).
battery.
STEP 7
Remove the main electronic control box (B).

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4003-4
Engine electronic control box

STEP 5
K33
K2 K3 K5
K6
K4
CRPH06C010A
Label and remove the relay-glow plug (K2), the relay-
horn (K3), the relay-working light (K4), the relay-
rotary light (K5), the relay-air conditionner condenser
fan (K6) and the main relay (K33).
E
CRPH06A027A
Disconnect the connectors CNA0 and CNA1 from the

engine controller (E).
STEP 6
Remove the retaining screws from the engine
electronic control box (E).
STEP 7
Remove the engine electronic control box (E).
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.

5001
Section Copyright
5001

OF THE TRACKS SET

Printed in France
Case Cre 9-42910GB January 2002
Copyright
5001-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 2
SPECIAL TORQUE SETTINGS ............................................................................................................................... 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

Copyright
5003-3
SPECIFICATIONS
Upper roller oil quantity.......................................................................................... 250 cc (15.25 ci) Gear oil ISO320
Lower roller oil quantity.......................................................................................... 280 cc (17.08 ci) Gear oil ISO320

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
A .....................................................................................................................................................................356 mm
B .....................................................................................................................................................................282 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 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 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.

pressure. Disassembly without releasing 1
pressure may result in serious injury or JD01076A
death. Do not disassemble the track com- At each end of the track, install wood blocks (1) under
! pensating system before completely releas- the track.
ing the grease pressure. Release grease
pressure by loosening check valve. Do not STEP 6
remove the non-return check valve or the
retaining bracket.
STEP 3
Lower the attachment to lift the machine until a suffi-
cient 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 Section 4
1002 for wear limits.
5
Disassembly
STEP 1
JS00303A
Remove the face seals (5) from the end bearings (4)
2 with a screwdriver or similar tool. Be careful not to
damage the seal bore in the end bearing. 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 (1).
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
Using a hammer and a brass punch, drive the bush- roller (1) using a hydraulic press and a proper size
ings (8) from the lower roller (1). Be careful not to rod.
damage the seal bore in the lower roller. Discard
bushings. STEP 2
5
Inspection
STEP 1
Clean all components with solvent.
5
STEP 2
Inspect the bushing surfaces on the shaft (6) for scor-
ing, pitting, and other damage. Measure the diameter
of the shaft at four opposing points. Compare the val-
1
ues with the specifications, replace them if neces-
sary.
STEP 3 JS00310A
Install an O-ring and a face seal metal bushing (5) in
Inspect bushings (8) for wear and damage. Measure the seal bore on each side of the lower roller.
the inner diameter and width of the bushing. Com-
pare the values with the specifications, replace them
if necessary.
STEP 4
Inspect the bore in each end bearing 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 a 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 inspec-
5 tion 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 specifica-
5
tions. Install the drain plug (2) in the end bearing (4).
JS00313A
Install the O-ring and remaining face seal metal bush-
ings (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 bearings 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
A B C
12
4
11
2
6 7 9 10 8 1
CS02B504
1 UPPER ROLLER 7 SHAFT
2 OIL DRAIN PLUG 8 FACE SEAL
3 SCREW 9 BUSHING
4 COVER 10 BUSHING
5 SEAL 11 BRACKET
6 THRUST PLATE 12 CLIP
A .................................................................................................................................................................... 186 mm
B .....................................................................................................................................................................103 mm
C .................................................................................................................................................................... 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.

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
2
JD00319A
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.
STEP 6
CS02B505
Clean the upper roller (1) using a suitable solvent.
Remove the drain plug (2) and drain the oil.
STEP 2
3
4
JD00320A
Support the upper roller. Remove the two screws 5
holding the upper roller to the undercarriage.
Remove the upper roller.
1
CS02B506
Remove the screws (3), and the cover (4) from the
upper roller (1). Remove and discard the O-ring (5)
from the cover (4).

Copyright
5003-13
STEP 3 STEP 6
8
3
6
7
1
CS02B507 CS02B509
Secure the upper roller in a vice. Remove the three Remove and discard the face seal (8) from the upper
screws (3) holding the thrust plate (6). Remove the roller (1) using a screwdriver or other suitable tool. Be
thrust plate (6). careful not to damage the seal bore in the upper
roller. Scrap the face seal.
STEP 4
STEP 7
1
7
8
7
7
8 11
11
CS02B508
Pull the upper roller (1) from the shaft (7). CS02B510
Remove and scrap the face seal (8) from the
NOTE: Carry out step 5 only if inspection reveals that
bracket (11) using a screwdriver or other suitable
the shaft (7) needs to be replaced.
tool. Be careful not to damage the seal bore in the
STEP 5 bracket.
Using a press, remove the shaft (7) from the
bracket (11). 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 (9 and 10) need to be replaced.
STEP 1
STEP 8
Clean all the components with cleaning solvent.
9 STEP 2
Inspect the bushing surfaces on the shaft (7) for
1 scoring, pitting, and other damage. Measure the
diameter of the shaft at four opposing points.
Compare the values with the specifications, replace if
10 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
CS02B511 necessary.
Using a hammer and a brass punch, drive the
bushings (9) and (10) 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 thickness of the thrust plate. Compare
the values with the specifications, replace if
necessary.
STEP 5
Inspect the bore in the bracket (11) 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
7 1
8
11
CS02B509
Install an O-ring and a face seal (8) metal bushing in
CS02B512 the seal bore of the upper roller (1). Liberally apply
If the shaft (7) has been removed from the clean oil on the edge of the face seal.
bracket (11), install the shaft in the bracket using a
press. Be careful not to damage the seal bore in the STEP 4
bracket.
NOTE: The retaining ports of the thrust plate (6)
should be perpendicular to the retaining plane of the
bracket (11).
NOTE: Respect the recess dimension of the shaft in
8 12 11
the bracket, see page 10.
STEP 2 8
12
9
7
CS02B514
1 Install the O-ring and the remaining clip (12) of the
face seal (8) in the seal bore in the bracket (11).
9 Apply clean oil copiously to the face seal.
1 STEP 5
10
1
10
CS02B513 7
Install the bushings (9) and (10) in the upper
roller (1).
NOTE: The grooves of the bushings should be
rotated by 90.
CS02B508
Apply clean grease on the surface of the shaft (7) and
install the shaft in the upper roller (1).

Copyright
5003-16
STEP 6 STEP 9
2
3
6
1
CS02B515 CS02B505
Apply grease on the inside of the thrust plate (6). Fill the upper roller (1) with synthetic oil (see the
Position the thrust plate on the shaft (7) and install specifications for quantity). Install the drain plug (2) in
the three screws (3). Apply brake thread fluid to the the cover (4). Tighten the plug to a torque of 24.5 Nm.
screws and tighten to a torque of 62.8 to 72.6 Nm.
STEP 7
3
4
5
1
CS02B506
Apply grease on the seal (5) and install in the groove
of the cover (4). Install the cover on the upper
roller (1) using screws (3). Apply brake thread fluid to
the screws and tighten to a torque of 62.8 to
72.6 Nm.
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
Case Cre 9-36890GB February 2002
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 the tracks
(Section 5001) and removing 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
that attach the sprocket to the reduction gear.
STEP 6
JD00291A
Rotate the upperstructure so that the cab is over the
side of the machine where the sprocket to be
removed is located. Using the attachment, lift the side
of the machine until the teeth of the sprocket are free
from the chain.
machine model, but the procedure is the same.
JD00294A
Drive the sprocket from the reduction gear housing
using a soft hammer. Remove the sprocket from the
machine.

Copyright
5004-4
Installation STEP 3
STEP 1
JD00293A
Apply Loctite 262 to the screw threads (2). Assemble
the hardened washers and the screws.
STEP 4
JD00292A
Install the sprocket on the drive reduction gear taking
1
care to align the reference marks (1).
STEP 2
3 4
JS00296A
Tighten the four screws to torque in the order shown,
see "specifications". Then progressively tighten the
remaining screws to the same torque setting.
JD00295A STEP 5
If necessary, use a soft hammer to seat the sprocket
properly on the flange of the reduction gear. To install the tracks, see Removing and installing the
tracks.

Copyright
Section
5005
IDLER WHEEL AND TENSION

SHOCK ABSORBER
5005

Printed in France
Copyright
5005-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 3
SPECIAL TOOLS ..................................................................................................................................................... 3
REMOVING AND INSTALLING THE IDLER WHEEL AND THE TENSION SHOCK ABSORBER ......................... 4
Removal ............................................................................................................................................................... 4
Installation ............................................................................................................................................................ 6
DISASSEMBLING AND ASSEMBLING THE IDLER WHEEL.................................................................................. 8

Description ........................................................................................................................................................... 8
Reconditioning ..................................................................................................................................................... 8
Disassembly .........................................................................................................................................................9
Inspection ........................................................................................................................................................... 10
Assembly ............................................................................................................................................................ 11
Leakage test .......................................................................................................................................................13
DISASSEMBLING AND ASSEMBLING THE TENSION SHOCK ABSORBER ..................................................... 14

Description ......................................................................................................................................................... 14
Disassembly .......................................................................................................................................................15
Assembly ............................................................................................................................................................ 15
TRACK TENSION CYLINDER ............................................................................................................................... 16

Description ......................................................................................................................................................... 16
Removal ............................................................................................................................................................. 17
Disassembly .......................................................................................................................................................17
Inspection ........................................................................................................................................................... 18
Assembly ............................................................................................................................................................ 18
Installation .......................................................................................................................................................... 19

Copyright
5005-3
SPECIFICATIONS
Idler wheel oil capacity ..........................................................................................250 cc (15.25 ci) Gear oil ISO320
Mounting length of spring ............................................................................................................... See section 1002

Shock absorber spring yoke screw * .................................................................................................. 267 to 312 Nm
Tension cylinder screw * ..................................................................................................................... 267 to 312 Nm
Tension cylinder non-return valve ......................................................................................................... 58.8 9.8 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
REMOVING AND INSTALLING THE IDLER WHEEL

AND THE TENSION SHOCK ABSORBER
Removal STEP 4
STEP 1
Disconnect the chain.
See "Removing and installing a set of tracks", Sec-
tion 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
STEP 7 idler wheel from the yoke.
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
and install them in the undercarriage housing. Push
the idler wheel and the tension shock absorber into
the undercarriage. Remove the lifting device from the
JD00362A
Attach a suitable lifting device to the idler wheel and idler wheel and from the back of the tension shock
bring it into position on the yoke. Apply Loctite 262 to absorber.
the threads of the idler wheel retaining screws. Install STEP 4
four hardened washers and screws to fasten the idler
wheel to the tension shock absorber yoke. Tighten
the screws to torque (see specifications).
STEP 2
JD00363A
Insert the lifting device Nylon sling into the central ori-
fice of the tension shock absorber yoke.
JD01078A
Attach the lifting device Nylon sling to the assembly.

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

Copyright
5005-8
DISASSEMBLING AND ASSEMBLING THE IDLER WHEEL

Description
C
2
8 7 5 6 3 4
B
A
CS02B516
1 PLUG 5 SEAL
2 IDLER WHEEL 6 SHAFT
3 RETAINER PIN 7 FACE SEAL
4 SLIDE 8 BUSHING
A .....................................................................................................................................................................345 mm
B .....................................................................................................................................................................252 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
5
2 6
4
4 CS02B519
Remove and scrap the O-ring (5) from the shaft (6).
CS02B517 Remove the shaft (6) with the slide (4) from the idler
Clean the idler wheel (2) with a suitable solvent. wheel (2).
Install the idler wheel (2) on supports, with the drain
plug (1) at the bottom. Remove the drain plug (1) STEP 4
from the slide (4) and drain the oil.
STEP 2
3
6 4
3 6
5
4
4
2
CS02B520
Remove the retainer pin (3) from the slide (4).
Remove the slide (4) from the shaft (6), remove and
CS02B518 scrap the O-ring (5) from the shaft (6).
Remove the retainer pin (3) at one end. Remove the
slide (4) from the shaft (6). STEP 5
7
4
7
CS02B521
Remove and scrap the face seal (7) from the slide (4)
using a screwdriver or equivalent tool. Be careful not
to damage the seal bore in the slide.

Copyright
5005-10
STEP 6 Inspection
7 2 7 STEP 1
Clean all the components with cleaning solvent. Also
clean the cavity in the idler wheel. Dry all the compo-
2 nents with compressed air at low pressure and apply
clean oil to all the components.
STEP 2
Inspect the bushing surfaces on the shaft for scoring,
7 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.
CS02B522 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. Meas-
sure you do not damage the idler wheel seal bore. ure the inner diameter and width of the bushing.
Compare the values with the specifications. Change
STEP 7 them if necessary.
8 STEP 4
Check for damage which could give rise to leaks at
the slide seal and idler wheel bores. Replace the
components with new components as required.
Measure the depth of the slide seal bores. Compare
8 the values with the specifications. Change them if
necessary.
2
CS02B523
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
4
7
A
8 8
CS02B521
2 Install the remaining O-rings and remaining face seal

(7) metal bushing in the slide seal bore (4). Apply
8 clean oil copiously to the face seals.
STEP 4
2 3
4
CS02B524
A. Clean the inside 6
Carefully install the bushings (8) in the idler wheel 5
using a press and a suitable rod.
STEP 2
CS02B520
7 2 7 Lubricate the O-rings (5) with clean grease. Install an
O-ring on the shaft (6), then install the shaft in the
hub (4). Secure the slide and the shaft with a retainer
2 pin (3).
7
CS02B522
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
5
1
2 6
4 4
CS02B519 CS02B517
Apply clean grease around the shaft (6). Install the Fill the idler wheel (2) with clean oil (see specifica-
shaft and slide (4) assembly in the idler wheel (2). tions). Install the drain plug (1) in the slide (4).
STEP 6
6
3
4
2
5
1
CS02B572
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 slide (4) on the shaft and install a
retainer pin (3) to fasten the slide and the 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 dam-
age 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 regula- incorrect assembling.
tor (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 cou-
pler.

Copyright
5005-14
DISASSEMBLING AND ASSEMBLING THE TENSION SHOCK ABSORBER

Description
4 5
3
2
CI02B500
1 SHOCK ABSORBER SPRING 4 COMPENSATOR
2 RETAINER PIN 5 SPRING GUIDE
3 SLOTTED NUT

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
compensator (4) in the hydraulic press on the spring
guide (5).
STEP 2
STEP 3
Place the shock absorber spring in a hydraulic press.
Use the press to compress the shock absorber spring Operate the hydraulic press to compress the shock
(1). absorber spring (see specifications for the value).
STEP 3 STEP 4
Drive out the retainer pin (2) from the slotted nut (3). Install the slotted nut (3) and install a new retainer pin
Remove the slotted nut from the spring guide (5). (2) in the slotted nut and the spring guide shaft (5).
STEP 4 STEP 5
Operate the hydraulic press to release tension in the Remove the shock absorber spring from the
shock absorber spring (1). hydraulic press.
STEP 5
Remove the compensator (4) and the shock absorber
spring (1) from the spring guide (5).

Copyright
5005-16
TRACK TENSION CYLINDER

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

6001
Section Copyright
6001
REMOVAL AND INSTALLATION OF

THE TRAVEL-MOTOR REDUCTION GEAR ASSEMBLY

Printed in France
Copyright
6001-2
TABLE OF CONTENTS
SPECIFICATIONS .................................................................................................................................................. 2
SPECIAL TORQUE SETTINGS ............................................................................................................................. 2
TRAVEL MOTOR/REDUCTION GEAR ASSEMBLY ............................................................................................. 3
Removal and installation ..................................................................................................................................... 3
SPECIFICATIONS
Hydraulic fluid ................................................................................................................................. See Section 1002
Lubricant for reducing gear pinion
Type............................................................................................................................................ See Section 1002
Quantity...................................................................................................................................... See Section 1002
Weight of the travel motor/reduction gear assembly....................................................................... See Section 1002

Travel motor/reduction gear assembly to track frame retaining screw ........................................... See Section 1002
(apply Loctite 262 to the screw threads)
Drain plug, oil filling and oil level plug .............................................................................................. 147.1 14.7 Nm
(put Teflon tape around the threads)

Copyright
6001-3
TRAVEL MOTOR/REDUCTION GEAR ASSEMBLY

Removal and installation
STEP 1 STEP 5
To prevent any fluid leaks when disconnecting
hydraulic lines, connect a vacuum pump to the
hydraulic reservoir (see Section 8000).
STEP 6
1
JS00163A
attachment to the ground.
STEP 2
Release pressure in the hydraulic system and in the CD00F067
hydraulic reservoir (see Section 8000). Remove the four screws and washers (1) then
remove the access panel to the travel motor.
STEP 3
STEP 7
CD02B005
CD01K026
Remove the oil filler plug and the oil level plug (1) and To facilitate reassembly, attach identification tags to
the drain plug (2) and drain the oil. the different hoses connected to the travel motor (1).
NOTE: When installing, refer to Section 1002 for the STEP 8

recommended quantity and type of oil. Tighten the Start the vacuum pump.
plugs to a torque of 147.1 14.7 Nm.
STEP 4
Put Teflon tape around the plug thread and put it back
in place. Install the filling plug.

Copyright
6001-4
STEP 9 STEP 13
2
CD02B005 JD00838A
Disconnect the hoses (1) from the travel motor (2). Remove the retaining screws from the travel motor/
Plug the hoses and the unions. reduction gear assembly of the undercarriage.
STEP 10 Remove the travel motor/reduction gear assembly

from the machine.
Stop the vacuum pump.
NOTE: When installing, tighten the screws to the
STEP 11 torque specified in Section 1002.
Refer to Section 5004 and carry out the steps for the STEP 14
removal of the sprocket wheel.
STEP 12
6002-11
Place the travel motor/reduction gear assembly on a
flat surface with the drive motor turned upwards.
JD00836A
Remove the lifting equipment.
Connect a suitable lifting device to the travel motor/
reduction gear assembly. NOTE: When installing, follow the same procedure in
the reverse order. Replace all O-rings with new
NOTE: See Section 1002 for the weight of the travel
O-rings. Fill the housing with hydraulic oil using the
motor/reduction gear assembly.
leak return port. Before operating the machine, check
the circuit for leaks. Check the hydraulic oil level in
the reservoir and the oil level in the housing of the
travel reduction gear, top up if necessary.

Copyright
Section
6003
6003
OF THE SWING REDUCTION GEAR

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

Screws which attach the swing motor to the swing reduction gear ............................................... 568.4 to 649.4 Nm
Screws which attach swing reduction gear to the upperstructure frame ........................................ See Section 1002
TOOLS REQUIRED
- Hand pump CAS-10090.

Copyright
6003-3
SWING REDUCTION GEAR

Removal STEP 5
STEP 1
Carry out steps 1 to 10 of "Removing the swing
motor" (see Section 8008).
STEP 2
JD00437A
Carefully lift the upperstructure swing motor and
reduction gear assembly, move it away from the
1 machine.
2 STEP 6
CD02B034
Attach an identification tag to the hoses (1) and (2),
disconnect them and plug the ports.
STEP 3
Mark the position of the swing reduction gear on the
upperstructure frame by making alignment marks on
the swing reduction gear and the upperstructure
frame.
STEP 4 1
JS00379A
Place a container of 6 litres capacity under the swing
reduction gear drain plug. Remove the drain plug (1)
and drain the oil. Install the drain plug.
JD00449A
Remove the twelve swing reduction gear retaining
screws (1) and the centring pin.

Copyright
6003-4
STEP 7 Installation
Lower the swing motor/reduction gear assembly to STEP 1
the ground and place it on suitable stands.
NOTE: The stands must be high enough to prevent
the pinion touching the ground.
STEP 8
2 1
JD00446A
Connect a suitable lifting device to the swing motor
and move it into position above the reduction gear.
Carefully lower the swing motor onto the reduction
gear.
JD00386A
To facilitate reassembly, make an alignment mark (1) STEP 2
on the swing motor and on the reduction gear.
Remove the twelve swing motor retaining screws (2).
STEP 9
Carefully raise the swing motor and move it away
from the swing reduction gear. Place it in a clean
area.
1
JD00386A
Install the twelve swing motor retaining screws (1).
NOTE: Tighten the screws to a torque of between
568.4 and 649.4 Nm.
STEP 3
Clean the upperstructure mating surface.

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6003-5
STEP 4 STEP 6
JD00437A JD00473A
Raise the swing motor/reduction gear assembly off Connect the hand pump CAS-10090 to the swing
the ground. Apply No. 2 EP lithium grease over the motor brake release orifice (A).
pinion (A).
STEP 7
NOTE: Before installing the swing motor/reduction
gear assembly, check that the drain hose (B) is Check that the hand pump is filled with fluid.
installed on the side of the reduction gear housing. STEP 8
STEP 5 Operate the hand pump until the pressure gauge
shows 29 bar. The swing motor brake should be
released, thus allowing the reduction gear output
shaft to turn.
STEP 9
Lower the swing motor/reduction gear assembly onto
the upperstructure mating surface, using a dowel pin.
NOTE: Make sure that the reduction gear output gear
is correctly engaged in the upperstructure crown
wheel.
STEP 10
JD00385A
Raise the swing motor/reduction gear assembly and
bring it into position above the upperstructure mating
surface, ensuring that it is in line with the alignment
marks previously made.
JD00449A
Apply Loctite 262 to the screw threads (1) and tighten
them to the torque specified in Section 1002.

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6003-6
STEP 11 Fill the swing reduction gear with the quantity (capac-
ity) and type of oil specified in Section 1002. Install
the oil dipstick and check the oil level. The oil level
should be on the lower part of the dipstick. Add oil as
required and install and tighten the oil filler plug.
STEP 13
A 2
JD00473A
Release the hydraulic pressure in the hand pump 1
CAS-10090 and disconnect it from the swing motor
brake release orifice (A). Remove the lifting equip-
ment from the swing motor.
STEP 12 CD00E162
1 AIR BLEED PLUG
2 LUBRICATION ORIFICE
2 Remove the air bleed plug on the side of the swing
reduction gear. Pump No. 2 EP lithium grease into
the reduction gear until grease comes out of the air
bleed orifice. Install the air bleed plug.
STEP 14
Connect a vacuum pump to the hydraulic reservoir
(see Section 8000). Start the vacuum pump.
3
CD00F055
CD00E187
Check that the swing reduction gear oil drain plug (1)
is correctly tightened. Remove the oil level dipstick (2)
and the oil filler plug (3).

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6003-7
STEP 15 STEP 18
1
2
CD02B034 CD01K071
Remove the plugs and connect the hoses (1) and (2). Connect the earth cable (1) to the battery.
STEP 16 STEP 19
Refer to the removal of the hydraulic swing motor and See Section 8001 and adjust the swing motor sec-
carry out step 8 in the reverse order. ondary relief valves.
STEP 17 STEP 20
Stop and disconnect the vacuum pump from the
1
2
CS02B555
Install the upper panel (1) using retaining screws (2).
NOTE: Before operating the machine, start the
engine, check the system for leaks and check the
fluid level in the hydraulic reservoir, top up if neces-
sary.

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6003-8

Copyright
Section
6004
6004

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

Description ........................................................................................................................................................... 3
Disassembly .........................................................................................................................................................4
Assembly .............................................................................................................................................................. 7

Cover retaining screws .................................................................................................................. 568.4 to 649.7 Nm

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6004-3

Description
13 15
14 16
12
21 17
18
11
10 19
9 8
6 20
4 5
2 3
1
7
CI02B502
1 PINION 12 RING GEAR
2 SPACER 13 FIRST STAGE SUN GEAR
3 SNAP RING 14 SHIM
4 PLATE 15 FIRST STAGE PLANETARY GEAR
5 SPHERICAL ROLLER BEARING 16 FIRST STAGE PLANET WHEEL CARRIER
6 HOUSING 17 SECOND STAGE PLANETARY GEAR
7 SHAFT 18 RETAINER PIN
8 LIP-SEAL 19 SECOND STAGE PLANET WHEEL CARRIER
9 SPACER 20 SPACER
10 SPHERICAL ROLLER BEARING 21 SECOND STAGE SUN GEAR
11 PIN

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6004-4
Disassembly STEP 4
NOTE: The swing reduction gear is extremely heavy.
Use suitable lifting equipment to lift and move the 1
components.
machine model, but the procedure remains the same.
STEP 1
Place the reduction gear in a clean working area.
STEP 2
CD02B037
Remove the second stage sun gear (1).
STEP 5
CD02B035
Remove the first stage sun gear (1) and thrust ring.
STEP 3
1 CD02B038
Remove the second stage planet wheel carrier (1).
CD02B036
Remove the first stage planet wheel carrier (1).

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

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6004-6
STEP 11 STEP 13
3
1
4
CD02B039 2 2
Remove the roller bearing (1) from the gear housing.
STEP 12
CI02B503
Place the shaft (1) under a press. Insert two
1 shims (2), press the shaft (1) from the bearings (3).
Remove the spacer (4).
STEP 14
JD00459A
Using a suitable tool remove the lip seal (1) from the
gear housing. Discard the lip seal.
1
CD02B040
Place the planetary gear assembly on a workbench.
Press the retainer pins (1) in the axles just enough to
remove the axles.

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6004-7
STEP 15 Assembly
2 NOTE: The photos below do not correspond to the
machine model, but the procedure remains the same.
STEP 1
Place the planet wheel carrier on a clean workbench.
STEP 2
2 1
1
CD02B041
Support the planetary gears and remove the axles
from the planet wheel carrier (2). Press the pins com-
pletely from the axles (1). Remove the pins.
STEP 16
6003-106
Assemble the planetary gears (1), slide the thrust
washers (2) under the pinions (boom).
STEP 3
1
1
6003-105
Remove the planetary gears (1).
STEP 17
1
6003-105
Align the pinions with the bores of the planet wheel
carrier and install the axles. Take care to position the
axle retaining bore correctly (1) with respect to the
bore of the planet wheel carrier.
6003-106
Remove the thrust washers (1) from the planetary
gears.

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6004-8
STEP 4 STEP 6
WARNING: Take precautions (gloves), risk of

B ! burns.
A
2
3
6003-107
Install a new pin (A) in the shaft using a suitable tool.
Recess dimension in the planet wheel carrier:
B = 1 mm.
Lock it, using two strokes of a punch.
1
STEP 5
Position the retainer pins in the second stage planet
wheel carrier.
CI02B504
Install the spacer (1) on the shaft (2). Heat the bear-
ing (3) to 50C above the ambient temperature.
Assemble the hot bearing on the shaft (2), use pro-
tective gloves.
STEP 7
CS00K512
Boom: direction of rotation.
JD00465A
Degrease the reduction gear housing and apply Loc-
tite 504. Fix the reduction gear housing in a press,
install the lip seal in the reduction gear housing.
Lubricate the lip seal with No. 2 EP lithium grease.
Install the spacers, then install the bearing on the
reduction gear side.

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6004-9
STEP 8 STEP 10
6 6 1
5 1
2
7
1
JD00469A
Degrease the mating surfaces of the gear housing,
3 ring gear, and the four dowel pins. Install the four
dowel pins (1) into the gear housing. Apply Loctite
4 4 504 liquid packing to the mating surfaces.
STEP 11
CI02B505
Coat the roller bearings (1) with 800 grams of No. 2 EP
lithium grease (2). Place the shaft assembled (3) on
the shims (4) under a press. Position the housing (5) 2
equipped with the bearing and the lip seal on the
shaft (3). Position the shims (6) on the bearing (7).
Assemble the housing using the press (booms).
STEP 9
1
1 JD00470A
Install the ring gear (1) ensuring the alignment marks
are aligned. Assemble four screws (2) in opposition to
hold the ring gear (1).
4 3
5 7 6
CI02B506
Assemble the plate (1). Assemble the snap ring (2)
with a gap of about 30 mm with respect to the notch
on the housing. Install the spacer (3). Lubricate and
assemble the pinion (4). Assemble the stop plate (5).
Install the brake plate (6), assemble and tighten the
screws (7). Bend the corners of the brake plate (6) on
the screw heads (7).

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6004-10
STEP 12 STEP 14
1
1
CD02B038 CD02B036
Install the second stage planet wheel carrier (1) so Install the first stage planetary assembly (1) so that it
that it meshes correctly with the internal teeth of the meshes with the internal teeth of the ring gear. Turn
ring gear. Turn the planetary assembly slightly to the planetary assembly slightly to mesh the teeth of
engage the splines of the pinion shaft. the planetary gears with the teeth of the second
stage sun gear.
STEP 13
STEP 15
1
1
CD02B037
Install the second stage sun gear (1) so that it CD02B035
meshes with the planetary gear assembly. Install the thrust shim on the second stage sun gear.
Install the first stage sun gear (1) so that it meshes
correctly with the teeth of the planetary gears. Turn
the first stage planetary assembly by hand and check
that the output shaft rotates smoothly.

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6004-11
STEP 16
1
A
12
10
7
CS00K516
Measure the dimension (A), position of the sun gear.
Make sure that the distance between the end surface
of the sun gear No.1 (1) and the ring gear (12) is 1.04
to 3.70 mm. If the distance falls short of reaching 1.04
mm:
Gear shaft (7) and the roller bearing (5) are dislo-
cated.
The roller bearing (10) is not inserted completely.
Foreign substances are engaged.
If the distance is larger than 3.70 mm:
The wire (3) is not installed properly.
The ring gear (12) is not completely tightened into the
gear case (6).
Foreign substances are engaged.

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6004-12

Copyright
Section
6005
TRAVEL REDUCTION GEAR

DISASSEMBLY AND ASSEMBLY
6005

Printed in France
Copyright
6005-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 2
SPECIAL TORQUES................................................................................................................................................ 2
REDUCTION GEAR ................................................................................................................................................. 3

Description ........................................................................................................................................................... 3
Disassembly .........................................................................................................................................................4
Inspection ............................................................................................................................................................. 7
Assembly .............................................................................................................................................................. 9
SPECIFICATIONS
See Section 1002.
SPECIAL TORQUES
Screw (24) ............................................................................................................................................ 68.6 6.8 Nm
Screw (25) ........................................................................................................................................... 402 39.2 Nm
Plug (26) .............................................................................................................................................. 147 14.7 Nm

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6005-3
REDUCTION GEAR
Description
24 17 16 14 13 12 15 21 22 19 18 25 23
4
20
5
1
7
3
10
8
6
9
11
2
71 26
CS02B540
1 COVER 15 SPRING PIN
2 CARRIER 16 THRUST WASHER
3 CARRIER PIN 17 RING GEAR
4 NEEDLE BEARING 18 HOUSING
5 THRUST WASHER 19 ANGULAR BEARING
6 PLANETARY GEAR 20 SHIM
7 SPRING PIN 21 LOCK WASHER
8 THRUST PLATE 22 SUPPORT RING
9 SUN GEAR 23 FLOATING SEAL
10 SUN GEAR 24 SCREW
11 CARRIER 25 SCREW
12 CARRIER PIN 26 PLUG
13 NEEDLE BEARING 71 O-RING
14 PLANETARY GEAR

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6005-4
Disassembly
WARNING: Safety is priority while disassem-
General precautions bling. Be careful and avoid hands from being
1. Its common that a reduction unit which has been ! caught between parts or lifted parts from fall-
dismounted from the machine is covered with dirt ing on your feet.
or dust. Wash and dry the exterior of the unit.
2. Loosen the drain and filler plug (26) to drain oil in STEP 2
the reduction unit.
WARNING: If the oil is still hot, internal pres-

sure still remains. Care should be taken
! because the oil can blow out.
3. Placing counter marks. Place counter marks on

the outer side of each mating face in order to put
the faces back into their original locations when
assembling.
NOTE: Numbers in parentheses following the part
names shown in the description below correspond to
symbols in the structural drawings. CD02B007
Remove the remainder of M10 hexagon socket head
STEP 1 cap screws (24).
COUNTER MARKS
STEP 3
CD02B008
Sealing material is applied to the contact surface
between the cover (1) and ring gear (17).
Therefore, remove the cover (1) by patching the pro-
CS02B541
Installing travel unit onto cradle. Remove the screw truding part of the cover and hitting it diagonally
(24) which are screwed into three locations on the upwards.
cover (1) at equal intervals, and install eyebolts in
their place.
Then, lift the cover and install the cradle with the
cover facing upward and the motor downward.

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6005-5
STEP 4 STEP 7
CD02B009 CD02B012
Remove the thrust plate (8). Remove the lock washer (21) by placing a screw-
Remove the sun gear (9). driver or equivalent to the washers split part and tap-
Attach three M10 eyebolts onto the carrier (2) and ping the driver with a hammer.
remove carrier (2) assemblies (3), (4), (5), (6) and (7).
STEP 8
STEP 5
CD02B013
CD02B010 Attach eyebolts on three locations at equal intervals

Remove the sun gear (10). among the M10 screw holes on the ring gear (17),
Attach three M10 eyebolts onto the carrier (11) and and remove the housing assembly (ring gear (17),
remove carrier (11) assemblies (12), (13), (14), (15) housing (18), bearing (19) and floating seal (23))
and (16). while lifting it evenly.
STEP 6
CD02B011
Remove the support ring (22).

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6005-6
STEP 9 STEP 14
19 23 25 18
17
CS02B542 CD02B015
Place the assembly on the cradle with the ring gear Remove the floating seal (23) from the motor side.
(17) facing downward and the housing (18) upward.
Put counter marks on the housing and the peripheral STEP 15
of ring gear.
STEP 10
Remove the floating seal (23) from the housing (18).
STEP 11
Remove the M18 hexagon socket head cap screws
(25) with tow bolts left diagonally.
STEP 12
The ring gear (17) can be easily removed from the
housing (18) by slightly hitting the heads of the bolts
with a hammer while having those two screws loos- CD02B016
ened. Push the spring pin (7) into the carrier pin (3).
Remove carrier pin (3) from the carrier (2).
STEP 13 Remove the thrust washer (5), planetary gear (6) and
needle bearing (4).
STEP 16
CD02B014
Handle with care to avoid damage to the sliding sur-
faces of the floating seal (23) and O-rings.
The circumference of bearing (19) are extremely CD02B017
firmly attached. Pull out the spring pin (7) temporarily from the carrier
Do not disassemble except when bearings must be pin (3).
replaced. Always replace three of them together in pairs when
When removing bearings from the housing, do not changing carrier pins (3) or planetary gears (6).
reuse them. Replace them with new ones.

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6005-7
STEP 17 Inspection
1. Thrust washers
Inspect if there is any seizure, abnormal wear,
uneven wear, or other.
Check that the wear is within allowable values.
2. Gears
Check for pitching and seizure on the face of
tooth.
Check the colour on the root of tooth to find out
cracks.
3. Bearing
Make sure that there are no noises or engage-
ment by manually rotating the bearing.
CD02B018
Push the spring pin (15) into the carrier pin (12). 4. Floating seal
Remove carrier pin (12) from the carrier (11). Check if there is any damage on the sliding faces
STEP 18 of O-rings.
CD02B019
Remove the thrust washer (16), planetary gear (14)
and needle bearing (13).
Pull out the spring pin (15) temporarily from the car-
rier pin (12).
Always replace three of them together in pairs when
changing carrier pins (12) or planetary gear (14).

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6005-8
D E
F
C
CS02B543
Mark Item Reference value Allowable value Remedy
A Wear on the planetary Smooth, no abnormal Smooth, no abnormal Replace all three
shaft wear and seizure wear and seizure together
B Conditions on face of Smooth, no abnormal No pitching of dia. 1.6 Replace all three
tooth and root of tooth wear and seizure or more, no cracks on planetary gears
the root of tooth together
C Thrust spaces in the - 0.08 to 0.02 - 0.08 to 0.02 Changing shims

inner race of angular (Interference) (Space) (Interference) (Space) (See 2-3. 6)
bearings
D Thickness of thrust 3.3 mm to 3.7 mm Wear 0.1 mm Replace

washer 1
E Thickness of thrust 5.2 mm to 5.7 mm Wear 0.1 mm Replace

washer 2
F Thickness of thrust 4.34 mm to 4.66 mm Wear 0.15 mm Replace

plate
G Lubrication oil 2.000 working hours (engine hour meter) Replace

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6005-9
Assembly STEP 3
General precautions
1. Wash each part with treated oil, then dry it com-
pletely with air. For the surfaces to which Loctite is
applied, degrease with thinner or equivalent.
2. Check for any abnormality on each part.
3. Tighten hexagonal socket head cap screws upon
application of Loctite.
4. Apply a thin coat of gear oil to assembly parts
prior to the assembly.
WARNING: Be careful and avoid hands from CD02B022

being caught between parts or lifted parts Crimp them on two 180 symmetrical locations.
! from falling on your feet.
STEP 4
STEP 1
CD02B015
Insert the planetary gear (6), needle bearing (4) and
CD02B020 thrust washer (5) into the carrier (2).
Insert the planetary gear (14), needle bearing (13)
and thrust washer (16) into the carrier (11). STEP 5
STEP 2
CD02B023
Insert the carrier pin (3) into the carrier (2) with its
CD02B021 spring pin hole direction aligned.
Insert the carrier pin (12) into the carrier (11) with its Insert the spring pin (7) into carrier (2) and carrier pin
spring pin hole direction aligned. (3). (Hammer it down 1 or 2 mm deep below the hit-
Insert the spring pin (15) into carrier (11) and carrier ting surface).
pin (12). (Hammer them down 1 or 2 mm deep below
the hitting surface).

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6005-10
STEP 6 STEP 9
23 25 18
17
CD02B024 CS02B542
Crimp them on two 180 symmetrical locations. Attach three eyebolts on the housing (18) and lift it
with a wire to install onto the ring gear (17) with the
STEP 7 counter marks aligned.
Apply Loctite No. 242 to hexagonal socket head cap
screws (25) and fasten them with tightening torque of
402 39.2 Nm.
STEP 10
CD02B025
Install the floating seal (23) for the motor side.
STEP 8
LOCTITE No. 515 18 CD02B026

Install the floating seal (23) for the housing side.
HOUSING SIDE
CS02B544
Apply Loctite No. 515 to the mating surfaces of hous-
ing (18) and ring gear (17).

Copyright
6005-11
STEP 11
NOTE: This process is necessary when any motor (casing), housing (18), bearing (19) or lock washer (21) is
changed. As this is not the case, use the old shims (20) as they are.
21 22 17 19 18 20
D A S
C B
CS02B546 CS02B547
1. Press two inner races of the bearing (19) equally, 5. Suppose the thickness of a shim (20) to be used
and measure the assembly width of inner race is S, the space X is expressed as follows:
(A). X = (B + C) - (A + D + S)
2. Measure the assembly width of motor bearing (B). 6. In this unit case, select one shim to make the
space X as follows: - 0.08 to 0.02 mm.
3. Measure the groove width of motor (C).
(+ value is space, while - value is extrusion).
4. Measure the width of lock washer (21) (D).
STEP 12 STEP 14
Place the motor on a level surface with its shaft
upward, and put the shims (20) selected in the above
mentioned step on the end face of the bearing inser-
tion section on the motor.
STEP 13
Attach three eyebolts to the gear ring (17) to lift, and
then insert the bearing (19) attached to the inner
diameter of the housing (18) into the motor by lower-
ing it slowly, vertically along with the motors centre.
With a press, press and insert the inner race section
of bearing (19) into the deep end.
CD02B013
Engage the lock washer (21) into the groove while
pressing the flange part of housing (18) with a press.

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6005-12
STEP 15 STEP 18
CD02B011 CD02B010
Insert the support ring (22) into the outer side of lock Install the carrier (2) assembly into gear ring (17) and
washer (21). adjust its position by manually rotating the planetary
gear (6) to engage it into the sun gear (10).
STEP 16
STEP 19
14
CS02B548
Place the carrier (11) assembly into the ring gear (17) CD02B009
so that the three planetary gears (14) are located as Insert the sun gear (9).
shown in the figure, and then, engage them into the Engage the thrust plate (8) into the carrier (2).
spline of the motor.
STEP 17
Insert the sun gear (10).
The reason why the carrier (11) is reassembled as
shown in the figure is to facilitate proper oil lubrica-
tion.

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6005-13
STEP 20
LOCTITE No. 515 1
CS02B549
Apply Loctite No. 515 to the mating surfaces of cover
(1) and ring gear (17), and install the cover (1) onto
the ring gear (17).
STEP 21
CD02B027
Apply Loctite No. 242 to hexagonal socket head cap
screws (24) and fasten them with tightening torque of
68.6 Nm.

Copyright
6005-14

Copyright
Section
8000
PRESSURE RELEASE AND DECONTAMINATION

OF THE HYDRAULIC SYSTEM, USE OF THE VACUUM
PUMP AND BLEEDING OF 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 remarks .................................................................................................................................................. 7
Types of contamination ........................................................................................................................................ 7
Decontaminating the hydraulic circuit .................................................................................................................. 8

Copyright
8000-3
SPECIAL TOOLS
806128
CAS 10508 Kit for unions
806127
CAS 10162A Portable filter
CS99B532
CAS 30038 Set of unions for pressure test and
hydraulic flow
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, the pressure in all the systems
must be 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 the right and
left and backwards and forwards.
STEP 5
CD00E060
Turn the ignition key to the "ON" position (ignition).
STEP 3
CD00E080
Turn the ignition key to the "OFF" position (shut
down).
STEP 6
CD00E006
Lower the function cancellation control arm (exit
safety bar).
CD01K024
Press the button located above the breather to
release any possible pressure.

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

IMPORTANT: After bleeding the components, shut Attachment cylinders
down the engine for five minutes, then check that
there are no air bubbles in the hydraulic fluid in the Start the engine in idle mode. Extend and retract all
reservoir. the cylinder rods four to five times without bringing
them against the stops, then repeat the operation
Hydraulic pump three or four times, this time bringing all the cylinder
rods against the stops.
Hydraulic swing motor
CRPH06E006A
Using a solvent, clean the upper surface of the pump
and the air bleed plug. Remove the air bleed plugs.
CD01K072
Fill the pump with hydraulic fluid via that orifice. Install Start the engine in idle mode. Loosen the air bleed
and tighten the air bleed plugs. plug and make sure that hydraulic fluid flows out of
Start the engine, engine speed in idle mode. Loosen that port. If required, shut down the engine and top
the pump air bleed plugs. Retighten the plugs as up via this port. Install the plug without tightening it,
soon as the fluid flows without air bubbles from the then start the engine in idle mode and let it run until
ports. Clean carefully around the plugs. the hydraulic fluid flows out from the port. Completely
retighten the air bleed plug. Carry out at least two
complete rotations to the left and to the right of the
upperstructure frame.

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.
CD01K024
Removal
Remove the plate (A) from the top of the hydraulic
reservoir.
STEP 1
NOTE: Do not remove the O-ring from the reservoir. Disconnect the vacuum pump harness from the bat-
teries.
NOTE: The photos for steps 3 and 4 are not for the
same model, but the procedure remains the same. STEP 2
STEP 3 Disconnect the vacuum pump from the elbow union
of the adaptor plate (B).
B STEP 3
Remove the adaptor plate (B) from the hydraulic res-
ervoir and discard 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 remarks Types of contamination
Contamination of the hydraulic system is a major Contamination exists basically in two forms: micro-
cause of incorrect operation of hydraulic components. scopic or visible.
The contamination results from the presence of for-
1. We speak of microscopic contamination when
eign bodies in the hydraulic fluid. Contamination of
very small particles of foreign bodies are in sus-
the hydraulic system can occur in any of the following
pension in the hydraulic fluid. These particles are
situations:
too small to be seen or felt. One can detect micro-
1. When draining the fluid or reconnecting the scopic contamination by identifying the problems
hydraulic lines. relating to the microscopic contamination or by
laboratory tests. Here are a few examples of prob-
2. When removing a component.
lems caused by microscopic contamination:
3. Due to normal component wear.
A. The cylinder rod seals are leaking.
4. Due to damaged or worn seals.
B. Control valve spools do not return to the neutral
5. Due to a damaged component in the hydraulic sys- position.
tem.
C. The operating temperature of the hydraulic sys-
All hydraulic systems can function even if they are tem is too high.
slightly contaminated. The components of the D. Components wear quickly.
hydraulic system are designed to support slight con-
tamination. Any increase in the degree of contamina- 2. One speaks of visible contamination when the pres-
tion can cause serious problems in the hydraulic ence of foreign bodies can be detected visually, by
system. touch or by smell. Visible contamination can cause a
sudden failure of a component. Here are a few
Here is a non-exhaustive list of these problems: examples of problems caused by visible contamina-
1. The cylinder rod seals are leaking. tion:
2. Control valve spools do not return to the neutral A. The fluid contains metal or other fragments.
position. B. The fluid contains air.
3. The control valve spools do not move easily. C. The fluid is dark and thick.
4. Hydraulic fluid is too hot. D. There is a smell of burning in the fluid.
5. Hydraulic components wear quickly. E. The fluid contains water.
6. Safety valves or non-return check valves do not
close due to contamination.
7. Repaired components break down soon.
8. Cycles are slow; the machine does not have enough
power.
If one of the above situation occurs, it shows exces-
sive contamination of the hydraulic system. To elimi-
nate this contamination effectively, use the portable
filter CAS 10162A.

Copyright
8000-8
Decontaminating the hydraulic STEP 7

circuit
1
STEP 1
Prepare the portable filter CAS 10162A as follows:
1. Eliminate all hydraulic fluid from the inlet and out-
let hoses of the portable filter.
2. Remove the cartridge of the portable filter.
3. Eliminate all the hydraulic fluid from the portable fil-
ter.
4. Clean the interior of the cartridge housing.
5. Install a new filter cartridge. CD01K081
Remove the plug (1) from under the hydraulic reser-
STEP 2 voir.
Release pressure in the hydraulic system, see page 4. STEP 8
STEP 3 Install the shut-off valve from the union kit CAS 10508
Drain the hydraulic fluid from the reservoir, see the under the hydraulic reservoir.
operators manual. NOTE: Make sure that the valve is closed.
NOTE: Do not assemble the access door under the STEP 9
hydraulic reservoir.
Fill the hydraulic reservoir with clean hydraulic fluid,
STEP 4 see the operators manual.
Change the breather cartridge, the return filter and STEP 10
clean the inlet filter, see the operators manual.
Install the inlet hose from the portable filter on the
NOTE: Do not install the plate complete with the valve under the hydraulic reservoir.
breather.
STEP 11
STEP 5
Install the long pipe from the union kit CAS 10508 on
Change the pilot circuit filter, see the operators man- the portable filter return hose.
ual.
STEP 12
STEP 6
Insert the long pipe in the hydraulic reservoir. Move
Change the Ultra Clean filter, see the operators man- the inlet filter long pipe as far away as possible.
ual.
STEP 13
Open the valve under the hydraulic reservoir.

Copyright
8000-9
STEP 14 STEP 20
Install the portable filter on the upperstructure in such With the engine running at full speed, operate the
a manner that the machine can be operated. Attach swing control several times by 180 degrees to the left
the portable filter firmly to the machine. and then to the right.
STEP 15 STEP 21
Connect the electric cable from the portable filter to With the engine running at full speed, position the
the batteries. Make sure that the electric cable is attachment at right angles to the frame. Use the
away from all moving parts. attachment to raise the track off the ground. Operate
the travel pedal, in one direction for 2 minutes and
STEP 16 then in the other direction for 2 minutes. Repeat this
Start the portable filter running. cycle for 10 minutes.
STEP 17 STEP 22
Start the engine, run it at half the maximum speed for Repeat step 21 for the other track.
10 minutes. During those ten minutes, stir the hydrau-
STEP 23
lic fluid in the hydraulic reservoir with the long pipe.
Bring back the engine to idle mode.
STEP 18
STEP 24
Run the engine at maximum speed and bring the
hydraulic fluid to its operating temperature by pro- Stir the hydraulic fluid in the hydraulic reservoir for
ceeding as follows: 10 minutes with the long pipe.
1. Operate the bucket and dipper controls in one STEP 25
direction (cylinders against the stops) for 30 sec-
onds. Shut down the portable filter and the engine.
2. Operate the bucket and dipper controls in the other STEP 26

direction (cylinders against the stops) for 30 sec- Close the valve under the hydraulic reservoir.
onds.
STEP 27
3. Repeat steps 1 and 2 until the hydraulic fluid tem-
perature reaches 45-55C. (Third bar on the hydrau- Remove the inlet pipe of the valve under the hydraulic
lic oil temperature indicator of the monitor display on reservoir.
the illuminated instrument panel).
STEP 28
STEP 19
Remove the long pipe from the hydraulic reservoir.
With the engine running at full speed, cycle each cyl-
inder (in, out) twice, one after the other for 45 min- STEP 29
utes. Disconnect the electric cable of the portable filter
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
CD01K081
Remove the shut-off valve from the union kit
CAS 10508 and install the plug (1).
STEP 33
Shut down the vacuum pump and remove it from the
hydraulic reservoir, see page 6.
STEP 34
Install the access door under the hydraulic reservoir.
STEP 35
Change the return filter and clean the inlet filter, see
the operators manual.
STEP 36
Change the pilot system filter, see the operators
manual.
STEP 37
Change the Ultra-Clean filter, see the operators man-
ual.
STEP 38
Check the hydraulic fluid level. Top up as necessary,
see the operators manual.

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

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

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

Pump.................................................................................................................................................................... 6
Control valve ........................................................................................................................................................ 7
6 solenoid valve bank........................................................................................................................................... 8
PREPARATION BEFORE INSPECTION .................................................................................................................. 9

Releasing pressure in the hydraulic system......................................................................................................... 9
Installing the pilot pressure test point.................................................................................................................. 10
Installing the flowmeter ....................................................................................................................................... 10
Flow curve CX330 Tier 3..................................................................................................................................... 11
Display on the "CHK1" monitor display ............................................................................................................... 12
Warming up the engine ....................................................................................................................................... 12
Warming up the hydraulic fluid............................................................................................................................ 12
CHECKING AND SETTING PROCEDURE ............................................................................................................ 13

Main pilot system relief (H).................................................................................................................................. 14
Checking the pilot accumulator ........................................................................................................................... 14
Main relief (A)...................................................................................................................................................... 14
Attachment control valve secondary reliefs
(B, C, D, E, F and G) ............................................................................................................................................... 16
Boom safety valve secondary reliefs (B1 and B2) ..............................................................................................17
Dipper safety valve (D1)...................................................................................................................................... 18
Swing port secondary relief ................................................................................................................................. 18
Checking the swing brake release pressure ....................................................................................................... 19
Travel secondary relief (K, L) .............................................................................................................................. 19
Checking the pressure delivered by the proportional valve (Y7)......................................................................... 21
Checking travel drift ............................................................................................................................................ 21
Checking for leaks on the travel motor................................................................................................................ 21
Checking the swing motor for leaks .................................................................................................................... 22

Copyright
8001-3
TROUBLESHOOTING ............................................................................................................................................24
Travel drift .......................................................................................................................................................... 24
Not possible to select 2nd travel speed ............................................................................................................. 25
No swing or slow swing ...................................................................................................................................... 26
With the excavator on a slope, the swing brake does not hold .......................................................................... 26
No movement on any function ........................................................................................................................... 27
Lack of power or speed on one of the attachment movements ......................................................................... 27
Not possible to select cushion control ................................................................................................................ 28
The boom or the dipper does not lower ............................................................................................................. 28
PROCEDURE FOR CHANGING OPERATION TYPE ............................................................................................29

ISO type ..............................................................................................................................................................29
Old Sumitomo type..............................................................................................................................................29
Old Mitsubishi type ..............................................................................................................................................30
Old Kobelco type .................................................................................................................................................30

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 rpm and flow.
1 Multi-Handy 2051 tester ..........................D5444448
2 pressure detectors (0-600 bar) ................V5344460
2 straight unions for detector .....................W5344461
1 elbow union for detector ..........................X5344462
1 engine rpm detector ................................ Z5344463
3 cables (5 m long) .....................................E3144472
CD98M009
1 electrical outlet 220V 50Hz......................D5344467
3. 600 LITRE FLOWMETER, ORDER THE FOL-
1 cigarette lighter cable ..............................E5344468
LOWING:
1 instruction manual ....................................-------------
1 carrying case ...........................................N5344476 ONE FLOWMETER RE3 Z5344486
TWO PLATES (M45X2) D4323359
TWO FLANGES ( 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 XXXXX (INCLUDING TWO HIGH
PRESSURE HOSES).

Copyright
8001-6
IDENTIFICATION OF HYDRAULIC COMPONENTS

Pump
330-1-03-00-24A_1
Port Description Location

A1, 2 Delivery port SAE6000 psi 1"
B1 Suction port SAE2500 psi 21/2"
Dr1 Drain port G 3/4 - 20
PH1, H2 Press, sensor port G 3/8 - 17
PSV Servo assist port G 1/4 - 15
Pi1, i2 Negative control port G 1/4 - 15
a1, 2, 4 Gauge port G 1/4 - 15
a3 Gauge port G 1/4 - 14
A3 Gear pump delivery port G 1/2 - 19
B3 Gear pump suction port G 3/4 - 20.5
Dr3 Gear pump drain port G 3/8 - 15
T Air drain port

Copyright
8001-7
Control valve
Pbu PS1 A5
T2 PS2
T1 T3
T5
PC3
Dr Pc3 PC1
PC2 B8 B5 A3
B7 B3 A2
A8
B2 PT
B6
A7 B1
P3
PH
A6 T4
P2 P4 PP
P1
A1 PA
CS01M603 CS01M602
Port Description Port Description

B7 Bucket opening T1 T2 Return
A7 Bucket closing Ps1
Negative signal check
B8 Boom lowering Ps2
A8 Boom raising PT Travel pilot pressure switch
A6 LH forward travel PH Main relief power boost control
B6 LH reverse travel PA Attachment and swing pressure switch
A5 Dipper out Dr Leak return
B5 Dipper in Pc1 Dipper load holding
B3 RH swing Pc2 Boom load holding
A3 LH swing T4 By-pass return
A2 Option circuit T5 To shock absorber (pre-heat)
B2 Option circuit T3 Swing return
A1 LH forward travel Pc3-Pc3' Priority to swing
B1 LH reverse travel Pbu Swing priority cancellation
P1
Pump pressure PP Pilot pressure
P2
P3
Option circuit
P4

Copyright
8001-8
6 solenoid valve bank

Y1 Y5 Y4 T
Y6 P Y3 Y2
CD05L001
Port Description
B Pilot manifold supply
P Pilot line (from the pump)
T Return to reservoir
Y1 Swing pilot shut-off
Y2 Pilot pressure cancellation control
Y3 Swing brake control
Y4 Select travel 2nd speed
Y5 Power boost
Y6 Pilot cushion control cancellation

Copyright
8001-9
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 connections 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 attempt to
operators manual are accredited to use or repair it Non-observance of these instructions
maintain this machine. and the procedure shown below can cause
serious or fatal injury.
Releasing pressure in the hydraulic system

NOTE: Operation to be carried out before every serv- 7. Lower the pilot control cancellation lever.
ice operation on the hydraulic system. 8. Operate each control more than 10 times in both
1. Position the machine on hard, flat ground. directions 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 with the diagnostic display in "S" mode
that the following values are shown.
CS00E544
CHK MODE II S ENG 1800 rpm
1 9. Press the button located on the hydraulic reser-
P1 034.5 MPa I 0450 mA voir breather to release pressure in the reservoir.
P2 034.5 MPa WT 0080 C
N 0.25 MPa OT 0055 C
Engine rpm 185010 rpm

Current 410 mA (hhen operating)
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
8001-10
Installing the pilot pressure test Installing the flowmeter

point (Checking hydraulic pump flows)
A2
7
M3
4
2 3
6
A1
5 1
330-1-05-00-25AE
Install a pressure test point (M3) on the port a3 (G 1/ CI01M520
4), using the quick union supplied in the CAS 30038 1. Disassemble hose (1) from port (A2) of the pump
kit. being checked.
2. Install the elbow union (2) (CAS xxxxx) on the
hose (1).
3. Connect the elbow union (3) (CAS xxxxx) to port
(A2) of the pump.
4. Install the hose (4) (CAS xxxxx) on the elbow
union (3).
5. Install the flowmeter (6) on the hoses (4).
6. Install the hose (5) (CAS xxxxx) on the flowmeter
(6) and on the elbow union (2).
7. Connect the multi-handy 2051 connecting cable
to the plug on the flowmeter (6) detector (7).
8. Proceed in the same manner to check the other
stage of the pump (A1).

Copyright
8001-11
Flow curve CX330 Tier 3

Curve valid for a new pump
330-3-01-04-03A_1
I: Current valve for electromagnetic proportional pressure reducing valve.
Pd: Delivery pressure.
Pf: Power shift control pressure (at reference value).
Pi: Pilot pressure.
Tin: Input torque.
Pressure in this curve shows total pressure P1 + P2 or Pf + Pr
(Consumption torque for point gear pump is not included in Torque line graph)

Copyright
8001-12
Display on the "CHK1" monitor N: Pump negative pressure in MPa (B43 pres-
sure sensor).
display
ENG: Engine speed in rpm (B49 sensor).
To access this screen: Select work mode H or S I: Intensity in mA (Y7 Proportional solenoid).
using control (2).
WT: Engine coolant temperature in C (B1 Temper-
ature sensor).
OT: Hydraulic oil temperature in C (B2 Tempera-
ture sensor).
Warming up the engine

1. Start the engine. The engine will have warmed
up in 10-15 minutes.
2. Run the engine until the message "AUTO WARM
UP" disappears from the display monitor.
1
2
Warming up the hydraulic fluid
1. Display the "CHK1" monitor display.
CM00E001
Press simultaneously on the travel speed control (1) 2. Actuate the bucket and dipper controls in one
and on the work mode selector control (2) as shown direction (against the cylinder stops) for 30 sec-
above until the diagnostic screen CHK1 appears onds.
(3 seconds). 3. Actuate the bucket and dipper control in the
other direction (against the cylinder stops) for 30
seconds.
CHK MODE II H ENG 2000 rpm
1 4. Repeat Steps 1 and 2 until hydraulic temperature
P1 034.0 MPa I 0407 mA
reaches 45-55C on display "CHK1".
5. Actuate the boom, swing and travel controls in
P2 034.0 MPa WT 0080 C both directions to warm up all the circuits to 45-
55C.
N 0.28 MPa OT 0055 C
P1: P1 pump pressure in MPa

(B42 Pressure sensor)
Boom raising
Dipper retracting and extending
Pressure checked
LH and RH swing
RH travel
P2: P2 pump pressure in MPa

(B44 Pressure sensor)
Raising - lowering boom

Dipper extending - retracting
Pressure checked
Bucket opening - closing
LH travel

Copyright
8001-13
CHECKING AND SETTING PROCEDURE

Location of secondary relief valves
B D1 B2 B1
D
C
G A
CS01M603 CS01M602 CI01M518 CI01M517
J I
L CS00M501
H 330-1-05-00-25au 330-1-05-00-25av
Tool used Pressure for 1 turn

Set pressure
Adjusting of the screw (or for
Item Description Lock nut (as single component)
screw 1 shim*)
Main relief (standard pressure) 27 mm 27 mm 343 3 bar (34.3 0.3 MPa) 213 bar (21.3 MPa)
A
Main relief (power boost) 32 mm 267 mm 373 5 bar (37.3 0.5 MPa) 284 bar (28.4 MPa)
B Boom raising port secondary relief 392 5 bar (39.2 0.5 MPa) 212 bar (21.2 MPa)
C Boom lowering port secondary relief 274 5 bar (27.4 0.5 MPa) 212 bar (21.2 MPa)
Hexagon
D Dipper out port secondary relief wrench 212 bar (21.2 MPa)
17 mm
E Dipper in port secondary relief 6 mm 212 bar (21.2 MPa)
392 5 bar (39.2 0.5 MPa)
F Bucket open port secondary relief 212 bar (21.2 MPa)
G Bucket close port secondary relief 212 bar (21.2 MPa)
Hexagon
H Pilot circuit main relief 24 mm wrench 39 1 bar (3.9 0.1 MPa) 20 bar (2.0 MPa)
6 mm
I RH swing port secondary relief Hexagon
48 bar (4.8 MPa)
41 mm wrench 294 4bar (29.4 0.4 MPa)
J LH swing port secondary relief 48 bar (4.8 MPa)
14 mm
K Reverse travel secondary relief 3805 bar (380.5 MPa) 10 bar (1 MPa)*
L Forward travel secondary relief 3805 bar (380.5 MPa) 10 bar (1 MPa)*

Copyright
8001-14
Main pilot system relief (H) Main relief (A)

Test Test
1. Connect a 0-100 bar pressure gauge to pressure 1. Display the "CHK1" monitor display.
test point M3. 2. With the engine at full speed, select mode "S".
2. With the engine at full speed, select mode "S". 3. Operate and hold in position the dipper retracting
3. Move the pilot cancellation lever to its low posi- control (against cylinder stops).
tion. 4. Read the pressure on the monitor display:
4. With the attachment, swing and travel controls in
neutral, read the value on the pressure gauge:
The value should be 391 bar (3.90.1 MPa). 2
1
Adjustment
1. Loosen the lock nut and turn the valve adjusting
screw (H) until 391 bar (3.90.1 MPa) is
reached. 1
2. Tighten the lock nut while holding the adjusting
screw in position.
APPROX.
3. When the adjusting screw has been tightened, 2 SEC. 8 SEC.
check the pressure again and make sure there
are no leaks.
1. Standard pressure
Checking the pilot accumulator 2. Power boost
1. Raise the boom completely and extend the dip- When the dipper cylinder is against the stops,
per. the pressure is the standard value for 2 seconds,
then at the higher pressure - 2-stage relief value
2. Shut down the engine, with the starter key switch
for 8 seconds before falling back to standard
on "ON".
pressure.
3. Operate the boom lowering or dipper retracting
control several times consecutively. Pump Standard pressure 2-stage relief level
4. The pressure in the accumulator should enable 3433 bar 3735 bar
the boom lowering or dipper retracting function to P1-P2
(34.30.3 MPa) (37.30.5 MPa)
be performed about six times.
NOTE: To read the higher pressure - 2-stage relief
level again, the control lever should be released, then
operated against the cylinder stops.

Copyright
8001-15
Setting the power boost pressure Adjusting the standard pressure
NOTE: Carry out the procedure below only if the
power boost pressure is correct, otherwise carry out
the power boost pressure setting procedure.
2
1
3 4 3 4
CS00E550
CS00E550
1. Disconnect and plug the power boost pilot hose
1. Disconnect and plug the power boost pilot hose on the main relief.
on the main relief.
2. Using a wrench, hold the adjusting screw (3) in
2. Using a wrench, hold the adjusting screw (3) in position and loosen the lock nut (4).
position and loosen the lock nut (4).
3. Start the engine and run it at maximum speed,
3. Tight the adjusting screw (3) up to the stop. select mode "S".
4. Tighten the lock nut (4). 4. Operate and hold in position the dipper retracting
5. Start the engine and run it at maximum speed, control (against cylinder stops).
select mode "S". 5. Turn the adjusting screw (3) until the standard
6. Operate and hold in position the dipper retracting pressure is reached.
control (against cylinder stops).
NOTE: Tighten the screw (3) to increase the pres-
7. Loosen the lock nut (2) and turn the adjusting sure. Loosen the screw (3) to reduce the pressure.
screw (1) until the power boost pressure is
reached.
position and tighten the lock nut (4).
NOTE: Tighten the screw (1) to increase the pres- 7. Check the pressure again. If the desired value is
sure. Loosen the screw (1) to reduce the pressure. not obtained, repeat steps 2 to 6.
8. Using a wrench, hold the adjusting screw (1) and 8. Stop the engine.
tighten the lock nut (2).
9. Reconnect the power boost pilot hose to the
9. Check the pressure again. If the desired value is main relief.
not obtained, repeat steps 6 to 9.
10. Cary out the standard pressure setting.

Copyright
8001-16
Attachment control valve 8. Read the pressure on the monitor display, the
pressure should be:
secondary reliefs (B, C, D, E, F and Set pressure Values meas-
G) (as single ured on actual
component) machine
NOTE: If the excavator is equipped with safety valves
Boom 3925 bar 400 bar
on the boom and the dipper, secondary reliefs (B) P1-P2
raising (39.20.5 MPa) (40 MPa)
and (D) are not fitted or are overset. In this case it is
necessary to set the pressures on the reliefs (B1-B2 Boom 2745 bar 290 bar
P2
and D1) mounted on the safety valves. lowering (27.40.5 MPa) (29 MPa)
Dipper 3925 bar 400 bar

NOTE: The attachment main reliefs are set to a P1-P2
in (39.20.5 MPa) (40 MPa)
higher pressure than the main relief valve. To check
Dipper 3925 bar 400 bar
or set the attachment main reliefs, the main relief P1-P2
out (39.20.5 MPa) (40 MPa)
must be overset.
Bucket 3925 bar 405 bar
NOTE: On the CX330 and CX350, since the pressure P2
opening (39.20.5 MPa) (40.5 MPa)
of the boom lowering valve is lower than the main
Bucket 3925 bar 405 bar
relief, there is no need the overset the main relief P2
closing (39.20.5 MPa) (40.5 MPa)
(Steps 1 to 4 and 15 to 19).
9. Carry out Steps 10 to 14 only if one of the attach-
Checking and setting the pressure ment secondary reliefs has to have its pressure
set. Otherwise go on to step 15.
1 2
3
4
CS00E550

on the main relief. CS01K554
2. Using a wrench, hold the adjusting screw (1) in 10. Using a wrench, hold the adjusting screw (4) of
position and loosen the lock nut (2). the secondary relief concerned in position and
loosen the lock nut (3).
3. Tighten the adjusting screw (1) 180.
11. Operate and hold in position the corresponding
4. Using a wrench, hold the adjusting screw (1) in attachment control (against the cylinder stops).
12. Turn the adjusting screw (4) of the secondary
5. Start the engine and run it at maximum speed, relief concerned until the correct pressure is
select mode "S". obtained.
6. Display the "CHK1" monitor display. 13. Using a wrench, hold the adjusting screw (4) in
7. Operate and hold in position the corresponding position and tighten the lock nut (3).
attachment control (against the cylinder stops). 14. Check the pressure again. If the desired value is
15. Using a wrench, hold the adjusting screw (1) of
the main relief concerned in position and loosen
the lock nut (2).
16. Operate and hold in position the dipper retracting
control (against cylinder stops).
17. Turn the adjusting screw (1) until the correct
standard pressure of the main relief concerned is
obtained.
NOTE: Tighten the screw (1) to increase the pres-
sure. Loosen the screw (1) to reduce the pressure.

Copyright
8001-17
19. Check that the standard pressure of the main
relief is correct, otherwise carry out steps 15 to
19 again.
20. Stop the engine.
21. Reconnect the power boost pilot hose to the 7 6
main relief.
Boom safety valve secondary

reliefs (B1 and B2)
Checking and pressure setting the RH
side (B1) CD01B007
Disconnect and plug the pilot hose (6) from the valve
to be adjusted, located behind the bottom of the
boom. Place the hose (6) in a receptacle to catch any
9 leaks. Plug the elbow union (7). Start the engine. Set
8 the speed to 1000 rpm at the gauge on the instru-
ment panel. Move the boom to mid-height. Actuate
the boom lowering control and note the secondary
5 3 relief pressure setting (B1). Repeat this manoeuvre
several times, noting the pressure each time.
4 Pressure setting 3925 bar (39.20.5 MPa)
1 If the value is not correct, loosen the lock nut (8) and
turn the screw (9) to adjust the pressure while operat-
2 ing the boom lowering control. Tighten to increase the
pressure, untighten to decrease. Tighten the lock nut
CD01B008
(8). Stop the engine. To release pressure in the large
Disconnect the balance hose (1). Install on the hose
chamber of the cylinder, first reconnect the pilot hose
a male coupling connection, complete with its union
(6). Start the engine to fill the accumulator. Shut
(2). Plug the elbow union (3). Connect to the hose (1)
down the engine. Release pressure in the hydraulic
a female coupling connection complete with a pres-
system. Remove the union plug (3). Disconnect the
sure test point (4). Connect the Multi-Handy tester or
coupling connection (2). Reconnect the balance hose
a 0-600 bar pressure gauge (5) to the pressure test
(1).
point (4).
Checking and pressure setting the LH
side (B2)
Carry out the same operations as for the RH side.
The difference between the two valves must be less
than 5 bar.

Copyright
8001-18
Dipper safety valve (D1) Swing port secondary relief

NOTE: The safety valve secondary relief (D1) has a (I, J)
higher pressure setting than the control valve main
Test
relief (A). To carry out checks or pressure setting on
the secondary relief (D1), the main relief (A) has to be
overset.
1 2
CS00E550

CD00E143
on the main relief.
1. Disconnect the connector (green) from the swing
cancellation solenoid valve.
position and loosen the lock nut (2).
3. Tighten the adjusting screw (1) 180.
3. Start the engine and select mode "S".
position and tighten the lock nut (2). 4. Switch on the swing brake control on the instru-
ment panel (indicator lamp ON).
5. Start the engine and run it at maximum speed,
select mode "S". 5. Slowly operate the swing control lever to the right
and gradually increase the engine speed to full
speed to make sure that the swing is locked.
7. Operate and hold the dipper extend control.
6. Repeat step 5, for the LH swing, the pressures
8. Note the pressure on the check screen. The must be:
pressure should be at 3925 bar
(39.20.5 MPa). Set pressure Values meas-
(as single ured on actual
component) machine
RH swing P1 2944 bar 290 bar

(29.40.4 MPa) (29 MPa)
LH swing P1 2944 bar 290 bar

(29.40.4 MPa) (29 MPa)
1
CD01M021
9. If the value is not correct, loosen the lock nut (1)
and turn the pressure setting screw (2) to adjust
the pressure. Tighten to increase the pressure,
untighten to decrease. When the pressure is cor-
rect, hold the screw (2) and tighten the lock nut
(1). Reset the control valve main relief (A).

Copyright
8001-19
Adjustment Checking the swing brake release
pressure
J
I
CS99B596
(I) RH swing port secondary relief CD05L003

(J) LH swing port secondary relief
1. Disconnect the swing brake supply hose at the
hydraulic motor end and connect a pressure test
2 point 0-100 bar pressure gauge to the hose.
2. With the engine at full speed, select mode "S".
3. With the swing control in the neutral position,
switch on the swing brake control on the instru-
ment panel (indicator lamp ON), the pressure
should be between 0 and 3 bar.
4. With the swing control in the neutral position,
switch off the swing brake control on the instru-
ment panel (indicator lamp OFF), the brake
release pressure should be about 39 bar.
1
CI01M524
Travel secondary relief (K, L)
1. Carry out steps 1 to 5 in "Checking". Tools required
2. Using a wrench, hold the adjusting screw (2) and
3. Slowly operate the swing control lever to the right
and gradually increase the engine speed to full
speed to make sure that the swing is locked.
4. Turn the adjusting screw (2) until the correct 3.149 inch
pressure is reached. 80 mm
5. Using a wrench, hold the adjusting screw (2) and
6. Check the pressure again. If the desired value is
CS99B579
1 locking pin with the dimensions shown below

Copyright
8001-20
Checking and adjustment
1. Overset the secondary relief. Attachment main
relief chapter).
2. Start the engine.
K
L
CD05L002
K. Reverse secondary relief
L. Forward travel secondary relief
9. Remove the swing motor secondary relief con-
cerned. If the two secondary reliefs have to be
CS99B580
removed, mark them to ensure they are replaced
3. Carefully lock the travel on the side to be in their original position.
checked by positioning the locking pin (A)
between the sprocket and the undercarriage as
shown above.
4. With the engine at full speed, select mode "S". 2 3 4 5 1 6
6. Operate and maintain the corresponding travel
control (locking the sprocket).
7. Read the pressure on the monitor display, the
pressure should be: Pressure setting 3805 bar
(380.5 MPa).
Note the pressures if they are not correct to deter-
mine the number of shims needed for adjustment.
One 0.1 mm shim corresponds to 10 bar pres-
CI01M519
sure.
10. Tighten the body of the secondary relief (1) in a
8. Go on to step 9 if one of the secondary reliefs vice and remove the plug (2), the guide (3), the
has to have its pressure set. Otherwise, reset the shims (4), the spring (5) and the check valve (6).
pressure on the main relief.
11. Remove (to reduce pressure) or add (to increase
pressure) the number of shims (4) needed to
obtain the correct pressure.
12. Install parts (1 to 6) in the secondary relief and
tighten the plug to 156 Nm.
13. Install the secondary relief on the travel motor
and tighten it to 78.5 Nm.
14. Check the pressure again. If the desired value is
15. Rest the pressure of the main relief.

Copyright
8001-21
Checking the pressure delivered by Checking travel drift

the proportional valve (Y7) Make sure that the track tension is correct.
This test must be carried out at a hydraulic oil tem-
perature of 50C and on hand, flat ground over a
length of about 30 m.
With the engine at full speed in mode "H", press and
hold the travel pedals against the stops.
Travel forward over a distance of 25 metres.
Note the drift over the last 20 metres travelled.
If this value is greater than 1 m:
1. Check the pilot pressure values on both travel
a4 spools (must be higher than 30 bar).
CS01K501
2. Check the hydraulic leak values on the travel
motors.
1. Connect a pressure test point and a 0-100 bar
pressure gauge to pump port a4.
Checking for leaks on the travel
motor
3. With the engine at full speed, select mode "H"
and then mode "S". Tools required
Pressure (bar)
Pressure (MPa)
3.149 inch
80 mm
CS99B579
1 locking pin with the dimensions shown below
Input current (mA) 1 receptacle with a capacity of 20 litres
Controlled line graph 1 hose
1 plug
700-1-05-00-24AR
H mode S mode
Pressure 14.8 bar (1.48 MPa) 19.2 bar (1.92 MPa)
Intensity Max. 470 mA 410 mA

Copyright
8001-22
Checking for leaks 8. Repeat steps 1 to 7 to check the other motor.
9. Compare the quantities of oil collected; if the dif-
(With the hydraulic oil between 45 and 55C)
ference between the two motors is greater than
1. Press the breather to release pressure in the 1 l/min, repair or change the motor which has
hydraulic reservoir. output the greatest quantity of oil.
2. Remove the travel motor protective shield.
Checking the swing motor for leaks
Tools required
1 receptacle with a capacity of 20 litres
1 hose
1 plug
Checking for leaks
(With the hydraulic oil between 45 and 55C)
CS00E546
3. Disconnect the hydraulic motor drain hose and
plug it.
4. Use a hose to connect the drain port to the
receptacle.
A B
CD05L001
1. Disconnect the connector (green) from the swing

cancellation solenoid valve.
3. Start the engine and select mode "S".
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
CS99B580
A: Locking pin ensure that the swing is locked.
B: Forward 6. Shut down the engine.
5. Lock the travel mechanically on the side to be 7. Press the breather to release pressure in the
checked by positioning the locking pin (A) between hydraulic reservoir.
the sprocket and the undercarriage as shown
above.
6. With the engine at full speed, select mode "S".
7. Operate the travel control of the hydraulic motor
to be checked and measure the quantity of oil
which leaves the drain for 1 min.

Copyright
8001-23
CD05L003
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 and run it at full speed in mode
"S". Operate the swing control to the right or the
left and measure the quantity of oil which flows
out of 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
8001-24
TROUBLESHOOTING
Travel drift
(Pressures P1 and P2 correct)
No. Tests Results Repairs

With the tracks lifted, check the swing Difference in speed between the two
1 Check travel motor leaks (No. 4)
speed at the sprockets sprockets
The pressure difference between P1
Check pressures P1 and P2 during Check the negative pressure (N) of
2 and P2 is greater than 30 bars
travel the pump (No. 3)
(3 MPa)
Check the main relief:
Adjust or change
Pressure above 6 bars (0,6 MPa) Check the pump regulator or body
that is at fault:
Adjust or change
Check the travel spool pilot pressure
Check the negative pressure (N) of
3 on the side that is at fault
the pump
Pressure below 30 bars (3 MPa)
Check the operation of the control
Pressure below 6 bars (0.6 MPa)
pedal spool, replace or repair
Pressure above 30 bars (3 MPa)
Check the travel spool (sticking,
scratches ...)
Higher than 14 litres Replace or repair the travel motor
Check the travel pressure without
load (with track raised)
Normal pressure:
Replace the central seal
4 Check the travel motors for leaks
Lower than 14 litres Higher than normal pressure:
Drain the reduction gear and check if
there is any contamination (metal par-
ticles).
Replace or repair the travel reduction
gear

Copyright
8001-25
Not possible to select 2nd travel speed

Press the travel speed control and
Refer to troubleshooting electrical fail-
1 check that the speed changes from I Speed II not displayed
ures
to II on the monitor display
Check pressures P1 and P2 on the
monitor display "CHK1" when the
machine is travelling
Check on the monitor display "CHK2"
1) Both pressures are less than
2 if the information changes to "ON" Information stays on "OFF"
40 bar: refer to troubleshooting elec-
when the machine is travelling
trical 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 sole-
Pressure too low
noid valve coil (No. 5 and 6)
Check the pilot pressure at the output
4 Check the pilot pressure at the travel
from the 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 sole- Infinite or 0 Ohm Replace the solenoid valve
6
noid valve coil About 40 Ohm Replace the solenoid valve coil
Internal leak at hydraulic swivel,
Pressure too low
repair or replace 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 replace the travel motor

Copyright
8001-26
No swing or slow swing

(No problems with other functions)

Adjust or change the secondary
1 Check the swing pressure Pressure too low
reliefs
Reconnect the solenoid valve and
check the swing brake release pres-
Disconnect the swing brake solenoid No swing or slow swing
sure at the output from the solenoid
2 valve (pink connector) and operate valve (No. 3)
the swing
Check the solenoid valve supply elec-
The swing operates normally
trical circuit
Check or replace the swing brake
With the engine running and the Pressure below 30 bar (3.0 MPa)
release solenoid valve
3 swing brake deactivated, check the
swing brake release pressure Pressure higher than 30 bar Check the swing motor for leaks
(3.0 MPa) (No. 5)
Check or replace the swing cancella-
Disconnect the swing cancellation No swing or slow swing
tion solenoid valve
4 solenoid valve (green connector) and
operate the swing Check the solenoid valve supply elec-
The swing operates normally
trical circuit
With the engine at full speed, and Higher than 16 litres Replace or repair the swing motor
5 hydraulic oil at 50C, check for leaks Check the swing brake, repair or
on the swing motor during the swing Lower than 16 litres
replace
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
replace
Adjust or change the secondary
2 Check the swing pressure Pressure too low
reliefs
With the engine at full speed, and
3 hydraulic oil at 50C, check for leaks Higher than 16 litres Replace or repair the swing motor
on the swing motor during the swing
Check the swing brake pilot pressure Check electrical supply and the sole-
4 Pressure higher than 1 bar (0.1 MPa)
at the solenoid valve output noid 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 Replace the solenoid valve
6 Check the pilot solenoid valve coil
About 40 Ohm Replace the solenoid valve coil

Copyright
8001-27
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 main relief,
2 Check the pilot pressure at P3 Pressure below 30 bar (3.0 MPa)
replace it if necessary
Check the pilot pressure at outlet Check the electrical supply and the
3 Pressure below 30 bar (3.0 MPa)
port B on the 6 solenoid valve bank solenoid valve coil (No. 4 and 5)
Check the electrical supply and
mechanical adjustment of the controls
Check the voltage at the pilot solenoid
4 Voltage < 24 V cancellation contact switch.
valve connector (blue)
Check the harness between the con-
tact switch and the solenoid valve
Infinite or 0 Ohm Replace the solenoid valve
5 Check the pilot solenoid valve coil
About 40 Ohm Replace the solenoid valve coil
Lack of power or speed on one of the attachment movements

(No problems with other movements)

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

Copyright
8001-28
Not possible to select cushion control

Check the signal at the electronic
Check on monitor display "CHK3" if
input box:
information displayed changes to
1 Information stays on "OFF" Below 5 volts: replace the electronic
"ON" when cushion control is
box
selected/deselected
5 volts: replace the electronic box
Check the electrical supply and the
Pressure too low
Check the pilot pressure at the cush- solenoid valve coil (No. 3 and 4)
2
ion control solenoid valve output (C4) Repair or replace the cushion control
Pressure correct (39 bar - 3.9 MPa)
valve
3 plug on the cushion control solenoid Voltage < 24 V Check the electrical harness
valve
Check the cushion control solenoid Infinite or 0 Ohm Replace the solenoid valve
4
valve coil About 40 Ohm Replace 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 replace the load holding
2 Check the load holding operation Sticking
valve
Check the pilot pressure at the control Check the operation of the control
valve spool lever spool, replace or repair

Copyright
8001-29
PROCEDURE FOR CHANGING OPERATION TYPE

Select operation type by changing hoses located under the bulkhead joint behind the cab.
After it has been changed, replace the instruction sticker for operation and take off ISO approved label.
ISO type Old Sumitomo type

Adopted manufacturers: KATO, IHI, YUTANI, CAT, Adopted manufacturers: SUMITOMO, KOMATSU,
LBCE. HITACHI.
Operation Levers Operation Levers
V1 S1 V1
A1
A1 A2 B2 B1
S1 S2
B2
B1
A2
V2 V2
S2
CS00F530 CS00F530S
Illustration of changing hoses Illustration of changing hoses

A1: Arm out (move to S1)
A1: Arm out A2: Arm in (move to S2)
A2: Arm in B1: Bucket open
B1: Bucket open B2: Bucket closed
B2: Bucket closed V1: Boom down
V1: Boom down V2: Boom up
V2: Boom up S1: Swing left (move to A1)
S1: Swing left S2: Swing right (move to A2)
S2: Swing right
000-8-02-01-07B
000-8-02-01-07B

Copyright
8001-30
Old Mitsubishi type Old Kobelco type

Adopted manufacturers: MITSUBISHI, NIKO. Adopted manufacturers: KOBELCO, FURUKAWA.
Operation Levers Operation Levers
V1 V1
A2 A1
S1 S2 S1 S2
B1 B2 B1 B2
A2
A1
V2 V2
CS00F530M CS00F530K
Illustration of changing hoses Illustration of changing hoses

A1: Arm out (move to V1)
A1: Arm out (move to V1) A2: Arm in (move to V2)
A2: Arm in (move to V2) B1: Bucket open (move to S2)
V1: Boom down (move to A2) B2: Bucket closed (move to S1)
V2: Boom up (move to A1) V1: Boom down (move to A1)
V2: Boom up (move to A2)
S1: Swing left (move to B1)
S2: Swing right (move to B2)
B1: Bucket open (move to S2)

B2: Bucket closed (move to S1)
S1: Swing left (move to B1)
S2: Swing right (move to B2)
000-8-02-01-07B

Copyright
8002
Section
8002

OF THE HYDRAULIC RESERVOIR

Printed in France
Copyright
8002-2
TABLE OF CONTENTS
SPECIFICATIONS .................................................................................................................................................. 2
HYDRAULIC RESERVOIR ..................................................................................................................................... 3
Removal .............................................................................................................................................................. 3
Installation ........................................................................................................................................................... 4
Description .......................................................................................................................................................... 6
SPECIFICATIONS
See Section 1002.

Copyright
8002-3
HYDRAULIC RESERVOIR
Removal
NOTE: The numbers within brackets refer to the fig- STEP 8
Remove the screws (7) and the protective plate (8) on
STEP 1 top of the control valve.
STEP 9
Loosen the 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
Loosen the circlips (12) and disconnect the hose (13)
under the hydraulic reservoir.
STEP 11
JS00163A
Park the machine on hard, flat ground. Lower the Attach identification tags to the output hoses. Discon-
attachment to the ground. nect the hoses.
STEP 2 STEP 12
Release pressure in the hydraulic system and in the Remove the screws (14) and the retaining shims (15).
hydraulic reservoir (see Section 8000). STEP 13
STEP 3 Using a hoist, remove the hydraulic reservoir (1) from
Attach a "DO NOT OPERATE" tag to the ignition key the machine.
in the cab.
STEP 4
Remove the screws and the access panels under the
hydraulic reservoir (1).
STEP 5
Using a container of suitable capacity, drain the
hydraulic reservoir (1), by removing the plug (2).
STEP 6
Remove the screws (4) on top and inside the front
boot, then remove the protective housing (3).
STEP 7
Remove the screws (5) and the protective plate (6) on
top of the hydraulic reservoir (1).

Copyright
8002-4
Installation
NOTE: The numbers within brackets refer to the fig-
STEP 1
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 under-
carriage, tighten the screws to a torque, see the
specifications. Install the drain plug (2).
STEP 3
Connect the hose (13) using the 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 res-
ervoir 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
Hydraulic reservoir
12
13
15
14
CS02B508
1 HYDRAULIC RESERVOIR 13 HOSE
2 PLUG 14 SCREW
12 CIRCLIP 15 SHIM

Copyright
8002-6
Description
Location
3 4 8
10 7
4
7
11
6 5
10 9
5
CS02B557 CS02B556
3 PROTECTIVE HOUSING
4 SCREW
5 SCREW
6 PROTECTIVE PLATE OF THE HYDRAULIC RESERVOIR
7 SCREW
8 PROTECTIVE PLATE OF THE CONTROL VALVE
9 SCREW
10 SCREW
11 PROTECTIVE PLATE OF THE RESERVOIR

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
HYDRAULIC PUMP COUPLING ............................................................................................................................ 9
Section ................................................................................................................................................................ 9
Removal and installation .................................................................................................................................... 10

Copyright
8003-3
SPECIFICATIONS
See Section 1002.

Screw for fixing the main pump to the coupling flange (5).................................................................. 367 to 496 Nm
Screw for fixing the coupling flange (5) to the engine....................................................................... 63.8 to 73.6 Nm
Screw for fixing the coupling (9) to the shaft of the hydraulic pump (8) ......................................................... 295 Nm
Screw for fixing the coupling flange (2) to the engine flywheel........................................................................ 49 Nm
Nuts for fixing the circlip of the silencer ............................................................................................ 68.7 to 98.1 Nm
Silencer bracket fastening screw ............................................................................................................ 64 to 74 Nm
Screw for fixing the hydraulic reservoir cover ....................................................................................... 2.9 to 4.9 Nm

Copyright
8003-4
MAIN HYDRAULIC PUMP

Removal and installation STEP 4
STEP 1
JS00163A 1
STEP 2
Release pressure in the hydraulic system and in the CS02C508
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 res-
1 ervoir. Open the drain cock and drain the hydraulic
fluid. Close the cock.
CT05I063
Disconnect the battery ground (-) cable (1) from the
battery.

Copyright
8003-5
STEP 6 STEP 8
1
2
CD00F108
Remove the circlip (1) fastening the silencer pipe to
the turbocompressor.
NOTE: Let the engine and the exhaust system cool
before trying to remove the silencer.
STEP 9
1
CS02B556
Remove the engine hood (1) then the protective
grille (2).
STEP 7
CD00F110
A Remove the four retaining nuts from the silencer cir-
B clips, then remove the two circlips.
NOTE: When installing, tighten the nuts to the torque
specified on page 3.
STEP 10
CRPH06E001A
Remove all the retaining screws (A) from the panel
(B), then remove the panel (B).
CD00F111
Remove the silencer assembly from the machine (1).

Copyright
8003-6
STEP 11 STEP 15
Remove the retaining screws of the hydraulic pump.
torque specified in Section 1002.
1 STEP 16
Remove the hydraulic pump from the motor and put it
away from the machine. Place the hydraulic pump on
a clean workbench using suitable brackets.
NOTE: Carry out the following step only if a new
hydraulic pump needs to be installed.
STEP 17
CD00F076
Remove the three retaining screws (1) from the Remove the connections of the hydraulic pump that
silencer bracket, then remove the silencer bracket. has just been removed and install them on the new
NOTE: When installing, tighten the screws to the hydraulic pump. Remove and install the connections
torque specified on page 3. one after another to avoid improper installation of the
connections on the new hydraulic pump.
STEP 12 NOTE: For installing the hydraulic pump, proceed in
the reverse order to that of removal. Replace all rings
with new rings.
CRPH06E001A
To aid proper installation, attach identification tags to
all hoses and electrical connections of the main
hydraulic pump and the pilot pump.
STEP 13
Remove the pipes, the hydraulic hoses and the elec-
trical connections. Seal all hoses and unions of the
main pump as well as those of the pilot pump.
STEP 14
Install an appropriate lifting apparatus on the hydrau-
lic pump. Do not leave any slack so that the pump
can be supported once the fastening screws of the
pump are removed.

Copyright
8003-7
STEP 18 NOTE: Before carrying out any work with the
machine, operate the swing, travel and the attach-
ment for five minutes with the engine at idle speed.
Check that there are no leaks in the system, check
the oil level in the hydraulic reservoir. Top up if neces-
sary. Adjust the hydraulic pump, refer to Section
2 8001.
CD00E176
Remove the four screws and washers (1). Remove
the cover (2) and the O-ring from on top of the
hydraulic reservoir. Scrap the O-ring. Fill the hydrau-
lic reservoir with hydraulic fluid (see Section 1002) up
to a level in between the "high" and "low" marks on
the visual gauge. Install the lid with a new O-ring, fas-
ten it using four screws and washers (1), tighten the
screws to a torque of 2.9 to 4.9 Nm.
STEP 19
CT05I063
Connect the ground (-) cable (1) of the battery.
STEP 20
NOTE: Always drain the air out from the hydraulic
pump before starting the engine. If the air has not
been drained out, the pump can get damaged. For
the procedure, see Section 8000.

Copyright
8003-8
PILOT PUMP
STEP 1 Remove the retaining screws from the pilot pump
then remove the pilot pump.
Refer to "Removing the hydraulic pump" in this Sec-
tion and carry out steps 1 to 3. STEP 5
STEP 2 Stop the vacuum pump.
To prevent any fluid leaks when disconnecting NOTE: When installing, proceed in the reverse order
hydraulic hoses, connect a vacuum pump to the to that of removal. Replace the O-rings with new
hydraulic reservoir (see Section 8000). Start the vac- O-rings.
uum pump. NOTE: Before carrying out any work with the
STEP 3 machine, operate the swing, travel and the attach-
the level of oil in the hydraulic reservoir, top up if nec-
essary. Adjust the hydraulic pump, refer to Section
2 8001.
CD02C150
Place an appropriate container under the pilot
pump (1) to recover the hydraulic fluid that could
escape from one of the disconnected hoses or from
the hydraulic pump when the pilot pump (1) has been
removed. Disconnect the hoses (2) from the upper
union of the pilot pump. Seal the union and the
hoses.

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8003-9
HYDRAULIC PUMP COUPLING

Section
9
2
A
B 5
7 8
A
3 4
CRPH06E005G
1 SCREW 6 RETAINING SCREW
2 COUPLING FLANGE 7 SCREW
3 SCREW 8 HYDRAULIC PUMP
4 WASHER 9 COUPLING
5 COUPLING FLANGE
A: Disassembly and assembly port of the coupling
flange (2).

Copyright
8003-10

NOTE: The numbers within brackets refer to the
schematic on page 9.
STEP 1
Run the engine so that the screws (1) can be posi-
tioned facing the port (A). Remove the screws (1)
from the coupling flange (2).
STEP 2
Remove the screws (3) and the washers (4) from the
coupling flange (5). Remove the assembly from the
hydraulic pump.
STEP 3
Remove the retaining screw (6) from the coupling (9),
then remove the coupling flange (2).
NOTE: Procedure to fix the coupling hub on the
pump shaft:
a) Adjust the hub face (spot facing) and spline shaft
end to same surface.
b) Fix (c) coupling hub by tightening the (a) hex.
Socket head bolt.
Procedure to fix flange to the engine flywheel:
a) Apply loctite 262 (3) or equal on the female thread
of flywheel.
b) Fix (b) pa flange by tightening the (2) hex. Socket
head bolt.
a b
CRPH06E003A
STEP 4
Remove the coupling (9) from the coupling flange (2),
make a visual inspection of the wear and the condi-
tion of the coupling, replace it if necessary.
STEP 5
Remove the screws (7) and the coupling flange (5)
from the hydraulic pump (8).
NOTE: When installing the hydraulic pump coupling,
proceed in the reverse order to that of removal.

Copyright
Section
8004
8004
OF THE MAIN HYDRAULIC CONTROL VALVE

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

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

Control valve mounting on upperstructure frame............................................................................ See Section 1002

Copyright
8004-3
MAIN CONTROL VALVE

STEP 1
2 3
1 4
CS02B555
Remove the engine hood (1). Remove the screws (2)
JS00163A then remove the access panels (3) and (4).
attachment to the ground. STEP 6
STEP 2 Start the vacuum pump.
Release pressure in the hydraulic system and in the STEP 7

Attach an identification tag on the hoses then discon-
STEP 3 nect and plug the hoses.
NOTE: Plug the hoses with plugs and the adaptors
1 with caps to prevent any contamination of the hydrau-
lic system when disconnecting pipes and hydraulic
hoses.
STEP 8
STEP 9
Install lifting rings in the threaded orifices on the top
of the control valve.
STEP 10
CT05I063
Disconnect the earth cable (1) from the battery. Connect a suitable lifting device to the control valve.
See Section 1002 for the weight of the control valve.
STEP 4

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8004-4
STEP 11
1
CI02B519
Remove the retaining screws (1) and washers from
the control valve.
torque specified in Section 1002.
STEP 12
Carefully raise and guide the control valve out of the
upperstructure frame. Move all the hoses and pipes
out of the way. Remove the control valve from the
machine and place it on suitable stands.
NOTE: The following step is to be performed only if
the control valve has to be changed.
STEP 13
Remove the unions and manifolds from the control
valve which has just been removed and mount them
on the new control valve. Remove and install the
unions and manifolds one after another to make sure
that they are correctly installed on the new control
valve.
NOTE: When installing, follow the same procedure in
the reverse order. Replace all seals with new seals.
NOTE: Before carrying out any work with the
machine, operate the swing, travel and the attach-
the level of oil in the hydraulic reservoir, top up if nec-
essary. Adjust the valves in the control valve (see
Section 8001).

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

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

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8005-3
BOOM CYLINDER
Description
4
2
6
3
4 5
1
8
4
7
5 7
6
3
8
9 2
CS02B563
1 NUT 6 SCREW
2 SCREW 7 SHAFT
3 LOCKING BUSHING 8 BOOM CYLINDER
4 SHIM 9 SHAFT
5 WASHER

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8005-4
Removal STEP 3
NOTE: The numbers within brackets in the following 2 2
steps refer to the boom cylinder schematic on page
9
3.
STEP 1
4
3
A 1
JS00579A
Remove the nuts (1) and the screws (2). Remove the
screws from the shaft (9) and the locking rings (3).
Push the shaft far enough so that it does not intefere
with the removal of the boom cylinder. Remove the
shims (4) and the locking rings.
JS00577A
Disconnect the lubrication hose (A) from the boom STEP 4
cylinder.
NOTE: Lift the cylinder carefully, the cylinder is
heavy, its weight has to be balanced with slings dur-
ing lifting.
STEP 2
JS00580A
Install a support (A) in front of the boom cylinder.
Lower the front of the boom cylinder on the support.
STEP 5
JS00578A
Attach a suitable lifting device to the boom cylinder.
Use the total movement to get sufficient support dur-
ing removal of the boom cylinder.
B
JS00581A
Attach a sling (B) to hold the cylinder rod to the cylin-
der barrel.

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8005-5
STEP 6 STEP 10
STEP 7 6
5
7
A
A
CS02B565
Remove the screw (6) and the washer (5).
Remove the shaft (7), using a suitable sliding ham-
JS00582A
mer.
Disconnect the hydraulic supply hoses (A) from the
boom cylinder.
STEP 8
(Only if the machine is equipped with a safety
valve)
JS00584A
Carefully lift the boom cylinder and move it away from
the machine. Place the boom cylinder on suitable
supports. Remove the sling that holds the cylinder
rod to the cylinder barrel.
CS00G501
Disconnect the hydraulic pilot hoses from the safety
valve and disconnect the harness from the pressure
sensor.
STEP 9
Plug the hoses with plugs and the unions with caps.

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8005-6
STEP 11 STEP 2
(Only if the machine is equipped with a safety (Only if the machine is equipped with a safety
valve) valve)
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 screws (C). Connect the pipe (A).
O-ring (E).
NOTE: Lift the cylinder carefully. The cylinder is
STEP 12 heavy, its weight has to be balanced with slings dur-
ing lifting.
Repeat steps 1 to 11 to remove the other cylinder.
STEP 3
Installation
STEP 1
JS00587A
Using a suitable lifting device, lift the boom cylinder.
Align the boom cylinder with the mounting brackets of
JS00586A
the frame. Place a suitable support under the boom
Attach a suitable sling (B) to the boom cylinder to
cylinder to support it.
hold the cylinder rod to the cylinder barrel.

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8005-7
STEP 4 STEP 5
6 valve)
5
7
CS02B565
Install the shaft (7) using washers (5) and screws (6).
Using a strip thickness gauge, check that there is a
clearance of 1 to 3.5 mm between the mounting CS00G501
bracket and the mounting ring of the cylinder barrel. If Connect the hydraulic pilot hoses to the safety valve
necessary, remove the screw, the shaft and add one and connect the harness to the pressure sensor. Stop
or more shim(s) as required in order to get the correct the vacuum pump. Remove the sling that holds the
clearance. Install the pin and the screw. cylinder rod to the cylinder barrel.
STEP 6
JS00589A
Start the vacuum pump. Remove the plugs from the JS00590A
hydraulic hoses (A) and the caps from the unions. Lift the boom cylinder and align the rod end of the cyl-
Connect the two hydraulic supply hoses on the boom inder with the mounting ports of the boom.
cylinder. STEP 7
Repeat steps 1 to 6 to install the second boom cylin-
der.

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8005-8
STEP 8 STEP 10
9
JS00591A JS00656A
Install the pin (9) and the shims (4). Connect the lubrication hose (A) to the boom cylin-
ders.
STEP 9
STEP 11
2
Remove the vacuum pump and bleed the air from the
boom cylinders (see Section 8000).
STEP 12
Check the hydraulic fluid level in the reservoir. Top up
3 as required.
STEP 13
1 Lubricate the linkages.
JS00592A
Install the locking bushings (3). Install the screws (2)
through the locking rings and the shaft. Using a set of
spacer rings, check that there is a clearance of 1
to 3.5 mm between the mounting bracket and the
mounting ring of the cylinder rod. 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 (1) on the screw and tighten until the nut
touches the locking ring. Unscrew the nut by a quar-
ter of a turn and, using two wrenches, install the sec-
ond nut (1) to lock the first nut in position. Remove
the sling from the boom cylinder.

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8005-9
DIPPER CYLINDER
Description
6
5
4
2
1
CS02B564
1 SCREW 5 WASHER
2 WASHER 6 PIN
3 PIN 7 DIPPER CYLINDER
4 SCREW 8 SHIM

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8005-10
Removal STEP 4
NOTE: The numbers within brackets in the following Start the vacuum pump.
steps refer to the dipper cylinder schematic on page 9.
STEP 5
STEP 1
JS00598A
JS00594A
Disconnect the two hydraulic supply hoses (A) from
Place a wooden shim (A) under the dipper cylinder (8). the dipper cylinder.
STEP 2
3
2
1
CS02B566
Remove the shaft (3) carefully.
STEP 3
JS00586A
Attach a suitable sling (B) to hold the cylinder rod to
the cylinder barrel.

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8005-11
STEP 6 STEP 9
(Only if the machine is equipped with a safety A
valve)
JS00600A
Attach a suitable lifting device to the dipper cylinder.
Use the total movement to get sufficient support
CS00G503
during removal of the dipper cylinder.
Disconnect the hydraulic pilot hoses from the safety
valve.
STEP 10
STEP 7
Plug the hydraulic hoses with plugs and the unions
with caps. Stop the vacuum pump.
STEP 8
6
A 5
4
CS02B567
JS00599A
Disconnect the lubrication hose (A) from the dipper
cylinder.
heavy, its weight has to be balanced with slings
during lifting.

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8005-12
STEP 11 STEP 13
8 (Only if the machine is equipped with a safety
valve)
A B
C
JS00602A E
Carefully lift the dipper cylinder and move it away
from the dipper. Remove the shims (8). Place the D
dipper cylinder on suitable supports. CS00G504
Disconnect the pipe (A) from the safety valve (B).
STEP 12 Remove the screws (C), the base (D) and the safety
valve (B) from the dipper cylinder. Scrap the
O-ring (E).
Installation
B STEP 1
JS00586A
Remove the sling (B) that holds the cylinder rod to
JS00586A
Attach a suitable sling (B) to the dipper cylinder to
hold the cylinder rod to the cylinder barrel.

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8005-13
STEP 2 STEP 4
valve)
A B 6
5
4
C
E CS02B567
Install the shaft (6) using washers (5) and screws (4).
D Using a set of spacer rings, 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 mounting ring of the cylinder barrel. If
install the safety valve (B) and the base (D) with the necessary, remove the screw, the shaft and add or
screws (C). Connect the pipe (A). remove one or more shim(s) (8) as required in order
to get the correct clearance. Install the pin and the
NOTE: Lift the cylinder carefully, the cylinder is screw.
heavy, its weight has to be balanced with slings
during lifting. STEP 5
STEP 3
8
A
JS00604A
Connect the lubrication hose (A) to the dipper
JS00602A cylinder.
Attach a suitable lifting device to the dipper cylinder,
lift the dipper cylinder and bring it in position. Align
the dipper cylinder mounting ports with the boom
brackets and install the shims (8).

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

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8005-15
STEP 10
3
2
1
CS02B566
Install the shaft (3), the washer (2) and the screw (1).
Using a set of spacer rings, check that there is a
clearance of 0.5 to 3 mm between the mounting
bracket and the mounting ring of the cylinder rod. If
necessary, remove the screw and the shaft and add
one or more shim(s) as required in order to get the
correct clearance. Install the pin and the screw.
STEP 11
dipper cylinder (see Section 8000).
STEP 12
as required.
STEP 13
Lubricate the linkages.

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8005-16
BUCKET CYLINDER
Description
4
11
3
6 6
12 9
7 7
9
4 6
5
5 4 2
13
9 1
7 12
8
9 6
10 13
5
10 4
2
1
2
1
2 3
CRPH06C012G
1 NUT 7 BINDER
2 SCREW 8 LINK
3 SHAFT 9 SEAL
4 SHIM 10 O - RING
5 BUSHING 11 BUCKET CYLINDER
6 O - RING 12 COMPENSATOR
13 O - RING

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8005-17
Removal STEP 3
NOTE: The numbers within brackets in the following 2
steps refer to the bucket cylinder diagram on page 16.
STEP 1 1
12
JS00609A
11 Remove the nuts (1) from the screw (2) and remove
the screw from the compensator (12).
STEP 4
700-5-03-00-22R
Place a wooden shim (A) under the bucket
cylinder (11).
NOTE: Lift the cylinder carefully, the cylinder is 3
heavy, its weight has to be balanced with slings dur-
ing lifting.
STEP 2
JS00610A
STEP 5
B
700-5-03-00-22R
Attach a suitable lifting device to the bucket cylinder.
Use the total movement to get sufficient support dur-
ing removal of the bucket cylinder.
4
JS00611A
Move the bucket cylinder away from the connecting
rods by lifting it. Attach a suitable sling (B) to the
bucket cylinder to hold the cylinder rod to the cylinder
barrel. Remove the shims (4).
NOTE: Remove the wooden shim when the bucket
cylinder is raised.

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8005-18
STEP 6 STEP 9
A
700-5-03-22G1 JS00586A
Start the vacuum pump. Disconnect the two hydraulic Remove the sling (B) that holds the cylinder rod to
hoses (A) from the bucket cylinder. Plug the hydraulic the cylinder barrel.
hoses with plugs and the unions with caps. Stop the
vacuum pump. Installation
STEP 7 STEP 1
C B
A
B
JS00586A
700-5-03-00-22J1
Attach a suitable sling (B) to the bucket cylinder to
Remove the screw (A) and the washer (B). hold the cylinder rod to the cylinder barrel.
Remove the shaft (C) from the dipper.
STEP 8 heavy, its weight has to be balanced with slings dur-
ing lifting.
A
STEP 2
A
B
JS00614A
Carefully lift the bucket cylinder and move it away
from the dipper. Remove the shims (A). Place the
bucket cylinder on suitable supports. JS00614A
Install the bucket cylinder on the dipper and install
the shims (A).

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8005-19
STEP 3 STEP 5
With the cylinder and the shims in position, install the
shaft (C), the screw (A) and the washer (B). Using a
set of spacer rings, check that there is a clearance of
0.5 to 3 mm between the mounting bracket and the
mounting ring of the cylinder barrel. If necessary,
B
remove the screw, the shaft and add or remove one
or more shim(s) (A) as required in order to get the
correct clearance. Install the pin and the screw.
STEP 4
JS00586A
Remove the sling (B) that holds the cylinder rod to
STEP 6
11
B
700-5--03-00-22M1
Start the vacuum pump. Remove the plugs from the
hydraulic hoses (B) and the caps from the unions.
Connect the hydraulic hoses to the unions of the
bucket cylinder. Stop the vacuum pump. 12
700-5-03-00-22 01
Lift the bucket cylinder (11) to align the cylinder rod
and the compensators (12). Install the shims (4).

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8005-20
STEP 7
2
3
1
JS00619A
Install the pin (3) and the screw (2). Using a set of
spacer rings, check that there is a clearance of 1 to
2 mm between the connecting rod and the mounting
ring of the cylinder rod. If necessary, remove the
screw and the shaft and add or remove one or more
shim(s) as required in order to get the correct clear-
ance. Install the pin and the screw. Install the first
nut (1) on the screw and tighten until the nut touches
the boss. Unscrew the nut by a quarter of a turn and,
using two wrenches, install the second nut (1) to lock
the first nut in position.
STEP 8
bucket cylinder (see Section 8000).
STEP 9
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. 1
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
CD01K071
Disconnect the earth cable (1) from the battery.
STEP 4
To prevent any fluid loss when disconnecting hydraulic
lines, connect a vacuum pump to the reservoir (see
Section 8000).

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8006-4
STEP 6 STEP 11
1
3
2
CD02C137 CS02C504
To facilitate installation, attach identification labels to Remove the retaining screws (1), the locking bar (2)
all the hydraulic swivel hoses (outer and inner). and the retaining screws (3) from the hydraulic swivel
outer component.
STEP 7
NOTE: When installing, tighten to the torque
Start the vacuum pump. specified in Section 1002.
STEP 8 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
travel, stop the engine and check that there are no
leaks. If there is a leak, tighten the hose connections,
check the level of hydraulic oil in the reservoir and top
up if necessary.
CS02C503
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.

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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 ............................................................................................................ 12
6 solenoid valve block ....................................................................................................................................... 13

Control lever block lever locknut ....................................................................................................................... 41 Nm

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8007-3
PILOT FUNCTION BLOCKS

Travel pedal block STEP 5
Removal and installation Attach identification tags on all hoses of the control
pedal block.
STEP 1
STEP 6
STEP 7
Provide for a container to recover any possible
hydraulic fluid leaks.
STEP 8
1
2
JS00163A
STEP 2
Release pressure in the hydraulic system and in the
1
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.
NOTE: When installing, replace all O-rings with new
O-rings.
1
STEP 9
CD01K071
Disconnect the battery ground (-) cable (1) from the
battery.
STEP 4

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

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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
the inner cab access bar, then remove the access arm angle adjustment and function cancellation lever,
bar. 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 dis-
remove the compartment control casing assembly (2). connect the electrical connections.
STEP 5 STEP 8
CD00G052 CD00G055
Loosen and remove the four retaining screws from Loosen the locknut, unscrew the control lever and
the rear upper portion of the control arm. remove the upper portion of the control arm.
NOTE: When installing, tighten the locknut to a
torque of 41 Nm.

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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 connec-
tor (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 con-
tamination.
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 retaining 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 (2). lever block. Remove and seal the hydraulic hoses.
Remove the junction unions, put plugs on the ports of
STEP 15 the control lever block, then discard the O-rings.
Loosen and remove the two retaining screws (1) from
the plate (2).
O-rings.
STEP 19
2 Stop the vacuum pump.
NOTE: When installing, proceed in the reverse order
1 to that of removal. Start the engine and operate the
control levers. Stop the engine, check the circuit for
up if necessary.
CD00G061
Take the control lever block (1) out from the
bracket (2).
STEP 16
STEP 17

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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 boot. Loosen and remove the four retaining
CD00G066 screws from the front upper portion of the control
Remove the trim panel (1) then remove the retaining 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).

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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 dis- 1 CLIP
connect 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 connec-
tor (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 con-
tamination.
STEP 9
CD00G072
Loosen the locknut, unscrew the control lever and
remove the upper portion of the control arm.
NOTE: When installing, tighten the locknut to a
torque of 41 Nm.
CD00G073
Loosen and remove the two upper retaining screws
as well as the two lower retaining screws from the
front portion of the control arm.

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

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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 con-
trol levers, stop the engine, check the circuit for leaks
and the hydraulic oil level in the reservoir, top 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 Servo control and return manifold

Removal and installation block
NOTE: Refer to page 3 and carry out steps 1 to 4. Removal and installation
STEP 1 NOTE: Refer to page 3 and carry out steps 1 to 4.
Open the left-hand side doors. STEP 1

STEP 2 To aid installation, put identification tags on all the
hydraulic hoses.
2
STEP 2
1 STEP 3
STEP 4
3
CI01N512
To aid installation, put identification tags on the
2
hydraulic hoses.
3
STEP 3
3
STEP 4
1
Disconnect the hydraulic hoses from the cushion con- 3
trol valve (1). Plug the hydraulic hoses and the ports
CS01N583
of the cushion control valve (1). Remove and seal the hydraulic hoses.
STEP 5 STEP 5
Stop the vacuum pump. Stop the vacuum pump.
STEP 6 STEP 6
Remove the screws (2) from the bracket and from the Remove the screws (1) then remove the block (2).
cushion control valve. Remove the cushion control Remove the junction unions (3), discard the O-rings,
valve. put plugs on the ports of the block.
NOTE: When installing, proceed in the reverse order NOTE: When installing, replace all O-rings with new
to that of removal. Start the engine, operate the con- O-rings.
and the hydraulic oil level in the reservoir, top up if NOTE: When installing, proceed in the reverse order
necessary. to that of removal. Start the engine, operate the con-
and the hydraulic oil level in the reservoir, top up if
necessary.

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8007-13
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 left-hand side door of the machine.
STEP 7
STEP 2
CD00F051
CD01N012 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 Stop the vacuum pump.
disconnect the connectors from the protective hous-
ing. STEP 9
STEP 4 Loosen the retaining screws from the solenoid valve
block. While supporting the solenoid valve block,
remove the screws and the washers. Remove the
solenoid valve block from its bracket.
STEP 10
For proper installation of the connections, mark the
locations of the elbow unions. Hold the solenoid valve
in a vice. Remove the elbow unions and the straight
unions from the ports of the solenoid valve. Seal the
ports of the solenoid valve with plugs to avoid any
penetration of foreign bodies into the block.
NOTE: When installing, proceed in the reverse order
to that of removal. Start the engine. Energise several
CD00F050
Disconnect the connectors by pressing on the tongue times the solenoid valves (second speed selection,
fastener then by pulling to separate them (the con- swing brake control, power boost, pilot cushion con-
nectors are identified by rings of different colours). trol cancellation, swing locking, negative control,
boom priority, pilot pressure). Stop the engine, check
the circuit for leaks and the hydraulic oil level in the
reservoir, top up if necessary.

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8007-14
NOTES
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Copyright
Section
8008

OF THE SWING MOTOR
8008

Printed in France
Copyright
8008-2
TABLE OF CONTENTS
SWING MOTOR ....................................................................................................................................................... 3

Swing motor retaining screw ........................................................................................................ 568.4 to 649.4 Nm

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8008-3
SWING MOTOR
STEP 1 STEP 5
1
2
JS00163A CS02B555
Park the machine on hard, flat ground. Lower the Remove the upper panel (1) retaining screws (2),
attachment to the ground. then remove the upper panel (1).
STEP 2 STEP 6
Release pressure in the hydraulic system and in the To facilitate installation, attach labels to all the hoses
hydraulic reservoir (see Section 8000). and hydraulic unions which are disconnected during
removal.
STEP 3
STEP 7
STEP 8
1 2
1
CD01K071
4 5
Disconnect the earth cable (1) from the battery.
STEP 4 3 6
To prevent any fluid leaks when disconnecting CD01K072
hydraulic lines, connect a vacuum pump to the Attach identification tags to the hydraulic hoses.
hydraulic reservoir (see Section 8000). Remove the hoses (1), (2), (3), (4), (5) and (6). Plug
the hoses and the unions.
O-rings.

Copyright
8008-4
STEP 9 STEP 13
Stop the vacuum pump. To prevent any contamination of the gear oil, cover
the reduction gear with a cloth or a suitable protec-
STEP 10 tion.
NOTE: When installing, follow the same procedure in
the reverse order.
STEP 14
See Section 8001 and adjust the swing motor sec-
ondary relief valves.
NOTE: Before operating the machine, start the
engine, check the system for leaks and check the
hydraulic oil level in the reservoir, top up if necessary.
JD00385A
Connect a suitable lifting device to the swing motor.
STEP 11
2 1
JD00386A
To facilitate reassembly, make an alignment mark (1)
on the swing motor and on the reduction gear.
Remove the twelve retaining screws (2) from the
hydraulic swing motor.
NOTE: When installing, tighten the screws to a
torque of 568.4 to 649.4 Nm.
STEP 12
Carefully lift the swing motor and move it away from
the swing reduction gear. Move the swing motor away
from the machine and place it on a clean workbench.
NOTE: When installing, apply Loctite 504 to the mat-
ing surfaces between the reduction gear and the
swing motor.

Copyright
Section
8010
MAIN HYDRAULIC PUMP

8010

Printed in France
Copyright
8010-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 2
REGULATOR HANDLING........................................................................................................................................ 4
EXPLODED VIEW OF REGULATOR .................................................................................................................... 10
EXPLANATORY DIAGRAM OF REGULATOR OPERATION................................................................................ 12
CROSS - SECTIONAL VIEW OF HYDRAULIC PUMP.......................................................................................... 13
DISASSEMBLING THE REGULATOR................................................................................................................... 15
DISASSEMBLING THE HYDRAULIC PUMP......................................................................................................... 16
WEAR INSPECTION.............................................................................................................................................. 19
ASSEMBLING THE REGULATOR......................................................................................................................... 20
ASSEMBLING THE HYDRAULIC PUMP............................................................................................................... 22
SPECIFICATIONS
See Section 1002.

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8010-3

Pump:
Hex screw S.H.C (401). .................................................................................................................................. 430 Nm
Hex screw S.H.C (406) ..................................................................................................................................... 29 Nm
Hex screw S.H.C (414) ..................................................................................................................................... 57 Nm
Plug (466) ......................................................................................................................................................... 36 Nm
Plug (467) ......................................................................................................................................................... 74 Nm
Plug (468) ....................................................................................................................................................... 170 Nm
Plug (490) ........................................................................................................................................................ 8.8 Nm
Tilting pin (531)............................................................................................................................................... 240 Nm
Servo piston (532) .......................................................................................................................................... 240 Nm
Nut (806)......................................................................................................................................................... 130 Nm
Nut (808)......................................................................................................................................................... 240 Nm
Regulator:
Hex screw S.H.C (412) (413)............................................................................................................................ 29 Nm
Hex screw S.H.C (436) (438)............................................................................................................................ 12 Nm
Plug (496) ........................................................................................................................................................ 8.8 Nm
Lock nut (630)................................................................................................................................................. 160 Nm
Nut (801)........................................................................................................................................................... 16 Nm
NOTE: The numbers within brackets refer to the diagrams on page 10, 13 and 20.

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8010-4
SH330
REGULATOR HANDLING
NOTE: The numbers within brackets refer to the diagrams on page 10, 12, 13 and 20.
1.Description
The regulator KR 3*-9N** for KAWASAKI incline type axial piston pump K3V Series use is composed of the follow-
ing control mechanism.
1) Power control
As the discharge pressure P1 at the self pump and discharge pressure P2 at the counterpart pump rise, restrain the
input torque to a constant value or less by reducing the pump incline rotation angle (discharge flow) automatically
(when the number of revolutions is constant, the input power is kept constant).
As this is a simultaneous total power mechanism, overload on the motor is automatically prevented. It is operated
by the sum of load pressures at the two pumps of the tandem type double pumps. And the regulators of the each
pump are kept at the same incline rotation angle (discharge flow), under the state where the power control is acti-
vated.
2) Power shift control
Set power values can be shifted by changing command current values for the electromagnetic proportional pres-
sure-reducing valve that is attached to the regulator.
There is only one electromagnetic proportional pressure-reducing valve but the secondary pressure Pf (power shift
pressure) is introduced into the power control section in the regulator of each pump through the passage inside the
pump. Each pressure is shifted into the same set power value. As the pump's output power can be changed to an
arbitrary value through this mechanism, it is possible to obtain optimal power according to the work condition.
3) Flow control
By changing pilot pressure Pi, the pump incline rotation angle (discharge flow) can be arbitrarily controlled.
This regulator adopts a negative flow control (negative control) method where the discharge flow Q decreases as
the pilot pressure Pi increases. Through this mechanism, a pilot pressure matching the flow required for the work is
instructed, the pump discharges only the required flow, thus no useless power is consumed.
This regulator has those three control mechanisms above described, but each control works in a combined way.
The priority is given to the low incline rotation (low flow) command by mechanical computing which is to be
described later.

Copyright
8010-5
2. Description of Operation
(1) Flow control
As shown in the figure on the right, the pump discharge flow is controlled arbitrarily by
pilot pressure Pi.
Discharge flow Q
1) Flow decrease operation
When pilot pressure Pi rises, pilot piston (643) moves to the right and stops at a posi-
tion where the force of pilot spring (646) and the oil pressure force are balanced. As
Pin (875) fixed on lever 2 (613) is fitted in the grooved section [Section A] made on
the pilot piston, when the pilot piston moves, lever 2 turns around the fixation point as
a fulcrum due to the function of fulcrum plug (614) and pin (875). As pin (897) fixed
on feedback lever (611) is projected into the larger hole section on lever 2 [Section C], Pilot pressure PI
pin (897) moves to the right as lever 2 rotates. The part formed with two surfaces
[Section D] on the feedback lever has the pin (548) fixed onto incline rotation pin
(531) which oscillates the swash plate, the feedback lever rotates with Section D as its fulcrum when pin (897)
moves. As the feedback lever has spool (652) jointed to it via pin (874), the spool moves to the right.
When the spool moves, discharge pressure P1 is communicated with Port Cl through the spool and is introduced
into the servo piston's large diameter part. The discharge pressure P1 is always introduced into the servo piston's
small diameter part but the servo piston moves to the right because of the differential area, and the incline rotation
angle is reduced.
When the servo piston moves to the right, Point D also moves to the right. As the spool has a return spring (654) fit-
ted and the spring force to pull to the left always acts on the spool, pin (897) is pushed against the larger hole sec-
tion [Section C] on the lever 2. Therefore, the feedback lever turns around Point C as its fulcrum as Point D moves,
and the spool moves to the left.
In junction with this movement, the opening between the sleeve (651) and spool (652) starts closing gradually and
the servo piston stops at the position where the opening has completely closed.
2) Flow increase operation
When pilot pressure Pi decreases, pilot piston (643) moves to the left by the force of pilot spring (646) and lever 2
(613) turns around Point B as its fulcrum. As pin (897) is pushed against the larger hole section [Section C] on lever
2 by return spring (654) via spool (652), pin (874) and feedback lever (611), the feedback lever turns around Point D
as its fulcrum as the lever 2 rotates and the spool moves to the left.
As Port Cl is opened to the tank port when the spool moves, the pressure in the large diameter part is released and
the servo piston moves to the left by action of discharge pressure P1 in the small diameter section. As a result, the
flow increases.
As the servo piston moves, Point D moves to the left, the feedback lever turns around Point C as its fulcrum, and the
spool moves to the right. The spool continues to move until the spool sleeve opening is closed. It stops at the posi-
tion where the opening has been closed.

Copyright
8010-6
(2) Power control
As shown in the figure on the right, the overload on the motor is prevented by reduc-
ing the pump incline rotation angle when the load pressure rises.
Discharge flow Q
As this regulator has adopted a simultaneous constant power control method, the
incline rotation angles of two pumps (displacement) are controlled at the same value
as shown in the following equation:
Since the operation of power control is the same as described in the flow control, its Discharge pressure
brief description is given below. (P1 +P2)
(For the detailed operations of each part, refer to 3-1. Flow control.)
1) Overload preventive operation
When the discharge pressure P1 at the self pump or the discharge pressure P2 at the counterpart pump rises as P1
and P2 act on the stepped section of compensation piston (621), compensation rod (623) is pushed to the right and
moves to the position where the forces of the outer spring (625) and inner spring (626) are balanced with the
hydraulic oil force. The motion of the compensation rod is transferred to lever 1 via pin (875) and lever 1 turns
around the center of pin (875) (Point E) fixed on casing (601). As pin (897) fixed on feedback lever (611) is projected
into the larger hole section on the lever 1 [Section F], the feedback lever turns around Point D as its fulcrum and
spool (652) moves to the right as the lever 1 rotates.
When the spool moves, discharge pressure P1 is introduced into the servo piston's larger diameter part via Port Cl.
As a result, the servo piston moves to the right, the pump discharge flow is reduced and overload on the motor is
prevented.
The motion of the servo piston is transferred to the feedback lever via Point D, the feedback lever turns around Point
F as its fulcrum, and the spool moves to the left. The spool moves until the opening between the spool and sleeve
(651) is closed. It stops at the position where the opening has been just closed.
2) Flow return operation
When the discharge pressure P1 at the self pump or the discharge pressure P2 at the counterpart pump falls, com-
pensation rod (623) is pushed back by the force of springs (625 and 626) and lever 1 turns around Point E. The
feedback lever turns around Point D as its fulcrum as lever 1 rotates, and the spool moves to the left. Therefore, Port
Cl is opened to the tank port, the pressure in the large diameter part of the servo piston is released and the servo
piston moves to the left, as a result, the pump discharge flow increases.
The motion of the servo piston is transferred to the spool through the feedback mechanism, and the mechanism
continues to operate until the opening between the spool and sleeve is closed.

Copyright
8010-7
(3) Low incline rotation (low flow) command priority mechanism
As described above, an incline rotation command to the flow control or power control is transferred to the feedback
lever and spool via the larger hole section [Sections C and F] on lever 1 and lever 2, but only the lever which makes
the incline rotation smaller can contact pin (897). On the other hand, the hole (dia. 8) on the side under the com-
mand of larger incline rotation is not in contact with pin (897) and in a free state because Sections C and F have a
structure where pin (dia. 4) is projected into the large holes (dia. 8). Through this mechanical selection method,
priority is given to a command which belongs to the low incline rotation side at the flow control and power control.
(4) Power shift control
As shown in the figure on the right, pump's set power is controlled arbitrarily by
Discharge flow Q
power shift pressure Pf. When power shift pressure Pf increases, since compensa-
tion rod (623) moves to the right via pin (898) and compensation piston (621), the
pump inline rotation angle decreases and set power increases as described in 3-2-
1. Overload preventive operation in 3-2. Power control. On the contrary, as power
shift pressure Pf decreases, the set power increases.
3- Adjusting the Regulator
The maximum flow, minimum flow, power controlling characteristics and flow con- Discharge pressure
trolling characteristics can be adjusted by using adjusting screws on this regulator. (P1 +P2)
(Each adjustment is shown in Attached List 1.)
(1) Adjusting maximum flow
Loosen hexagon nut (808), and fasten (or loosen) set screw (954) to do adjustment.
The maximum flow, but not other controlling characteristics will change. Discharge flow Q
Pilot pressure PI
(2) Adjusting minimum flow
Loosen hexagon nut (808), and fasten (or loosen) hexagonal socket set screw (953)
to do adjustment. As with adjusting maximum flow, other controlling characteristics
Discharge flow Q
do not change but if it is fastened too far, required power may increase at the time of
maximum discharge pressure (at the time of relief). This needs special attention.
(3) Adjusting input power
As this is a simultaneous total power mechanism, when changing set power, do the
same amount of adjustment by using the adjusting screws on both front and rear
pumps. Changes in pressure by adjustment are valves where pressures of two Pilot pressure pi
pumps increase at the same time.
1) Adjusting outer spring

Loosen hexagon nut (630), and fasten (or loosen) adjusting screw C (628) to do
adjustment. If the adjusting screw is fastened, the input power moves to the right as
Discharge flow Q
shown in the figure on the right and the input power increases. If the adjusting screw
C is rotated by N turns, the setting on the inner spring changes. Once rotate back
adjusting screw CI (925) by N x A turns in the reverse direction.
Discharge pressure
(P1 +P2)

Copyright
8010-8
2) Adjusting inner spring
Loosen hexagon nut (801), and fasten (or loosen) adjusting screw CI (925) to do
adjustment. If the adjusting screw is fastened, the flow increases as shown in the fig-
Discharge flow Q
ure on the right and the input power increases.
Discharge pressure
(P1 +P2)
(4) Adjusting flow controlling characteristics
Loosen hexagon nut (801), and fasten (or loosen) hexagonal socket set
screw (924) to do adjustment. If the adjusting screw is fastened, the control
Discharge flow Q
line moves to the right as shown in the figure on the right.
Pilot pressure pi

Copyright
8010-9
Troubleshooting
If malfunctions possibly caused by regulator occurs, disassemble and reassemble it referring to the maintenance
instructions.
(1) Motor Overloading
Apply a load onto each pump separately and find out which pump (front or rear) is abnormal? If both are abnormal,
first check the following (1) and (2):
If only one side is available, start from (3).
1- Check that the power shift command current value is normal.
2- Lower power shift pressure:
- Check for dither on the amplifier.
- Replace electromagnetic proportional pressure-reducing valves.
3- Compensation piston/compensation rod sticking:
- Disassemble and clean.
4- Pin (898) sticking:
- Disassemble and clean.
(2) Maximum flow is not available
1- Ensure that pilot pressure Pi is normal.
2- Pilot piston sticking:
- Disassemble and clean
3- Spool sticking:
- Disassemble and clean
NOTE: If the parts have deep scratches, replace the parts.

Copyright
8010-10
EXPLODED VIEW OF REGULATOR
330.7.01.01.55K
Copyright
8010-11
Description
412 - HEX SCREW C.H.C 651 - SLEEVE
413 - HEX SCREW C.H.C 652 - SPOOL
436 - HEX SCREW C.H.C 653 - SPRING SEAT
438 - HEX SCREW C.H.C 654 - RETURN SPRING
496 - PLUG 655 - SET SPRING
601 - CASING 656 - BLOCK COVER
611 - FEEDBACK LEVER 708 - O-RING
612 - LEVER (1) 722 - O-RING
613 - LEVER (2) 724 - O-RING
614 - CENTER PLUG 725 - O-RING
615 - ADJUSTING PLUG 728 - O-RING
621 - COMPENSATOR PISTON 730 - O-RING
622 - PISTON CASE 732 - O-RING
623 - COMPENSATOR ROD 733 - O-RING
624 - SPRING SEAT (C) 734 - O-RING
625 - OUTER SPRING 735 - O-RING
626 - INNER SPRING 755 - O-RING
627 - ADJUSTING STEM (C) 756 - O-RING
628 - ADJUSTING SCREW (C) 763 - O-RING
629 - COVER (C) 801 - NUT
630 - LOCK NUT 814 - SNAP RING
631 - PF SLEEVE 836 - SNAP RING
641 - PILOT COVER 858 - SNAP RING
643 - PILOT PISTON 874 - PIN
644 - SPRING SEAT (Q) 875 - PIN
645 - ADJUSTING STEM (Q) 876 - PIN
646 - PILOT SPRING 887 - PIN
897 - PIN
898 - PIN
924 - SET SCREW
925 - ADJUSTING SCREW (Q)

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8010-12
EXPLANATORY DIAGRAM OF REGULATOR OPERATION
Regulator function diagram
330.7.01.01.55I

Copyright
8010-13
CROSS - SECTIONAL VIEW OF HYDRAULIC PUMP
330-7-01-01-53U1

Copyright
8010-14
Description
111 - SHAFT 468 - PLUG
113 - REAR SHAFT 490 - PLUG
116 - GEAR 1ST 531 - TILTING PIN
123 - ROLLER BEARING BEARING 532 - SERVO PISTON
124 - NEEDLE BEARING 534 - STOPPER (L)
127 - BEARING SPACER 535 - STOPPER (S)
141 - CYLINDER BLOCK 541 - SEAT
151 - PISTON 543 - STOPPER 1
152 - SHOE 544 - STOPPER 2
153 - SET PLATE 545 - STEAL BALL
156 - SPHERICAL BUSHING 548 - FEED BACK PIN
157 - CYLINDER SPRING 702 - O-RING
211 - SHOE PLATE 710 - O-RING
212 - SWASH PLATE 717 - O-RING
214 - TILTING BUSH 724 - O-RING
251 - SUPPORT S.P. 725 - O-RING
261 - SEAL COVER (F) 726 - O-RING
271 - PUMP CASING 728 - O-RING
312 - VALVE BLOCK 732 - O-RING
313 - VALVE PLATE (R) 774 - OIL SEAL
314 - VALVE PLATE (L) 789 - BACKUP RING
326 - COVER 792 - BACKUP RING
401 - SCREW 806 - NUT
406 - SCREW 808 - NUT
414 - SCREW 824 - SNAP RING
466 - PLUG 885 - VALVE PLATE PIN
466 - PLUG 886 - SPRING PIN
901 - EYE BOLT
953 - SET SCREW
954 - SET SCREW
981 - NAME PLATE
983 - PIN

Copyright
8010-15
DISASSEMBLING THE REGULATOR

In order to avoid changing the pump settings, the
cover (C) (629) is equipped with adjusting screws (C)
(628) and (Q) (925), a adjusting stem (C) (627), a
lock nut (630), an set screw (924) and a nut (801).
Do not loosen these screws and nuts, failure to com-
ply with this instruction will cause maladjustment of
pressure and flow.
Compensation section
Remove the cover (C) (629) by removing the hex
screws (438). Remove the outer spring (625), the
inner spring (626) and the spring seat (C) (624).
Pilot section
Remove the adjusting stem (Q) (645), the pilot spring
(646) and the spring seat (Q) (644).
Remove the hex screws (438) and remove the pilot
cover (641) and the set spring (655). Extract the snap
ring (814), the spring seat (653), the return spring
(654) and the sleeve (651) and remove the outer
snap ring (836) from the sleeve (651).
Extract the snap rings (858), the center plug (614)
and the adjusting plug (615).
Remove the side lever (2) (613) without removing the
pin (875).
Remove the pin (874) and remove the control feed-
back lever (611).
Remove the side lever (1) (612) without removing the
pin (875).
Remove the pilot piston (643) and the spool (652).
Remove the piston case (622) by pushing the inner
spring (626) to the opposite side.
Remove the compensating piston (621).
Remove and discard the seals.
Replace all defective parts.

Copyright
8010-16
DISASSEMBLING THE HYDRAULIC PUMP

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

Copyright
8010-17
STEP 5 STEP 8
NOTE: Operation to be carried out in case of wear of
the piston or the control pivot.
1 4
1
5
6
7
CD01G107 3
Remove the front flange (1) by gently tapping it with a
plastic mallet. Discard the seal. 2
STEP 6 Remove the seal plates (1) and (2), discard the
CI01G502
seals (3) and (4). Force the control pivot (5) blocking
pin (6) out. Remove the control pivot (6).
2 NOTE: The control pivot is installed using Loctite.

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

Copyright
8010-18
STEP 10
CD01G110
Remove the low pressure pump. Remove the retain-
ing screws and extract the power take-off housing (1)
from the low pressure pump.
STEP 11
CD01G111
Remove the snap ring, drive out the shaft and remove
the intermediate pinion (1). Remove the two shims.
STEP 12
CD01G112
Remove the snap ring, drive out the bearing assem-
bly and the secondary pinion (1).

Copyright
8010-19
WEAR INSPECTION
Standard dimension / Replacement of parts

recommended
Location Pump types Part to be replaced

K3V63, K3V112, K3V180,
K3V140
K5V80 K5V140 K5V200
0.028 / 0.039 / 0.043 / 0.0375 / Replace the pistons

Play between piston/bore (D-d)
0.056 mm 0.067 mm 0.070 mm 0.078 mm (151) or the cylinder
block (012)
Play at the shoe piston and the 0-0.1 / 0.3 0-0.1 / 0.3 0-0.1 / 0.3 0-0.1 / Replace the pistons
guide (A) mm mm mm 0.35 mm (151) and the piston
retaining plate (153)
Shoe thickness (t) 3.9 / 3.7 4.9 / 4.7 5.4 / 5.0 5.4 / 5.0 Replace the pistons
mm mm mm mm (151) and the piston
retaining plate (153)
Free height of cylinder springs 31.3 / 41.1 / 47.9 / 40.9 / Replace the springs
(L) 30.5 mm 40.3 mm 47.1 mm 40.1 mm (157)
Height of the base plate and 19.0 / 23.0 / 23.7 / 23.7 / Replace the base plate
the spherical bushing (H-h) 18.3 mm 22.0 mm 22.7 mm 22.7 mm and the spherical bush-
ing
Overhaul dimension of the cylinder, the distribution machined plate and the swash plate (machined sur-
face)
Distribution machined plate (sliding contact surface) Standard roughness after 0.1 RA or less
Swash plate (at the plate) grinding
Cylinder (sliding contact surface)
Roughness of the sur- 0.8 RA
Irregularity of each surface
face at the wear limit
d
L
CS02B595
CS02B596
A
t
H
h
CS02B597 CS02B598

Copyright
8010-20
ASSEMBLING THE REGULATOR
330-701-01-55J1

Copyright
8010-21
Regulator assembly instructions
Assembly is done in the reverse order of disassem- Install the pilot cover (641) and tighten the hex
bly, taking into account the following instructions: screws (436).
- Clean the components with detergent and dry them Install the spring seat (Q) (644), the pilot spring (646)
with compressed air. and the adjusting stem (Q) (645) in the housing at (E)
- Tighten the screws and plugs to the recommended (see disassembly).
torque.
Install the spring seat (C) (624), the inner spring
- Coat the moving parts with clean oil before assem-
(626), the outer spring (625) in the housing at (D)
bling them.
(see disassembly).
- Install new seals and O-rings.
Install the cover (C) (629) complete with adjusting
Assembly screws (C) (628), (Q) (925) and set screw (924), the
Press the pin (876) into the casing (601). adjusting stem (C) (627), the lock nuts (630) and nut
(801).
Press the pin (875) into the lever (1) (612).
Install and tighten the retaining hex screws (438).
Install the compensating rod (623) in the casing
(601).
Install the lever (1) (612) on the pin (875) by engaging
the pin (875) in the groove of the compensating rod
(623).
Install the snap ring (836) on the sleeve (651), grease
and install the spool (652) in the sleeve (651), install
the assembly in the casing (601) at port (A) by adjust-
ing the spool (652). Check that the sleeve and the
spool are sliding freely.
Install the control feedback lever (611) complete with
its pin (897), maintaining the orientation (reference
mark made during disassembly), align the bores of
the feedback lever (611) and the spool (652) and
install the pin (874).
Install the pilot piston (643) at (C) in the casing (601).
Install the lever (2) (613), engaging the pin (875) in
the groove on the pilot piston (643).
Install the center plug (614) complete with the pin
(875) in the casing (601). Position the lever (2) (613)
correctly so that the pin (875) is engaged in the orifice
on the lever (2) (613), then install the snap ring
(858).
Install the adjusting plug (615) and the snap ring
(858).
Install the return spring (654), the spring seat (653)
on the spool (652) and install the snap ring (814).
Install the set spring (655).
Install the compensating piston (621), the piston case
(622), the pf sleeve (631) and the pin (898) at orifice
(B).

Copyright
8010-22
ASSEMBLING THE HYDRAULIC PUMP

Pump assembly instructions STEP 3
Assembly is done in the reverse order of disassem-
bly, however, the following instructions need to be fol-
lowed:
1
- Respect the reference marks made during disas-
sembly.
- Lubricate the seals and the sliding parts.
- Do not mix the parts of the front and rear pumps.
- Use light Loctite when installing the control pivot.
STEP 1
2
5
3 CD01G114
Place the pump housing (1) with the regulator side
facing downwards. Coat the swash plate bearings (2)
2 with grease. Install the swash plate (2) by engaging
the housing of the plate in the control pivot. Check
4 that the swash plate (2) is fully home against the
1 housing bearings (1). Ensure that the swash plate (2)
is able to move freely by pressing on each side with
fingers of both hands.
6
CI01G502
Install the control piston (1) and the control pivot (2)
in the housing (3), coat with light Loctite that part of
the control piston that is in contact with the control
pivot (arrow). Position the pivot in such a way that the
locking pin (4) is installed, wipe off excess Loctite.
Lubricate the control piston (1) and its housing, fit
new seals on the seal plates (5), (6) and install them
in the housing (3).
STEP 2
2 1
CD01G113
Fit a new O-ring on the flange (1). Install the
flange (1) on the housing (2), respecting the refer-
ence marks made during disassembly.

Copyright
8010-23
STEP 4 STEP 6
1
6 2
CD01G116
5 Grease the lip seal of the cover (1). Install the
cover (1) taking care not to damage the lip seal on
the splines of the shaft (2). Install and tighten the
3 screws (3) to a torque of 29 Nm.
STEP 7
1
4
2
2
CI01G504
Install the shim (1) on the shaft (2). Heat the 1
bearing (3) to 80C in an oven.
NOTE: The bearing locking shim (4) is oriented 3
towards the shaft splines.
Adjust the bearing (3) properly. Install the bearing (3)
on the shaft (2) using heat protective gloves. Install CD01G117
the shim (5). Install the snap ring (6). Install the springs, the spherical bushing, the pistons
complete with the thrust ring on the cylinder block.
STEP 5 Install the piston plate on the swash plate. Install the
cylinder block assembly (1) in the housing (2) by
engaging the splines of the spherical bushing and the
cylinder block on the shaft (3).
CD01G115
Install the shaft assembly (1) in the flange (2) while
supporting the swash plate. Tap with a plastic mallet.

Copyright
8010-24
STEP 8 STEP 10
4
1
2
3
1
CD01G118 CD01G112
Install new needle bearings (1) in the intermediate Position the pinion complete (1) with two bearings on
housing (2). Stick the cylinder plate (3) with grease the power take-off housing, install the assembly
on the intermediate housing (2) by adjusting it so that under a press and push in until stopped. Install the
the retaining pin is engaged in the plate housing. snap ring.
Install a new seal (4). Position the intermediate hous-
ing on the pump body according to the reference STEP 11
marks made during disassembly.
STEP 9
1
2
1
1 CD01G111
Install the intermediate pinion (1) complete with its
bearing (2). Install a shim on each side of the pinion.
CD01G119 Install the shaft (arrow). Install the snap ring.
Install and tighten the screws (1) alternately to a
torque of 431 Nm. Install the coupling pinion in the STEP 12
intermediate housing. Proceed in the same manner
to install the second pump body (step 2 to 10).
CD01G110
Install a new seal on the intermediate housing. Install
the power take-off housing (1). Install and tighten the
screws to a torque of 98 Nm.

Copyright
8010-25
STEP 13
1
3
CD01G103
Install a new O-ring (1) on the regulator block (2).
Align the control lever (3) with the axle (4) of the con-
trol pivot and install the regulator block (2). Install and
tighten the retaining screws to a torque of 29.4 Nm.
Proceed in the same manner when assembling the
second regulator block.

Copyright
8010-26
TROUBLESHOOTING
1) General precautions
Following are countermeasures if you find abnormality during the operation of Kawasaki swash plate type axial pis-
ton pump and motor.
General precautions are:
a) Considerations before starting repair.
Determine the characteristics of the abnormality before starting repair. Consider if the cause is originated from the
wrong circuit, failure of regulator, or attached valve. Double check that the problem involves the pump motor.
b) Before disassembling a system, make sure to read through the service manual. Conduct the disassembly in a
correct manner.
c) When disassembling a system, be careful not to allow dust to enter.
d) Parts are finished precisely. Be careful not to damage them when handling.
2) Troubleshooting for the pump main body
Pumps are often attached to a regulator, attached valves and attached pumps. It can be difficult to find the cause of
the problem. Checking the following points is useful to identify the problem area.
a) Filter check and drain oil check.
Check the filter element. Check if a considerable amount of contamination is found.
It is normal that a little amount of metal dust originated from abrasion of the shoe or cylinders is seen. However, if
the amount of metal dust is extremely high in the filter, the shoe might be damaged. Check drain oil of inside the
pump casing, as well.
b) Abnormal noise / abnormal vibration
Check for abnormal noise or abnormal vibration in the main pump. Examine if the sound repeats with regular fre-
quency such as, a hunching sound in the regulator or hunching sound of the valve relief.
If there is an abnormal vibration or sound, cavitation or damage inside the pump should be considered.
c) When using two pumps.
If piping uses two single pumps or two motors, change the pipe of each pump.
By changing the pipe, the problem can be identified whether it is caused by a pump failure or a piping failure after
the pump.
d) Perform pressure measurement.
If the problem is related to the controlling function, examine the problem areas using pressure measurement tools
instead of performing overhaul inspection.

Copyright
8010-27
3) Overload on the motor
Causes Countermeasures Notes

1.Rotational speed-check if pres- Set pressure at an expected
sure is set higher than expected value.
value.
2.Check if the torque set of the Recheck the regulator. Refer to the regulator instruc-
regulator is high. tion manual.
3.Damage and burning on the Replacement of damaged Check filter and drain oil for
internal parts of the pump. parts. abnormal dust from abrasion.
4.Wrong piping for the regulator. Correct the regulator piping.
4) When pump flow rate declines significantly or discharging pressure does not increase.

1.Faulty regulator. Repair the regulator. Refer to the regulator instruc-
tion manual.
2.Damage and burning on the Replacement of damaged Check filter and drain oil.
internal parts of the pump. parts.
3.Attached faulty pump. Replace damaged parts. Disconnect the attached pump
and check the shaft coupling
section.
4.Attached faulty valve. Check attached valve. (Check Refer to the attached valve
especially poppets and seat instruction manual.
springs.)
5.Wrong regulator piping. Correct the regulator piping.
5) Abnormal noise / abnormal vibration

1.Cavitation Prevention of cavitation. Boost pressure is too low.
Check hydraulic oil for white Failure of auxiliary pump.
turbidness. Air is drawn from the intake
pipe.
Intake resistance is too high.
2.Damage on the shoe Replacement of piston shoe,
caulking area. shoe plate or others.
3.Cracks on the cylinder Replacement of the cylinder
4.Failure of pump installation Reinstallation
5.Hunching of the regulator Repair of the regulator Refer to the regulator instruc-
tion manual.
6.Hunching of the relief valve on Repair the attached valve. Refer to the attached valve
the attached valve instruction manual.

Copyright
8010-28

8011
Section Copyright
8011

OF THE CONTROL VALVE

Printed in France
Copyright
8011-2
TABLE OF CONTENTS
SPECIFICATIONS .................................................................................................................................................. 2
TOOLS REQUIRED ............................................................................................................................................... 2
CONTROL VALVE ................................................................................................................................................. 4
Description .......................................................................................................................................................... 4
Identifying the ports ............................................................................................................................................. 9
Disassembly ...................................................................................................................................................... 10
General instructions .......................................................................................................................................... 10
Separating the sections ..................................................................................................................................... 10
Load holding block ............................................................................................................................................ 11
Cleaning ............................................................................................................................................................ 14
Inspection .......................................................................................................................................................... 14
Precautions before assembly ............................................................................................................................ 14
Assembly ........................................................................................................................................................... 15
TROUBLESHOOTING ......................................................................................................................................... 20
SPECIFICATIONS
Weight of control valve ................................................................................................................... See Section 1002
Safety valve settings....................................................................................................................... See Section 8001
TOOLS REQUIRED
1. Loctite 262
2. Torque wrench OEM 6472, OEM 6474 and OEM 6476

Copyright
8011-3

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

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

Copyright
8011-5
92
44 45
36
97
64
91
50
36 51
35
49 G-G
47
48 46
73 73
34 35 53 54
55 H-H
68
92 I-I 34 35 53 54 55
CS02C564

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

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

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

Copyright
8011-9
Identifying the ports

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

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

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

Copyright
8011-11
STEP 5 STEP 4
Remove the O-rings (7) from sections (1) and (13) of Loosen, then remove the end (22) of the spool (19),
the control valve. then remove the spring seats (20) and the spring (21).
NOTE: To avoid abrasion of the spool surface during Spool assembly (27)
removal of the spool assembly, use a vice with pro-
tective jaws and tighten the spool as close as possi- NOTE: When removing the plug (24), make sure that
ble to the head in order to avoid any deformity. When you do not drop parts which under pressure from the
the threaded portion of the screw is coated with Loc- springs.
tite, heat the head of the screw using an industrial STEP 1
drier until removal becomes easy (normally the tem-
perature should be in between 200 and 250C). If this Loosen and remove the plug (24) and remove the
operation causes the spring to be deformed and mal- O-ring (25).
function, replace the spring.
STEP 2
STEP 6 Remove the spring (26).
B C B D STEP 3
31 B
A
CS01K596
Remove the spool screws (D) on the spring side of
the spools (2) to (6) and (14) to (17). Remove the 30 C
spring seats (B) as well as the springs (C). CS01K597
Remove the spool (A) from the sleeve (B). Extract the
NOTE: In the spools (3) and (14), only remove the
sleeve (B) from the control valve body. Remove the
check valves, the springs, the O-rings, the back up
piston (C), the O-ring (30) and the back up rings (31).
rings and the plugs if it is necessary. If it is necessary
to remove them, heat the periphery of the spool in Load holding block
order to make it easier to remove the plug.
NOTE: Be careful when removing components, some
Dipper load holding valve parts are subject to spring pressure.
decompression spool 1
STEP 1
STEP 1
Loosen and remove the screws (75) and remove the
Loosen and remove the screws (78) that fasten the caps (37).
cap (18) and remove the cap (18).
STEP 2
STEP 2
Remove the springs (35), the check valves (34) and
Remove the O-ring (23) from the cap (18). (51), the O-rings (36) from the control valve body.
STEP 3 NOTE: The straight-line travel valve does not have
springs or check valves (see section H-H).
Remove the spool (19) from the control valve body
taking care not to damage it. STEP 3
NOTE: For removal of the spool, refer to the instruc- Loosen and remove the screws (75) and remove the
tions previously cited for removal of spool assem- caps (52).
blies.

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

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

Copyright
8011-13
Load holding valve (67) Valves
NOTE: Do not operate the valve components, as this
67 P will affect the pressure, otherwise see Section 8001
E for the valve settings.
STEP 1
A 69
CS02C563
Q L H J K R M F D C B N Loosen and remove the six safety valves (69) from
CS01K599 the control valve body. Remove the O-ring (A) from
NOTE: Be careful when removing components, some the safety valve body.
parts are subject to spring pressure.
STEP 2
STEP 1
68
Loosen and remove the plug (N) and remove the A
O-ring.
STEP 2
Remove the piston (C), the spool (D) and the
spring (F).
STEP 3
CS02C560
Loosen and remove the plug (B) and remove the Loosen and remove the relief valve (68) from the con-
O-ring (M). trol valve body. Remove and discard the O-ring (A).
STEP 4 STEP 3
Remove the sleeve (E), the check valve (A) from the
A 70 B
load holding valve body (67). Remove the O-rings (H)
and (J), the back-up rings (K) and (L) from the periph-
ery of the sleeve (E).
STEP 5
Remove the spring seat (Q) and the spring (G).
STEP 6
Loosen and remove the plug (P), if this is required.
NOTE: The steel ball (R) is a press fit, do not remove
it.
CS01K600
Loosen and remove the two safety valves (70) and
remove the O-rings (A) and (B).

Copyright
8011-14
Auxiliary assembly Cleaning
STEP 1 Clean all the parts removed with clean oil. Dry with
Loosen and remove the screws (75) from the caps compressed air and place each part on a clean sheet
(88) and remove the O-rings (89). of paper or vinyl for inspection.
STEP 2 Inspection
Loosen and remove the two plugs (87) and remove Inspect the surface of each part for scratches, abra-
the O-rings and the back up rings. sion and other damage.
Plug assembly 1. Check that there are no scratches or dents on
the non-return load check valve seat in the con-
STEP 1 trol valve body and that there are no traces of
Loosen and remove the plug (60) and remove the rust or contaminants.
O-ring (see section J-J). 2. Check that there are no scratches or dents on
the periphery of the spool. Remove small
STEP 2 scratches using a piece of cloth soaked in an
Loosen and remove the plug (61) and remove the abrasive product.
O-ring (62) (see section K-K). 3. Check that all sliding surfaces are moving freely.
STEP 3 Check for the absence of foreign matter in holes
and in grooves.
Loosen and remove the plug (63) from its port (see
4. Replace the springs in case of damage, deform-
section A1-A1).
ity or wear and tear.
STEP 4 5. Replace all O-rings and back up rings with new
Loosen and remove the plug (92) and remove the ones.
O-ring (see section I-I). 6. After removing the caps and plugs, ensure that
STEP 5 there is no trace of paint at the level of the port
of the body or on the rim of the plug. (Any trace
Loosen and remove the plugs (72) and remove the of residual paint is likely to cause contamination
O-rings. that could cause the system to malfunction and
lead to possible leaks).
Precautions before assembly

Before beginning assembly, check the quantity of the
parts, be sure of their final position and get all the
required tools ready.

Copyright
8011-15
Assembly Dipper load holding valve

Spool assembly
STEP 1
NOTE: Take care not to apply too much Loctite, it
could seep through inside the spool and cause it to Apply Loctite 242 on the threaded portions of the
malfunction. spool (19) and install the spring seats (20), the spring
(21) and the spool end (22).
NOTE: If the spool (3) boom section 1 (opposite the
spring) and the spool (14) dipper section 1 (spring STEP 2
side) have been removed for assembly, proceed in
Install the spool in a vice with protective jaws. Tighten
the following manner:
the end of the spool to a torque of 19 to 22 Nm.
STEP 1 Load holding valve (67)
Install the check valve and the spring in the spool,
install the back up ring and the O-ring on the plug.
Apply Loctite 242 on the threaded portion of the plug. 67 P
Install the spool in a vice with protective jaws and E
tighten the plug at the end of the spools (3) and (4).
STEP 2
G
Apply Loctite 242 on the spring side on the threaded
portions of the spools (2) to (6) and (14) to (17).
Install the spool in a vice with protective jaws. A
STEP 3
B C B D
Q L H J K R M F D C B N
CS01K599
STEP 1
Install the O-rings (H) and (J) and the back up
CS01K596
rings (K) and (L) on the peripheral grooves of the
Install the spring seat (B), the spring (C), the spring sleeve (E).
seat (B) on the screw (D) and tighten it on the spool
NOTE: Respect the positions of the O-rings and back
to a torque of 20 to 22 Nm. up rings. Any wrong installation will cause lacerations
to the O-rings and will encourage the cylinder to drift.
STEP 2
Install the check valve (A) and the spool (D) in the
port of the sleeve (E).
STEP 3
Install the spring seat (Q) at the end of the check
valve (A), install the spring (G). Insert the assembly
into the load holding valve body (67).
NOTE: Apply grease on the spring seats to make
installation easier.

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8011-16
STEP 4 STEP 3
Install the spring (F) and the piston (C) in the A 70 B
plug (B).
STEP 5
Install the plug (N) equipped with an O-ring on the
plug (B). Tighten to a torque of 147 to 157 Nm.
STEP 6
Install the plug (B) equipped with a new O-ring (M) on
the load holding valve body (67). Tighten to a torque
of 147 to 157 Nm.
STEP 7
CS01K600
Install the plug (P) equipped with a new O-ring on the Install the two safety valves (70) equipped with an
load holding valve body (67). Tighten to a torque of O-ring (A) and (B). Tighten to a torque of 103 to
14 to 18 Nm. 113 Nm.
Valves Load holding block

NOTE: Do not operate the valve components, as this STEP 1
will affect the pressure, otherwise see Section 8001
Install the O-rings (36) in the control valve housing,
for the valve settings.
dipper sections 1 and 2 (see section D-D), boom sec-
STEP 1 tion 1 and 2 (see section E-E), swing and bucket sec-
tion (see section F-F), install the check valves (34)
68 and the springs (35).
A
STEP 2
Install the caps (37) and fasten them using screws
(75). Tighten to a torque of 58 to 64 Nm.
STEP 3
Install the O-rings (36) in the housing of the travel
CS02C560 control valve section (see section H-H), install the
Install the main relief (68) equipped with an check valves (51) and the springs (35).
O-ring (A). Tighten to a torque of 78 to 88 Nm.
STEP 4
STEP 2
Install the caps (37) and fasten them using screws
(75). Tighten to a torque of 58 to 64 Nm.
STEP 5
Install the O-ring (36) in the housing of the straight-
line travel control valve section (see section H-H).
NOTE: The straight-line travel valve is not equipped
A 69 with springs or check valves.
CS02C563
STEP 6
Install the six safety valves (69) equipped with an Install the cap (37) using screws (75). Tighten to a
O-ring (A). Tighten to a torque of 78 to 88 Nm. torque of 58 to 64 Nm.

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8011-17
STEP 7 STEP 3
Install the check valve (34) and the spring (35) (see C B
section I-I), install the spacer (53) complete with an 40
O-ring (54) and a back up ring (55).
NOTE: Respect the positions of the O-rings and back
up rings. Any wrong installation will cause lacerations
to the O-rings and will encourage the cylinder to drift.
A
STEP 8
Install the cap (52) using screws (75) and tighten to a
torque of 39 to 44 Nm.
STEP 9
CS01K598
Install the O-ring in the option section (see section
Install an O-ring (A) on the spacer (40), install the
G-G), install the check valve (44) and the spring (45).
O-ring (C) and the back up ring (B).
Install the cap (43) and fasten it using screws (96).
Tighten to a torque of 58 to 64 Nm. NOTE: Respect the positions of the O-rings and back
up rings. Any wrong installation will cause lacerations
STEP 10 and external leaks.
Install the plug assembly (92) equipped with an STEP 4
O-ring. Tighten to a torque of 205 to 227 Nm.
Install the spacer assembly (40).
STEP 11
STEP 5
Install the check valve (49) and the spring (48) on the
travel portion (see section G-G). Install the plug (46) Install the load holding valve (67) and fasten it using
equipped with an O-ring (47). Tighten to a torque of screws (76). Tighten to a torque of 39 to 44 Nm.
107 to 117 Nm.
Auxiliary assembly
STEP 12
STEP 1
Install the check valve (32) and the spring (33) on the
dipper portion 1 (see section C-C). Install the plug Install the caps (88) equipped with an O-ring (89) and
(72) equipped with an O-ring. Tighten to a torque of fasten them using the screws (75). Tighten to a
73 to 79 Nm. torque of 58 to 64 Nm.
STEP 13 STEP 2
Install the plugs (87) complete with an O-ring and a
Install the check valve (32), the spring (33) and the
back up ring. Tighten to a torque of 78 to 88 Nm.
spacer (57) on the dipper portion 2 (see section L-L).
Install the plug (72) equipped with an O-ring. Tighten
to a torque of 73 to 79 Nm.
Load holding valve
STEP 1
Install the O-rings (41) and (42) on the dipper control
valve body 1 (see sections D-D and A2-A2) and
boom 1 (see sections E-E and B1-B1).
STEP 2
Install the check valve (38) and the spring (39).

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8011-18
Spool assembly (27) STEP 3
STEP 1 Install the caps (10) and the caps (12) on the control
valve body and fasten them using screws (74).
31 B Tighten to a torque of 39 to 44 Nm.
A
STEP 4
Install the caps (8) and the caps (9) on the control
valve body and fasten them using screws (74).
Tighten to a torque of 39 to 44 Nm.
30 C NOTE: Check the proper positioning of the caps (9)

and (10).
CS01K597
Install the O-ring (30) and the back up rings (31) on STEP 5
the sleeve (B). Install the piston (C) and the spool (A)
in the sleeve (B). Install the assembly in the control Install the plugs (73) equipped with an O-ring on the
valve body. long cap of the boom section 2 (see section E-E), on
the long cap of the straight-line travel section (see
STEP 2 section H-H). Tighten to a torque of 19 to 22 Nm.
Install the spring (26) inside the plug (24) equipped STEP 6
with an O-ring (25). Screw the plug on the control
valve body. Tighten to a torque of 103 to 113 Nm. Install the plug (97) equipped with an O-ring on the
short cap of the option section (see section G-G).
Dipper load holding valve Tighten to a torque of 19 to 22 Nm.
STEP 7
STEP 1
Install the plug (73) equipped with an O-ring on the
Install the spool assembly (19) in the control valve short cap of the straight-line travel section (see sec-
body without forcing it. tion H-H). Tighten to a torque of 19 to 22 Nm.
NOTE: Ensure that it is functioning properly by mak- STEP 8
ing it slide manually.
Install the plug (91) equipped with an O-ring (64) on
STEP 2 the long cap of the option section (see section G-G).
Install the cap (18) equipped with an O-ring (23) and
fasten it using screws (78). Tighten to a torque of 8,8 Plug assembly
to 10,8 Nm.
STEP 1
Spool assemblies (2) to (6) and (14) to (17)
Install the plug (60) equipped with an O-ring. Tighten
STEP 1 to a torque of 103 to 113 Nm (see section J-J).
Install the O-rings (7) on the control valve body. STEP 2
STEP 2 Install the plug (61) equipped with an O-ring (62).
Tighten to a torque of 39 to 44 Nm (see section K-K).
Install the assembled spools (2) to (6) and (14)
to (17) in the ports of the control valve body. STEP 3
NOTE: Ensure that the spool is installed in its original Install the plug (63) in its port. Tighten to a torque of
port, install it without pressing too hard. After install- 14 to 18 Nm (see section A1-A1).
ing the spool, make it slide manually to check its
proper functioning.

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8011-19
STEP 4 NOTE: For installation of the control valve, see Sec-
tion 8004.
Install the plugs (92) equipped with an O-ring.
STEP 5
Install the plugs (72) equipped with an O-ring.
Assembling the sections
STEP 1
65 66
66
65
65
65
66
65
65
CI01K542
Install new O-rings (65) and (66).
STEP 2
77 81
77 81
CI01K541
Assemble the two sections (1) and (13) using
screws (77) and washers (81). Tighten to a torque of
167 to 177 Nm.

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8011-20
TROUBLESHOOTING
Control valve in general
Problems Possible causes Countermeasures

Spool does not 1.Oil temperature has abnormally risen. Remove any part causing resistance to oil flow
move. in piping.
2.Dirty hydraulic oil Change oil and clean circuit at the same time.
3.Over-tightening of piping port joints Check torque.
4.Deformed valve housing by incorrect mount- Loosen mounting bolts and check their condi-
ing tion.
5.Pressure is too high. Check pressure by placing a pressure gauge
between pump and cylinder port.
6.Deformed spool Replace valve as an assembly.
7.Damaged return spring Replace damaged parts.
8.Dislocated spring or cap Loosen cap first, and then center and
retighten it.
9.Temperature is not uniform inside the valve. Warm up entire circuit.
10.Valve is blocked with dirt. Eliminate dirt (flushing).
11.Lack of pilot pressure Check pilot valve and pilot relief pressure.
Load cannot be 1.Oil leakage from cylinder Check seals in cylinder for damage.
held.
2.Oil bypasses spool. Check spool for damage.
3.Oil leakage from overload relief valve Clean valve housing seats and relief valve
seats.
4.Oil leakage from anti-drift valve Disassemble anti-drift valve and clean seat
section in each part.
If damage is found in seat section, replace
poppet or apply lapping to poppet together
with the section.
If any abnormality is found on anti-drift valve,
replace spool and sleeve at the same time
because they are press-fit.
Load drops when 1.Load check valve is blocked with dirt. Disassemble and clean check valve.
switching spool
2.Damage on poppet or seats in the check Replace poppet or apply lapping to poppet
from neutral to
valve and seats.
raised position.

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8011-21
Relief valve

Pressure does 1.Main poppet, sleeve or pilot poppet sticks Replace relief valve.
not rise at all. and keeps open, or seats in valve are blocked
with dirt.
Unstable relief 1.Seats in pilot poppet are damaged.
pressure
2.Piston or main poppet sticks.
Incorrect relief 1.Wear in seats due to dirt
pressure
2.Looseness in lock nut and adjuster Reset pressure and tighten lock nut to speci-
fied torque.
Oil leakage 1.Damage on relief valve seats Replace relief valve.
2.Each part sticks due to dirt.
3.Worn O-rings Replace O-rings for adjuster or in mounting
section.
Hydraulic system in general

Hydraulic sys- 1.Faulty pump Check pressure or replace pump.
tem malfunc-
2.Faulty relief valve Replace relief valve.
tions or does not
operate at all. 3.Faulty cylinder Repair or replace it.
4.High load pressure on pump Check circuit pressure.
5.Cracks on the valve Replace valve as an assembly.
6.Spool does not move with a complete stroke. Check spool for its movement.
7.Oil level in tank is too low. Refill hydraulic oil.
8.Filter blockage in circuit Clean or change filter.
9.Restricted circuit piping Check piping.

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8011-22
NOTES
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Copyright
8012
Section
8012

OF THE ATTACHMENT CYLINDERS

Printed in France
Copyright
8012-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 2
MAINTENANCE INSTRUCTIONS ........................................................................................................................... 4
SPECIAL TOOLS ..................................................................................................................................................... 8
CYLINDERS ............................................................................................................................................................. 9
Boom cylinder description .................................................................................................................................... 9
Dipper cylinder description ................................................................................................................................. 11
Bucket cylinder description ................................................................................................................................ 13
BOOM CYLINDER ................................................................................................................................................. 11

Disassembly .......................................................................................................................................................11
Inspection ........................................................................................................................................................... 13
Assembly ............................................................................................................................................................ 14
ERROR DIAGNOSIS.............................................................................................................................................. 18
SPECIFICATIONS
See Section 1002.

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8012-3

Boom cylinder
Piston nut (4) ................................................................................................................................... 294 29.4 Nm
Bearing retaining screw (2) .......................................................................................................... 529.7 78.5 Nm
Piston nut screw (3)........................................................................................................................ 66.2 7.35 Nm
Dipper cylinder
Piston nut (4) ................................................................................................................................... 294 29.4 Nm
Bearing retaining screw (2) .............................................................................................................. 892 137 Nm
Bucket cylinder
Piston nut (4) ................................................................................................................................... 294 29.4 Nm
Bearing retaining screw (2) .......................................................................................................... 529.7 78.5 Nm

Copyright
8012-4
MAINTENANCE INSTRUCTIONS
1. Description of Functions
1) Basic functions
The hydraulic piston system is a kind of hydraulic actuator which converts hydraulic energy supplied from the
hydraulic pump into a larger force for linear movement via a piston. In addition, it switches its operational direc-
tion between extension and retraction by way of lever operation on the hydraulic oil direction switch-over valve.
This larger force, linear movement, and operational direction switching over are the basic functions.
2) Function by section
1) Cylinder head assembly
The piston assembly has a bearing function for the piston rod (16) provided by means of bushing (05) press fitted
into the inside surface of cylinder head (17). It prevents external oil leakage by means of a buffer ring (03), Rod
packing (04) inserted into the inside surface of cylinder head. It also prevents dust from the outside by means of
a dust seal (02) press fitted into the inside surface of the cylinder head.
Engaging with the plunger (12) at the cylinder's most extended position, it generates high pressure in the cushion
chamber and this softens the cylinder's impact at the most extended position.
In addition, it also supplies and drains high-pressure oil from the inside of cylinder tube to the ports.
000-7-05-02-20AA
Bushing (05)
The bushing is press fitted into the inner face of the cylinder head and is in contact with the piston rod. It reduces
eccentricity, which adversely affects the seal performance, by sharing lateral load applied on the cylinder
together with the slide ring located on the outer circumference of the piston, performing high-bearing linear
motion against the piston rod, as well as supporting one end of the piston rod.
Buffer ring (03)
The buffer ring is located between the rod packing and bushing. It prolongs the life of the rod packing, which is
the main seal, by relieving high pressure with the auxiliary seal which is directly in contact with the high pressure
oil in the cylinder, and reducing the load acting on the rod packing.
Rod packing (04)
The rod packing is located between the dust seal and the buffer ring. The rod packing seals the annular space
formed between the piston rod and cylinder head against the pressure oil between the rod packing and the
backup ring. It also forms suitable oil films on the piston rod to prevent rust.
Dust seal (01)
The dust seal is located at the opening end where the piston rod enters into and exits from the cylinder. It pre-
vents dust and water from entering into the rod seal section of the rod packing and the buffer ring in the cylinder
from the outside. It also scrapes off mud attached on the surfaces of piston rod through piston rod movements.
2) Piston assembly
The piston assembly prevents pressure oil from leaking from one chamber to the other chamber by the insertion
of piston ring (08) in the center of the piston. It has a bearing function to receive lateral cylinder load by the inser-
tion of the wear ring (09) on both ends of the piston ring. It also has a bearing function and a function to capture
contaminants by the insertion of ring (10) in the outer side.

Copyright
8012-5
Piston ring (08)
The sealing, which is located at the center of the piston, seals the annular space formed between the piston and
cylinder tube. It divides into high pressure and low pressure chambers by using the piston as a boundary.
Ring (09) and (10)
The wear rings are located at both ends of the piston ring and are in contact with the inner surface of the cylinder
tube. They reduce eccentricity, which adversely affects the seal performances, by sharing lateral load applied on
the cylinder together with the bushing located on the inner surface of the cylinder head. They also perform high-
bearing linear motion against the cylinder tube inner surface, as well as supporting one end of the piston rod.
The ring (10) submerges and captures contaminants engaged between the cylinder tube and the wear ring.
000-7-05-02-20AB
Screw (11)
Screw prevents the piston from turning.
Plunger (13)
It generates high pressure in the cushion chamber and this softens the cylinder's impact at the most shorten
position.
Ball (14)
Ball is an omission stop of plunger. Moreover, eccentric of plunger is prevented.
Cap (15)
Cap prevents the ball from coming off.
3) Pipes (A) and (B)
A pair of pipes are located on each port on the extension and retraction side on the cylinder tubes (1). The pipes
supply and drain high-pressure oil from the flexible hose connection end to the cylinder tube port.
000-7-05-02-20AB

Copyright
8012-6
2. Precautions for Handling: Cautions
1) When installing the cylinder on the machine
When installing the cylinder onto the machine, lift the cylinder while ensuring its safety.
Lifting the cylinder by its piping section is not only dangerous but also may cause damage to the cylinder.
Fix the rod at its most retracted position by using a band or the like. Otherwise, the rod can pop out. In addition,
the damaged rod could be unusable.
Welding after installing cylinder may cause serious damage to the cylinder.
Electric welding on the cylinder and even at a location far from the cylinder may cause sparks in the cylinder,
resulting in the need for cylinder replacement.
When painting the machine, use masking tape on the cylinder.
If the cylinder is operated when there is paint on the rod surface and dust seal, the dust seal will not work cor-
rectly, and contaminants and paints easily get into the cylinder, which may lead to damage to seal parts or
extreme shortening of the life of cylinder.
Clean the cylinder before installing.
2) Precautions for use
Use them under specified conditions.
If you use hydraulic oil other than the specified one, sealing parts could deteriorate very quickly, leading to break-
age.
Setting the relief valve at a higher value than shown in the assembly drawing is dangerous because it may result
in damage to the cylinder.
General sealing materials are damaged quickly under high temperatures (approximately 100C or higher) and
cold temperatures (-30C or colder).
In this case, as special seals are required, please confirm the suitability of the seal with your cylinder.
The first major cause of cylinder defaults is oil leakage caused by damaged rods.
Careful operating is needed to avoid damage.
Before operating, warm the cylinder fully.
If the cylinder has been used for a long time, the seal parts in cylinder become stuck with metal on the sliding
surface. Avoid sudden operations under maximum pressure, at high speeds.
If the cylinder is brand new or has been left without being operated for a long time, a lot of air has accumulated
and prevents smooth movement of the cylinder.
Furthermore, pressuring quickly without bleeding causes heat due to air adiabatic compression, which burns and
carbonizes the sealing parts. As a result, the performance can be significantly reduced.
Before starting the operation, move the cylinder slowly several times without load at full stroke to remove air from
the inside of the cylinder.
Keep a safe fixed position when temporarily stopping or storing.
Cylinders cannot be kept in a given position for a long time while attached to the machine.
Cylinder oil leaks and the volume of the hydraulic oil in the cylinder may change due to the changes in hydraulic
oil temperature. As a result, the extended or retracted cylinder may make the machine move unexpectedly. This
is a very dangerous situation.
Always temporarily stop or store the cylinder in a safe fixed position.
At first stage of operation, please draw out the residual air, which is inside of the cylinder assembly.
If there is residual air and press it rapidly, seals and packing may be burnt by diesel effect.
Aeration must be performed completely as follows.
1) In the first operation after assembling
2) At first operation equipped it other machine
3) In case of aeration reassembling tubes
How to aeration
1) Reduce oil pressure (Engine: Low rotating speed)
2) Operate hydraulic cylinder 4 to 5 times, stopping 20-30 mm from stroke end
3) Next operate cylinder 3 to 4 times to stroke end
3) Maintenance and inspection precautions
Always conduct daily maintenance and inspections.
Daily maintenance and inspections are the key to maintaining and prolonging the full performance of the cylin-
der.
Follow 4. Maintenance/Inspections and Servicing to achieve full performance. Always remove mud, water, dust
Copyright
8012-7
and grease attached to the rod.
Wipe off the dust seal and sealing sections with a cloth instead of washing with water.
If leaving without being used for a week or longer, apply corrosion inhibitor to the surface of the rod for rust proof-
ing.
For part replacement, use CASE parts.
If you use parts other than CASE parts, you may not gain the expected full performance. It is recommended that
you always use CASE parts.
We also manufacture dedicated jigs designed to make it possible to perform disassembling and reassembling
work safely and quickly.
Special care should be also directed to disassembling and reassembling.
It is particularly dangerous to disassemble the cylinder head while it is still attached to the machine because the
machine may move unexpectedly. Always disassemble the cylinder after dismounting it from the machine.
If you reassemble the cylinder with dirty hands, contaminants may get into the cylinder. This shortens life and
also damage other hydraulic devices. Try to reassemble cylinders under clean conditions.
Tighten threaded parts by following and using tightening torque shown in the drawing.
Too high and too low torque may damage screws.
Observe the cylinder storing standards.

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8012-8
SPECIAL TOOLS
Bush Tool Kit Number ---------
The composition item is as follows .
Tool Item Name Item Number Remarks

U1 Wrench Assembly -----
U2 Piston Ring Expander -----
U3 Clamp ----- Outside diameter of piston for 120 ~ 135
----- Outside diameter of piston for 100 ~ 115
U4 Ring (Rubber band) ----- Outside diameter of piston for 120 ~ 135
----- Outside diameter of piston for 100 ~ 115
Wrench Assembly U1
Use it for detaching type of screwing piston
A B C
A
E
B
CRPH06B104A
A 14 mm (9/16 in) B 11.15 mm (29/64 in)

A 8 mm (0.55 in) C 10 mm (0.39 in)
B 11.15 mm (29/64 in) C 5 mm(0.19 in)
U2
F
C
U3 U4
CRPH06B103B
A 5.556 mm (7/32 in) D 6.35 mm (1/4 in)

B 19.05 mm (3/4 in) E 7.938 mm (5/16 in)
C Mini 50.8 mm (2 in) F 2.381 mm (3/32 in) CRPH06B105A
C Max 152.4 mm (6 in) The teflon ring used for the oil pressure cylinder is not
possible to install it by as is shape.
Turns a handle of piston ring expander, the teflon ring
can be swollen easily without damage.
Also the ring can surely install the teflon ring in the
piston.
(Piston Ring Expander, range can be adjusted diam-
eter 35 to 310 mm (1.37 to 12.20 in)).

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8012-9
CYLINDERS
Boom cylinder description
8
4
12
45
44
34 9
2 33
47
18 37
38
43 48
39
35
46 36
26 27
19 24
26
27
16 20
15 23
17
45
1
46 25 41
42
11
10 7
6
3
5
CRPH06C005H01

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8012-10
1 GREASE GUN
2 WASHER
3 WASHER
4 SCREW
5 NUT
6 WASHER
7 COLLAR
8 PIPE HYDRAULIC
9 O-RING
10 PIPE HYDRAULIC
11 O-RING
12 WASHER
13 NOT USED
14 NOT USED
15 SCREW
16 WASHER
17 RETAINING CLIP
18 SCREW
19 STEEL BALL
20 SCREW
21 NOT USED
22 NOT USED
23 PISTON
24 SEALING RING
25 BACKUP RING
26 WEAR RING
27 RING
31 NOT USED
32 NOT USED
33 O-RING
34 BACKUP RING
35 BUSHING
36 BUFFER RING
37 DUST SEAL
38 SNAP RING
39 SNAP RING
40 NOT USED
41 O-RING
42 PLUNGER
43 BUSHING
44 CYLINDER ROD
45 CYLINDER BARREL
46 BUSHING
47 ROD PACKING
48 COLLAR

Copyright
8012-11
Dipper cylinder description
44
35
36
2 47
18 45
8
1 48 9
39
43
33 12
46
38 37 34
4
19
26 24 23
27
27
26 4
3
32
5 11
42 5 31
6 46
6
8 43
7 17 14
17
41 25
45
22
21
44 16
20
15
7
15
15 16 10
13 16
CRPH06C006H01

Copyright
8012-12
1 GREASE GUN
2 WASHER
3 WASHER
4 SCREW
5 NUT
6 WASHER
7 COLLAR
8 PIPE HYDRAULIC
9 O-RING
10 PIPE HYDRAULIC
11 O-RING
12 WASHER
13 PIPE CLAMP
14 CUSHION PLUNGER
15 SCREW
16 WASHER
17 RETAINING CLIP
18 SCREW
19 STEEL BALL
20 PLUG
21 O-RING
22 SPRING
23 PISTON
24 SEALING RING
25 BACKUP RING
26 WEAR RING
27 RING
31 BALLS
32 CAP
33 O-RING
34 BACKUP RING
35 BUSHING
36 BUFFER RING
37 DUST SEAL
38 SNAP RING
39 SNAP RING
40 NOT USED
41 O-RING
42 PLUGER
43 BUSHING
44 CYLINDER ROD
45 CYLINDER BARREL
46 BUSHING
47 ROD PACKING
48 COLLAR

Copyright
8012-13
Bucket cylinder description
44
45
2 19
48
18
33 34 8
9
46 39
4
36 12
35
38 37 47
4
1 3
43
11 1
10
43
15 46
17 16
17
16
16 8
15
15
23
13 41 20
25
42
15 16
27
26
27 26 24
CRPH06C007H01

Copyright
8012-14
1 GREASE GUN
2 WASHER
3 WASHER
4 SCREW
5 NOT USED
6 NOT USED
7 COLLAR
8 PIPE HYDRAULIC
9 O-RING
10 PIPE HYDRAULIC
11 O-RING
12 WASHER
13 PIPE CLAMP
14 NOT USED
15 SCREW
16 WASHER
17 RETAINING CLIP
18 SCREW
19 STEEL BALL
20 SCREW
21 NOT USED
22 NOT USED
23 PISTON
24 SEALING RING
25 BACKUP RING
26 WEAR RING
27 RING
31 NOT USED
32 NOT USED
33 O-RING
34 BACKUP RING
35 BUSHING
36 BUFFER RING
37 DUST SEAL
38 SNAP RING
39 SNAP RING
40 NOT USED
41 O-RING
42 PLUGER
43 BUSHING
44 CYLINDER ROD
45 CYLINDER BARREL
46 BUSHING
47 ROD PACKING
48 COLLAR

Copyright
8012-15
BOOM CYLINDER
Disassembly STEP 3
NOTE: The boom, dipper and bucket cylinders are
3
basically identical in construction. What changes is
the hydraulic tube connections. Before installing the
cylinder in the repair stand, remove the hydraulic
tubes.
STEP 1
The numbers within brackets in the following steps
refer to the boom cylinder schematic on page 9.
1
CRPH06B010A01
2 3 A
CRPH06B008A01
Remove the piping from the cylinder assembly.
Remove the mounting bolts and disconnect head
assembly (1).
Pull out piston rod assembly (2).
CRPH06B011A01
Place an oil receiving pan under the cylinder to Remove piston assembly set screw (3).
receive the oil. If screw (3) is caulked too strongly and you cannot
STEP 2 remove it, tighten it temporarily and cut the female
threads with a tap (A), and then remove it.
U1
CRPH06B009A01
Disassemble the piston rod assembly according to
the following procedure.
Set piston rod assembly (2) to tool U1.

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8012-16
STEP 4 STEP 6
4 9 8 10
U2
1
CRPH06B012A01 CRPH06B014A01
Using tool U2, remove piston assembly (4). Remove cap (8) and take out balls (9), and the
If you do not use tool U2, loosen the piston assembly remove cushion plunger (10), (only for the arm cylin-
by using the holes (1) (10mm: 2 places). der).
STEP 5 STEP 7
14
5
11
6 12
7
10
12
11
Remove plunger (5). Remove ring (11), wear ring (12), the piston ring (13)
Remove collar (6). and the O-ring and backup ring (14) from the piston
Remove head assembly (7). assembly.
STEP 8
21
20
15
19
17 18
16
CRPH06B016A01
Remove O-ring and backup ring (15), snap ring (16)
and dust seal (17), rod packing (18), buffer ring (19),
snap ring (21) and the bushing (20) from the cylinder
head assembly.
Copyright
8012-17
Inspection
STEP 1
Inspect the seals, U-rings, back up rings, and O-rings
prior to installation for any imperfections, tears, or
other damage. If the seals or the bushings are worn
out or damaged, replace the component(s). Ensure
seals and bushings are installed correctly with no
twisting of the seal or bushing. Install all new seals
and rings wet with hydraulic oil.
STEP 2
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 (43). If
the internal diameter of the bushings is greater than
the specifications, replace the bushing(s).

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8012-18
Assembly STEP 2
STEP 1 U6
U5 13
U3 U4 13
17
20
CRPH06B033A01
Using tool U5, expand piston ring (13), set the piston
CRPH06B017A01
ring to tool U5 and give the handle 8 - 10 turns, set
tool U6 and tighten piston ring (13) on the piston.
21
14
11
20
15 12
19
17 18 10
16 12
11
CRPH06B016A01
Using tool U3, press fit bushing (20) and set snap CRPH06B015A01
ring (21), install buffer ring (19), install rod packing Install backup ring and O-ring (14), wear ring (12)
(18), using tool U4, install dust seal (17) and fix it with and the ring (11) on the piston rod.
snap ring (16), install backup ring and O-ring (15) on NOTE: Take care not to increase the closed gap of
the piston rod. the ring too much.
NOTE: Take care not to damage the packings, dust Ring groove:
seals, O-rings, etc. Grease (G2-L1)
Do not insert each backup ring forcibly, but warm it in
water at 50 - 60C (122 - 140 F) and then insert it.

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8012-19
STEP 3
9 8 10
u1
CRPH06B014A01
CRPH06B009A01
Set cushion plunger (10) to the piston rod, and then
Set piston rod to tool U1. set balls (9) and secure them with cap (8) (only arm
cylinder). Assemble piston assembly (4) according to
4 the following procedure.
5
NOTE: When reusing the rod and piston assembly
6 (2)
Clean the rod and piston assembly thoroughly to
7 remove iron chips and dirt.
STEP 4
4
U2
CRPH06B013A01
Install head assembly (7), fit the O-ring and backup
ring to collar (6), and then install them on the piston
rod.
Install plunger (5) on the piston rod.
NOTE: Check that the plunger end has a small play.
2
CRPH06B012A01
Using tightening tool U2, tighten piston assembly (2)
until the screw holes are matched to each other
Remove burrs and fins with a file.
Tighten screw (3) to the torque specified on page 3.

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8012-20
STEP 5 STEP 7
3
4
2
Caulk 4 places around the screw with a punch. When Cut a screw hole to install screw (3)
replacing either or both of the rod and piston assem- Set the drill to the V-grooves of the threads of piston
bly (2) with new one (4) and rod (2) and cut a screw hole horizontally.
When using the cylinder (arm cylinder) with the bot-
NOTE: When using the rod with the bottom cushion,
tom cushion, avoid cutting a screw hole on the cush-
make a mark of the position of the cushion plug on
ion plug.
the rod end.
Screw cutting dimensions (mm)
(Only arm cylinder)
STEP 6 Cylin- Tap drill Tap Tap size Tapping
der hole diam- drill depth
A name eter hole
5 3 depth
2 Boom 10.3 24 12x1.75 20
Bucket
Arm 10.3 43 12x1.75 29
STEP 8
CRPH06B038A01
Screw in piston assembly (4) until touches the rod
end, and then tighten it with tool U2 to the torque
NOTE: After tightening the piston, check that plunger
(5) has play.
CRPH06B010A01
After cutting the screw hole, remove chips and dirt
from it, and then clean it thoroughly. Tighten screw
(3) to the torque specified on page 3. Caulk 4 places
around the screw with a punch.

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8012-21
STEP 9
CRPH06B046A01
Install piston rod assembly (2):
Ring groove (grease (G2-L1)).
Set the closed gap of the ring horizontally (on the
side) and insert the piston rod assembly, aligning it
with the cylinder tube.
NOTE: After inserting the piston rod assembly half-
way, check that the ring is not damaged or removed,
and then insert to the end.
STEP 10
CRPH06B008A01
Tighten the mounting bolts (2) of head assembly (1)
to the torque specified on page 3.

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8012-22
ERROR DIAGNOSIS
Hydraulic cylinder errors and their remedy measures
It is not easy to locate faulty parts. General symptoms, possible reasons and remedy measures are shown in the
table below. For repairs, refer to the possible causes and remedy measures in the table.
However, it is often the case that machine troubles occur because not only one part but many other relating parts
have problems.
Measures other than ones shown in the table may be required.
Item Symptom
1 Oil leakage on the sliding section of piston rod.
2 Oil leakage from cylinder head fitting section
3 Oil leakage from welded section between pipe and cylinder tube
4 Bad operation
Item Symptom Related parts Error Item Preventive/remedy measures

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

Copyright
8012-23

1 Oil leakage on Rod packing Packing has lost Replace.
piston rod sliding rubber elasticity and The life of the packing or hydraulic oil deteriora-
section is crumbling. tion or high temperature may be the cause.
The whole lip is also Change hydraulic oil.
missing. Check hydraulic oil temperature.
(The oil temperature should be 80C or less.)
Check for uneven hot temperatures.
Heel part of the Replace.
packing. Abnormal high pressure may act on the packing.
Too much extrusion Check the pressure when starting operation.
Abnormality in the buffer ring if the buffer ring is
attached.
Inspect buffer rings.
Dust seal Foreign substances Remove foreign substances.
engaged in the lip
The lip is damaged. Replace.
Other abnormal
damages
Bearing mate- Extreme wear, the Replace.
rial (bushing) clearance with pis-
ton rod exceeds the
allowable maximum
value.
Significant damage Replace.
in sliding surfaces Inspect the piston rod.
Cylinder head Scratches or rust in Remove scratches and rust with an oil stone.
seal fitting area. If repair is not possible, replace the cylinder head.

Copyright
8012-24

2 Oil leakage from O-ring Foreign substances Remove foreign substances.
cylinder head fit- on the inside and If O-ring is damaged, replace it.
ting section outside surfaces Inspect the tube inside:
Damaged O-ring If scratches and rust are found, smooth the sur-
faces with oilstone.
Check O-ring grooves in the cylinder head:
Same as above
Check Rod Packing:
If distortion or extrusion is found, replace it.
Rod Packing Distortion and extru- Replace with a new one.
sion.
Cylinder head Looseness Disassemble cylinder head to check O-rings and
Rod Packing.
If damage is found, replace it.
Check tube and cylinder head threaded sections
to ensure that there is no damage.
If damage is found, replace it.
Upon completion of inspection, fasten with speci-
fied tightening torque. Refer to Tightening torque.
Bolt Looseness, exten- Replace all bolts and fasten them with specified
sion and breakage tightening torque.
Cylinder Abnormal swelling Replace with new ones.
tubes Oil leakage on the fitting section may be caused
by abnormally high pressure (including cushion
pressure). Check for bulging, deformation and cir-
cuit pressure on the tubes.
3 Oil leakage from Cylinder tube Cracks on welded Replace with a new one.
welded section pipe (hollow section CAUTION:
between pipe piston rod) Cracks will progress and end up with breakage.
and cylinder tube Breakage is a very dangerous condition.
If cracks are found, immediately stop the opera-
tion and replace the parts.
No effect can be gained if additional welding is
performed on cracked surfaces.

Copyright
8012-25

4 Bad operation Piston rod, Curved too much; Replace with a new one.
4-1 cylinder tubes exceeds specified Check seals and sliding materials also because
Does not move curve distortion they may be damaged. If abnormality is found,
smoothly level. replace.
Cylinder Dents Replace with new ones. Same as above
tubes described, check seals and sliding materials.
Piston rod, Abnormal wear and Replace with new ones. Same as above
cylinder damage on the slid- described, check seals and sliding materials.
tubes, ing parts Remove foreign substances. Same as above
sliding materi- Foreign substances described, check seals and sliding materials.
als engaged in the pis-
ton and cylinder
head sliding parts
Piston seal Damage such as Replace with a new one. Also check the cylinder's
scratches and wear inner face.
is found.
Cylinder Scratches and rust Remove scratches and rust by honing or with oil-
4-2 tubes on the inside sur- stone to smooth the surfaces.
Internal oil leak- face. If scratches are too big to repair, replace cylinder
age makes the tubes with new ones.
piston rod extend Replace piston seals with new ones.
or retract or fall
Piston tight- Loose tightening Fasten with specified tightening torque. Refer to
abnormally while
ening Tightening torque.
operating or can
not give specified Valves Leakage from Check the valve leakage volume and repair if
speed output. valves necessary.
CAUTION:
Hydraulic oil tends to expand and shrink according to changes in temperature and pres-
sure. This also causes cylinders to extend and retract; therefore, we sometimes see this
as internal oil leakage. Check internal oil leakage under a given pressure condition.

Copyright
8012-26

4 4-3 Air Air remains in the Bleed air.
Operation is not cylinder. Cylinder without air bleeder:
stable. Bleed air by operating the cylinder several full
strokes under low pressure and at a slow speed.
Cylinder with air bleeder:
To prevent high temperature inside the cylinder,
remove the load and loosen air bleeder to release
air fully.
When the cylinder stops suddenly, it can extend
or retract to a certain extent. This phenomenon is
caused by hydraulic oil compressibility. This phe-
nomenon tends to occur especially on long stroke
cylinders.
4-4 Pin bushing Too much clear- Measure the dimensions of pin and pin bushing,
Strong impact Pin ance between the replace the parts that exceed the measured
when switching fitting section and dimensions.
over between pin bushing
extension and
retraction
4-5 Lubrication Lack of lubrication Lubricate.
Cylinder sliding
Pin bushing Scuffing on fitting Replace with a new one and lubricate.
operation makes
Pin surfaces
noise.
CAUTION
Hydraulic oil tends to expand and shrink according to changes in temperature and pressure. This also
causes cylinders to extend and retract; therefore, we sometimes see this as internal oil leakage. Check
internal oil leakage under given temperature and pressure conditions.

Copyright
Section
8013
8013
OF THE CONTROL LEVERS

Printed in France
Copyright
8013-2
TABLE OF CONTENTS
SPECIFICATIONS .................................................................................................................................................. 2
CONTROL LEVER ................................................................................................................................................. 3
Description .......................................................................................................................................................... 3
STRUCTURE ......................................................................................................................................................... 4
FUNCTIONS ........................................................................................................................................................... 4
OPERATION .......................................................................................................................................................... 5
CONTROL LEVER ................................................................................................................................................. 7
Disassembly ........................................................................................................................................................ 7
Inspection .......................................................................................................................................................... 10
Assembly ........................................................................................................................................................... 11
TROUBLESHOOTING ......................................................................................................................................... 15
SPECIFICATIONS
Torque settings
Orifice plate retaining screws ........................................................................................................... 20.6 1.5 Nm
Universal joint on control lever ......................................................................................................... 47.1 2.9 Nm
Lock-nut on universal joint................................................................................................................ 68.6 4.9 Nm
Primary pressure Maximum pressure 6.9 MPa

Secondary pressure 0 to 4.4 (Maximum control pressure) MPa
Allowable back pressure Maximum 0.3 MPa
Rated flow 20 L/min
Operating inclination 19, 25 (single)
Mass 1.9 kg
Piping To obtain better response, suitable piping is inner diameter 8, length 3 M. In
addition, the return oil should be directly returned to the tank to avoid the
influence of back pressure.

Copyright
8013-3
CONTROL LEVER
Description
20
3
19
4
5
6
17 8
18 9
22 10
11
12
16
15
13
21
14
18
CRPH06B059G01
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 PUSH-ROD
7 O-RING 18 SEAL WASHER
8 SPRING SEAT 19 LIP-SEAL
9 SPRING 20 UNIVERSAL JOINT
10 SPRING 21 PLASTIC PIN
11 SPOOL 22 WASHER

Copyright
8013-4
STRUCTURE
The structure of a pilot valve is as shown in the assembly sectional drawing. The casing has openings along the
vertical axis, in which pressure reducing valves are integrated.
The pressure reducing valve section consists of spools (201), springs (241) for setting secondary pressure, return
springs (221), spring seats 1 (216) and washers 2 (217). The spring (241) for setting secondary pressure is
configured to obtain reduced secondary pressures of 0.49 to 0.98MPa (depending on models). The spool (201) is
pushed against the push rod (212) by the return spring (221).
As the push rod (212) is pressed down when the operating part of the handle is inclined, the spring seat 1 (216) is
also lowered at the same time, as a result, the settings of the spring for setting secondary pressure (241) change.
The casing (101) and port plate (111) have oil entry ports P (Primary pressure) and exit ports T (Tank), and the
secondary pressure is delivered from the ports 1, 2, 3 and 4.
FUNCTIONS
1) Basic functions
The pilot valve is a valve designed for controlling the strokes and directions of the control valve spool. This is
achieved by acting output pressures from the pilot valve on the end of the control valve spool.
To meet requirements for this function, the pilot valve is composed of the following segments:
Entry port (P) through which the hydraulic pump supplies oil
Multiple output ports (1, 2, 3 and 4) which are designed to apply pressure supplied from the entry port on the end of
spool in the control valve.
Tank port (T) which is required to control the output pressures described above.
Spool which connects an output port to the entry port or tank port.
Mechanical measures including springs which act on the spool described above in order to control output pressure.
2) Major component functions
The function of the spool (201) is to receive pressure oil supplied from the hydraulic pump at the port P, and by
switching the oil paths, to introduce the pressure oil at port P to output ports (1, 2, 3 and 4) or introduce to port P. It
is the role of the spring for setting secondary pressure (241) to determine output pressure by acting on this spool
(201).
The push rod (212) is inserted in the plug (211) so that it can slide and change the deflection of the spring for
setting secondary pressures (241).
The return spring (221), regardless of the output pressure, acts on the casing (101) and spring seat (216) to return
the push rod (212) in the direction of zero displacement, ensuring that the spool (201) can return to its neutral
position. This return spring also functions as reaction spring, to give good operational responsiveness.

Copyright
8013-5
OPERATION
This section describes the operation of pilot valves based on the Hydraulic Oil Circuit Drawing (Figure 1) and
Operation Description Diagrams (Figures 2 through 4). Figure 1 shows a typical usage of the pilot valve.
Figure 1. An example of pilot valve use
5 6
4
2
CRPH06B106E
1 PILOT VALVE 4 CONTROL VALVE
2 PILOT PUMP 5 HYDRAULIC MOTOR
3 MAIN PUMP 6 HYDRAULIC CYLINDER
1) When the handle is in neutral (Figure 2)

The force of the spring for setting secondary pressures (241), which
determines the output pressure on the pilot valve, is not applied on
the spool (201). Therefore, the spool (201) is pushed upward by the
return spring (221) (by the spring seat 1 (216)), the output ports (2,
4) are connected with the port T. At this moment, the output
pressure is equal to the tank pressure.
216
241
221
201
000-7-06-01-15B

Copyright
8013-6
2) When the handle is inclined (Figure 3)
As the push rod (212) is pushed in by inclining the handle, the
spool (201) (spring seat 1 (216)) moves downward and the port P
and ports (2, 4) are connected. As a result, the oil supplied from
the pilot pump flows into ports (2, 4), thus generating pressure.
212
216
201
000-7-06-01-15c
3) When the handle is held (Figure 4)
When the pressures at ports (2, 4) rise up to a pressure equivalent
to the force of the spring (241), which was set by inclining the
handle, the hydraulic force and the force of the spring are in
balance. When the pressures at ports (2, 4) are more than the set
pressure, ports (2, 4) and port P close and ports (2, 4) and port T
open. When the pressures at ports (2, 4) are less than the set
pressure, ports (2, 4) and port P open and ports (2, 4) and port T
close. As a result, secondary pressures are maintained constantly.
(T) Port T
(P) Port P
241
000-7-06-01-15d
4) Operation in ranges where the handle is greatly

inclined (depends on models)
In some models, when the handle is inclined more than a given degree, the upper end of the spool touches the
bottom part of the push rod bore and the output pressure remains equal to the port P pressure as connected.
What's more, if a structure where the spring seat and spring are integrated in the inside of push rod is used, when
the handle is inclined more than a given degree, the bottom part of the push rod bore contacts the spring, and the
force of the spring causes the secondary pressure gradient to change. Afterwards, the bottom part of the push rod
bore contacts the upper end of the spring seat; thus the output pressure remains equal to the port P pressure as
connected.

Copyright
8013-7
CONTROL LEVER
Disassembly STEP 3
NOTE: The numbers in brackets in the following
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
CRPH06B110A
CD00G088
Remove the lock-nut from the control lever.
CRPH06B111A
Used the special tool 380001055.
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.

Copyright
8013-8
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
8013-9
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
8013-10
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 to
determine the cause of an abnormal noise or a
all the components.
reduction in primary pressure, change the control
NOTE: Components can rust if left in the open air lever.
after cleaning.

Copyright
8013-11
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
20.6 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
8013-12
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
8013-13
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.
STEP 11 STEP 14
CD00G111 CRPH06B110A
Install the plunger in the body. Depending on the
condition of the return springs, the friction of the
O-rings may keep the plungers in place in the body.
STEP 12
Repeat steps 5 to 11 for the other three bodies.
CRPH06B111A
Used the special tool 380001055.
Tighten the universal joint to a torque of 47.1 2.9
Nm (34.7 2.1 lb-ft).

Copyright
8013-14
STEP 15 STEP 17
CD00G113 CD00G115
Install the disc on the universal joint. Tighten until the Place a few spots of grease on the push-rods.
disc touches the four push-rods equally.
STEP 18
STEP 16
CD00G116
CD00G114
Install the protective boot (2) on the control lever.
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
8013-15
TROUBLESHOOTING
It is not easy to find the faulty part. The following table lists some possible problems. As repairs are not easy, refer
to the possible causes and countermeasures in the table.
The table below shows general symptoms/possible causes and countermeasures. However, as a machine's trouble
is generally caused not by a single faulty component but by other related components as well, it may be necessary
to apply measures other than those listed in the Table.
The table shown below does not necessarily include all possible causes and remedies. Therefore, the technician in
charge of repairs must further investigate problems and their causes as necessary.
Problem Causes Countermeasures

Secondary pressure doesnot rise. 1.Lower primary pressure Ensure given primary pressure
2.Breakage and fatigue of secondary Replace with new one
pressure spring (241)
3.Abnormally large gap between Replace as a remote valve complete
spool (201) and casing (101) assembly
4.Loose handle section Disassemble/assemble and replace
handle section
Unstable secondary pressure 1.Engaged sliding part Repair engaged part
2.Fluctuations in tank line pressure Direct return to oil tank
3.Entrapped air in piping Bleed air by several operations
High secondary pressure 1.High tank line pressure Direct return to oil tank
2.Engaged sliding part Repair engaged part

Copyright
8013-16

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 ........................................................................................................................ 58.8 4.9 Nm
Cam articulation pin locking screw ..................................................................................................... 14.7 1.4 Nm
Flange screw ...................................................................................................................................... 4.9 0.98 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
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
Theory of operation ............................................................................................................................................. 5
Disassembly and assembly ................................................................................................................................. 6
Inspection ............................................................................................................................................................ 7

Copyright
8015-3
SIX SOLENOID VALVES BLOCK

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

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

Copyright
8015-5
Theory of operation
The hydraulic pressured oil delivered from port P is supplied to
the electromagnetic valves, S1 to S5 when the electromagnetic
selector valve SP is energized, and the hydraulic pressured oil is
supplied to the ports, C1 to C5, according to the energization on
the electromagnetic selector valves S1 to S5.
Electromagnetic selector valves S1, 3, 4
and 5:
Oil passes through when energized
Electromagnetic selector valve S2:
Oil passes through when not energized
000-7-07-01-11B

Copyright
8015-6
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
8015-7
Inspection
1. Clean all parts using suitable cleaning solvent. spools slide easily into the grooves of the
Immerse the solenoid valve housing in a solenoid valve block spools. If any of these
cleaning solvent for several minutes to dissolve conditions are seen, replace the solenoid valve
dirt or other foreign matter inside the solenoid block.
valve housing. Use low pressure compressed air
4. Check that the internal threading is not worn out
to blow out any foreign matter from interior of
and that the solenoid valve block is not damaged
valve housing. Dry parts using clean cloths.
inside. If any of these conditions are seen,
2. Inspect springs for cracks, distortion, or evidence replace the solenoid valve block.
of permanent set. Replace a spring if any of 5. Measure the play between the spool groove and
these defects are observed. the spool. The play must be approximately
3. Check for cracks, holes, deformities and other 0.01 mm. If this is not the case, replace the
signs of wear on the spools. Check that the solenoid valve block.
Troubleshooting
Fault Symptom Cause Remedy

Spool malfunction Does not operate due to foreign Remove foreign substances, disassemble,
substances clean and exchange the hydraulic oil.
Damaged parts, abnormal wear Replace the valve.
Solenoid malfunction Loose terminal Insert the terminal securely.
Damaged coil Replace the solenoid.
Lead disconnection
External leakage Loose screws Retighten by applying specified torque.
Damaged O-ring Replace the O-ring.

Copyright
8015-8
NOTES
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Copyright
Section
8016

OF THE CUSHION CONTROL VALVE
8016

Printed in France
Copyright
8016-2
TABLE OF CONTENTS
SPECIAL TORQUE ................................................................................................................................................ 2
CUSHION CONTROL VALVE ................................................................................................................................ 3
Description .......................................................................................................................................................... 3
OPERATIONAL DESCRIPTION ............................................................................................................................ 4
Changed over to "SOFT" .................................................................................................................................... 4
Arm OUT, operating ............................................................................................................................................ 5
Arm OUT, stopped .............................................................................................................................................. 5
CUSHION CONTROL VALVE ................................................................................................................................ 6
Disassembly ........................................................................................................................................................ 6
Inspection ............................................................................................................................................................ 8
Assembly ............................................................................................................................................................. 8
SPECIAL TORQUE
Plugs (5) and (12)..........................................................................................................................39.2 Nm to 49 Nm
Plug (13) .........................................................................................................................................9.5 Nm to 10 Nm

Copyright
8016-3
CUSHION CONTROL VALVE

Description
Identifying the ports
T G H
E F
B
A
C D R
CRPH06B062G01
A DIPPER RETRACTION (TOWARDS CONTROL LEVER) F BOOM LOWERING (TOWARDS CONTROL LEVER)
B DIPPER EXTENSION (TOWARDS CONTROL LEVER) G BOOM LIFTING (TOWARDS CONTROL VALVE)
C DIPPER RETRACTION (TOWARD CONTROL VALVE) H BOOM LOWERING (TOWARDS CONTROL VALVE)
D DIPPER EXTENSION (TOWARDS CONTROL VALVE) R RETURN TO RESERVOIR
E BOOM LIFTING (TOWARDS CONTROL LEVER) T LEAK RETURN
NOTE: The cushion control valve can have a machined or moulded body. This manual deals with only the machined
body.

Copyright
8016-4
Section
6 11 8 10 9
12 12
6
SECTION X-X 2
SECTION Y-Y 3 5
14 SECTION X-X
1 13 7 15 4 SECTION Y-Y
CNPH06E007F
1 CONTROL VALVE HOUSING 9 CAP SCREW
2 SPOOL 10 O-RING
3 SPOOL 11 SPRING
4 SPOOL 12 PLUG
5 FLOW RESTRICTION ADAPTOR 13 PLUG
6 O-RING 14 SPOOL
7 SPRING 15 SPACER
8 SPOOL

Copyright
8016-5
OPERATIONAL DESCRIPTION
Changed over to "SOFT"
Lever in Neutral
(1) The heat oil separated from the oil cooler line enters the cushion valve Port R.
(2) Then, the oil passes the reverse notch spool and goes through passages e and f. After passing the outer cir-
cumference of each cushion spool, the oil returns to the hydraulic oil tank via Port T.
TO CONTROL VALVE FROM CONTROL VALVE
1 5
2 4
3
CRPH06C008F
1 FROM REMOTE CONTROL VALVE 4 THROTTLE

2 CUSHION SPOOL 5 TO REMOTE CONTROL VALVE
3 CUSHION SPOOL

Copyright
8016-6
Arm OUT, operating

(1) Pilot pressure enters the cushion valve at Port A from the remote control valve. As this pilot pressure enters the
left end of the cushion spool and the left end of the reverse notch spool, each spool moves to the right.
(2) The pilot pressure in the cushion spool enters the chamber g via the spool opening.
Then, the pressure passes the outer circumference of the reverse notch spool and goes into the control valve via
Port C.
(3) The pilot pressure return oil from the control valve passes the outer circumference of the reverse notch spool
and goes into the chamber f via Port D. Then, the oil passes the outer circumference of the cushion spool and
returns to the hydraulic oil tank through Port T.
(4) At this time, as the reverse notch spool is switched over to the right, the passages e and f are closed to the heat
oil at the Port R. Therefore, the oil passes passage h and enters the left end of the cushion spool. The heat oil
passes the cushion spool throttles c and d and enters the remote control V via Port B. (The heat oil releases the
remote control valve).
Arm OUT, stopped
FROM CONTROL VALVE R
2 3
CTRPH06C009F
1 TO REMOTE CONTROL VALVE 3 THROTTLE
2 CUSHION SPOOL
(1) As the pilot pressure from the remote control valve stops, the reverse notch spool returns to the neutral position.
(2) The cushion spool also returns to the neutral position and the pilot return oil from the control valve passes the
throttles.
(3) Due to this restricting effect, the spool of the main control valve returns gradually to the neutral position.

Copyright
8016-7
CUSHION CONTROL VALVE

Disassembly STEP 3
NOTE: The numbers within brackets in the following
STEP 1
5
5
JD00551A
Remove the spring (11) and the O-ring (6) of the plug.
Scrap the O-ring.
STEP 4
JD00549A
If the cushion control valve has to be replaced,
remove the adaptors and elbow unions and install
them on the new control valve. Do not remove the
four flow restriction adapters (5) 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 (8) with the O-ring (10), the cap
screw (9) and the spring (11) of the control valve.
STEP 5
JD00550A
Remove the plug (12) with the O-ring (6) and the
spring (11).
JD00553A
Put the spool (8) in a vice using wooden shims to pro-
tect the spool. Remove the cap screw (9) from the
spool (8).

Copyright
8016-8
STEP 6 STEP 10
JD00554A JD00557A
Remove the O-ring (10) from the cap screw (9). Remove the spring (7).
Scrap the O-ring.
STEP 11
STEP 7
Repeat steps 2 through 6 for the other spool.
STEP 8
JD00558A
Install an cap screw (A) in the tapped hole of the
spool (2). Remove the spool (2) with the spacer (15)
and the spring (7). Remove the cap screw.
JD00555A STEP 12
Remove the flow restriction adaptor (5) and the
O-ring (6).
2
STEP 9
7
15
JD00559A
Remove the spring (7) and the spacer (15) from the
spool (2).
JD00556A STEP 13
Remove and discard the O-ring (6) and the flow
restriction adaptor (5). Repeat steps 9 through 12 for the remaining three
spools.

Copyright
8016-9
Inspection Assembly
STEP 1 NOTE: The numbers within brackets in the following
Clean all parts using suitable cleaning solvent.
Immerse valve housing in cleaning solvent for sev- NOTE: Lubricate all parts with clean hydraulic oil.
eral minutes to dissolve dirt or other foreign matter Ensure that parts are assembled in the same groove
inside valve housing. Use low pressure compressed as they were removed from.
air to blow out any foreign matter from interior of
STEP 1
valve housing. Dry parts using clean cloths.
STEP 2 2
Inspect springs for cracks, distortion, or evidence of
permanent set. Replace a spring if any of these 7
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 15
observed replace the cushion valve.
STEP 4
JD00559A
Check the plugs, flow restriction adapters, and spring Install the spacer (15) on the spool (2).
guides for damaged threads. Check the ports in flow STEP 2
restriction adapters for foreign matter, chipping, or
other damage. Check spring guides for bent condi-
tion. Replace a defective part.
STEP 5
Check the spacer for chipping, wear and signs of
damage. If any of these conditions are seen replace
7
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 (7), the spool (2) and the spacer
(15) in the control valve housing.

Copyright
8016-10
STEP 3 STEP 7
JD00561A JD00563A
Install the spring (7) in the spool (2). Install the spring (11) on the spool (8).
STEP 4 STEP 8
JD00562A JD00564A
Install a new O-ring (6) on the flow restriction adaptor Install the spring (10), the cap screw (9) and the
(5). Install the flow restriction adaptor in the control spool (8) in the groove of the control valve housing.
valve housing, tighten to the torque specified on page
2. STEP 9
STEP 5
Repeat steps 1 through 4 for remaining three spools.
STEP 6
JD00565A
Install the spring (11).
JD00554A
Install the cap screw (9) using a new O-ring (10) on
the spool (8).

Copyright
8016-11
STEP 10
JD00566A
Install a new O-ring (6) on the plug (12). Install the
plug and O-ring in the housing, tighten to the torque
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
8016-12
NOTES
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Copyright
Section
8018
DISASSEMBLY AND REASSEMBLY

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 ...................................................................................................................... 62.7 to 72.5 Nm
Thrust plate retaining screw .............................................................................................................. 31.4 to 37.3 Nm

Copyright
8018-3
HYDRAULIC SWIVEL
Description
4 5
5
9
10
8 6 7
CS02B552
1 PIVOT 6 THRUST PLATE
2 "V" SEAL 7 SCREW
3 BUSHING 8 O-RING
4 O-RING 9 COVER
5 SEALING RING 10 SCREW

Copyright
8018-4
NOTE: For removing the hydraulic swivel, refer to STEP 3
Section 8006.
Disassembly 7
Always handle the components carefully. Never force,
6
hit or drop components. Avoid any contamination by
dust, water or foreign bodies. Work in a clean area
with clean tools. Always remove the pivot (inner com-
ponent) and the bushing (outer component) using a
1
press.
STEP 1 3
10
JS00027A
Remove the screws (7) and the thrust plate (6).
STEP 4
9
3
3
JS00025A
Remove the screws (10) and the cover (9).
STEP 2 1
JS00028A
Using a press, remove the pivot (inner component) (1)
8 from the bushing (outer component) (3).
STEP 5
3
2
1
JS00026A
Remove and discard the O-ring (8).
JS00029A
Remove the "V" seal (2) from the pivot (inner compo-
nent) (1) and discard it.

Copyright
8018-5
STEP 6
4
5
5
5
JS00030A
Remove the O-ring (4) and the sealing rings (5) from
inside the bushing (outer component) (3). Discard the
sealing rings and the O-ring.

Copyright
8018-6
Assembly
Clean all the components. Polish any scratches or 4
rough areas with an oil stone. Use seals, O-rings and
new sealing rings. Take the same precautions as dur-
ing removal. 5
STEP 1
5
JS00034A
Coat the O-ring (4) with hydraulic oil and insert it in
the upper groove of the bushing (outer component).
Coat the six sealing rings (5) with hydraulic oil and
insert them, starting from the second groove down
JS00032A
from the top of the bushing (outer component).
Clean the bushing (outer component) with a cleaning
solvent or low pressure compressed air. STEP 3
STEP 2
4 A
5
5
B 5
3
JS00035A
Check the proper installation of the O-ring and the
sealing rings using a mirror. Apply hydraulic fluid,
make sure that the components are not protruding,
twisted, etc.
JS00033A
A: 1 O-ring
B: 6 sealing rings

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8018-7
STEP 4 STEP 7
2
8
1 3
CS00G519 JS00039A
Install a new "V" seal (2) on the pivot (inner compo- Install the O-ring (8).
nent) (1) and coat it with clean hydraulic oil.
STEP 8
STEP 5
10
3
1
JS00040A
JS00037A
Install the cover (9) and the screws (10). Tighten the
Insert the pivot (inner component) (1) in the bushing screws to torque (see page 2).
(outer component) (3).
NOTE: Do not cut through the "V" seal, or graze it.
STEP 6
7
JS00038A
Install the thrust plate (6) and the screws (7).

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8018-8

Copyright
Section
8019
DISASSEMBLY AND REASSEMBLY

OF THE SWING HYDRAULIC MOTOR
8019

Printed in France
Copyright
8019-2
TABLE OF CONTENTS
SPECIFICATIONS ................................................................................................................................................... 3
TORQUE SETTINGS .............................................................................................................................................. 3
SPECIAL TOOLS .................................................................................................................................................... 3
HYDRAULIC SWING MOTOR ................................................................................................................................ 4
Description .......................................................................................................................................................... 4
Disassembly ........................................................................................................................................................ 6
Inspection ............................................................................................................................................................ 9
Maintenance Reference Table .......................................................................................................................... 10
Assembly ........................................................................................................................................................... 11
TROUBLESHOOTING .......................................................................................................................................... 16
SECONDARY RELIEF .......................................................................................................................................... 18
Description ........................................................................................................................................................ 18
Disassembly ...................................................................................................................................................... 19
Inspection .......................................................................................................................................................... 19
Assembly ........................................................................................................................................................... 19

Copyright
8019-3
SPECIFICATIONS
See Section 1002.
TORQUE SETTINGS
Bypass valve plug.............................................................................................................................................. 78 Nm
Non return check valve plug ............................................................................................................................ 137 Nm
Cover screw..................................................................................................................................................... 392 Nm
Safety valve ..................................................................................................................................................... 137 Nm
SPECIAL TOOLS
A B
F G H
A
E
C
B
D R2
C
D
CRPH06C015A CRPH06C017A
Press fitting jig for inner ring (1) and taper roller Seal protector
bearing (4) A 3 mm E 15
A 54.7 mm C 60 mm B 35 mm F 43.9 to 44.1 mm
B 45.1 to 45.3 mm D 70 mm C 40 mm G 45.9 to 46.1 mm
D 55 mm H 49.85 to 50 mm
A B C
C
D
A
E B
F
G H
CRPH06C016A
CRPH06C017A
Installation jig for oil seal (3)
A 100.7 mm E 3 mm Installation jig for brake piston (12)
B 71 mm F 2.3 to 2.4 mm A 150 mm C 30 mm
C 49.9 to 50.1 mm G 17.4 mm B 190 mm
D 30 H 15 mm

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8019-4
HYDRAULIC SWING MOTOR

Description
1 SLEEVE
2 SNAP RING
3 SPY JOINT
4 BEARING
5 BACKUP WASHER
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 COVER
16 O-RING
17 PLUNGER ASSEMBLY
18 PISTON
19 WASHER
20 TEFLON RING
21 BUSHING
22 DISTRIBUTION PLATE
23 NEEDLE BEARING
24 CYLINDER
25 HOUSING
26 SPRING
27 BY-PASS VALVE
28 CHECK VALVE
29 SPRING
30 O-RING
31 BACKUP RING
32 BACKUP RING
33 NON RETURN CHECK VALVE
34 CHECK VALVE
35 SPRING
36 O-RING
37 O-RING
38 VALVE HOUSING
39 PISTON
40 O-RING
41 BACKUP RING
42 O-RING
43 PLUNGER ASSEMBLY
44 SLEEVE
45 LINER
46 NUT
47 SAFETY VALVE ASSEMBLY
48 SCREW
49 SCREW
50 O-RING
51 PLUNGER ASSEMBLY
52 PLUG
53 RETAINING RING
54 SHIM
A SHOE
B BRAKE PILOT PORT

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8019-5
30 31 33 37 48 38
30
41
29
40
28
47
26
42 43
27 44
49 45
46
52 50 32 34 35 36 39
21 20 19 15 17 16 18
14
13
12
22
11
10
B
9
23
8
53
7
A 24
25
6
5 54 4 3 2 1
CS02C516

Copyright
8019-6
Disassembly
STEP 1 STEP 3
48 48
49
52
15
26
33
C 27
D
CS02C517 CS02C519
Remove the oil level dipstick (C) and dipstick tube (D). Remove the four cover (15) retaining screws (49).
Remove relief valve assemblies (48) from swing Remove the cover (15) from the motor housing.
motor.
Remove the by-pass valve assemblies (27), as well STEP 4
as the plugs (52), the springs (26) and the non-return
check valves (33).
53
Remove and discard all the O-rings of each compo-
nent. 23
STEP 2
22
A
18
15
CS02C520
Place the cover with the shaft on top and remove the
retaining ring (53) from the shaft.
Remove the needle bearing (23) and the distribution
plate (22).
Remove the pistons (18) from the distribution plate (22).
CS02C518
To aid assembly, put alignment marks (A) on the
cover and motor housing.

Copyright
8019-7
STEP 5 STEP 8
NOTE: Protect the housing and the piston surfaces
with rags when you lever the piston out of the hous-
ing.
13
13
15 A A 12
12
CS02C521
Remove and discard the large O-ring (13) from the
25
cover (15).
STEP 6
21
CS02C524
Install two M6 screws (A) in tapped holes of the brake
20 piston (12). Lever these screws and free the brake
piston (12) from the housing.
Remove and discard the O-ring (13). Remove the two
19 M16 screws (A) from the brake piston.
STEP 9
15
10
CS02C522
Remove the bushings (21), the Teflon rings (20) and

the washers (19) from the cover (15). 9
STEP 7
14 25
25
CS02C525
Remove the four friction plates (9) and the four disc
plates (10) from the swing motor housing.
CS02C523
Remove the springs (14) from the brake piston (12).

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8019-8
STEP 10 STEP 12
24
4
25
CS02C526
Remove the cylinder assembly (24) from the motor CS02C528
housing (25). Remove the retaining ring (2) from the fluted shaft.
Remove the conical roller bearings and the sleeve (1)
STEP 11 using an antisticking pin puller.
4 STEP 13
NOTE: Mark the location of the pistons on the base
3
plate and on the cylinder. Pistons must be installed in
same positions during assembly.
54
3
6
7
8
CS02C527
Remove the bearing (4) from the motor housing.
Position the motor housing in a press. Using a suita-
ble sleeve or a centring piece, drive the spy joint (3)
out from the housing. Scrap the spy joint (3).
24
CS02C529
Remove the shim (54) from the cylinder (24).
Remove the piston plate (6), the piston assembly (8)
and the base plate (7) from the cylinder (24).

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8019-9
STEP 14 Inspection
6 STEP 1
7
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
Check for wear of the pistons. Replace the motor if
the depth of any shoe sliding surface is less than
8 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.
CS02C530
Slip the piston plate (6) out of the sliding surfaces of STEP 3
the piston assemblies (8), while ensuring that it does
not get damaged. Remove the pistons from the base Check for signs of seizing or wear on the piston plate
plate (7). sliding surface. The plate should be replaced if there
is evidence of seizing or wear.
STEP 15
STEP 4
Check for signs of seizing, wear or damage on the
5 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.
24
CS02C531
Remove the backup washer (5) from the fluted shaft.

Copyright
8019-10
Maintenance Reference Table

Table 1
Part name Locations to be in-
Reference valves Measuring instru- Instructions for repair
spected and mea-
(tolerance limits) ments and remedies
sured
Piston assembly (8) Roughness on Surface roughness Repair with paper
0.8 S
shoe sliding face gauge lap.
Groove depth in Replace with new
0.45 mm or more Micrometer
shoe sliding section ones.
Looseness on the
ball joint section be- Replace with new
0.4 mm or less Dial gauge
tween piston and ones.
shoe
Almost no wear. If scratches or seizure are found, replace with new
Piston diameter
ones.
Piston face (6) Surface roughness
Surface roughness 0.8 S Lap
gauge
Cylinder (24) Roughness on the Surface roughness
0.4 S Lap
edge gauge
Piston hole Almost no wear. If scratches or seizure are found, replace the motor.
Distribution plate (22) Surface roughness
Surface roughness 0.8 S Lap
gauge
Piston assembly (8) Clearance between
Micrometer
Cylinder (24) piston diameter and 0.04 mm or less Motor replacement
Air micrometer
cylinder bore
Table 2
Part name Inspection and Maintenance Reference
Taper roller bearing (4) Replace bearings with new ones every 3,000 hours even if they function normally.
Needle bearing (23) Additionally, always replace bearings when reassembling, even if it's within 3,000
hours.
Spy joint(3) If damage is found on the lip, replace it with a new one.
Additionally, replace seals with new ones every 3,000 hours even if they function
normally with no leaking.
Additionally, always replace seals when reassembling, even if it's within 3,000
hours.
O-rings (11), (13), (16), (30), If damage is found on O-ring, replace it with a new one.
(36), (37), (40), (42), (50) and Additionally, replace rings with new ones every 3,000 hours even if they function
(37) normally with no leaking.
Additionally, always replace rings when reassembling, even if it's within 3,000
hours.
Backup rings (31) and (32) Always replace rings when reassembling.

Copyright
8019-11
Assembly
STEP 1 STEP 3
5 7
24
24
CS02C532
Apply grease (No. 2 EP lithium grease) on the spheri- CS02C534
cal portion of the cylinder shaft that is touching the Apply clean hydraulic fluid on the cylinder (24) bores.
backup washer (5) and install the backup washer (5). Install the piston assemblies (8) and the base plate (7)
in the cylinder (24). Be sure that the pistons are
STEP 2 installed in the same bores as removed from.
STEP 4
8
54
7 6
CS02C533
Apply clean hydraulic fluid on the sliding surface of 24
the piston assemblies (8). Install the piston assem-
blies (8) in the ports of the base plate (7).
CS02C535
Apply clean hydraulic fluid on the sliding surfaces of the
piston assemblies (A) and install the piston plate (6).
Install the shim (54) on the fluted shaft.

Copyright
8019-12
STEP 5 STEP 7
4 3
24
CS02C538
Before installation, apply grease on the lip of the spy
joint (3). Position housing in a press. Apply Loctite
CS02C536 504 to the periphery of the lip seal. Install and centre
Install a new conical roller bearing (4) on the cylinder the spy joint (3) in the bore of the housing. With a
shaft (24). suitable sleeve (A), fit the spy joint (3) in the bore of
the housing.
STEP 6
STEP 8
4
1
25
CS02C539
24 Install the other new conical roller bearing (4) in the
housing (25).
CS02C537
Apply a thin coat of Loctite 515 or 518 where the
sleeve (1) is installed on the cylinder shaft. Fit the
sleeve (1) on the shaft and install the retaining ring (2).

Copyright
8019-13
STEP 9 STEP 11
13
24
12
11
25
25 CS02C542
Apply grease on the new O-rings (11) and (13); install
the O-ring (11) in the housing (25) and the O-ring
(13) on the brake piston (12).
STEP 12
A A
CS02C540
Install the housing (25) on shims (A).
Carefully install the cylinder assembly (24) in the
housing (25). Be careful when installing the cylinder 12
assembly not to damage the splines on the shaft.
STEP 10
10
25
9 CS02C543
Apply clean hydraulic fluid on the periphery of the
brake piston (12). Drive the brake piston (12) into the
housing (25).
STEP 13
25
14
CS02C541
Apply clean hydraulic fluid to both faces of the friction
plates (9) and the disc plates (10). First, install a steel 25
disk then a friction disk, then a steel disk, a friction
disk, then a steel disk, a friction disk, finally the last
steel disk and the last friction disk.
CS02C544
Install the springs (14) in the brake piston (12) in their
original locations.

Copyright
8019-14
STEP 14 STEP 16
22 13
18
21
20
19
15
CS02C547
15 Install a new, greased O-ring (13) on the cover (15).

STEP 17
CS02C545
Install the washers (19) in the cover (15). Apply No. 2
EP lithium grease on the bushings (21), the new
Teflon rings (20) and in the cover (15). Install a teflon
ring on each of the bushings. Install the bushings with
rings in the bushing ports on the cover.
Apply No. 2 EP lithium grease on the pistons and
install the pistons (18) in the distribution plate (22). Loctite 504
Be sure that the pistons are installed in same bore as
removed from. Install the pistons and the distribution
plate on the cover.
STEP 15
CS02C548
53 Apply Loctite 504 to the mating surfaces of the motor
housing and cover.
STEP 18
23
15
15
25
CS02C546
Install the new needle bearing inner race (23) on the
shaft and install the retaining ring (53).
CS02C549
Install carefully the cover (15) and the distribution
plate (22) on the housing, by making sure that the
distribution plate and bushings do not fall off the
cover. Align the motor housing and cover alignment
marks.

Copyright
8019-15
STEP 19
49
15
25
CS02C550
Install the four cover retaining screws (49) and tighten
to a torque of 392 Nm.
STEP 20
48 48
52
26
33
C 27
CS02C551
Remove the oil level dipstick (C) and dipstick tube (D).
Install the relief valve assemblies (48) of the swing
motor.
Install the by-pass valve assemblies (27), as well as
the plugs (52), the springs (26) and the non-return
check valve (33).
Install new O-rings on each component.

Copyright
8019-16
TROUBLESHOOTING
Described below are measures to be taken when any abnormalities or malfunctions are found while the hydraulic
motor is used.
Details on disassembling/inspection and reassembling are also described later but careful handling is absolutely
needed to avoid any damage to the sliding parts of the motor while conducting these procedures.
Table 1
Symptom Cause Exterior inspection Remedy Repairs
Does not Motor's internal Measure drain output. If motor supply input is equal See Table 2.
rotate breakage to the drain output, there is
high possibility of breakage
in sliding section. Disassem-
bling/inspection is required.
Motor's internal Open the inlet and outlet If the output shaft does not Replace dam-
breakage ports on the motor and apply rotate smoothly with the aged parts or
pilot pressure of 2.9 to 4.9 torque stated to the left, motor assembly.
MPa to the brake relief port. there is high possibility of
Then attempt to rotate the internal breakage. Disas-
output shaft with torque of 30 sembling/inspection is
to 40 Nm. required.
Incorrect settings Measure load pressure with Reset to specified set pres-
at relief valve in pressure gauge. sure.
the circuit
Excessive Wear or damage Measure drain output. If the drain output is more See Table 2.
slippage in the sliding part than 2.5 L / min., the leakage
of the motor and in is too high. Disassembling/
the high pressure inspection is required.
seal section
Oil temperature is Measure oil temperature. Lower the oil temperature.
too high and there
is excessive inter-
nal leakage inside
the motor
Lack of Wear or seizure of Open the inlet and outlet If the output shaft does not Inspect parts (a)
torque the motor sliding ports on the motor and apply rotate smoothly with the to (e) listed in
Abnormal section pilot pressure of 2.9 to 4.9 torque stated to the left, Table 2, and also
noises MPa to the brake relief port. there is high possibility of the bearings.
Then attempt to rotate the internal breakage. Disas- Change them if
output shaft with a torque of sembling/inspection is any abnormality is
approx. 30 to 40 Nm. required. found.
Incorrect settings Measure load pressure with Reset to specified set pres-
at relief valve in pressure gauge. sure.
the circuit

Copyright
8019-17
Symptom Cause Exterior inspection Remedy Repairs

Lack of Motor's internal Check whether there are any If any foreign metal sub- Repair or replace
torque breakage foreign metal substances in stances are found, there is damaged parts.
Abnormal the motor oil drain and drain high possibility of motor's Motor assembly
noises filters. internal breakage. Disas- replacement.
(cont.) sembling/inspection is
required.
A lot of air is Check the oil in the tank and Bleed air completely.
mixed in the oil motor case.
Looseness on Looseness on piping fix- Fasten them with proper
tightening sections tures. tightening torque.
Check for looseness on the
fixture mounting bolts, motor
mounting bolts and bolts on
the motor.
Abnormal Seizure of motor's Check for foreign metal sub- If any foreign metal sub- Repair or replace
heat sliding and rotat- stances in the motor oil drain stances are found or the out- damaged parts.
ing sections and drain filters. Apply pilot put shaft does not rotate Motor assembly
pressure of 2.9 to 4.9 MPa to smoothly with the torque replacement.
the brake relief port and above, there is a high possi-
attempt to rotate the output bility of internal breakage.
shaft with torque of 30 to 40 Disassembling/inspection is
Nm. required.
Oil leak- O-ring is dam- Replace O-rings.
age from aged.
mating
Oil seal surface is Repair or replace
faces
damaged. seal surfaces.
Loose bolts Check for loose bolts. Fasten them with proper
tightening torque.
Oil leak- Wear or damage Replace oil seal.
age from on the lips of oil
oil seal. seal
Wear or damage Repair or replace
on seal sections of motor assembly.
shaft
Abnormal pres- Check the internal pressure Internal pressure in the case Replace oil seal.
sure in the case and drain output in the case. should be 0.3 MPa or less. Repair or replace
If drain output is too large, damaged parts.
disassembly/inspection is Motor assembly
required. replacement.

Copyright
8019-18
Table 2
Letter Parts to be inspected Repairs
a Wear in the sliding part of the distribution plate (22) Repair or replace parts.
b Damage in the sliding section of the piston plate (6) Repair parts or replace the
motor.
c Damage in the sliding section of the piston assembly (8) Repair parts or replace the
motor.
d Wear in piston outer diameter of the piston assembly (8) Repair parts or replace the
motor.
e Wear in piston hole of the cylinder (24) Replace motor.
f Damage in Teflon ring (20) Replace parts.
SECONDARY RELIEF
Description
38 41 47
40
44
34 35 36 37 39 45 46 43 42
CS02C552
34 SPRING SEAT 41 O-RING
35 CHECK VALVE 42 BACK-UP RING
36 SPRING 43 O-RING
37 O-RING 44 PLUG
38 SHIM 45 SLEEVE
39 VALVE BODY 46 LINER
40 PISTON 47 NUT

Copyright
8019-19
Disassembly Inspection
STEP 1 NOTE: Individual relief valve assembly parts cannot
be replaced. If a relief valve assembly fails to operate
Remove the nut (47), the plug (44), discard the properly for any reason other than dirt or foreign mat-
seal (43) and the back up ring (42). ter, the entire assembly must be replaced.
STEP 2
Assembly
Remove the sleeve (45) and the piston (40).
STEP 3 steps refer to the schematic on page 15.
Remove the liner (46), the shim (38) and discard the NOTE: When installing, install new seal rings.
O-ring (41).
STEP 1
STEP 4
Install an O-ring (37) on the valve body (39).
Remove the spring (36), the check valve (35) and the
spring seat (34). STEP 2
STEP 5 Install the spring seat (34) in the valve body (39).
Remove and discard the O-ring from the valve STEP 3

body (39). Oil the inside of the spring seat (34). Install the check
valve (35) in the spring seat (34).
STEP 4
Install the spring (36) on the valve body (39).
STEP 5
Install an O-ring (41) on the liner (46). Install a shim
(38) on the spring (36).
STEP 6
Install the liner (46) in the valve body (39), taking care
not to damage the O-ring (41).
STEP 7
Install the piston (40) in the sleeve (45). Install the
sleeve (45) in the liner (46).
STEP 8
Install a back up ring (42) and an O-ring (43) on the
plug (44). Install the plug (44) in the liner (46).
STEP 9
Install the blank nut (47).

Copyright
8019-20
NOTES
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Copyright
Section
8020
HYDRAULIC FUNCTIONS
8020

Printed in France
Copyright
8020-2
TABLE OF CONTENTS
HYDRAULIC FUNCTIONS....................................................................................................................................... 3
List of functions .................................................................................................................................................... 3
High Speed Travel Circuit .................................................................................................................................... 6
Low Speed Travel Circuit ..................................................................................................................................... 8
Straight Travel Circuit......................................................................................................................................... 10
Swing Parking Circuit (Lever in Neutral / Swing Locked) ................................................................................... 12
Swing Parking Circuit (Brake Released) ............................................................................................................ 14
Swing Push Digging ........................................................................................................................................... 16
Arm-Out Circuit .................................................................................................................................................. 18
Arm-In Load Holding .......................................................................................................................................... 20
Arm-In Circuit ..................................................................................................................................................... 22
Boom-Up Circuit (Single) ................................................................................................................................... 24
Boom-Up Circuit (Combined) ............................................................................................................................. 26
Boom-Down Load Holding ................................................................................................................................. 28
Boom-Down Circuit ............................................................................................................................................ 30
Combined Circuit (Breaker Circuit) .................................................................................................................... 32
Combined Circuit (High Speed Confluence Circuit) ........................................................................................... 34

Copyright
8020-3
HYDRAULIC FUNCTIONS
List of functions
Functions Description Pages
Travel Circuits
High speeds can be achieved by setting the two-step inclinatory angle of the
travel motor to the smaller angle side.
High speed
Load pressure applied to the travel motor automatically changes the speed to a Page 6
travel circuit
lower one.
Travel load pressure does not control the controller.
Low speed Low speeds can be achieved by setting the two-speed inclinatory angle of the
Page 8
travel circuit travel motor to the larger angle side.
Straight Maintains machine's straight travel even when attachment or swing operations
Page 10
travel circuit are performed during its travel.
Swing Circuits
When the swing lever is in neutral, the swing parking is activated and the swing
is fully held.
When the swing lever is operated, the parking brake is released by signals from
the pressure switch.
Swing park-
When the swing lever is in neutral, the parking brake is released by load pres- Page 12
ing circuit
sure generated by attachment operation.
The parking brake starts to operate 5 seconds after the swing lever comes in
neutral and after the load pressure has become lower than the specified values.
When the swing lock switch is turned on, the parking brake starts to operate.
When swinging and arm operation are conducted simultaneously, swing pushing
Swing push
function can be obtained by the swing override throttle valve integrated in the Page 14
digging
control valve.
Vibration The reversal prevention valve attached to the swing motor reduces backlashes
backlash that occur when the swing stops
Arm (Dipper) Circuits
Arm-out Switching over arm (1) and (2) spools makes hydraulic oil flows merge, achiev-
Page 18
circuit ing faster speed.
Load holding valve integrated in the control valve reduces natural drop on the
Arm-in load arm-in side.
Page 21
holding Arm-in pilot pressure enables arm-in operation by releasing the load holding
valve.
Arm-in The regenerative circuit and forced regenerative release valve in the arm (1)
Page 22
circuit spool function achieves faster arm speed.
Boom Circuits
Switching over boom (1) and (2) spools makes hydraulic oil flows merge, achiev-
ing faster speed.
Boom-up
When the arm is operated wiht the boom simultaneously, the restrictions is Page 24
circuit
opened in the swing override variable restriction valve and flow volume to the
arm side secured.
Load holding valve integrated in the control valve reduces natural drop of the
Boom-down boom.
Page 28
load holding Boom-down pilot pressure enables boom-down operation by releasing the load
holding valve.

Copyright
8020-4
The regenerative circuit in the boom (1) spool serves to improve the boom's
Boom-down speed and prevent negative pressure from occurring.
Page 30
circuit boom (2) does not operates.
The bleed-off circuit in the spool reduces extra vibrations when boom is lowerd
Backup Circuits
Combined Backup circuit section is provided at control valve.
Page 32
circuit Switching over the spool in the control valve creates internal confluence.
Others
A cushion valve with heat circuit is attached to the pilot line to reduce shocks
Cushion when the arm or boom movement stops. -
There is no soft/hard switch.
Auto power Through the engine load ratio and circuit pressure, the pressure of the main
-
boost relief will be raised from 34.3 MPa to 37.3 MPa.
Negative con- This is designed to reduce power consumption by minimizing the flow of the dis-
-
trol charge from the hydraulic pump when operating with no load.
Legend
Pressure Line
Pilot Pressure Line
Drain line
Tank line
Pilot tank line
Electric line

Copyright
8020-5
This page has been left blank intentionally

Copyright
8020-6
High Speed Travel Circuit

With High Speed Travel, high speeds can be achieved by setting the two-level inclinatory angle of the travel
motor to the smaller angle side. The circuit has a travel motor that automatically switches over to lower speed by
utilizing load pressure on the travel motor when travelling at high speed.
Discharged oil from the hydraulic pump A1 enters the Port P1 of control valve while discharged oil from the
hydraulic pump A2 enters the Port P2 of control valve. Each flow goes into the travel motor by switching between
the right and left travel spools. By these flows, the machine travels forward and backward.
By operating the travel mode switch, electric signals are sent to the controller, and from the controller,
electric signals are sent to the solenoid valve for 2-speed (high speed) travel in the 6-way solenoid
valve. By the switchover of the solenoid valve, the original pilot pressure (3.9 MPa / 39 bar / 565 psi)
from Port C1 on the 6-way solenoid valve enters Port P of right and left travel motors via the rotating
joint to set the inclinatory angle of the travel motor to the smaller angle side, which enables high
speeds.
Pa1/A1. RH forward travel

Pb1/B1. RH reverse travel
Pa6/A6. LH forward travel
Pb6/B6. LH reverse travel
10. Main hydraulic pump
15. Main control valve
21. Travel motors
25/26. Boom cylinders
52. 6 solenoid valve bank
108. Straight travel valve
A1. Computer / Controller
C1. Travel 2nd speed pilot
S2. Travel mode switch
Y2. Pilot pressure solenoid valve (blue band)
Y4. 2 stage travel solenoid valve (red band)

Copyright
8020-7
High Speed Travel Circuit

BOOM CYLINDER
26 25
T2 T1
A8
B8
21 21
VA VB
VB VA
B6
A6 pb6 TRAVEL
P P
TRAVEL MOTOR pa6 (RIGHT)
B1
A1
TRAVEL pb1
SWITCH PANEL (LEFT) pa1
S2 15
TRAVEL
PP
P1 P2
108 CONTROL VALVE
SPEED TRAVEL LEVER LOCK
Y2 STRAIGHT TRAVEL
VALVE
C1
A1
CONTROLLER
P
Y4
A1 A2 A3
10
52 6-WAY SOLENOID VALVE HYDRAULIC PUMP
330-1-03-03-19A

Copyright
8020-8
Low Speed Travel Circuit

The two-level inclinatory angle in the travel motor is set to the larger angle side. When the travel status is set to
high speed and the key switch is turned off and turned on again, the speed setting will always return to Low
Speed.
Discharged oil from the hydraulic pump A1 enters the Port P1 of control valve while discharged oil from the
hydraulic pump A2 enters the Port P2 of control valve. Each flow goes into the travel motor by switching between
the right and left travel spools. By these flows, the machine travels forward and backward.
The solenoid valve for high speed travel is turned off and the oil in Port P of the travel motor enters the tank line
and establishes a connection. As a result, the inclinatory angle of the travel motor is set to the larger angle side.

21. Travel motors
52. 6 Solenoid valve bank

Copyright
8020-9
Low Speed Travel Circuit
BOOM CYLINDER
26 25
T2 T1
A8
B8
21 21
VA VB
VB VA
B6
A6
pb6 TRAVEL
P P pa6 (RIGHT)
TRAVEL MOTOR
B1
A1
TRAVEL pb1
SWITCH PANEL (LEFT) pa1
15
S2 TRAVEL
PP
P1 P2
108 CONTROL VALVE
2- SPEED TRAVEL LEVER LOCK
T Y2 STRAIGHT TRAVEL
VALVE
A1 C1
CONTROLLER
P
Y4
A1 A2 A3
10
330-1-03-03-19B

Copyright
8020-10
Straight Travel Circuit

As an example, we describe the operation where travel and boom up are operated at the same time.
The pilot oil pressure enters from Port PP of the control valve and communicates with the tank side via passages
of travel spool and spools for attachments (boom, arm, bucket and swing). When travel and boom-up operations
are performed simultaneously, all circuits, which have been communicating with the tank, will be shut off by
spools. This makes pilot pressure oil entered from the port PP to lose where to flow and original pressure
(3.9MPa / 39 bar / 565 psi) switches over the straight travel selector valve. The pressure works to the pilot cham-
ber in straight travel valve allowing the valve to be switched over.
As the result of the switch over of the straight travel valve, the pressurized oil in the control valve P1 drives the
right and left travel motors and the pressurized oil in the control valve P2 drives the attachments. The right and
left pressures become equal because one pump drives both the right and left motors. This realizes straight travel.
Additionally, extra hydraulic oil from P2 is supplied via the check with travel confluence restriction to the travel
side, and speed reduction is minimized. The same theory applies and the circuits operate the same way when
upper actuators other than boom and travel are operated at the same time.
Pa8/A8. Raising the boom

Pb8/B8. Lowering the boom
Pb4. Boom 2 spool
21. Travel motors

Copyright
8020-11
Straight Travel Circuit
BOOM CYLINDER
26 25
Dr T2 T1
A8
B8
21 21 pb8'
pb8
pa8'
pb4
VA VB pb4'
pa8
VB VA
B6
A6
TRAVEL MOTOR P pb6 TRAVEL
P pa6 (RIGHT)
B1
A1
SWITCH PANEL TRAVEL pb1
(LEFT) pa1
S2 TRAVEL 15
P1 PP
108 P2 CONTROL VALVE
2-SPEED TRAVEL LEVEL LOCK Y2
T STRAIGHT TRAVEL
A1 C1 VALVE
CONTROLLER
P
Y4
A1 A2 A3
10
330-1-03-03-19C

Copyright
8020-12
Swing Parking Circuit (Lever in Neutral / Swing Locked)

When the engine is started and the swing lever is in neutral, the swing brake solenoid valve becomes turned on
(24 V input) and the swing parking brake is activated.
When the swing lock switch is on, even if the swing pressure switch or attachment pressure switch is turned on,
the swing lock switch overrides and the parking brake remains unreleased. When the swing lock switch is on and
the swing lever is shifted into operation, the swing spool in the main control valve will be switched over.
Pa3/A3. LH swing
Pb3/B3. RH swing
22. Swing motor
27. Dipper cylinder
54. Swing dipper control lever
81. Swing shuttle block
C2. Swing brake pilot
B22. Swing pilot pressure switch
B26. Upper pilot pressure switch
B42. Pump pressure sensor P1
Y3. Swing brake solenoid valve (pink band)

Copyright
8020-13
Swing Parking Circuit (Lever in Neutral / Swing Locked)
SWING MOTOR
22
A5
27 B5
ARM CYLINDER
pc3'
pc3
A B
B3
A3
pa3
REMOTE CONTROL VALVE

54
SHUTTLE VALVE
81
LEVER LOCK
Y2
T 3 1 15
P1 PT PP PA P2
CONTROL VALVE
B22 ATTACHMENT
SWING PRESSURE B26
PRESSURE
SWITCH
SWITCH
C2
SWITCH PANEL
SWING LOCK G4 G5 PRESSURE
Y3 SWING BRAKE B44 SENSOR
A1 A2 A3
S2 B42
PRESSURE
52 SENSOR
6-WAY SOLENOID VALVE
A1
CONTROLLER HYDRAULIC PUMP
10
330-1-03-04-20A

Copyright
8020-14
Swing Parking Circuit (Brake Released)

When the swing pressure switch is turned on by operating the lever, output to the swing brake solenoid valve
from the controller is turned off and the swing parking brake is released by pilot pressure. Also, in order to pre-
vent brake dragging caused by swing lateral force that is generated when digging attachments are moved with
the swing lever being in neutral, a mechanism which senses main pressure and releases the parking brake is
introduced. Signals from the pressure sensor on Port G4 or Port G5 of the hydraulic pump enter the controller.
When either pressure reaches 15 MPa, the output to swing brake solenoid valve from the controller is turned off.
This releases the swing parking brake.
When the pressure switch for attachments is kept off for more than 5 seconds, the swing pressure switch will be
turned off. Then 5 seconds after the pressure of the hydraulic pumps G4 and/or G5 becomes 15 MPa or less, the
solenoid valve turns on and the swing parking brake starts operating. When the pressure on G4 and/or G5
becomes 15 MPa or more, the swing brake is released. However, if the attachment switch was kept off for more
than 5 seconds, the swing parking brake works. (When travelling)
Swing Pressure received on

Swing brake Swing motor
Key switch pressure G4 or G5
solenoid valve parking brake
switch pressure sensor
OFF OFF 0 OFF Operates
15 MPa or less ON Operates
OFF Released
OFF Turns on 5 seconds
15 MPa or more after attachment
ON Operates
pressure switch
is turned OFF.
15 MPa or less OFF Released
ON
15 MPa or more OFF Released
Pa3/A3. LH swing
Pb3/B3. RH swing
22. Swing motor
27. Dipper cylinder

Copyright
8020-15
Swing Parking Circuit (Brake Released)

SWING MOTOR
22
P
27
ARM CYLINDER
T2
A5
B5
pc3
pbu
A B
B3
A3
pb3
pa3
REMOTE CONTROL VALVE
SHUTTLE
VALVE 54
2S
81
LEVER LOCK S2 S3
Y2 SWING PRESSURE 3 1
52 15
SWITCH
P1 PT PP PA P2
B22 CONTROL VALVE
P B26 ATTACHMENT
PRESSURE
SWITCH
C2 B44
Y3 SWITCH PANEL G5
G4 PRESSURE
SWING LOCK
SWING BRAKE SENSOR
HYDRAULIC PUMP
A1 A2 A3
S2 B42
PRESSURE
SENSOR
CONTROLLER
A1 10
330-1-03-04-20B

Copyright
8020-16
Swing Push Digging

The swing pilot pressure is supplied port Pc3 via shuttle valve and enable the swing priority variable restriction to
be held to the right-hand side.Putting restriction on the parallel circuit secures swing force for enforced digging
operation with raised swing pressure even when the arm and swing are operated at the same time.
Pa3/A3. LH swing
Pb3/B3. RH swing
22. Swing motor
27. Dipper cylinder
S2. travel mode switch

Copyright
8020-17
Swing Push Digging

SWING MOTOR
22
P 27
ARM CYLINDER T2 T1
A5
B5
pb5'
pb5 pb9
pa5' pa5
pa9
pc3'
pc3
A B
B3
A3 pb3
pa3
SHATTLE
VALVE 81 REMOTE CONTROL VALVE
54
2S
SWING PRESSURE
SWITCH S2 S3
B22
3 1 15
P1 PT PP PA
P2 CONTROL VALVE
Y2 LEVER LOCK
P B26
ATTACHMENT
C2 PRESSURE
SWITCH PANEL B44 SWITCH
Y3 SWING BRAKE SWING LOCK G4 G5
PRESSURE
A1 A2 SENSOR A3
B42
S2
PRESSURE SENSOR
52

CONTROLLER
A1 HYDRAULIC PUMP 10
330-1-03-04-20C

Copyright
8020-18
Arm-Out Circuit
Oil discharged from hydraulic pump A1 is supplied to the arm (1) spool through the center bypass oil passage in
the control valve. Oil discharged from hydraulic pump A2 is also supplied to the arm (2) spool through the parallel
oil passage, and merges at the upstream of the arm (1) spool, then flows into the rod side of the arm cylinder via
the load holding valve. Oil returning from the bottom returns to the tank oil passage via the arm (1) and (2)
spools.
Pa5/A5. Extending the arm (dipper) (Arm 1)

Pb5/B5. Retracting the arm (dipper) (Arm 1)
Pa9/Pb9. Dipper 2 spool
27. Arm (Dipper) cylinder
54. Arm (Dipper) control lever
56. Dipper control shock absorber
57. Boom and arm (dipper) control shock absorber

Copyright
8020-19
Arm-Out Circuit
BOOM CYLINDER
T2 T1
pc1
27
A5 26 25
B5
pb5'
pb5 pb9
ARM
pa5' pa9
CYLINDER pa5 pc2
pc3' A8
pc3 B8
pb8'
pbu pb8
pb4 pa8'
pb4' pa8
56
B CUSHION VALVE
15
P1 P2
CONTROL VALVE
CUSHION VALVE
57
P
54
A1 A2 A3
T
2 4 B
REMOTE CONTROL VALVE D
10
C HYDRAULIC PUMP
330-1-03-06-19A

Copyright
8020-20
Arm-In Load Holding

When the arm is in neutral, oil on the arm cylinder rod side is sealed by the load holding valve check. This mech-
anism reduces internal leakage from the main spool.
When the arm-in is operated, the pilot pressure enters Port 5pb5 of the control valve and moves arm (1) spool to
the arm-in side. Also, the pilot pressure separated from Port Pb5 enters Port Pc1 and moves the load holding
valve spool to the right. Through this mechanism, the oil in the spring chamber of the load holding valve check is
connected to the tank line passing the load holding valve spool. As a result, the pressure on the spring chamber
decreases and the load holding valve check is released. The hydraulic oil in the rod of the arm cylinder is
returned to the tank line, the arm cylinder extends and the arm moves in.

31. Dipper load holding valve

Copyright
8020-21
Arm-In Load Holding
BOOM CYLINDER
Dr T2 T1
pc1
27
A5 26 25
B5
pb5' pb9
ARM pb5
CYLINDER pa5' pa9
pa5 pc2
pc3' A8
Detail pc3 B8
pb8'
pbu pb8
pb4 pa8'
LOAD HOLDING pb4' pa8
VALVE SPOOL
pc1 A
LOAD HOLDING 56
A5 VALVE CHECK
CUSHION VALVE
31 B
ARM(1)
15
PP
P1 P2
CONTROL VALVE
CUSHION VALVE
REMOTE CONTROL VALVE 57

P
54
A1 A2 A3
2 4
D
10
C
HYDRAULIC PUMP
A
33-01-03-06-19B

Copyright
8020-22
Arm-In Circuit
For arm-in operation, pilot pressure is supplied to Port 5pb5 and Pb9 of the control valve and the arm spool
moves to the arm-in side.
At the same time, the arm load holding valve is released by the pilot pressure, and the discharged oil on the cyl-
inder rod side is restricted by the forced regenerative release valve. This forces the returned oil to be regenerated
into the cylinder bottom side via the check within arm (1) spool, securing the arm speeds required for floor dig-
ging work. When the load pressure rises on the cylinder bottom side, the forced regenerative release valve
switches over to the large diameter restriction side. As a result, the orifice for return becomes large and returned
oil on the rod side stops recycling.
When the reverse notching operation is pressure oil supplied to the cylinder remains the same as the volume of
two pumps, and only the arm (1) spool return line stays open. This caused extensive shock. To reduce this
shock, a cushion valve (in line) is provided in the arm (2) spool out pilot line which softens the switch over of the
spool.

110. Arm regeneration valve

Copyright
8020-23
Arm-In Circuit
BOOM CYLINDER
Dr T2 T1
pc1
27
A5 26 25
B5
pb5 pb5' pb9
ARM pa5' pa9
CYLINDER pa5 pc2
pc3' A8
pc3 B8
pb8'
Detail pbu
pb8
pb4 pa8'
pb4' pa8
A5 LOAD HOLDING
H/V VALVE CHECK
A
B5
56
pb5 B
CUSHION VALVE
110
FORCED RECYCLE RELEASE VALVE
15
P1 PP P2
CONTROL VALVE
CUSHION VALVE
57
REMOTE CONTROL VALVE P
54
A1 A2 A3
2 4
D
10
C HYDRAULIC PUMP
A
300-1-03-06-19C

Copyright
8020-24
Boom-Up Circuit (Single)

Oil discharged from hydraulic pump A1 is supplied to the boom (2) spool from the parallel oil passage via the
control valve and merges at the downstream of the boom (1) spool. Oil discharged from hydraulic pump A2
merges with the discharged oil from the boom (2) via the boom (1) spool through the parallel oil passage and
flows into the bottom side of the boom cylinder via the holding valve.
P1. Outlet flow A1

P2. Outlet flow A2
Pb8B8. Lowering the boom

Copyright
8020-25
Boom-Up Circuit (Single)
BOOM CYLINDER
Dr T1
pc1
27
A5 26 25
B5
pb5'
pb5 pb9
ARM pa5'
pa9
CYLINDER pa5
pc2
pc3' A8
pc3 B8
pb8'
pbu pb8
pb4 pa8'
pb4' pa8
56
CUSHION VALVE
15
P1 PP P2
CONTROL VALVE
CUSHION VALVE
E
57
REMOTE CONTROL VALVE G
54 H
A1 A2 A3
2 4
10
HYDRAULIC PUMP
330-1-03-07-19A

Copyright
8020-26
Boom-Up Circuit (Combined)

When floor digging operation is performed, the boom-up pilot pressure, which is supplied to port Pbu, releases
the restriction on flow to the arm by moving the swing priority variable restriction to the left. This makes the arm
move smoothly.
P1. Outlet flow A1

P2. Outlet flow A2
Pc2. Lowering load holding
Pa8/A8. Lowering the boom
Pb8B8. Raising the boom

Copyright
8020-27
Boom-Up Circuit (Combined)
BOOM CYLINDER
T2 T1
pc1
27 A5 26 25
B5
pb5' pb9
ARM
CYLINDER pa5' pb5 pa9
pa5 pc2
pc3' A8
pc3 B8
pb8'
pbu pb8
pb4 pa8'
pb4' pa8
56
B CUSHION VALVE
15
P1 PP P2
CONTROL VALVE
E
CUSHION G
REMOTE CONTROL VALVE P VALVE
54 57 H
A1 A2 A3
2 4
D
10
C
A HYDRAULIC PUMP
330-1-03-07-19B

Copyright
8020-28
Boom-Down Load Holding

When the boom is in neutral, oil on the boom cylinder bottom side is sealed by the load holding valve check. This
mechanism reduces internal leakage from the main spool. For boom-down operation, the pilot pressure enters
Port Pb8 of the control valve and moves the spool of the control valve to the boom-down side. Also, the pilot pres-
sure enters Port Pc2 and moves the load holding valve spool to the left. Through this mechanism, the oil in the
spring chamber of the load holding valve check passes the load holding valve spool creating a connection to the
tank. Consequently, the pressure on the spring chamber decreases and the load holding valve check is released.
The hydraulic oil at the bottom side of the boom cylinder is returned to the tank line, the rod of the boom cylinder
shrinks, and the boom is lowered.

Pa8/a8. Raising the boom
Pc2. Boom load holding
1. Load holding valve spool
32. Boom load holding valve

Copyright
8020-29
Boom-Down Load Holding
BOOM CYLINDER
Dr T1
pc1
27
A5 26 25
B5
pb5'
pb5 pb9
ARM pa5' pa9
CYLINDER pa5
pc2
pc3' A8
pc3 B8
pb8'
pbu pb8
pb4 pa8'
pb4' pa8
CUSHION VALVE
56
Detail 1
LOAD HOLDING
VALVE SPOOL
pc2
LOAD HOLDING
VALVE CHECK
32 A8
15
P1 PP
P2 BOOM(2)
CONTROL VALVE BOOM(1)
CUSHION VALVE
57
P
54 H
A1 A2 A3
F
T
4
2
10
HYDRAULIC PUMP
330-1-03-07-19C

Copyright
8020-30
Boom-Down Circuit
For boom-down operation, pilot pressure is supplied at Port 4pb3 and 5pa4 of the control valve, and the boom
spool moves to the boom-down side. At the same time, the pilot pressure opens the boom load holding valve and
partially regenerates the discharged oil from the bottom side of boom cylinder at the rod side via the check in the
spool.
Although the boom (2) spool is changed over, oil will not be supplied to the cylinder as it is center-bypassed.

Pc2. Boom load holding
2. Non-return check valve
3. Jet
4. Jet
28. Bucket cylinder
32. Boom load holding valve
53. Boom control lever

Copyright
8020-31
Boom-Down Circuit
BOOM CYLINDER
Dr T1 ps2
pc1
27
A5 26 25
B5
pb5'
ARM pb5 pb9
pa5' pa9
CYLINDER pa5
pc2
pc3' A8
pc3 B8
pb8'
pb8
pb4 pa8'
pb4' pa8
56
CUSHION
VALVE
LOAD HOLDING
Detail VALVE CHECK
32
H/V A8
2
B8
4
pb8
15
P1 PP P2
CONTROL VALVE 3
T1
BLEED-OFF
P2
CUSHION VALVE
57
P
54 H
A1 A2 A3
F
T
4
10
HYDRAULIC PUMP
330-1-03-07-19D

Copyright
8020-32
Combined Circuit (Breaker Circuit)

Through remote control operation, the pilot pressure that is supplied to Port Pa2 of the control valve switches the
backup spool. This allows the discharged oil from the hydraulic pump A1 to flow into the breaker.
The pilot pressure operates the pressure switch at the same time. Through signals, the control gives an instruc-
tion to engine controller to adjust the engine speed to preset numbers.
Return oil from the breaker passes by way of 3-direction valve, and oil exceeding the set pressure flows from the
stop valve via the relief valve to return to the hydraulic oil tank.
Pa2/A2. Breaker/Crusher circuit

Pb2/B2. Crusher circuit
72. Control pedal
75. Flow re injection block
76. 3-way selector
78. Return filter
79. Control shuttle block
83. Shut-off valve
84. T-shuttle block
85. Hand/foot control pilot filter
B25 B23. Breaker pilot pressure switch
Y9. Breaker/Crusher two flow solenoid valve

Copyright
8020-33
Combined Circuit (Breaker Circuit)

SHUTTLE VALVE
84
FILTER
78
STOP VALVE
76 1
pb5'
2 pb5 pb9
pa5' pa9
83 pa5
72
B2
pb2 A2
pa2
P4
P T
1 2 D
85
PRESSURE
P
SWITCH
A 15
B25 B23 P1 PP P2 P3
A1 S1 A2 75 CONTROL VALVE
P T B
HOLDING VALVE
79
SHUTTLE S2 A
B1 B2
VALVE Y9
A1 A1 A2 A3
CONTROLLER
HYDRAULIC PUMP
10
330-1-03-09-17A

Copyright
8020-34
Combined Circuit (High Speed Confluence Circuit)

Through remote control operation, the pilot pressure that is supplied to Port Pa2 (or Pb2) of the control valve
switches the backup spool. This allows the discharged oil from the hydraulic pump A1 to flow into the end attach-
ment.
The pilot pressure operates the pressure switch at the same time, and its signals switch over the solenoid valve.
Through the switch over of the solenoid valve, the pilot pressure, which is supplied to port Pb9 of the control
valve, switches the arm (2) spool to block the center bypass. Through this process, discharged oil from the
hydraulic pump A2 is supplied to holding valve B via ports P2 and P3 of the control valve.
The pilot pressure from the solenoid valve acts on port P of the holding valve at the same time and moves the
release spool as result, the oil in port B of the holding valve is discharged from port A and enters port P4 on the
control valve and merges with the discharged oil from the hydraulic pump A1 at the upstream of the backup
spool, achieving 2nd speed (high speed).
Pa2/A2. Breaker/Crusher circuit

Pb2/B2. Crusher circuit
72. Control pedal
75. Flow re injection block
76. 3-way selector
78. Return filter
79. Control shuttle block
83. Shut-off valve
84. T-shuttle block
85. Hand/foot control pilot filter
B25 B23. Breaker pilot pressure switch
Y9. Breaker/Crusher two flow solenoid valve

Copyright
8020-35
Combined Circuit (High Speed Confluence Circuit)
SHUTTLE VALVE
84
FILTER
78
T2
STOP VALVE
76
2 3 pb5'
pb5 pb9
pa5' pa9
pa5
83
72 B2
pb2 A2
pa2
T P4
D
PRESSURE 1 T 2
SWITCH 85
P
B23 15
A
P1 PP P2 P3
B25 A1 S1 A2 75 CONTROL VALVE
P T
B HOLDING VALVE
79
SHUTTLE B1 S2 B2 A
Y9
VALVE
A1 A1 A2 A3
CONTROLLER
HYDRAULIC PUMP
10
330-1-03-09-17B

Copyright
8020-36
NOTES
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8021
Section
Copyright
8021
TRAVEL HYDRAULIC MOTOR

ASSEMBLY AND DISASSEMBLY

Printed in France
Copyright
8021-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 2
SPECIAL TORQUES................................................................................................................................................ 2
SPECIAL TOOLS ..................................................................................................................................................... 3
TRAVEL MOTOR ..................................................................................................................................................... 5

Disassembly .........................................................................................................................................................7
Assembly .............................................................................................................................................................. 9
BEARING MEASUREMENT .................................................................................................................................. 12
INSPECTION.......................................................................................................................................................... 13
OVERLOAD RELIEF VALVE ................................................................................................................................. 16

Disassembly .......................................................................................................................................................16
SPECIFICATIONS
See Section 1002.
SPECIAL TORQUES
Screw (56) ........................................................................................................................................... 324 32.4 Nm
Pilot valve plug (35) ................................................................................................................................ 49 - 58.8 Nm
Overload relief valve (57)...................................................................................................................... 98.1 - 118 Nm
Plug (29) ............................................................................................................................................... 441 - 446 Nm
Plug (42) ....................................................................................................................................................... 14.7 Nm
Plug (38) ....................................................................................................................................................... 29.4 Nm
Plug (60) ........................................................................................................................................................ 98.1 Nm

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8021-3
SPECIAL TOOLS
C B A
D
E
C B E
F
D
CRPH06D001A CRPH06D006A
Mount metal (2 pieces) Jig for inserting oil seal
A 160 mm D 100 mm A 100 mm D 90 mm
B 70 mm E 37 mm B 7.7 mm E more than10 mm
C 20 mm C 67.5 mm F R 0. 5
H A A
F B C
C B
G
D
E
D
CRPH06D002A
CRPH06D004A
Jig for pulling out brake piston (2 pieces)
Jig for inserting rear bearing
A 12 mm E 100 mm
A 120 mm C 42 mm
B 24 mm F 60 mm
B 36 mm D 3 mm
C 40 mm G 6.5 mm
D 20 mm H Hex.socket head bolt 2-M6 x 100

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8021-4
E
F C
F E
D B
A
CRPH06D005A
Guide pin for rear cover (2 pieces)
A 100 mm D M 18
A B C D
B 32 mm E R2
C 25 mm F 10
J
I
K
L
CRPH06D006B
Jig for inserting brake piston
A 280 mm G 2 - M 18 x 35
B P. C.D. 251 mm H 2 - 20 drill hole
C 215 mm I 15 mm
D 195 mm J 50 mm
E 21 mm K 10 - plain washer 18
F 10 mm L 2 - M18 x 50

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8021-5
TRAVEL MOTOR
Description
43
48 49 47 46 55 24 53 25 44 45 42
2 5
8
6
52
9 7
51
58
54
59
4
38
3
39
10
11 13
1 18 12 15 14 17 20 22 23 21 50 56
18
31 19 33 32 34 35 36
36
57-3 37
57
48
61 60
29
30
28
27
26 40 41 42
43
CRPH06D011H

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8021-6
1 CASING 31 PILOT VALVE SPOOL DIA.
2 PLUG 32 PIN
3 OIL SEAL 33 SPRING HOLDER
4 CIRCULAR SNAP RING 34 SPRING
5 EXPANDER PLUG 35 PILOT VALVE PLUG
6 INCLINED PISTON 36 O-RING
7 PISTON SEAL 37 CONNECTOR
8 STEEL BALL 38 PLUG
9 SHAFT 39 O-RING
10 BEARING 40 RESTRICTOR (BRAKE VALVE)
11 PIVOT 41 RESTRICTOR SPRING (BRAKE VALVE)
12 SHOE PLATE 42 PLUG
13 CYLINDER BLOCK 43 O-RING
14 CYLINDER SPRING 44 CHECK VALVE
15 SPRING HOLDER 45 CHECK VALVE SPRING
16 BALL JOINT 46 RESTRICTOR (0.6)
17 SHOE RETAINER 47 O-RING
18 PISTON ASSEMBLY 48 RESTRICTOR (0.8)
19 SEPARATOR PLATE 49 O-RING
20 FRICTION PLATE 50 O-RING
21 BRAKE PISTON 51 BEARING
22 O-RING (SMALL) 52 SHIM
23 O-RING (LARGE) 53 PARALLEL PIN
24 REAR COVER 54 VALVE PLATE
25 PLUG 55 BRAKE SPRING
26 SPOOL ASSEMBLY 56 HEX. SOCKET HEAD BOLT
27 SPRING HOLDER 57 OVERLOAD RELIEF VALVE
28 SPRING 58 COUPLING
29 PLUG 59 RETAINING RING
30 O-RING 60 PLUG
61 O-RING

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8021-7
Disassembly 3. Review the sectional drawings prior to disassem-

bling and obtain the parts required according to
General precautions the specific purpose/scope of the job. Do not
1. Hydraulic devices are made of precision compo- reuse seals and O-rings that have been disas-
nents in general and structurally have small toler- sembled. Also, some parts must be replaced as
ances. Disassembling/assembling must be done subassembly because those parts are not sup-
in a clean area free of dust. Tools and cleaning oil plied separately.
must also be clean and must be handled with 4. Pistons and cylinders, when they are brand new,
care. do not need to be assemblied in a particular
2. If devices are removed from the main machine, order. When disassembling, however, they need
first clean the surrounding areas of the port, then to be marked if they are to be used again. Before
plug the ports and handle with utmost care to removing the pistons from the cylinders, mark
keep dust/water from entering the inside. them all so they can be put together in the exact
order they were assemblied in originally.
WARNING: Keep hands and fingers away from small gaps or crevices among parts. Lifted loads also require
! extra attention since they may fall on your feet.
NOTE: the numbers in brackets refer to the drawing STEP 7

on page 3.
STEP 1 Guide pin
Remove the plug (29) and O-ring (30). Hole for releasing
STEP 2 brake (left) 49
Remove spring (28), spring holder (27) and spool 47 55 24
assembly (26).
Put the mating mark on both spool assembly (26) and 52
rear cover (24) so that spool assembly (26) should
not be reversed on re-assembling.
It is impossible to disassemble this spool assembly
(26) further because spool assembly (26) is fixed by
adhesive.
STEP 3
Remove plug (42), O-ring (43), check restrictor spring
(41) and restrictor (40).
STEP 4
Remove overload relief valves (57).
When removing overload relief valve (57), valve seat
(57-3) easily comes off, so take great care not to fall
into the rear cover (24) or lose. 13 54 50 51 56
STEP 5
Remove pilot valve plug (35) and then, remove O-
ring (36), pilot valve spring (34), spring holder (33),
pilot valve spool (31) and pin (32). CRPH06D012B
Place the motor with the shaft horizontal, remove Hex.

STEP 6 socket head bolts Ml8 x 50 (56) of rear cover (24)
Remove coupling (58).
leaving two on diagonally upper and lower position.

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8021-8
STEP 8 STEP 14
Install two guide pins diagonally into rear cover (24).
(Purpose: Prevention of falling rear cover).
STEP 9
Loosen slowly and simultaneously the remaining two
Hex. socket head bolts Ml8 x 50 (56).
19 20
STEP 10 13
Remove rear cover (24) and brake springs (55) tak-
ing care cylinder block (13) is not coming out stuck
with rear cover (24).
STEP 11
Keep the cylinder block (13) in its position and 18
remove the valve plate (54).
Mark the valve plate (54) and the rear cover (24) to
differentiate the front from the back at assembly.
STEP 12
Press the cylinder block (13) onto the pressing jig
using the removed screw (56) to push out the inner 16 15 17 14
race of the rear bearing (51).
STEP 13
CS02B531
Secure the brake piston (21) with hand and push the
piston (21) out by supplying air through the brake
release oil hole.
WARNING: The procedure requires extra

attention: the piston may pop out due to the
! air pressure.
STEP 15
CD02B030 Take a soft material like a sheet of paper and roll it
Place the gear (bearing) extractor inner race of the into a tube to use for marking without scratching
bearing (51) to remove the bearing. parts.
Insert this into the piston (18) hole and mark the cir-
cumference of the cylinder block (13).
STEP 16
Remove the cylinder block (13), the spring bearing
(15) and the cylinder spring (14).
STEP 17
Remove the separator plate (19) and the friction plate
(20).

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8021-9
STEP 18 Assembly
Remove the nine piston assemblies (18), the shoe General precautions
retainers (17) and the ball joints (16), all at the same
1. Clean parts well with cleaning oil and blow dry
time.
with air.
NOTE: The procedures above are for the motor as a
2. Apply clean hydraulic oil to sliding parts prior to
single unit, but can also be applied on models with
assembling.
reduction gears. The disassembling for those can be
conducted in the same manner. The job with theses
models may be easier because there is less vibration WARNING: Keep hands and fingers away
due to larger shafts. from small gaps or crevices among parts.
STEP 19 ! Lifted loads also require extra attention since
they may fall on your feet.
3 10 1 6 12 STEP 1
1
11
9
CS02B533
Apply grease to the outer perimeter of the oil seal (3)

as well as to the inner perimeter of the casing (1).
Use jigs to gently and evenly tap the oil seal (3) into
CS02B532 casing (1) without slanting.
Remove the shoe plate (12).
STEP 2
STEP 20
Do not remove the inclined piston (6).
In the event that this must come out, secure it by 3 10 1 6 12
hand, push out by blowing air into the hole.
STEP 21
The shaft (9) will come out on its own. 4
STEP 22
Remove the retaining ring (4) and take out the oil seal
(3).
STEP 23
11
When changing the bearings, inner and outer races
are also to be removed with a bearing puller. Each
9
must be replaced as an assembly.
CS02B532
Secure the oil seal (3) with the snap ring (4).

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8021-10
STEP 3 STEP 9
Insert the outer race of the bearing (10) into casing
(1) and press fit the inner race into the shaft (9).
1 18 19 20 22 23 56
Heating the inner race to approximately 100C facili-
tates the insertion process here.
STEP 4
Place the shaft (9) into the casing (1). Prior to this 51
procedure, grease must be applied to the working
surface that contacts the seal (3).
STEP 5
Insert the inclined piston (6).
STEP 6
Insert the pivot (11) into the side where the markings
match. Also, if the machine has been in use for a long 21
time prior to servicing, insert in the direction so the
sliding traces on the spherical part of the shoe plate
(12) match the contact traces. CS02B535
Gently tap and insert the inner race of the rear bear-
STEP 7 ing (51) into the edge of the shaft (9), see jig for
inserting rear bearing on page 3.
STEP 10
17 18 15 13 The separator plates (19) and the friction plates (20)
need to be installed alternately and completely. Start
with a separator plate (19) and finish with one also.
STEP 11
Insert the O-rings (22) and (23) into the brake piston
(21), then install the piston into the casing (1) using
the jig for inserting the brake piston, see on page 3.
12
9
16 14
1 13
CS02B534
Apply a liberal amount of grease to the spherical sec-
tion of the shoe plate (12), then install.
STEP 8
Place the piston assembly (18), shoe retainer (17),
ball joint (16), spring (14) into the cylinder block (13)
and insert the whole assembly into the shaft (9). The
piston assembly (18) must be assembled into the
original hole.

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8021-11
STEP 12 STEP 16
49 Assemble overload relief valves (57), tighten to the
47 55 24 torque specified on page 2.
STEP 17
52
Assemble restrictor (40) and restrictor spring (41) to
58 rear cover (24), and then install G/18 plug (42) with
O-ring (43), tighten to the torque specified on
page 2.
B STEP 18
Inserting spool assembly (26) to rear cover (24) coin-
ciding mating mark made prior to disassembling, and
then assemble spring holder (27) and spring (28).
59 STEP 19
Assemble M 42 plug (29) with O-ring (30), tighten to
the torque specified on page 2.
13 54 50 51 56
CS02B530
Install two guide pins (B) diagonally on casing

(1).(Purpose: Guide for installing rear cover)
Lay down rear cover (24) to mount valve plate (54)
coinciding mating mark made prior to disassembling
and also place brake springs (55) with ample grease
to be attached to rear cover (24) while assembling.
Also set shim (52), outer race of rear bearing (51)
and O-rings (50), (47), (49) on rear cover (24).
STEP 13
Insert rear cover (24) to casing (1) along the guide
pin, and install two Hex. socket head bolts M18 x 50
(56) diagonally upper and lower position and tight
them to assemble rear cover (24) parallel.
Then, install the rest of Hex. socket head bolts M18 x
50 (56) and remove guide pin and install two the
remainder.
When removing outer race of rear bearing (51), install
shim (52) without fail.
Confirm that O-rings (47), (49), (50) are installed to
rear cover (24).
STEP 14
Assemble coupling (58).
STEP 15
Assemble spring (34), spring holder (33), pilot valve
spool (31) and pin (32) to rear cover (24), and then
install pilot valve plug (35) with O-ring (36), tighten to
the torque specified on page 2.

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8021-12
BEARING MEASUREMENT
E S
F
9 10 1 51 52 24
CRPH06D010F
This work should be done only when you have changed bearings (10), (51), shaft (9), casing (1) or rear cover (24).
Measure the assembling width E
Take care not to incline shaft (9).
Measure the depth F of rear cover (24)
Measure them at crossed 4 places on the circuit, then calculate their mean value.
When thickness of shim (52) to be used is placed as S, the clearance Y can be calculated as follows:
Y=F-(E+S)
Select one or two shim (52) so as the clearance Y to come to 0-0.1 mm (clearance) on this unit.

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8021-13
INSPECTION
Items to measure and

Criterion and remedy
methods of measurement
1. Sliding surfaces on cylinder Table 2. Items and Surface Surface Remedy
block, valve plate and shoe plate what to be roughness: roughness:
Measure the roughness of the inspected standard acceptable
sliding surfaces of these parts limit
using surface roughness gauge. Surface 0.4 Z or 3.0 Z or Repair or
roughness of below below replace
cylinder block,
valve plate and
shoe plate
Attention! Lapping is required to repair the surface roughness of cylinder
block and valve plate. (Lapping material: # 1200)
Measure the hardness of the sliding Table 3. Items and Hardness: Hardness: Remedy
surfaces of shoe plate using what to be standard acceptable
hardness meter. inspected limit
Shoe plate HS78 or HS74 Replace
above
2. Clearance between piston and Table 4. Items and Standard Allowable Remedy
cylinder block what to be values
Measure the outer diameter of inspected
piston and the inner diameter of Outer diameter of 0.01 mm 0.05 mm Replace
cylinder using a micrometer at piston d-d1 piston or
3 locations at least in the cylinder
Inner diameter of 0.01 mm 0.022 mm
longitudinal direction. block
cylinder bore D1-
The maximum outer diameter is D
represented as d, minimum 0.037 to 0.065 mm
Clearance D-d
diameter as d1, maximum hole 0.047 mm
diameter as D and minimum
Attention! All 9 pistons must be replaced together if replacement is
diameter as D1.
necessary.
3. Looseness on piston and shoe Table 5. Items and Standard Allowable Remedy
Hold the shoe on the surface what to be dimensions values
plate with jigs and pull out the inspected
piston upwards to measure Looseness of the 0 to 0.1 mm 0.3 mm Replace
looseness of the piston and crimping area of piston
shoe. piston and shoe

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8021-14
DIAL GAUGE
PISTON
JIGS
MAGNET
SHOE
SURFACE PLATE Looseness of crimping area
Measurement
CS02B536 CS02B537 CRPH06D013A

4. Negative braking force Table 6. Items and Standard Allowable Remedy
When the assembling is what to be inspected values values
complete, measure the torque at Brake torque 1.171 Nm 1.055 Nm Separator plate
start of rotation by placing a Friction plate
torque wrench at the end of the Spring
output shaft. Replace all of
the above
Standard of replacing friction and separating plate.
When measuring parking brake torque, it needs to disassemble travelling
unit to motor and reduction gear portion, and it's so hard.
The right allowable value is a standard of replacing friction and separating
plate.
If it is impossible to disassemble travelling unit, refer to the right value.
Standard of replacing friction and separating plate
Measure the total thickness of 6 pieces of friction plate and 7 pieces of
separating plate.
And if the total thickness is below the following allowable value, replace all
separating and friction plates and springs.
Criteria: 33.04 mm (Dimension in the

drawing)
Allowable Thickness: 31.5 mm

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8021-15

5. Shaft Usable up to 0.05 mm of wear with steps.
Use a roughness gauge and Attention! Replace the oil seal (3) also when replacing the shaft.
measure the extent of wear on Attention! The thickness of the shim (52) needs to be adjusted when
the seal of the shaft. replacing the shaft.
6. Bearing The bearings (10 and 51) need to be replaced before the hour meter
records 10,000 hours of operation.
Replace bearings.
Attention! Replace the inner and the outer race also when replacing the
bearings.
Attention! The thickness of the shim (52) needs to be adjusted when
replacing the bearings.
7. Spline The spline is reusable up to the 0.3 mm of wear with steps at the contact
Replace parts when the wear of surface.
the spline exceeds the allowable
limit.
8. Overload relief valve section Replace as a subassembly every 10,000 hours according to the main
The pressure check and the machines hour meter.
adjustment of the overload relief
section cannot be done unless
the applicable test bench is
available.

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8021-16
OVERLOAD RELIEF VALVE

Disassembly
NOTE: As a rule, overload relief valve (57) should be handled as one service part. If there are any trouble on over-
load relief valve (57), replace as an assembly.
57-3 57-2 57-1 57-12 57-13 57-4 57-9 57-8 57-12 57-10 57-11 57-6 57-7 57-5
CS02B539
NOTE: Valve seat (57-3) is fitted in bore of socket
(57-1) at clearance fit.
When removing overload relief valve (57), valve seat
(57-3) easily comes off, so take great care not to los
NOTE: When assembling overload relief valve (57) to
rear cover (24), apply grease sufficiently on engage-
ment part not to drop valve seat (57-3), tighten to the
torque specified on page 2.
GREASE
CRPH06D015A

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8021-17
TROUBLESHOOTING
1.Hydraulic motor never starts

SYMPTOM CAUSE REMEDY
Pressure never Malfunction of built-in relief valve. Repair or replace relief valve
increases
Pressure increases 1.Parking brake is not released 1.After inspection of clogging, repair or
Clogging of restrictor replace
2.Parking brake is not released 2.Re-install the spool in correct direc-
Spool is installed in wrong direction tion
3.Stuck friction or separating plate of 3.Replace friction and separating plate
parking brake portion
4.Stuck brake piston 4.Repair outer dia. of brake piston or
replace It.
5.Seizure of sliding piston 5.Check, repair or replace piston shoe,
swash plate, cylinder block valve plate
etc.
6.Malfunction of spool: 6.Repair or replace
- Stick between spool and body
- Clogging of restrictor
2.Hydraulic motor rotates weakly
Set pressure of over- Malfunction of spool: Repair or replace
load valve is - Stick between spool and body
correct, but brake is
released
belatedly
Negative brake is High oil viscosity. Raise oil temperature or change the
released, but hydraulic oil
motor is hard to start
Negative brake is 1.Negative brake is not completely 1.Check clogging of choke
released, but released.
motor starts weakly Clogging of choke of pressure release
passage
2.Relief valve catches small particles 2.Wash relief valve, check or replace
seat of it
3.Seizure of sliding portion 3.Check, repair or replace sliding por-
tion
3.Drive shaft never rotate up to the set value
Rotation of drive shaft 1.Shortage of oil coming in 1.Check oil flow or hydraulic circuit to
never reaches the set motor.
value 2.Large wear or flaw made on shoe, cyl- 2.Check, repair or replace the parts
inder block or valve plate

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8021-18
4.Brake refuses to work

SYMPTOM CAUSE REMEDY
Brake refuses to work Malfunction of negative brake: Check, repair or replace brake piston,
- Worn friction plate. friction plate, spring, etc.
- Broken spring.
Brake works on counter Malfunction of spool: Repair or replace or clean up
lever operation - Stick between spool and body.
- Stick of check valve or that by small
particle.
- Clogging of restrictor.
5.Oil leakage
Oil leakage 1.Loose Hex. socket head bolt or plug 1.Fasten it with given torque
2.O-ring is torn off 2.Replace O-ring
3.Oil leaks inside gear casing 3.Replace oil seal
6.Would not shift from high to low
Would not shift from Stick of spool of pilot valve Replace pilot valve assembly.
high to low
7.Abnormal noise
Abnormal noise appear Malfunction of spool: Bleed air
together with big vibra- - Air is caught inside brake valve
tion when brake is
Stick between spool and body Repair or replace
slowly applied or oil is
supplied to other cir-
cuits while motor is run-
ning
8.Hunting occurs while descending the slope
Severe hunting while Malfunction of spool: Repair or replace
inching 1) Stick between spool and body
1) Restrictor is not seated completely
Interference with parking brake: Repair or replace
1) Permanent set or broken spring

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Section
8030
HYDRAULIC COMPONENT FUNCTIONS
8030

Printed in France
Copyright
8030-2
TABLE OF CONTENTS
HYDRAULIC PUMP ................................................................................................................................................. 2
CONTROL VALVE ................................................................................................................................................... 4
SWING HYDRAULIC MOTOR ............................................................................................................................... 25
TRAVEL HYDRAULIC MOTOR ............................................................................................................................. 31
HYDRAULIC PUMP
Structure and Principle of the Function
This pump is structured to couple two pumps with the spline connection. By transmitting the rotational force from
the engine to the front side drive shaft (111), the two pumps are forced to be driven. The ports for adjusting and
discharging oil are located in valve block; the hitch of two pumps, and the port for adjusting oil is used for both
front and rear pumps. As front and rear pumps have the same configuration and the same principle of the func-
tion, the following explanation is for front pump.
This pump broadly consists of the rotary group which is the main part of the pump governing the rotational
motion, the swash plate group which adjusts the discharge rate, and the valve block group which switched the
intake and discharge of oil.
The rotary group consists of the drive shaft F (111), cylinder block (141), piston shoe (151, 152), retainer (153),
spherical bush (156), and cylinder spring (157). The drive shaft's ends are supported by the bearing (123, 124).
The shoe forms a spherical joint caulked by the piston. It contains a pocket area in order to reduce the thrust
force, which is generated by the loading pressure, and slide lightly on the shoe plate (211). The sub group of the
piston shoe is pressed on the shoe plate by the cylinder spring via the retainer and spherical bush in order to
move smoothly on the shoe plate. The cylinder block is also pressed on the valve plate (313) by the cylinder
spring.
The swash plate group consists of the swash plate (212), shoe plate (211), swash plate support (251), leaning
bush (214), leaning pin (531), and servo piston (532). The swash plate is supported on the swash plate support
by the cylindrical part formed on the opposite side of the shoe sliding side.
When the service piston moves to the right and left due to the regulator controlling hydraulic force being led to
the hydraulic compartment, the swash plate is able to swing the swash plate support and change the leaning
angle (a) via the spherical part of the leaning pin. The hydraulic compartment is located on the both sides of the
servo piston.
The valve block group consists of the valve block (312), valve plate (313), and valve plate in (885). The valve
plate which has two claw shaped ports installed on the valve block. If feeds and collects oil from the cylinder
block. Oil which is switched by the valve plate flows to the external pipe through the valve block.
When the drive shaft is driven by the motor (electric motor, engine, or others), the cylinder block rotates simulta-
neously via the spline connection. If the swash plate is leaned, the piston located inside the cylinder block rotates
with the cylinder block and exerts the reciprocal motions in relation to the cylinder correspondingly. Therefore,
when focusing on one specific piston. In one full rotation, the piston moves toward the direction which is leaving
apart from the valve plate (process of intake oil) during the first 180 degrees, and moves toward the direction
which is coming to the valve plate (process of discharging oil) during the remaining 180 degrees. When the
swash plate's angle is 0 degrees, the piston does not stroke, and therefore, oil will not be discharged.

Copyright
8030-3

Copyright
8030-4
CONTROL VALVE
Operation
1. Operation with all spools in neutral position
(1) Neutral passage (Figures 1 and 2)
Oil supplied from Port P1 enters the tank passage Ta from neutral passage L1, passing the
restriction Lc1 on the low pressure relief, and returns to Ports T1, T2, T3, T4 and T5.
Oil supplied from Port P2 passes the tank passage Ta through neutral passage R1, passing
the restriction Rc1 on the low pressure relief, and returns to Ports T1, T2, T3, T4 and T5.
Pressures in the pressure chambers L2 and R2 located in the upstream of the low pressure
relief valve are directed to the pump through Ports ps1 and ps2 and control the delivery vol-
umes of pumps P1 and P2.
In addition, if a large amount of extra oil flows into the neutral passage, the low pressure relief
mechanism functions to prevent pressures on Ports ps1 and ps2 from increasing abnormally.
LOW PRESSURE LOW PRESSURE

RELIEF VALVE (L) RELIEF VALVE (R)
ARM 1 ARM 2
(SECTION 5) (SECTION 9)
BOOM 2 BOOM 1
SWING BUCKET
BUCKUP TRAVEL
STRAIGHT
TRAVEL TRAVEL
(SECTION 1) (SECTION ST)
Figure 1
NTROL VALVE

8030-5
Issued 02-06
Copyright
Figure 2
ARM VARIABLE
REGENERATIVE
THROTTLE
ARM 1
(SECTION 5) ARM 2
(SECTION 9)
BOOM 2
(SECTION 4) BOOM 1
(SECTION 8)
SWING BUCKET
BUCKUP TRAVEL
STRAIGHT
TRAVEL TRAVEL
(SECTION 1) (SECTION ST)
Lep 9-49210EN
Copyright
8030-6
2. Signal passage (Figures 2 and 3)
Oil supplied from Port PP goes into Port PT through restriction Lc3. At the same time, it flows into
the drain passage DR through the Land Rc3, Passage (6) passing the Land Lc4 and passage (5).
Part of the oil supplied from Port PP goes into Port PA through the restriction Lc5. It also flows into
the drain passage DR through the bucket spool land Rc4, passing the passages L4, (8) and R4.
The oil that passes through the restriction Lc6 flows into the tank passage Ta through the Land Lc7.
It also passes the passage (4) and flows into the tank passage Ta through the travel spool land Rc5.
BUCKUP
(SECTION 2)
TRAVEL
(SECTION 6)
TRAVEL
(SECTION 1)
STRAIGHT
TRAVEL
(SECTION ST)
Figure 3

Copyright
8030-7
Single Operation
1. Travel spool switching (Figure 4)
When switching the travel spool by adding pressure through Pilot Port Pb1 (Pa1) in Travel (Section
1), the oil supplied from Port P1 flows into Port B1 (A1) passing the neck part of the spool via neutral
passage L1. The return oil passes the neck part of the spool via Port A1 (B1) and returns to the tank
passage Ta.
When switching the travel spool by adding pressure through Pilot Port Pb6 (Pa6) in Travel (Section
6), the oil supplied from Port P2 flows into Port B6 (A6) passing the neck part of the spool or pas-
sage S6-1 via neutral passage R1. At this moment, because pressures on parallel passage R3 and
passage S6-1 are equal, the puppet S6-2 does not open. The return oil passes the neck part of the
spool via Port A6 (B6) and returns to the tank passage Ta.
When switching only one side of the spool in Travel (Section 1 or 6), Land Lc4 or Rc3 closes. Since
the flow of oil supplied from Port PP to the tank passage is shut off, the pressure on Port PT increas-
es.
SWITCHED
POSITION
BUCKUP
(SECTION 2)
NEUTRAL
POSITION
TRAVEL
(SECTION 6)
SWITCHED
POSITION
SWITCHED
POSITION
TRAVEL
(SECTION 1)
NEWTRAL
POSITION
STRAIGHT
TRAVEL
(SECTION ST)
Figure 4

Copyright
8030-8
2. Backup spool switching (Figure 4)
When switching the swing spool by adding pressure through Pilot Port Pb2 (Pa2) in Backup (Sec-
tion 2), the neutral passage L1 closes. Oil supplied from Port P1 passes the load check valve S2-
2, the passage S2-1 and the neck part of the spool through the parallel passage L3 and flows into
Port B2 (A2).
The return oil passes the neck part of the spool via Port A2 (B2) and returns to the tank passage Ta.
If oil is supplied from Port P4, it passes the load check valve S2-2 and merges at the passage S2-1.
SWITCHED
POSITION
BUCKUP
(SECTION 2)
NEUTRAL
POSITION
TRAVEL
(SECTION 6)
SWITCHED
POSITION
SWITCHED
POSITION
TRAVEL
(SECTION 1)
NEWTRAL
POSITION
STRAIGHT
TRAVEL
(SECTION ST)
Figure 4

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8030-9
3. Swing spool switching (Figure 5)
When switching the swing spool by adding pressure through Pilot Port Pb3 (Pa3) in Swing (Section
3), the neutral passage L1 closes. Oil supplied from Port P1 passes the load check valve S3-2, the
passage S3-1 and the neck part of the spool through the parallel passage L3 and flows into Port B3
(A3). The return oil passes the neck part of the spool via Port A3 (B3) and returns to the tank pas-
sage Ta.
4. Bucket spool switching (Figure 5)
When switching the bucket spool by adding pressure through Pilot Port Pb7 (Pa7) in Bucket (Sec-
tion 7), the neutral passage R1 closes. Oil supplied from Port P2 passes the load check valve S7-
2, the passage S7-1 and the neck part of the spool through the parallel passage R3 and flows into
Port B7 (A7). The return oil passes the neck part of the spool via Port A7 (B7) and returns to the
tank passage Ta.
SWITCHED
POSITION
SWING
(SECTION 3)
NEUTRAL
POSITION
BUCKET
SWITCHED (SECTION 7)
POSITION
Figure 5

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8030-10
5. Boom spool switching
(1) Neutral position (Figure 6)
This valve has an anti-drift valve installed on the cylinder bottom side of the Boom 1. When in
neutral position, the puppet AD1 is firmly seated by the pressure on Port A8 that is directed
to the spring chamber AD4 through the passage AD2 and spool AD3.
NEUTRAL
BOOM 2
(SECTION 4)
BOOM 1
(SECTION 8)
Figure 6

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8030-11
(2) Boom-up (2-pump confluence) (Figure 7)
When switching the boom 1 spool by adding pressure through Pilot Port Pa8 in Boom 1 (Sec-
tion 8), neutral passage R1 closes. Oil supplied from Port P2 passes the parallel passage R3,
the load check valve S8-2, and the neck part of the spool and flows into Port A8. When switch-
ing the boom 2 spool by adding pressure through Pilot Port Pb4 also in Boom 2 (Section 4),
the neutral passage L1 closes. Oil supplied from Port P1 passes the parallel passage L3, the
load check valve S4-2, the neck part of the spool and passage (6), and merges and flows into
Port A8. The return oil passes the neck part of the spool via Port B8 and returns to the tank
passage Ta.
UP (2-PUMP CONFKUENCE)
BOOM 2
(SECTION 4)
BOOM 1
(SECTION 8)
Figure 7

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8030-12
(3) Boom-down (regeneration) (Figure 8)
When switching the boom 1 spool by adding pressure through Pilot Port Pb8 in Boom 1 (Sec-
tion 8), the neutral passage R1 closes. Oil supplied from Port P2 passes the parallel passage
R3, the load check valve S8-2 and the neck part of the spool and flows into Port B8. When
switching the spool AD3 in the anti-drift valve by adding pressure to Port Pc2 and reducing
the pressure in spring chamber AD4 at the same time, the puppet AD1 opens and the return
oil from Port A8 returns to tank passage Ta. Part of the return oil pushes open the puppet S8-
3 in boom 1 spool, passing the passage S8-1 and merging into Port B8 to prevent cavitation
on the cylinder rod side.
DOWN (REGENERATION)
BOOM 2
(SECTION 4)
BOOM 1
(SECTION 8)
Figure 8

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8030-13
6. Arm spool switching
(1) Neutral position (Figure 9)
This valve has an anti-drift valve installed on the cylinder rod side of Arm 1.
When in neutral position, the puppet AD1 is firmly seated by the pressure on Port A5 that is
directed to the spring chamber AD4 through the passage AD2 and spool AD3.
NEUTRAL
ARM 1
(SECTION 5)
ARM 2
(SECTION 9)
Figure 9

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8030-14
(2) Arm-in (2-pump confluence) (Figure 10)
When switching the arm 1 spool by adding pressure through Pilot Port Pb5 in Arm 1 (Section
5), the oil supplied from Port P1 flows into Port B5 passing the load check valve S5-2, the pas-
sage S5-1 and the neck part of the spool via the neutral passage L1. When switching the arm
2 spool by adding pressure through Pilot Port Pb9 also in Arm 2 (Section 9), the oil supplied
from Port P2 passes the load check valve S9-2, the passage S9-1, the neck part of the spool,
and the passage (9) from the neutral passage R1 and flows into Port B5 to merge.
The return oil from Port A5 passes the regenerative check in the spool, and is then divided
into two flows: one goes through the regeneration process at Port B5 and the other passes
the regenerative relief valve and returns to the tank passage Ta.
ARM-IN (2-PUMP CONFLUENCE)
ARM 1
(SECTION 5)
TO REGENERATIIVE RELIEF VALVE
ARM 2
(SECTION 9)
Figure 10

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8030-15
(3) Arm-in (variable regeneration) (Figure 11)
For Arm-in operation, return oil (a) from Port A5 is divided into the following two flows after
passing the notch (a): One flow returns to the tank passage Ta, after passing the fixed restric-
tion (d) in the regenerative relief valve, passage (e) and variable restriction (f). The other flow
merges at the bridge passage (S5-1) after passing the fixed restriction (b) in the arm 1 spool,
regenerative check (c), and fixed restriction (i).
At this time, if the load pressure rises at Port B5, the regenerative relief valve spool (h) is
pushed through the regenerative relief valve piston (g). This increases the open area in the
variable restriction section. As a result, the oil volume of return oil to the tank passage Ta in-
creases. On the other hand, the oil volume regenerating at Port B5 decreases.
ARM-IN (VARIABLE REGENERATION)
ARM 1
(SECTION 5)
REGENERATIVE RELIEF
VALVE (VARIABLE)
Figure 11

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8030-16
(4) Arm-out (2-pump confluence) (Figure 12)
When switching the arm 1 spool by adding pressure through Pilot Port Pa5 in Arm 1 (Section
5), the oil supplied from Port P1 flows into Port A5 passing the load check valve S5-2, the pas-
sage S5-1 and the neck part of the spool via the neutral passage L1. When switching the arm
2 spool by adding pressure through Pilot Port Pa9 also in Arm 2 (Section 9), the oil supplied
from Port P2 passes the load check valve S9-2, the passage S9-1 and the neck part of the
spool from neutral passage R1 and flows into Port A5 to merge.
The return oil from Port B5 passes the neck of the spool and returns to the tank passage Ta.
ARM-OUT (2-PUMP CONFLUENCE)
ARM 1
(SECTION 5)
ARM 2
(SECTION 9)
Figure 12

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8030-17
7. Parallel restriction for arm (Figure 13)
A restriction is installed in the parallel passage for the arm 1 use, which controls the arm speed while
performing a complex operation.
Oil supplied from the parallel passage L3 in Arm 1 (Section 5) pushes the puppet S5-3 open and
communicates with passage L4 (Figure 2) after passing the spool Lc8 in the variable restriction
spool.
At this time, the volume on the restriction can be changed by applying pressure to the Pilot Pbu.
BOOM-UP POSITION
(Pbu IS PRESSURIZED)
NORMAL
SIGNAL PASSAGE
Figure 13

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8030-18
8. Relief valve
(1) Main relief valve (Figure 14)
Oil supplied from Port P1 passes the puppet LP while oil supplied from Port P2 passes the
puppet RP, passage (3) and they are introduced into the main relief valve. When the main
relief valve is activated, the maximum pressure of the pump on both P1 and P2 sides is con-
trolled.
(2) Overload relief valve
An overload relief valve is installed on each cylinder port of boom 1, arm 1 and bucket, which
prevents abnormal increases in pressure on the actuator due to the external force.
In addition, this relief valve also has a function to prevent cavitation by sucking oil from the
tank when the pressure in the cylinder port becomes negative (suction feature).
Figure 14

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8030-19
Combined Operation
1. Travel combined operation (Figure 15)
If operation other than travel is carried out at the same time while performing simultaneous travel
left/right operation (at the time of forward or backward movement or pivot turn), or if simultaneous
travel left/right is carried out while performing operation other than travel, oil supplied from Port PP
is shut off from tank passage Ta at the signal land other than the travel section which has switched
Lc4, Lc7, Rc3 and Rc5. As a result, the pressure in the signal passage rises to the set relief pressure
for the oil pressure source used for signals.
Due to rising signal pressure, the straight travel spool is switched over. The pressures on Port PT
and PA also increase.
When the straight travel spool is switched over, oil supplied from Port P1 flows into Travel (Section
1) from the neutral passage L1, and at the same time it passes the passage (2), the neck of straight
travel spool, and the neutral passage R1 and flows into Travel (Section 6). Oil supplied from Port 2
passes through the neck of the straight travel spool and passage (1) and flows into the parallel pas-
sage L3.
If the load pressure on sections other than travel is higher than the load pressure on Travel (Section
6), part of the oil supplied from Port P2 pushes open puppet S6-2 and passes the restriction at the
tip of the puppet to merge at passage S6-1.
Because Travels (Section 1 and 6) operate with oil supplied from Port P1 while operational devices
other than Travels operate with oil from Port P2, even when the machine is in combined operations
of simultaneous travel left/right and other operations, curved travel is prevented.
TRAVEL
(SECTION 6)
TRAVEL
(SECTION 1)
STRAIGHT TRAVEL
(SECTION ST)
Figure 15

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8030-20
Anti-drift Valve
Anti-drift valves are attached on the arm (boom) cylinder side at the side of the arm rod (boom bottom)
in order to prevent the arm (boom) cylinder from its natural drop. (As a typical example, an arm side
A5 is shown below.)
1. Neutral state (Port A5 - holding state)
[1] The holding pressure at Port A5 pass-
es through passage (a), passage (b)
and passage (c) in this order and com-
municates with the spring chamber (d)
of the puppet (1).
[2] Due to this mechanism, the pressure
oil in the Port A5 is firmly locked by the
seat sections S1 and S2.
MAIN
SPOOL
2. Shut-off of continuity between Port A5 and spring chamber

[1] When adding pressure to the Port pc1,
the piston (2) moves and the spool (3)
operates.
[2] The spool (3) activates the puppet (4).
[3] Through the activation of the puppet
(4), the continuity between Port A5 and
spring chamber (d) is shut off by sec-
tion T1.
MAIN
SPOOL
3. Main puppet activated

[1] When the piston (2) operates, the
spring chamber (d) communicates with
the drain chamber DR through the pas-
sage (c) and passage (e) by section
T2.
[2] The pressure in the spring chamber (d)
becomes equal to drain pressure and
the main puppet (1) becomes activat-
ed.
MAIN
SPOOL

Copyright
8030-21
Relief Valve
1. Operation of the main relief valve
[1] This relief valve is integrated between
the neutral passage HP and low pres-
sure passage LP, and oil passes the
orifice in the puppet (C) and fills the in-
ternal space (D).
The sleeve (E) and main puppet (C) act
on different areas (A and B). They are
firmly seated.
[2] If the pressure in the neutral passage

HP reaches the set spring force of the
pilot puppet, the pilot puppet (F)
opens.
The oil flows around the puppet and
drilled hole (G) and is directed into the
low pressure passage LP.
[3] Since the pilot puppet has been

opened, the pressure in (D) reduces
and the main puppet (C) opens. As a
result, the oil flows directly into the
passage LP.
Boost operation
When applying pressure to the pilot port
PH, the piston (H) moves to the set position
by plug (I). Due to this, the pilot spring force
rises and the pressure in HP rises.

Copyright
8030-22
2. Operation of the overload relief valve
[1] This relief valve is integrated between
the cylinder port HP and low pressure
passage LP, and oil passes the orifice
in the piston (C) and fills the internal
space (G).
The sleeve (K) and main puppet (D)
act on the different areas (A) and (B).
They are firmly seated.
[2] When the pressure in the cylinder port

HP reaches the set spring force of the
pilot puppet, the pilot puppet (E)
opens.
The oil flows around the puppet and
drilled hole (H) and is directed into the
low pressure passage LP.
[3] Since the pilot puppet (E) has been

opened, a flow passing orifice (I) in the
piston (C) is generated. This flow pro-
duces a differential pressure between
the passage HP and the backside of
the piston (C). This moves the piston
(C) until it seats on the puppet (E).
[4] The oil flow from the passage HP to

the backside of the puppet (D) is only
through the puppet (D), annular space
in the piston (C) and the orifice (F). As
a result, the differential pressure in-
creases. Due to this, the puppet (D)
opens, and the oil flows directly into
the passage LP.

Copyright
8030-23
3. Draw-in-oil feature of the overload relief valve
[1] This relief valve has an anti-void unit
incorporated. This unit supplies oil to
the cylinder port HP when cavitation
takes place.
When the pressure in the cylinder port
HP is lower than the low pressure side
LP, the differential pressure between
(A) and (B) opens the sleeve (K). As a
result, oil enters the cylinder port HP
through the low pressure side LP and
this prevents cavitation.
4. Function of low-pressure relief valve

(1) Generation of signal pressure
Hydraulic oil supplied from the pump port (P1 [P2]) passes through the neutral passage (L1
[R1]), the low-pressure passage (L2 [R2]) and the orifice (Lc1 [Rc1]) to flow out to the tank
passage (Ta).
At this time, the pressure generated in the passage (L2 [R2]) by the orifice (Lc1 [Rc1]) is di-
rected to the low-pressure relief signal port (Ps1 [Ps2]).
When the main spool in upper course of the passage (L2 [R2]) is actuated, hydraulic oil flow-
ing through the passage (L2 [R2]) reduces which in turn signal pressure in the signal port (Ps1
[Ps2]) decreases.
PUPPET

Copyright
8030-24
(5) Relief function
When excessive oil flows through the passage (L2 [R2]), the pressure generated in the pas-
sage (L2 [R2]) by the orifice (Lc1 [Rc1]) is introduced in the back-chamber of the puppet and
as a result, the puppet is actuated by difference in pressure receiving area between the pas-
sage and the back-chamber.
The actuation of the puppet allows the oil to flow from the passage through the drilled hole in
the plug flowing out to the tank passage (Ta).
This prevents an excessive pressure from being generated in the low-pressure relief signal
port.
PUPPET

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8030-25
SWING HYDRAULIC MOTOR

Configuration of Components
SWASH PLATE TYPE AXIAL PISTON MOTOR
MECHANICAL BRAKE
MAKEUP VALVE
RELIEF VALVE
BYPASS VALVE
NOTE: Numbers in parentheses in the following text correspond to the circled numbers in the Internal
structural drawings.
Structure of Hydraulic Motor
The rotary component group is composed of a drive shaft integrated type cylinder (27) and nine piston
assemblies (8) arranged in the cylinder (27). Additionally, both ends of the cylinder (27) are supported
with bearings (4) and (25). Piston assemblies (8) are guided by return plates (6) and spring bearings
(7) so that they can slide on the cam plates (5) smoothly.
The balance plate (24) is pressed against the end face of cylinder (27) by the force of coned disc spring
(17) and hydraulic pressure acting on the bushing (15).
Mechanical brakes (9), (10), (11) and (14) that are used as parking brakes are installed between the
circumference of cylinder (27) and the housing (28).
Also, a relief valve (31) as cushion and makeup valves (35), (36) and (39) for preventing cavitation are
built in the cover section (29). In order to prevent swinging-back when swing operation is stopped, a
bypass valve (43) is integrated into the cover (29).
Operational Description of Hydraulic Motor

Hydraulic oil supplied from the pump via the control and other valves enters from Port A (or Port B) on
the cover (29) and is discharged from Port B (or Port A). Oil leaked from gaps in each sliding part is
returned to the tank through the drain Port "a" on the cover (29).
The pressurized oil supplied to Port A is supplied to the piston hole "f" in the cylinder (27), passing the
following components in order: passage "b" in the cover (29), passage "c" on the bushing (15) section
on the cover (29), passage "d" on the balance plate (24) which has a crescent-shaped port switching
between supply and discharge every 180? per one motor turn, as well as, passage "e" on the cylinder
(27).
The oil pressure acts on piston assembly (8), resulting in piston assembly (8) being pressed to the cam
plate (5) via the shoe section. Because the sliding face of the shoe on cam plate (5) is inclined at a
given angle, the pressing force on the piston assembly (8) to which the oil pressure pushes, is trans-
formed into a force that slides the shoe on the swash plate. Because the spherical shoe section of pis-
ton assembly (8) is connected so that it works as a universal joint, the shoe's sliding force on the swash
plate is transferred to the motor output shaft as a turning force via the piston assembly (8) and cylinder
assembly (27).

Copyright
8030-26
As mentioned above, each piston assembly (8) receives the pressurized oil while it travels the stroke
from the top dead center to the bottom dead center of the incline plane and transforms it into a turning
force to revolve cylinder assembly (27) and discharges oil while it travels the stroke from the bottom
dead center to the top dead center. The discharge route is the reverse of the supply route described
above and the oil is discharged from Port B.
The hydraulic motor operates in the manner as described above. Its output torque and the number of
revolutions are determined according to the hydraulic force and the volume of oil supplied respectively.
Operational Description of Mechanical Brake

Friction plate (9) is connected to the circumference of cylinder assembly (27) via spline. Also, the coun-
terpart plate (10) is connected to the housing (28). When the pressure in the mechanical brake release
chamber is zero, the cylinder assembly (27) (output shaft) is locked and will not turn as a result of the
brake piston (11) pressing the counterpart plate (10) and friction plate (9) through the spring force (14).
In the opposite manner, when the oil pressure of 2.9 to 4.9 MPa is reached on the brake release cham-
ber, the brake piston (11) overcomes the force and moves until it hits the end face of the cover (29),
creating space between friction plate (9) and counterpart plate (10). As a result, the mechanical brake
turns to a released status.
Operational Description of Make-up Valve

1. Half-braking condition (a state where relief valve (31) is not in operation)
When decelerating the swing body through the control valve using the half-lever function after ac-
celerating the swing body, the supply volume to Port A from the pump decreases but it is necessary
to supplement oil when the swing body is rotating at a relatively high speed because the pressure
applied to the "c" section tends to become negative due to motor's pumping action.
However, because the whole volume of oil which flows into "c" section from Port A is discharged into
control valve via Port B when the pressure on Port B is lower than the working pressure of relief valve
(31), the absolutely necessary oil volume at the "c" section is not met with the oil volume from the
control valve alone (as the valve is in the half-lever position, the oil volume is still restricted). To pre-
vent this, makeup check (39) is provided to supplement "c" section to make up for a lack of oil
through the makeup port.
2. Full braking condition (a state where relief valve (31) is in operation)
When changing to the neutral position from condition A by quick lever operation, the swing body is
turned by inertial force even though the oil supply volume from the pump to Port A becomes zero.
In this case, relief valve (31) on the Port B side operates, and the oil, which blew off the relief, passes
oil passages "g" and "h", presses open the makeup check (39) on Port A and is supplemented to the
passages "b" and "c". However, the oil lacks by its volume that which has leaked into the case drain
of the motor. To prevent this, the makeup check (39) is opened from the makeup port and the oil
flows into the passages "b" and "c" in order to prevent cavitation.

Copyright
8030-27
Operational Description of Relief Valve

(Internal structural drawing of relief valve)
1. When starting
The hydraulic oil supplied from Port A by operating the control valve does not immediately reach
the constant revolution level due to the large inertial force of the swing body. Part of the oil passes
oil passages "g" and "h" via relief valve (31) that works as a safety valve, presses open the check
(39) on Port B side and flows into Port B.
Oil in Port A presses open the poppet (47) by counteracting the force of spring (48), passes passage
"g" via a space between seat (46) and poppet (47) and flows into passage "h".
2. When braking (at time of cushioning)
When the control valve is returned to the neutral position, the return passage for the motor's drain
oil closes. Immediately after this operation, the motor is turned by large inertial force and attempts
to suck oil through Port A by pumping action and to discharge it to Port B. As a result, the pressure
on Port B increases because the return passage in the control valve is closed.
As the increased pressure on Port B presses open poppet (47) by counteracting the force of spring
(48), the oil flows into passage "c" by pressing open the makeup check (39) via oil passages "g" and
"h" through Port B. In this process, the inertial force of the swing body is absorbed and the swing
body comes to a stop.
Also, in the pressure increasing process above mentioned, the highly pressurized oil that flowed into
the front chamber of poppet (47) enters the piston chamber passing the small hole passage on the
central section of piston (52) via circumferential orifice "j" of poppet (47) and moves piston (52) until
it hits the end face of sleeve (51). Meanwhile, since poppet (47) is already forcedly opened, the
cushion relief begins to work at relatively low pressure, and then increases to a specified pressure
in minimal time. This dual-step action decreases the impact of motor starts and stops.
Operational Description of Bypass Valve
(Internal structural drawing of bypass valve)
When attempting to stop the swing body after operating the control valve to drive the swing body, brak-
ing pressure is generated on one side of the port as the hydraulic motor, which keeps rotating due to
its inertial force, continues its pumping action.
Suppose that this is Port A: This pressurized oil for braking flows into the back chamber of check (60)
on the Side A via small holes (a3) and (a2). As a result, the check (60) on Side A moves until it contacts
and presses seat (58) on Side A to shut off the bypass passage by pushing check (60) on Side B, which
is arranged as a counterpart, to the left in the process of decelerating the swing body. In due course,
the swing body stops once but reverses due to braking pressure. Therefore, the pressure on Side B
increases and check (60) on Side B attempts to move to the right by pushing check (60) on Side A,
which is arranged as a counterpart. However, this movement of check (60) is a little delayed because
the oil flow of the back chamber in check (60) on Side A is gently controlled through the action of the
flow control valve comprised of poppet (61) on Side A and spring (62) on Side A. In the meantime, the
pressurized oil of Port B flows into the intermediate chamber via small hole "b1" and bypasses Port A
side via small hole "a1". Subsequently, check (60) on Side B contacts and presses seat (58) on Side
B and moves to the position where it can shut off the bypass passage. As described above, the reverse
motion will be prevented without any trapping of the oil because the pressure is bypassed to Port A
side in the process of generating reverse pressure on the Port B side.

Copyright
8030-28
Internal Structural Drawing

Copyright
8030-29
Internal Structural Drawing of Externally Adjusted Shockless Relief Valve
Internal Structural Drawing of Bypass Valve

Copyright
8030-30
TRAVEL HYDRAULIC MOTOR

Structure
Figure 1. Structure drawing of travel motor
SYM PART NAME SYM PART NAME SYM PART NAME

1 casing 21 brake piston 41 restrictor spring (brake valve)
2 NPT1/16 plug 22 D-ring (small dia.) 42 G1/8 Plug
3 oil seal 23 D-ring (big dia.) 43 O-ring 1B P8
4 retaining ring IRTW68 24 rear cover 44 check valve
5 expander plug 25 NPT1/16 plug (MEC) 45 check valve spring
6 shifter piston 26 spool assy 46 M6 restrictor (0.6)
7 piston seal 27 spring holder 47 O-ring 1B P12.5
8 steel ball 28 spring 48 M6 restrictor (0.8)
9 shaft 29 M42 plug 49 O-ring 1B P15
10 bearing HR33209J 30 O-ring 1B G40 50 O-ring 215.57 x 2.62
11 pivot 31 pilot valve spool 51 bearing HR32207C
12 swash plate 32 pin 52 shim
13 cylinder block 33 spring holder 53 parallel pin
14 cylinder spring 34 spring 54 valve plate
15 spring holder 35 G3/8 pilot valve plug 55 brake spring
16 ball joint 36 O-ring 1B P14 56 HEX. socket head bolt M18 x 50
17 shoe retainer 37 connector 57 overload relief valve
18 piston assy 38 G1/4 Plug 58 coupling
19 separating plate 39 O-ring 1B P11 59 retaining ring C-type 40
20 friction plate 40 restrictor (brake valve) 60 G1/2 Plug
61 O-ring 1B P18
Table 1. Parts list of travel motor

Copyright
8030-31
Brief Explanation of Structure

The motor mainly consists of the following parts:
-Rotary group producing turning force to drive shaft
-Parking brake preventing host machine from self-running during its rest
-Capacity control parts that changes the motor capacity consequently rotating speed
-Overload relief valve that is attached to the rear cover
-Brake valve (counter balance valve) portion that control the hydraulic circuit
1. Rotary Group
The cylinder block (13) is inserted into the spline of shaft (9), both ends of which are supported by
bearings (10), (51). This cylinder block (13) is pushed toward the rear cover (24) together with valve
plate (54) by cylinder spring (14).
Nine pieces of piston assy (18) slide inside the cylinder block (13) along the surface of swash plate
(12). Hydrostatic bearings are provided on the end surface of piston assy (1 8) to reduce the sliding
resistance, and the ends of piston assy (18) are pushed toward swash plate (12) by cylinder spring
(14) through spring holder (15), ball joint (16) and shoe retainer (17).
2. Parking brake
Seven pieces of separating plates (19) and six pieces of friction plates (20) are alternately set on
the spline of cylinder block (13) and pushed together by 14 brake springs (55) through brake piston
(21).
3. Capacity control portion (refer to P.7/12)

They consist of: pivots (11) that support swash plate (12) and slide in two half-spherical recesses
in swash plate (12): shifter piston (6) that change the angle of swash plate (12) on the pivots (11):
stopper (1-1)of casing that limits the angle of swash plate (12): pilot valve portion that leads the oil
to shifter piston (6) by external pilot signal: three check valves (44) that select the maximum pres-
sure from the external pilot pressure, inlet pressure and outlet pressure of the motor and send it to
pilot valve portion.

Copyright
8030-32
4. Overload relief valve
This valve is screwed in the motor rear cover (24) and consists of: socket (57-1) that is screwed and
fixed in the rear cover (24) and supports the valve seat (57-3) which metallically seated in the hole
of rear cover (24): valve (57-2) that contact with valve seat (57-3) by adjusting spring (57-9) and
fitted in the hole of socket (57-1): coupling piston (57-4) that fitted in the hole of the valve (57-2) and
functions also as an oil passage: piston (57-7) that is inserted in the pilot body (57-6) and: shim (57-
8) that adjust the spring force.
Figure 2. Structure drawing of overload relief valve
SYM PART NAME SYM PART NAME

57-1 Socket 57-8 Shim
57-2 Valve 57-9 Adjusting spring
57-3 Valve seat 57-10 O-ring 1B P7
57-4 Coupling Piston 57-11 Back-up ring T2 P7
57-5 Cap 57-12 O-ring 1B G25
57-6 Pilot Body 57-13 Back-up ring T2 G25
57-7 Piston
Table 2. Parts list of overload relief valve

Copyright
8030-33
5. Brake valve portion
Spool control pressure: 0.59 to 0.95 MPa
Check valve cracking pressure: 0.015 MPa
Figure 3. Brake valve portion
The brake valve portion mainly consists of the following parts:

[1] spool
By shifting the spool (26), the discharged oil from hydraulic motor is automatically shut off or re-
stricted according to the condition and give the effect of holding, accelerating, stopping and coun-
terbalance operations.
[2] Check valve (built in the spool)
This valve is located in the oil supplying passage to hydraulic motor, and at the same time func-
tions to lock oil displacement. Therefore, this valve serves as not only a suction valve but also a
holding valve for hydraulic motor.

Copyright
8030-34
Function
Inlet Outlet Direction of Rotation

Port Port (Viewing from rear cover)
VB VA Right (clockwise)
VA VB Left (counterclockwise)
Figure 4. Location parts
1. Operation of motor
High pressure oil delivered from hydraulic pump is led to inlet port that is provided in the brake valve
portion and, through the rear cover (24) and valve plate (54), led to cylinder block (13).
The oil flow and direction of shaft rotation are indicated in Figure 4.
Figure 5. (a) Figure 5. (b)

As shown in Figure 5(a), high pressure oil is supplied to the pistons which are on one side of the
line Y-Y that connects upper and lower dead points and produces force F1
F1 = P x A (P : pressure, A : area of piston section)
The swash plate (12) with inclined angle of divides this force F1 into thrust force F2 and radial
force F31-F34 (or F35). (Figure 5 (b)) This radial force is applied to axis Y-Y as turning force and
generate drive torque of T
T=r1 F31 + r2 F32 + r3 F33 + r4 F34
(In case high pressure oil is applied to five pieces of pistons, r5 F35 should be added.)
This drive torque is transmitted via cylinder block (13) to driving shaft (9).

Copyright
8030-35
2. Operation of parking brake
Parking brake is released when high pressure oil, selected by the brake valve portion that is con-
nected directly to the rear cover (24), is applied to the brake piston (21).
Otherwise the braking torque is always applied.
This braking torque is generated by the friction between the separating plates (19), inserted into the
casing (1), and friction plates (20), coupled to cylinder block (13) by the outer splines.
When no pressure is activated on the brake piston (21), it is pushed by the brake springs (55) and
it pushes friction plates (20) and separating plates (19) towards casing (1) and generates the friction
force which brakes the rotation of cylinder block(13) and hence the shaft (9).
Figure 6. Parking brake portion

Copyright
8030-36
3. Operation of capacity variable mechanism
Figure 7. Operation of capacity variable mechanism
Figure 7 typically shows the capacity variable mechanism.

When high speed pilot line is charged with the pressure PA that overcome the spring (34), the spring
(34) is compressed and spool (3 1) shifts to the right to connect the port P and port C.
Then, the highest pressure is selected by the check valve (44) from inlet and outlet pressure of the
motor and high speed pilot line pressure and pushes shifter piston (6). As a result, swash plate (12)
turns around the line L which connect the two pivots (11) as shown by dotted lines. The turn stops
at the stopper (1-1) of casing and swash plate (12) keeps the position.
In this case, the piston stroke become shorter and motor capacity become smaller and motor ro-
tates faster, around 1.71 times, by the same volume of oil.
When no pressure is in the high speed pilot line PA, spool (31) is pushed back by the spring (34)
and pressure that pressed the shifter piston (6) is released to the hydraulic tank through restrictor
(46).
Here, nine pistons are there and they equally spaced on the swash plate (12). The force that
summed up those of pistons comes to almost the center of the swash plate (12) as shown. Since
the pivots (11) are off-set by S from the center, the rotating force of product S and the force moves
swash plate (12) to the former position and the speed returns to low.
When the power demand exceeds the engine power, such as in steep slope climbing or turning at
high speed mode, the system step down to the low speed automatically. The mechanism is that:
pump pressure is led to the port PB (Figure 7). and this pressure activate on pin (32). When the pres-
sure at PB exceeds predetermined value, spool (31) returns to the left by the counter-pressure
against pin (32) and the pressure on the shifter piston (6) through port C is released to the tank and
the motor comes to low speed.
When PB goes down, the spool (31) moves to the right and the speed become high.

Copyright
8030-37
4. Operation of overload relief valve
Two pieces of overload valves are located at cross-over position in the counterbalance circuit of
brake valve and have the following functions:
[1] When hydraulic motor starts, keep the driving pressure below predetermined value and while ac-
celerating, bypasses surplus oil to return line.
[2] When stopping the motor, keep the brake pressure, that develops on the outlet side of motor, un-
der the predetermined value to stop the inertial force.
[3] To accelerate sharply while starting, and to mitigate the braking shock while stopping. For these
purposes, the developed pressure is kept comparatively low for a short period, then keep the line
pressure as normal value. While the pressure is low, meshing of reduction gears, crawler and
sprocket etc. can be smoothly done and the shock are absorbed.
When starting, "A" port pressure of overload valve increases, this pressure is applied to the effective
diameter of valve (57-2) which seats on the valve seat (57-3) and, at the same time, is delivered,
via small hole, to the connecting piston (57-4) located inside the valve (57-2) and the piston bore
pressure increases up to "A" port pressure. The valve (57-2) opposes to adjusting spring (57-9) by
the force of the pressure exerted on the area difference between valve seat's effective diameter and
piston bore and keep the predetermined pressure.
When hydraulically braking, the piston (57-7) is at the left position by the driving pressure, and when
"A" port pressure increases, the pressure is applied also to the piston (57-7) through the small hole
in the valve (57-2) and connecting piston (57-4) moves rightward until it touches the cap (57-5). In
this while, the valve (57-2) maintains "A" port pressure at comparatively low against the adjusting
spring (57-9) force and exhaust oil to "B" port side. After the piston reached to the plug, the valve
acts the same as at starting.
Figure 8. Operation of overload relief valve

Copyright
8030-38
5. Operation of brake valve
(1) Holding status (see Figure 9)
When the control valve is at neutral position, VA and VB ports are connected to the tank, and
the spring (28) located on both spool ends holds the spool (26) at central position.
Therefore, the passages from VA to MA and VB to MB are closed, which result in closing MA
and MB ports connected to hydraulic motor.
Since the passage to parking brake is connected to the tank line, the brake cylinder pressure
is equal to the tank pressure and the brake is applied by the springs. Thus, the rotation of the
motor is mechanically prevented.
If external torque is exerted on the motor shaft, the motor would not rotate as usual by this
negative parking brake.
In case the brake should be released for some reason, pressure is built on MA or MB port.
But, due to oil leakage inside hydraulic motor or so, high-pressure oil escapes from the closed
circuit and motor rotates a bit. So, the cavitation tends to occur in the lower pressure side of
the closed circuit. Then, the check valve, built in the spool (26), operates to avoid the cavita-
tion and opens the passage from VA to MA or from VB to MB. Then the oil equivalent to the
leakage is sucked from the tank line to the closed circuit.
Figure 9. Holding status

Copyright
8030-39
(2) Accelerating operation (see Figure 10)
When VA and VB ports are connected respectively to pump and tank by operating the control
valve, hydraulic oil from pump is forwarded through VA port to push open the check valve pro-
vided inside spool (26), and oil flows to motor via MA port to rotate the motor.
Therefore, the pressure increases and negative brake is released by the pressure supplied
from pump. At the same time, the pressure of pilot chamber increases to push and move the
spool (26) left wards, overcoming the spring (28) force. Thus, the return line from MB to VB
opens to rotate the motor.
In case inertia load is too big to start rotation, accelerating pressure reaches the set pressure
of relief valve and high pressure oil is being relieved while the motor gains the rotational
speed. As the rotational speed goes up. the relieved volume decreases, and finally the motor
rotates at a fixed speed.
Figure 10. Accelerating operation

Copyright
8030-40
(3) Stopping operation (see Figure 11)
Returning the control valve to neutral position while running the motor, the oil supply is cut off
and VA and VB ports are connected to the tank line. Then the pressure of the pilot chamber
located on both spool ends become equal, and the spool (26) returns to the neutral position
by spring (28) force. Thus, the passage from MA to VA is closed.
Owing to the inertia force of the load, the hydraulic motor tends to continue the rotation. Here,
the motor functions as a pump and forwards the oil to MB port but the passage is blocked and
MB port pressure increases. Then the relief valve opens to relieve the pressure and rotational
speed decelerates and at last the motor stops.
Negative brake release pressure is gradually lowered due to the restrictor and finally the brake
works and the motor is mechanically stopped.
Figure 11. Stopping operation

Copyright
8030-41
(4) Counterbalance operation (see Figure 12)
Counterbalance operation is required to decelerate slowly the hydraulic motor while absorb-
ing inertia force.
In case the hydraulic oil is gradually decreased from pump to VB port, the drive shaft of hy-
draulic motor tends to rotate faster than that matched to the volume of oil supply.
Consequently, the pilot chamber pressure on MB to VB side decreases and the spring (28)
force moves the spool (26) left wards towards neutral position.
Therefore, the area of passage from MA to VA becomes smaller and the pressure on MA side
rises due to increased resistance in the passage and the motor receives hydraulic braking ef-
fect.
If the motor rotates slower than that matched to the volume of supplied oil, the pilot chamber
pressure on VB port increases, and spool (26) moves right wards to enlarge the area of pas-
sage from MA to VA. Therefore the braking effect becomes smaller and the rotational speed
of motor is controlled to correspond to the volume of supplied oil.
In order to give stable counterbalance operation, the restrictors (40) are set in the pilot cham-
ber to damp the spool (26) movement.
The parking brake is released during pressure adjusting action of the spool (26).
Figure 12. Counterbalance operation

Copyright
8030-42
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 ........................................................................................................................................................... 11

See Section 1002.
SPECIFICATIONS
Weight ............................................................................................................................................See Section 1002

Copyright
9002-3
UPPERSTRUCTURE
Inspection
STEP 1 STEP 5
Checking the turntable
If the upperstructure does not revolve properly or
creaks, this shows that the turntable is worn or dam-
aged. If the upperstructure pauses before revolving,
this shows that the crown wheel of the turntable is
damaged. When an operator is working with the
machine, he must pay attention to any unusual
noises which could indicate turntable wear. If the
operator hears unusual noises and if the upperstruc-
ture pauses before revolving, he must carry out the 1
following inspection.
STEP 2 2
Park the machine on hard, level ground. Lower the
STEP 3 3
CS02C505
Remove the three screws (1) that fasten the access
shut down the engine.
door (2) to the machine. Remove the access door (2).
STEP 4 Remove and discard the seal (3) from the access
door (2).
STEP 6
WARNING: If your hand is in the access port

of the crown wheel when the upperstructure is
revolving, you could get seriously injured.
Before applying grease by hand on the crown
! wheel, always check that the bucket or the
tool is placed on the ground and that the
engine is shut down.
Ask an assistant to help you operate the swing mech-

anism, check for scratches, missing teeth, scaling,
cracks or other damage on the crown wheel using a
pocket light. In case of damage, refer to "Removing
1 the upperstructure" and change the turntable of the
upperstructure.
CI00F500
Remove the screws (1) that attach the lower housing STEP 7
to the machine and remove the lower housing. Install a new seal (3) on the access door and install
the access door (2) on the machine using screws (1).

Copyright
9002-4
STEP 8 STEP 4
Install the lower housing on the machine using
screws and plate washers.
Removal
STEP 1
CD01K077A
Remove the lower access plate from the fuel reser-
voir. Place a container beneath the drain valve of the
fuel reservoir. Open the drain valve and drain the
JS00163A fuel.
attachment to the ground. NOTE: See Section 1002 for the capacity of the fuel
reservoir.
STEP 2
STEP 5
Release pressure in the hydraulic system and in the
STEP 3
2
1
CRPH06C011A
Remove the lower access plate (2) from the hydraulic
CT05L063
reservoir. Place a container beneath the bleed screw
Open the left-hand side door. Disconnect the earth
of the hydraulic reservoir. Remove the bleed screw
cable (1) from the battery. Close the LH side door.
and drain the hydraulic fluid into the container.
NOTE: See Section 1002 for the capacity of the
hydraulic reservoir and the capacity of the entire sys-
tem.
STEP 6
Refer to Section 8006 and remove the hydraulic
swivel.
STEP 7
Refer to Section 9003 and remove the bucket, the
dipper and the boom.

Copyright
9002-5
STEP 8 STEP 14
Refer to page 10 in this Section and remove the Remove the screws (3) that attach the turntable to
counterweight. the undercarriage. Carefully disengage the turntable
from the undercarriage by lifting it. Place the turntable
STEP 9 on suitable supports in order to protect the surfaces
Install lifting rings at the rear of the upperstructure. of the turntable from any damage. Remove the lifting
Connect a suitable lifting device to these lifting rings equipment from the lifting rings and disassemble the
and to the lifting rings located at the front of the lifting rings from the turntable.
upperstructure, above the boom brackets. Use the
total movement of the lifting device.
NOTE: Refer to specifications on page 2 for the
weight of the upperstructure. Make sure that the lift-
ing equipment has sufficient lifting and support
capacity for the upperstructure.
STEP 10
4
1
CD00G043
Using paint or another marking product, make marks
on the upperstructure, turntable (4) and the undercar-
riage, to facilitate re-assembly of the upperstructure
and the turntable.
STEP 11
Remove the screws (1) as well as the flat washers (2)
of the upperstructure turntable (4).
STEP 12
Carefully disengage the upperstructure from the
undercarriage by lifting it. Place the upperstructure
on suitable supports in order to protect the swing
reduction gear pinion from any damage.
STEP 13
Install lifting rings on the turntable (4). Connect suita-
ble lifting equipment to the lifting rings. Use the total
movement of the lifting device.
weight of the turntable.

Copyright
9002-6
Installation
Turntable
2
1
4
1
1 3
CS02C506
1 SCREW
2 FLAT WASHER
3 SCREW
4 TURNTABLE
STEP 1 STEP 3
Clean the surfaces of the undercarriage and the turn- Position the turntable (4) on the undercarriage. Align
table. the marks on the turntable (4) and on the undercar-
riage. Remove the lifting equipment and remove the
lifting rings from the turntable.
steps refer to the diagram of the turntable.
STEP 2
Install lifting rings on the turntable (4) and connect a
suitable lifting device to these rings. Use the total
movement of the lifting device.
weight of the turntable.

Copyright
9002-7
STEP 4 STEP 8
Remove the lifting device then remove the lifting
rings.
STEP 9
Refer to Section 8006 and reassemble the hydraulic
swivel.
STEP 10
Refer to Section 9003 and reassemble the boom, the
4 dipper and the bucket on the machine.
1
STEP 11
CD00G043 Make sure that the drain valve of the hydraulic reser-
Coat the screw threads (3) with Loctite 262. Install voir is closed. For filling the reservoir refer to the
the screws (3) to attach the turntable (4) to the under- chapter "Filling the reservoir" in the operators man-
carriage. Tighten the screws (3) to the torques speci- ual.
fied on page 2.
NOTE: See Section 1002 for the capacity of the
STEP 5 hydraulic reservoir and the capacity of entire system.
Connect a suitable lifting device to the lifting rings STEP 12
located in front of the upperstructure, on top of the
boom brackets, as well as to the rings installed on the
upper frame behind the upperstructure.
weight of the upperstructure. Make sure that the lift- 2
ing equipment has sufficient lifting and support
capacity for the upperstructure.
NOTE: When the upperstructure is lowered and
touches the turntable and the crown wheel, make
sure that the swing reduction gear pinion engages
perfectly with the teeth on the upperstructure crown
wheel.
CD01K081A
STEP 6
Fill the reservoir (see the operators manual). Install
Carefully install the upperstructure in position on the the lower access plate (2) of the hydraulic reservoir.
turntable. Align the marks on the upperstructure and
on the turntable. Check that the mounting ports of the
upperstructure are aligned with those of the turntable.
STEP 7
Coat the screw threads (1) with Loctite 262. Install
the screws (1) with flat washers (2) in the turntable
and the upperstructure to fasten the upperstructure
en position. Tighten the screws (1) to the torques

Copyright
9002-8
STEP 13 STEP 16
CD01K077A
3
Make sure that the drain valve of the fuel reservoir is
closed, fill the reservoir (see the operators manual). CS02C505
Remove the three screws (1) that fasten the access
Install the lower access plate of the fuel reservoir..
door (2) to the upperstructure. Remove the access
NOTE: See Section 1002 for the capacity of the fuel door (2). Scrap the seal (3).
reservoir and the hydraulic reservoir.
STEP 17
STEP 14
Apply grease by hand on the crown wheel.
STEP 18
Start the engine and turn the upperstructure by one
eighth of a turn. Shut down the engine.
1
STEP 19
Apply grease again by hand on the crown wheel.
STEP 20
Repeat the operation until all teeth of the turntable
are properly lubricated.
NOTE: Refer to the specifications on page 2 for the
quantity of grease to be applied.
CT05L063
Open the left-hand side door. Reconnect the earth
cable (1) to the battery. Close the LH side door (see
Section 4002).
STEP 15
Refer to page 10, "Installing the counterweight" and
put the counterweight back in place.
WARNING: If your hand is in the access port

of the crown wheel when the upperstructure is
revolving, you could get seriously injured.
Before applying grease by hand on the crown
! wheel, always check that the bucket or the
tool is placed on the ground and that the
engine is shut down.
Copyright
9002-9
STEP 21
CD00G043
Apply grease to the three grease fittings on the turn-
table. Install a new seal ring.
STEP 22
Install the access door with the seal, on the machine.
Fasten it in position with the three screws and the
locking washers.
STEP 23
CI00F500
Install the lower housing under the machine using
screws and washers.

Copyright
9002-10
COUNTERWEIGHT
Description
CS02C507
1 COUNTERWEIGHT 4 SHIM
2 SCREW 5 INSULATING MATERIAL
3 WASHER

Copyright
9002-11
Removal Installation
NOTE: The numbers within brackets in the following NOTE: The numbers within brackets in the following
steps refer to the schematic on page 10. steps refer to the schematic on page 10.
STEP 1 STEP 1
Attach a suitable lifting device to the lifting rings of the Attach a suitable lifting device to the lifting rings of the
counterweight (1). Use the total movement of the lift- counterweight (1).
ing device.
NOTE: Refer to the specifications on page 2 for the
NOTE: Refer to the specifications on page 2 for the weight of the counterweight.
weight of the counterweight.
STEP 2
STEP 2
Install the same number of shims (4) as those
Remove the four screws (2) and the flat washers (3) removed in step 4 of removal, at each anchorage
that fasten the counterweight (1) to the undercar- point of the counterweight on the undercarriage.
riage.
STEP 3
STEP 3
Move the counterweight (1) into position on the
Raise the counterweight (1) and remove it from the undercarriage. Align the ports of the counterweight
machine. Place it on flat ground. Remove the lifting with those on the undercarriage.
equipment.
STEP 4
STEP 4
Install the four screws (2) as well as the flat washers
Remove the shims (4) from the undercarriage (3) to attach the counterweight (1). Tighten to the tor-
anchorage points. ques specified on page 2.
NOTE: Count the number of shims (4), remove them STEP 5
from each anchorage point. Keep each set of
shims (5) to facilitate reassembly. Remove the lifting device from the lifting rings of the
counterweight (1).
STEP 5
Check the state of the insulating material (5) installed
on the counterweight. Change the insulating material
if it is damaged.

Copyright
9002-12

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
15
13 14
22
26
16 17
26 22
10
14 26
17
23 5 26
22 12
24 21 14
9 18
19 9 18
15
21
10
12
19 24
20 23
14
25
25 20 11
7
4
2 3
CRPH06C012G
1 NUT 14 SHIM
2 SCREW 15 YOKE
3 PIN 16 GREASE FITTING
4 BUCKET 17 BUSHING
5 CONNECTING ROD 18 BUSHING
6 NUT 19 BUSHING
7 SCREW 20 DUST SEAL
8 SHAFT 21 DUST SEAL
9 DUST SEAL 22 O-RING
10 GREASE FITTING 23 O-RING
11 NUT 24 O-RING
12 SCREW 25 O-RING
13 SHAFT 26 DUST SEAL
Copyright
9003-4
Removal STEP 7
STEP 1 Remove the nuts (11) and the screw (12). Remove
the shaft (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). If required,
the dipper. Shut down the engine.
remove the grease fitting (16) from the pin (13).
NOTE: Carry out step 9 only if the bushings (17), (18)
steps refer to the schematic of the bucket on page 3.
and (19) have to be changed. See specifications.
STEP 2 STEP 9
Remove the nuts (1) and (6), as well as the
Remove the bushings (17) and (19) from the con-
screws (2) and (7).
necting rod (5), as well as the bushing (18) from the
STEP 3 dipper, by using a hammer and a suitable drift on the
outer diameter of the bushing.
Installation
8 NOTE: Carry out step 1 only if the bushings (17), (18)
and (19) have been removed.
STEP 1
Using a suitable sleeve, install the bushings (17) (19)
in the connecting rod (5) and the bushing (18) in the
dipper.
3 NOTE: Carry out steps 2 to 6 only if the connecting
rod (5) and the yokes (15) have been removed.
Remove the pins (3) and (8).

CD00E097
STEP 2
Install new dust seals (21) on the dipper. Install the
STEP 4
pin (13) in a connecting rod (15) and install the pin on
Start the engine. Disengage the attachment from the the dipper. Install the second connecting rod (15) on
bucket and recover the coupling shafts. the pin and install the screw (12).
STEP 5 STEP 3
Remove and scrap the dust seals (9) and (20). Using a set of spacer rings, check that the play
between the dipper and the connecting rods (15) is 1
NOTE: Carry out steps 6 to 9 only if the connecting
to 1.5 mm. If required, remove the screw (12) and the
rod (5) and the compensators (15) have to be
pin (13) and add one or more shims according to the
changed.
requirement in order to get the correct play. Install the
STEP 6 pin and the screw.
Attach a suitable lifting device to the connecting STEP 4

rod (5). Disconnect the bucket cylinder rod from the
Install the first nut (11) on the screw and tighten until
connecting rod (5) and the yokes (15), see Section
the nut touches the boss on the connecting rod.
8005. Remove the grease fittings (10) if required.
Loosen a quarter of a turn and use two wrenches to
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 connecting rod (5) Using a set of spacer rings, check that the play
and position the connecting rod on the dipper. Install between the compensator and the bucket is 1 to
the bucket cylinder rod on the connecting rod (5) and 3.5 mm. If required, remove the screw (7) and the
the yokes (15), see Section 8005. Install the grease fit- pin (8) and add one or more shims according to the
tings (10). requirement in order to get the correct play. Install the
pin (8) and the screw (7).
STEP 7
STEP 14
Install new dust seals (9) on the connecting rod (5).
Install the first nut (6) on the screw and tighten until
STEP 8 the nut touches the boss on the connecting rod.
Install new dust seals (20) on the dipper. Loosen a quarter of a turn and use two wrenches to
tighten the second nut on the first. Do the same for
STEP 9 the nuts (1) and the screw (2).
STEP 15
Push the coupling shafts back in their positions.
STEP 16
Grease the linkages.
STEP 17
Carry out the shimming of the bucket, see page 6.
B9240128
Install new coupling shafts on the boss of the bucket.
STEP 10
Start the engine and align the dipper ports with the
ports in the bucket.
STEP 11
Install the pin (3) through the bucket and the dipper.
Install the screw (2).
STEP 12
align the ports of the connecting rod with the ports of
the bucket and install the pin (8) through the bucket
and the compensator. Install the screw (7).

Copyright
9003-6
Shimming the bucket NOTE: By tightening the cap screws (1), the inner
bushing moves towards the dipper and the play is
The machine is equipped with an adjusting system eliminated.
for the bucket play that helps eliminate the play that
develops on the bucket/dipper linkage due to wear. IMPORTANT: The inner bushing is equipped with a
This system delays the effects of wear and gives stud that prevents the bushing from rotating. The
longer life to bushings and pins. cap (1) is equipped with a port on its inner surface.
Make sure that the stud is inserted in that orifice
NOTE: Wrong adjustment of the play may cause fric- when the cap (1) is installed.
tion, unusual noises or excessive play and may dam-
age 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 thickness gauge and deter-
mine the number of shims required to eliminate the
play (J).
Install the number of new shims required.
Reinstall the cap (1) and the four screws.

Copyright
9003-7
DIPPER
Description
2
7
6 13 1
8
8
6
11
9
4
12
7
9
11
12
10
10
CRPH06C013G
1 SCREW 8 BUSHING
2 WASHER 9 BUSHING
3 SHAFT 10 BUSHING
4 DIPPER 11 DUST SEAL
5 BOOM 12 DUST SEAL
6 DUST SEAL 13 SHIM
7 GREASE FITTING

Copyright
9003-8
Removal NOTE: Carry out step 9 only if the bushings (8), (9)
or (10) have to be changed, see Specifications.
STEP 1
STEP 9
Remove the bucket, the connecting rods and the
compensator, see page 4. Remove the bushings (8), (9) or (10) from the dipper
or the boom by using a hammer and a suitable drift
STEP 2 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: Carry out step 1 only if the bushings (8), (9)
or (10) have been removed.
STEP 3
STEP 1
Remove the bucket cylinder and disconnect the dip-
per cylinder rod from the dipper, see Section 8005. Using a suitable sleeve, install the bushings (8), (9),
Attach the dipper cylinder rod on the boom. or (10).
NOTE: The numbers in the following steps refer to STEP 2
the diagram of the dipper on page 7.
Install new dust seals (6), (11) and (12) on the dipper.
STEP 4
STEP 3
Attach a suitable lifting device to the dipper. Use the
total movement of the lifting device. Attach a suitable lifting device to the dipper. Move the
dipper into position near the machine.
STEP 5
STEP 4
Remove the screw (1), the washer (2), the shims (13)
Start the engine and advance the machine so that the
and the shaft (3).
boom is aligned with the dipper. Check the alignment
STEP 6 of the mounting ports of the boom and the dipper.
Shut down the engine.
Start the engine, reverse the machine to separate the
dipper from the boom. Lower the boom to the ground STEP 5
and shut down the engine.
Install the pin (3).
STEP 7
STEP 6
Lower the attachment to the ground and unhook the
lifting device from the dipper. Using a set of spacer rings, check that the play
between the boom and the dipper is 0.5 to 2 mm. If
STEP 8 required, remove the pin (3) and add one or more
shims according to the requirement in order to get the
Remove and scrap the dust seals (6), (11) and (12). correct play. Install the pin (3).

Copyright
9003-9
STEP 7
Install the screw (1) and the washer (2).
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
Drain the cylinders, see Section 8000.
STEP 12

Copyright
9003-10
BOOM
Description
5
6
8
8
5
1
4 2
3
CRPH06C014G
1 SCREW 5 SHIM
2 WASHER 6 BUSHING
3 SHAFT 7 GREASE FITTING
4 BOOM 8 SEAL

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 res-
ervoir.
STEP 4 CS00F539
Remove the cover (A) from in front of the fuel reser-
voir.
A NOTE: The numbers within brackets in the following
B steps refer to the diagram on page 10.
C
STEP 7
E Attach a suitable lifting device to the boom, use the
total movement of the lifting device.
D
STEP 8
E
Remove the screw (1), the washer (2) and the
shaft (3).
CD00F117 STEP 9
Start the vacuum pump. Label and disconnect the
bucket (A) and dipper (B) supply hoses on the boom Lift the boom and recover the shims (5). Lower the
foot. If assembled, disconnect the option hoses (E). boom to the ground and remove the lifting device.
Plug the hoses. Stop the vacuum pump. If assem- NOTE: Carry out step 12 and 13, only if the bushings
bled, unclamp and move the pilot hoses (D) of the (6) have to be changed, see the specifications.
dipper cylinder relief away from the boom. Disconnect
the electrical harness (C) from the boom working STEP 10
light.
Remove the bushings (6) from the boom by using a
STEP 5 hammer and a suitable drift on the outer diameter of
the bushing.
Disconnect the boom cylinder rods from the boom,
see Section 8005. STEP 11
Remove and scrap the seals (8) from the boom.

Copyright
9003-12
Installation STEP 8
NOTE: Carry out step 1 and 2 only if the bushings (6)
were removed.
A
STEP 1 C B
Install new seals (8) on the boom.
STEP 2 E
Using a suitable sleeve, install the bushings (6) on D
the boom.
E
STEP 3
Attach a suitable lifting device to the boom. Lift the
boom and bring it in position, check the alignment of CD00F117
the ports of the boom and the undercarriage. Start the vacuum pump and remove the plugs from
the hoses. Connect the bucket (A) and dipper (B)
STEP 4 supply hoses at the bottom of the boom. If equipped,
connect the option hoses (E). Stop the vacuum
Install the pin (3).
pump. If assembled, clamp the pilot hoses of the dip-
STEP 5 per cylinder relief on the boom. Connect the electrical
harness (C) of the boom working light.
Using a set of spacer rings, check that the play
between the boom and the undercarriage is 0.5 to STEP 9
3 mm. If required, remove the pin (3) and add one or
more shims (5) according to the requirement in order A
to get the correct play. Install the pin (3).
STEP 6
Install the screw (1) and the washer (2).
STEP 7
Connect the boom cylinder rods to the boom, see
Section 8005.
CS00F539
Install the cover (A) in front of the fuel reservoir.
STEP 10
Install the dipper cylinder on the boom, see Section
8005.
STEP 11
Install the dipper and the bucket, see page 8.
STEP 12
Drain 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 ..................................................................................................................................................
Description .......................................................................................................................................................... 3
Removal .............................................................................................................................................................. 4
Repose ................................................................................................................................................................ 7
SAFETY BELT ........................................................................................................................................................ 8
Removal .............................................................................................................................................................. 8
Repose ................................................................................................................................................................ 8
SPECIFICATIONS
Weight of the operator's seat.............................................................................................................................. 46 kg

Copyright
9004-3
OPERATOR'S SEAT
Description
10
9
6
3 5
7
2
CS02A504
1 OPERATOR'S SEAT 6 SHOCK ABSORBER
2 MASK 7 BRACKET
3 BOOT 8 FRONT CONTROL ARM BRACKET
4 RAIL 9 CYLINDER
5 REAR CONTROL ARM BRACKET 10 BULB

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
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 boot. 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 to the side.
STEP 12
CD00G066
Remove the trim 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
Loosen 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 trim in front of the seat using the four
screws (1).

Copyright
9004-8
SAFETY BELT
Removal STEP 4
STEP 1
CD00G125
Loosen and then remove the screw (2) and the
JS00163A washer. Remove the inertia-reel.
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
CAB ........................................................................................................................................................................ 3
Removal .............................................................................................................................................................. 3
Installation ........................................................................................................................................................... 5
HEATING BLOCK/AIR-CONDITIONING BLOCK .................................................................................................. 8
Description .......................................................................................................................................................... 8
Removal ............................................................................................................................................................ 10
Installation ......................................................................................................................................................... 12
WINDSHIELD WIPER MOTOR ............................................................................................................................ 14
Description ........................................................................................................................................................ 14
Removal ............................................................................................................................................................ 15
Installation ......................................................................................................................................................... 16
SPECIFICATIONS
Cab weight........................................................................................................................................................ 255 kg

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

Copyright
9005-3
CAB
Removal STEP 8
STEP 1
CD00G003
Remove the trim panel at the rear of the cab, taking
JS00163A care to disconnect the connector for the cigarette
Park the machine on hard, flat ground. Lower the tool lighter and the solar radiation detector (only on air-
to the ground. conditioned models).
STEP 2 STEP 9
shut down the engine. 3
STEP 3 2
Disconnect the earth cable from the battery.
STEP 4
Fold the operator's seat-back down and move the
seat as far as possible.
STEP 5
1
Remove the floor mat from the cab.
STEP 6 CRPH06C010A
Remove the two controllers (1) and (2), as well as the
Remove the guardrail on the LH side of the cab. relays (3) (see Section 4003).
STEP 7
Remove the radio, if fitted.

Copyright
9005-4
STEP 10 STEP 14
4
CD00G006
Disconnect the windshield washer pipe and remove
the retaining clip.
STEP 15
Remove the windshield wiper motor (see page 13).
STEP 16
Remove the upper RH trim panel, disconnect the dis-
play and remove it.
CRPH06B077B
STEP 17
Remove the retaining plate of the relays (4).
STEP 11
Remove the controller brackets (5) and (6).
STEP 12
1
1
CD00G007
2 Remove the pollen filter guard, remove the pollen fil-
ter and remove the pollen filter conduit.
STEP 18
Remove the working light from the top of the cab.
CD00G005 Retract the radio aerial. Install suitable lifting rings on
Remove the screws (1) which fasten the rear ventila- the top of the cab. Install lifting equipment.
tion and remove the two conduits.
STEP 13
Remove the connectors (2) at the rear of the cab.

Copyright
9005-5
STEP 19 Installation
Remove the screws and washers which fasten the NOTE: Keep away from the cab while it is being low-
cab to the upperstructure frame. ered. Make sure that the cab is not damaged during
NOTE: Keep away from the cab while it is being low- lifting or lowering. Room for manoeuvre is very lim-
ered. Make sure that the cab is not damaged during ited at the rear, on the sides and inside the cab.
lifting or lowering. Room for manoeuvre is very lim- STEP 1
ited at the rear, on the sides and inside the cab.
STEP 20
CI99G501
Install suitable lifting rings on the top of the cab.
Using suitable lifting equipment, raise the cab. Guide
CI99G501
the cab so that it is correctly aligned with the mount-
Using the lifting equipment, carefully raise the cab
ing studs and orifices in the upperstructure frame.
until it is completely away from the machine, then
lower it to the ground. NOTE: The cab weighs 255kg.
NOTE: The cab weighs 255 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.
STEP 3
Install the working light on the top of the cab.

Copyright
9005-6
STEP 4 STEP 9
Install the windshield wiper motor (see page 13). 3
STEP 5
Use the screws to install the display and connect it to
the electrical harness. Install the upper RH trim
panel.
2
STEP 6
1
2
CD00G007
Install the pollen filter and the pollen filter conduit.
Using screws (1), fasten the pollen filter housing (2)
to the cab. CRPH06B077B
Install the controller brackets (1) and (2), as well as
STEP 7 the retaining plates of the relays (3).
Reconnect the blower motor conduit to the ventilation STEP 10
conduit at the front of the cab. Reconnect the ventila-
tion conduit at the rear of the cab. Connect the electrical harness behind the cab.
STEP 8 STEP 11
6
5
CD00G006 CRPH06C010A
Connect the windshield washer pipes together and Install the two controllers (4) and (5), as well as the
attach the circlip. relays (6) (see Section 4003).

Copyright
9005-7
STEP 12
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).
STEP 13
Install the radio, if fitted.
STEP 14
Install the guardrail using screws and washers.
STEP 15
Remove the floor mat from the cab.
STEP 16
Reconnect the earth cable from the battery.

Copyright
9005-8
HEATING BLOCK/AIR-CONDITIONING BLOCK

Description
1
3
10
11 6
2
7
CS02A501
1 CAB REAR VENTILATION CONDUIT 7 HEATER HOSE
2 CAB LOWER VENTILATION CONDUIT 8 RETAINING CLIP
3 CAP 9 UNION
4 POLLEN FILTER 10 UNION
5 CONDUIT 11 HEATER ASSEMBLY
6 SCREW

Copyright
9005-9
2
1 3 4
8
10
11
CRPH06B065H01
1 BLOWER MOTOR RELAY 7 HEATER CORE
2 CONTROLLER 8 MODE SWITCH-OVER MOTOR ACTUATOR
3 INSIDE AIR FILTER 9 INSIDE AIR FILTER
4 INSIDE/OUTSIDE AIR SWITCH-OVER MOTOR ACTUATOR 10 INTAKE CASE
5 BLOWER CASE 11 BLOWER CASE
6 AIR MIX MOTOR ACTUATOR

Copyright
9005-10
Removal STEP 5
STEP 1
WARNING: Boiling cooling fluid can spurt out
when the radiator cap is removed. To remove
the cap, proceed as follows: Wait until the sys-
tem 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 main-
tenance of the cooling system, refer to the
maintenance instructions.
Make sure that the radiator has cooled down and

remove the radiator cap.
JS00163A
Park the machine on hard, flat ground. Lower the tool STEP 6
to the ground. Use a container of suitable capacity and empty the
cooling system (see the operator's manual).
STEP 2
Reduce the engine speed to idle for 30 seconds, then STEP 7
shut down the engine. Remove the operator's seat from the cab (see
Section 9004).
STEP 3
STEP 8
CT05L063
Disconnect the earth cable (-) (1) from the battery. CD00G003
Remove the trim panel at the rear of the cab, taking
STEP 4 care to disconnect the connector for the cigarette
lighter and the solar radiation detector (only on air-
Raise the engine hood and lock it in the raised posi-
conditioned models).
tion.
STEP 9
Disconnect the electric blower supply harness.

Copyright
9005-11
STEP 10 STEP 14
CD00G007
7 7 Remove the pollen filter guard, remove the filter (4)
and remove the conduit (5).
CD00G044
Unscrew the clips (8) and disconnect the heater
STEP 15
hoses (7). Remove the screws (6) that secure the heating (11)
or air-conditioning block to the cab. Remove the block
STEP 11 from the cab.
Drain the air-conditioning system, contact an author-
ised technician.
STEP 16
STEP 12 Remove the inside air filter, and remove the 4 screws
to remove the intake case.
Remove the blower case by removing the 3 screws
that mount the blower case to the unit case. Remove
A the inside air filter, and remove the 4 screws to
remove the intake case.
Remove the blower case by removing the 3 screws
that mount the blower case to the unit case.
CD00G006
Remove the screw (A) and remove the hoses (B)
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.
STEP 13
Remove the ventilation conduits (1), (2) and (3) from
the cab.

Copyright
9005-12
Installation NOTE: Carry out Steps 5 and 6 only on air-condi-

tioned 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 pol- Fill the air-conditioning circuit, contact an authorized
len filter guard. engineer.
STEP 3 STEP 7
Install the ventilation conduits (1), (2) and (3) of the Connect the blower supply electrical harness.
cab (see page 8). STEP 8
STEP 4
7 7
CD00G003
Install the trim at the rear of the cab, taking care to
CD00G044
Install the heater hoses (7) and tighten the retaining reconnect the connector for the cigarette lighter and
clips (8). the solar radiation detector (only on air-conditioned
models).
STEP 9
Install the operator's seat in the cab (see Section
9004).

Copyright
9005-13
STEP 10 STEP 14
Pour suitable cooling fluid in the radiator (see the Start the engine and run it at maximum speed until it
Operator's manual). reaches normal working temperature.
STEP 11 STEP 15
1 STEP 16
When the radiator feels cold, remove the caps from
the radiator and the expansion reservoir. Top up if
necessary.
CT05L063
Connect the earth cable (1) to the battery.
STEP 12
Start the engine and run it at idle speed for one
minute. Shut down the engine.
STEP 13
Add cooling fluid according to requirement in the
expansion reservoir.
WARNING: Boiling cooling fluid can spurt out

when the radiator cap is removed. To remove
the cap, proceed as follows: Wait until the sys-
tem 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 main-
tenance of the cooling system, refer to the
maintenance instructions.

Copyright
9005-14
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
9005-15
Removal STEP 6
STEP 1 Note the position of the windshield wiper arm (2).
Remove the windshield wiper arm (2) from the wind-
shield wiper motor (4) by pulling it off the windshield
wiper motor shaft.
STEP 7
Remove the rubber cap (5).
STEP 8
Remove the nuts (6), washer (7) and plastic support
(8) from the windshield wiper motor shaft.
STEP 9
JS00163A
to the ground.
STEP 2
STEP 3
1 CD00G133
Remove the upper RH trim panel.
STEP 10
CT05L063 A
Disconnect the earth cable (-) (1) from the battery.
STEP 4
CD00G134
From the front of the cab, raise the protective flap (1) Remove the lower front trim panel inside the cab
located on the lower portion of the windshield wiper using screws (A).
arm (2).
STEP 11
STEP 5
Disconnect the electrical harness (10) from the wind-
Remove the nut (3). shield wiper motor (4).
STEP 12
Remove the screws (9) and (11) from the windshield
wiper motor. Remove the windshield wiper motor.

Copyright
9005-16
Installation STEP 9
STEP 1 1
Place the windshield wiper motor (4) in position on
the cab bracket. Connect the windshield wiper motor
connector (4) to the electrical harness (10).
STEP 2
Install the windshield wiper motor (4) on the cab pil-
lar, using the screws (9) and (11).
STEP 3
CT05L063
Connect the earth cable (1) to the battery
STEP 10
Switch on the windshield wiper motor and check that
everything is working correctly.
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
Install the rubber cap (5).
STEP 6
Install the windshield wiper arm (2) on the windshield
wiper motor shaft (4), positioning the windshield
wiper arm (2) in the same position as was noted at
disassembly.
STEP 7
Install the nut (3) on the windshield wiper motor shaft.
Tighten the nut.
STEP 8
Turn back the flap (1) located on the lower portion of
the windshield wiper arm (2).

Copyright
Section
9007
AIR CONDITIONER
9007

Printed in France
Copyright
9007-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 2
SPECIAL TORQUE .................................................................................................................................................. 3
AIR CONDITIONER ................................................................................................................................................. 4

Description ........................................................................................................................................................... 4
Disassembly and assembly .................................................................................................................................. 5
SPECIFICATIONS
Table 1
Replacement part Oil level adjustment

Compressor Measure the oil volume in compressor that is removed.
Remove all the oil except that remaining in the compressor that was
removed from the brand new compressor.
Example:
If 30 cc of oil remains in the removed compressor
(for a SD7H13WM7359 compressor), remove 105 cc from the brand
new compressor.
(135 cc - 30 cc = 105 cc)
Evaporator Refill 40 cc.
Condenser Refill 40 cc.
Receiver dryer Refill 20 cc.
NOTE: The oil type is different according to

compressors. Refer to the nameplate attached to the
compressor, which has indications for the oil type.
NOTE: Before starting the operation, stop the engine
and turn off the power for air conditioner related
devices. Avoid water or dust from entering the
refrigerating circuits. In addition, do not leave the
piping unattached from the machine. Avoid
conducting piping removal or fitting work under rainy
conditions. When the work is completed, check that
the faulty parts have been fully repaired by running
the air conditioner.

Copyright
9007-3
SPECIAL TORQUE
Table 2
Pipe fastening section Tightening torque Nm
1 D hose and compressor (M8 bolt) 20 to 30
2 S hose and compressor (M8 bolt) 20 to 30
3 D hose and condenser (1/2 inch nut) 20 to 25
4 Condenser and L hose (L pipe) (8 mm nut) 12 to 15
5 L hose (L pipe) and receiver dryer (M 6 bolt) 8 to 12
6 S hose, L hose and expansion valve 8 to 12
(M6 x P1.25)
Table 3
Category Type Nominal diameter Pitch Tightening torque
(mm) (mm) Nm
Bolt 7T M6 1.0 8 to 12
M8 1.25 20 to 30
M10 (air conditioning unit - 17 to 19
mounting section)
M10 1.25 40 to 54
M10 1.5 37 to 51
9T M8 1.25 24 to 36
M10 1.25 56 to 76
M10 1.5 53 to 72
Nut Pipe 8 mm 1.5 12 to 15
diameter
1/2 inch 1.5 20 to 25
5/8 inch 1.5 30 to 35
NOTE: About oil capacity for compressors

SD7H13WM7359 X1 Series compressors are filled
with 135 cc of oil (SP-10). Low oil level may cause it
to seize up at high speeds and reduce durability while
excessive oil may reduce its cooling performance.
While the air conditioning is running, the oil is
distributed in the refrigerating circuits. Therefore, the
oil level must be adjusted following the instructions in
table 1 when changing parts.

Copyright
9007-4
AIR CONDITIONER
Description
2
1 3 4
8
10
11
CRPH06B065H01
1 BLOWER MOTOR RELAY 7 HEATER CORE
2 CONTROLLER 8 MODE SWITCH-OVER MOTOR ACTUATOR
3 INSIDE AIR FILTER 9 SCREW
4 INSIDE/OUTSIDE AIR SWITCH-OVER MOTOR ACTUATOR 10 INTAKE CASE
5 BLOWER CASE 11 SCREW
6 AIR MIX MOTOR ACTUATOR

Copyright
9007-5
Disassembly and assembly STEP 5

IMPORTANT: Service work on air-conditioning
circuits must be carried out by approved service
engineers. 1
2
NOTE: Never attempt to service the air conditioning
system unless you are completely familiar with air
conditioning and the safety precautions which must 4
be followed when handling liquid refrigerant. Liquid
refrigerant can cause severe and painful frostbite.
Contact your dealer, who is experienced in servicing
and handling of refrigerants.
NOTE: When fastening the piping connection for 3
refrigerating circuits, apply special oil (SP-10) to O-
CRPH06B067A01
rings and fasten the connecting parts using tightening Drain the cooling water, detach the heat hose and
torque specified in Table 2, page 3. Further, tighten then remove the 2 screws (4) (5 x 16).
screws and bolts using torque specified in Table 3, Remove the pipe clamp (2) and the AHC bracket (3),
page 3. and then pull out the heat core (1).
STEP 1 STEP 6
Remove the inside air filter (3), and remove the 4
screws (3) (5 x 14) to remove the intake case (10)
(see page 4). 1
STEP 2
Remove the blower case (5) by removing the 3
screws (11) (5 x 14) that mount the blower case to
the unit case (see page 4).
STEP 3
1 2
CRPH06B068A01
2 Remove the rod D (1) from the rod holder (2)
3 mounted on the lever of the mode motor actuator.
5
6 4
CRPH06B066A01
After removing the cooling hose (5), remove the 3
bolts (4) (5 x 16) fitted under the blower case (1) and
pull out the blower motor (2).
NOTE: Do not remove the fan from the blower motor.
STEP 4
Remove the 2 screws (6) (4 x 14) under the blower
case (1) and pull out the blower controller (3).
NOTE: Do not disassemble the blower controller.

Copyright
9007-6
STEP 7 STEP 9
1 A 3 2
32
3 B
5
4
4
1
CRPH06B069A01
Remove the motor actuator mounted on the lower
unit case (5) and the upper unit case (1) by removing
3 screws.
Remove the 11 mounting screws (5 x 16) from the
lower unit case (5) and the upper unit case (1).
Pull upward the upper unit case (1).
WARNING: Paying attention not to have evaporation
sensor cords caught by the case.
5
STEP 8 CRPH06B071B01
Installing the evaporation sensor:

2 NOTE: Attach the evaporation sensor to the holder,
7
place the tip of the holder and sensor in place as
shown in the figure above.
3 (1) Insert sensor holder into 13th and 14th
columns.
(2) Insert sensor holder into 5th and 6th
6 columns.
(3) 3RD column.
(4) Ensure no unnecessary looseness.
4 (5) Do not allow tip of the thermistor to extrude
from tube to the left.
CRPH06B070A01
Pull out the evaporator (2) with its heat insulating
material attached from the lower unit case.
Pull out the evaporation sensor (4) with its sensor
holder attached from the evaporator.
Remove the 2 hexagon bolts (6) (M5x40) from the
evaporator, and then, remove the expansion valve (3)
from evaporator.
Install O-rings (7) (5/8 and 1/2 NFO rings) onto a new
evaporator and then fit the expansion valve.
NOTE: Special care should be taken while installing
to avoid O-ring engagement. Do not reuse O-rings.
Install O-rings with bare hands.

Copyright
9007-7
STEP 10 STEP 12
Replacement of the inside/outside air
switch-over motor actuator:
c F
CRPH06B072A01 E
Remove the rod clamp (C) interlocking the mode
motor actuator and mode cam by pushing to the
direction of ARROW. CRPH06B074A01
Remove 3 mounting screws from the motor actuator Remove the screw fixing the motor actuator with its
and remove the motor actuator with its rod clamp and lever (E) attached, and remove the motor actuator.
lever attached from the unit. Remove the lever from the motor actuator. Install a
Remove the rod clamp and lever. Then, install them new motor actuator in the reverse order of the
on a new motor actuator in the reverse order of the disassembly.
disassembly.
STEP 11
Replacement of the air mix motor
actuator:
CRPH06B073A01
Remove the rod (B) from the lever by pushing the rod
clamp (A), which is attached on the lever of the motor
actuator, to the direction of ARROW.
Remove the 3 mounting screws from the motor
actuator, and remove the motor actuator with its rod
clamp and lever attached from the unit.
Remove the rod clamp and lever from the motor
actuator. Install a new motor actuator in the reverse
order of the disassembly.

Copyright
9007-8
NOTES
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Copyright
A1 COMPUTER
65A 50A
A2 ENGINE CONTROLLER
1
5R 210 8R 207 8R 207 2 8R 207 A4 WIPER CONTROLLER
F21 3R 211
F23 1 F24 1
2
F27 1
A6 BLOWER CONTROLLER
2
1
CN.20
2
1
2
1
2 2
1 2 3 4 5 6
58L
A9 AIR CONDITIONER CONTROLLER
1.25YR 208
8R 100
3R 212
1
2
58L CN-A 58L
F25
CN.26
3R 213
F22 8R 207 B1 COOLANT TEMPERATURE SENSOR
91-A
1 1 CN.C1 CN.C4 CN.C5
2
1
2
1
1.25YR 208 2 2 1.25YR 208 B2 HYDRAULIC OIL TEMPERATURE SENSOR
1.25WR 209 1 BrR 544 (RED TAPE) CN-A CN-A (BLUE TAPE) 3R 002
K7 8B 797 E 24V 50A B3 FUEL TEMPERATURE SENSOR
X5 1.25R 206 2 BrW 545 8R 203 3WR 003
9 10 11 12 13 14 15 16 17 18
CN.C3 CN.C2
5 6 7 8
3 1.25WR 209 1.25GR 205 1.25LR 204 1.25LR 204
M5 B5 EVA SENSOR
206,208,209 4 1.25R 206 1.25RW 202 B6 AIR INTAKE TEMPERATURE SENSOR
IC
D
5 60R 200 60R 201 60R 001 B21 ENGINE OIL PRESSURE SWITCH
CN.22
E
SDL
C
BrW 545
REGULATOR
BrR 544
B22 SWING PILOT PRESSURE SWITCH
206,208,209
F A B 6 M8 M8
X3
F16
F15
F18
F13
F10
F19
F17
F14
F20
F11
F12
J
1 2 3 4
G 1.25LgR 540 B23 BREAKER / CRUSHER PILOT PRESSURE SWITCH
F3
F7
F9
F8
F2
F5
F6
F4
F1
15A
15A
15A
20A
20A
20A
15A
30A
10A
15A
10A
10A
10A
10A
15A
20A
10A
20A
H M10 M10 M10 M10
5A
5A
M4
DEUTSCH A B C D E F G H J
0.85RY 225
- + - +
1.25LgR 020 1.25LgR 020 1 R
G2 B24 SECOND OPTION PILOT CIRCUIT 2 PRESSURE SWITCH
WR 541 1.25BrR 030 1.25BrR 030
VW 280
2WR 050
2
O 255
VR 240
BrW 260
B25 BREAKER PILOT PRESSURE SWITCH
LR 250
R 221
HD14
1
2
2LR 310
0.85GW 290
1.25RW 220
0.85YW 270
1.25W 320
0.85OR 375
1.25LW 340
0.85VR 370
0.85OL 300
0.85BrW 230
1.25LgR 350
1.25GrR 330
0.85BrR 360
M4 L
0.85GR 231
R 222
CN.Z2
LR 251
B26 UPPER PILOT PRESSURE SWITCH (YELLOW BAND)
1.25W 322
P 592
PL 593
0.85BG 637
0.85PG 598
B 703
LR 251
0.85RY 225
60B 799
1.25R 206 1.25R 206
1.25W 325
1
0.85OR 375
R 223
0.85B 704
1.25B 700
2 1 B27 TRAVEL PILOT PRESSURE SWITCH
CN.C9
1 2
58X
1.25LgR 540 2 1.25LgR 540
SDL 1
WR 541 3 WR 541 B28 SECOND OPTION PILOT CIRCUIT 1 PRESSURE SWITCH
1
CN.29 12V 12V CN-A 0.5F
BrR 543 4 0.85BrR 543 8R 100 B B42 PUMP PRESSURE SENSOR (P1)
CN.T1
G1 K8
CN.T3
1P-M
CN-A
2 3
1
0.85GrR 010 5 0.85GrR 010 CN.C0 M6 B43 PRESSURE SENSOR (NEGA-CONT)
1
YR 830 6 0.85YR 830 B 779 B44 PUMP PRESSURE SENSOR (P2) (BLUE BAND)
7 B 3WR 003
B45 OVERLOAD INDICATOR PRESSURE SWITCH
OW 546 8 OW 546 0.85GrR 010 3 S 60R 001 M10 B
P1 B 734 B 734 VW 800 9 0.85VW 800 BG 651 0.85BrR 543 2 R
M B47 BOOST PRESSURE SENSOR
B 703 B 703 0.85VR 900 10 0.85VR 900 BG 641 B 759 1 E 3YR 004 3YR 004 M5 C B48 AMBIENT AIR (BAROMETRIC) PRESSURE SENSOR
0.85BG 660
0.85BG 630
M1
0.85BL 661
PWB
P2 0.85B 704 0.85B 704 0.85WY 400 11 0.85WY 400 1.25BrR 030 C B49 CRANKSHAFT POSITION SENSOR
BG 652
BG 650
CN.5 CN.6
S2 0.85WL 410 12 0.85WL 410 B50 CAMSHAFT POSITION SENSOR
CN.T2
ILLUMINATION
1P-F
1
IGN 1 1.25W IGN 1.25W 1 1.25W 322 0.85YL 411 13 0.85YL 411 2BG 600 B51 BOOST TEMPERATURE SENSOR
1 2 3
4 5 6
CN.9
10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8 17 18 19 20 21 22 23 24 25 26 24V 5.0kw
5 6 7 8 9
S3
1.25B 700
M
B+ 2 R B+ R 2 R 221 0.85L 412 14 0.85L 412 2B 700
9 10 11 12 13 14 15 16 27 28 29 30 31 32 33 34 35 36 JOINT CONNECTOR B52 COMMON RAIL PRESSURE SENSOR
TRAVEL MODE 3 BrG TRAVEL MODE BrG 3 BrG 441 0.85PL 417 15 0.85PL 417 3LR 060 3LR 060 1 5BW
AMP 040 MULTI LOCK B53 EXHAUST GAS RECIRCULATION VALVE POSITION
010,540,541,543
S4 WORK MODE 4 VY WORK MODE VY 4 VY 440 1 1.25B 700 0.85BW 420 16 0.85BW 420 M8
M8
2BG 600
B 759
SENSOR
2B 700
GND (G1)
CN.13
CN.A6
COMPUTER
1.25B 730
58Y
SDL
WG(OG) WG(OG) WG 446 B 710
CN.5
SOFT/HARD 5 SOFT/HARD 5 2 17
B 702
1
B61 SUNLOAD SENSOR
1.25B 701
0.85B 745
BEACON 6 VG BEACON VG 6 VG 447 3 B 711 18
A1 S5 B81 HORN
1 2 3 4
7 7 4 B 713
FILTER U
5V
POWER 24V 10 1.25LgR 351 AUTO MODE 8 OG(GY) AUTO MODE OG(GY) 8 OG 442 5 B 715 010,540,541,543 B82 REFUEL PUMP STOP ALARM
2 1.25LgR 350 BZ STOP 9 YG BZ STOP YG 9 YG 443 6 B 725 8R 100 R1 V M
M15 E1 WORKING LIGHT (UPPERSTRUCTURE)
CONTROL 24V 4 1.25W 320 S6 RXD 10 PW RXD PW 10 PW 583 W
E2 WORKING LIGHT (ATTACHMENT)
12 1.25W 321 TXD 11 PL TXD PL 11 PL 584
E3 WORKING LIGHT (CAB)
710,711 713,715,725
GND 1 1.25BG 600 SWING LOCK 12 LY SWING LOCK LY 12 LY 444 OW 546 0.75WB 870 8 0.75WR(U)
GND 9 1.25BG 601 WORKING LAMP 13 WR WORKING LAMP WR 13 WR 531 E51 0.75GB 871 7 0.75WB(V)
E4 CAB LIGHT
GND 3 ENG.STOP 14 BrR(BrY) ENG.STOP BrR(BrY) 14 BrR 530 1.25WR 209 1 1.25WR 209 0.75YB 872 6 0.75WL(W) E51 CIGARETTE LIGHTER
P3
1.25B 701
0.85B 745
GND 11 WASHER 15 GrR WASHER GrR 15 GrR 520 0.85BrW 230 B 715 1.25YR 208 2 1.25YR 208 1.25GrR 330 330,546 5 E52 AIR CONDITIONER
B 702
SINGLE CHIP CPU GND 5 S7 16 WIPER(INT) LR 16 LR 521 2LR 060 3 3LR 060 3LR 060 0.75WG 873 4 0.75GB(U) F1 FUSE 20A; ENGINE CONTROLLER
U
GND 13
S8
17 WIPER(CNT) YR 17 YR 522 1.25GrR 330 4 1.25GrR 330 0.75G 874 3 0.75GW(V)
V
B53 F2 FUSE 5A; COMPUTER CONTROL INSTRUMENT PANEL
PUMP OUT(PWM) YR 940 WIPER(INT) LR WINDOW L/SW. VR VR 523 1.25GR 394 1.25GR 394 0.75YG 875 0.75GY(W)
330,546
14 5
0.85BG 630
18 18 2 AND DIAGNOSTIC TEST SOCKET
CN.E0
PWM W
PUMP RET(PWM) 6 BY 941 WIPER(CNT) 19 YR ALTERNATOR BrW(BrR) 19 BrW 545 6 1
S9 F3 FUSE 20A; COMPUTER POWER
1.25B 730
NO USE 16 WINDOW L/SW. 20 VR GND 1.25BG 20 1.25BG 602 602,603,604,636,645,664 1.25B 700 7 2B 700 0.85YR 830 1
PWM2 OUT(PWM) 15 ALTERNATOR 21 BrW(BrR) 1.25BG 600 8 2BG 600 0.85B 760 2 Y2 F4 FUSE 10A; HYDRAULIC FUNCTION CANCELLATION
BG
CN.Q1
CN.Q0
D/A S10 LEVER SWITCH
DL090
SUMITOMO
SDL
SDL
1 2
1 2
PWM PWM2 RET(PWM) 7 GND 22 1.25BG 1.25BG 602 (BLUE TAPE)
5 6 7 8
1 2 3 4
CN.E2
CN.A4
8 bit F5 FUSE 10A; AIR CONDITIONER CONDENSER FAN
2 STAGE RELIEF 8 YW 802 BG 603
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
603,604,636,664
2 3 4
6 7 8
S11 0.85BG 604 F6 FUSE 10A; ROTARY LIGHT
CN.21
0.85VW 800 1
CN.S2
PROTECT
CN-A
0.85GR 0.85GR 0.85GR
2 2
Y3
2 3
VR 524
58M
1
24VB BG 636 0.85B 762 2 F7 FUSE 20A; FUEL FILLER PUMP
CN.15
PW 819
1 2 3
0.85B 0.85B 0.85B
SDL
1 1
S12 0.85BG 645 (PINK TAPE) K30 K31 B52
1
5
F8 FUSE 10A; FUEL FEED PUMP
CN.E1
0.85BrR 6 0.85BrR 360 0.85BG 664 VR 912 1 F9 FUSE 30A; GLOW PLUG
SDL
REFUEL PUMP 17 OW 546 GND E4 GrR 14 GrR 520 0.85LW 801 1 GW 329 2 S61
Y4 F10 FUSE 15A; OPTION LINE AND LUBRICATOR CONNECTOR
CN.P4
1 2 3 4 5
BEACON 18 GW 810 1 LR 12 LR 521 VW 280 1 VW 280 0.85B 761 2 L 913 3
1
2
F11 FUSE 10A; BACK-UP
CN.P0
WARNING BUZZER 19 W 820 2 WR YR 13 YR 522 R 223 2 R 223 (RED TAPE)
CN.E3
1 4 2 1 4 2
ENG.STOP 21 WR 501 5V 4.7k VR 3 VR 523 B 702 3 B 702 F12 FUSE 20A; KEY SWITCH
4
1
2
5
3
4
1
2
5
3
5 5
HYD.FAN REVERSE 22 0.85GR 11 0.85GR 892 0.85YW 802 1 3 3 0.75R 471 12 0.75W(5V) F13 FUSE 20A; HEATER / AIR CONDITIONER
P4 Y5
VR 912
OW 546
-
B 750
B49
VR 917
24V,10W
B 751
L 913
SWING BRAKE 27 VW 800 VW 2 VW 525 VW 280 6 24V IN (MAIN) 0.85B 763 2 0.75W 481 13 0.75G(COM-SIG) F14 FUSE 5A; AIR CONDITIONER COMPRESSOR
1.25LR 915
1.25GrR 330
0.85BrR 916
CN.S3 CN.S4 +
2 STAGE TRAVEL 28 LW 801 WR 1 WR 390 R 223 2 24V IN (BACKUP) (YELLOW TAPE) 0.75G 491 14 0.75B(GND)
F15 FUSE 15A; WORKING LIGHT
1 2 3
CN.P9
CN.P8
SDL
FPC
CN.E4
1 2
91A
CUSHION 29 LgW 803 LW 7 LW 972 B 702 5 GND 0.75G 950 1 0.75WL
F16 FUSE 15A; WORKING LIGHT (NOT USED)
0.85B
HIGH DUMP 30 BZ. BL 8 BL 973 0.85YR 281 1 12V OUT(MAIN) 0.85LgW 803 1 0.85BrR 916 0.75L 951 2 0.75BR
SWING LOCK BrW 804 YW YW 970 0.85RW 282 Y6 0.75Br
F17 FUSE 10A; DC-DC (24V-12V) CONVERTER
31 9 3 12V OUT(BACKUP) 0.85B 764 2 0.85B 749 B82 0.75BW 688 3
2 3
4 5 6 7 8
1 VW 2 VW F18 FUSE 15A; WIPER AND WASHER
SPARE 1(PNP) 32 WL 812 BY 10 BY 971 0.85BY 729 4 GND (LIGHT GREEN TAPE) 0.75W 952 4 0.75WR
CN.P3
12V OUTPUT
S53
SDL
CN.E5
3 BG 1 BG
SPARE 2(PNP) 20 WV 813 H1 WV 4 WV 930 7 SHUT OFF 24V 0.75L 953 5 0.75BW B50 F19 FUSE 15A; HORN
2
VARIABLE ISC 23 BW 5 BW 720 0.85BrW 804 1 0.75BL 686 6 0.75Br F20 FUSE 15A; CIGARETTE LIGHTER AND CAB SEAT
0.85YR 283
0.85BY 727
1
SWITCHED DROOP 36 X15 U1 0.85B 765 2 Y1 0.75WR 484 7 0.75RB(WT) COMPRESSOR ADJUSTMENT
BW 721
WV 931
330,546
CCW/ISC3(NPN) 24 P5 (GREEN TAPE) 0.75WL 483 15 0.75BR(BT)
F21 FUSE BOX
10 11 12 13 14 15 16 17 18 19 20
WR WR
5 6 7 8 9
1
7 8 9 10 11 12 13 14
4 5 6
CW/ISC2 (NPN) 26 0.75RG 477 8 0.75RW(5V)
4 5 6 7
1
MT090
SUMITOMO
VW 2 VW 12V F22 FUSE 20A; MAIN FUSE FOR F11 AND F12 CIRCUITS
CN.U9
M14
PA
ISC DECR.(NPN) 1.25GrR 330 1.25GrR 330 0.75L(BP-SIG)
CN.70
33 1 0.75GR 487 16
1 2
F23 FUSE 65A; MAIN FUSE FOR F3 TO F10 AND F13 TO F20
0.85B 763
0.85B 760
1 VR VR 3 VR t C
2 3
CN.14
ISC INCR.(NPN) OW 546 OW 546 1.25LR 915 0.75RL(GND)
SDL
34 3 1 2R M 0.75BR 497 17
0.85BG 637
1.25BG 600
S54
CN.24
3 BG BG 4 BG CIRCUITS
B1
SDL
2BG 600
2B 700
A/C CONT. 25 GY 566 1.25B 748 2 1.25B 748 1.25B 748 2 2B 0.75RY 478 9 0.75BL(5V)
1.25BG 600
2 BL(SPK:L-) 5 BL
1 2 3
PROTECT NO USE 35 OW 894 1 0.75YB 488 10 0.75LY(OP-SIG) F24 FUSE 20A; MAIN FUSE FOR F2 CIRCUIT
LW(SPK:L+) 6 LW
M20
1 2 3 4
F25 FUSE 20A; MAIN FUSE FOR F1CIRCUITS
CN.T8
B 772 2 0.75BY 498 11 0.75BY(GND)
2 3
4 5 6 7 8
1 2
58X
BY(SPK:R-) 7 BY
CN.S1
18 F27 FUSE 50A; SAFETY RELAY
CN.25
1.25W 325
1 2
58X
SDL
1 YW(SPK:R+) 8 YW 24V
X4
1 2 3
CN.P7
WR 571
CN.6
19 G1 BATTERY
91A
748,759
24V 5V 2
O 895
SUMITOMO
t C
MT090
LG 570
CN.Q2
20
3 G2 ALTERNATOR
1
B51
CN-A
E3
CN.16
10
11
12
13
14
15
16
1
2
1 2
P 585 LW 801 0.85LW 801
1
2
3
4
5
6
7
8
9
1 O 895 1 O 896 1 2BY

M
7 8 9 10 11 12 13
4
4 5 6
PG 586 YW 802 2 0.85YW 802 B 773 2 B 774 2 2B 0.85BO 492 1 t C H1 AUDIBLE WARNING DEVICE
5 RS232C
1 BY
PB 589
AMP MIC
B6 H2 TRAVEL ALARM
DL040
SUMITOMO
CN.P1
PG 588
BP 634
17
13
B 734
BP 587 LgW 803 3 0.85LgW 803 0.85OL 482 2
9
5
1
6 16 15 14 13 12 11 10 9 0.85GR 2 YW
CN.A2
1 R K2 RELAY-GLOW PLUG
18
14
10
6
2
8 7 6 5 4 3 2 1 WV 931 1 BrW 804 4 0.85BrW 804
7
PACKERD
1 2 3
CN.U8
19
15
11
0.85B
CN.U8
24V 70W 2
7
3
SWP
CN.A7
K3 RELAY-HORN
1 2
BG 633
58W
1 2
BG 620 PB 590 BW 721 2 GW 810 5 GW 810
X24
20
16
12
1 2
8
8
4
CN.Z1 24V
BrR 840 6 BrR 840 0.85B 752 K4 RELAY-WORKING LIGHT
CN-B
CN.P5
1
2
B 734 VR 841 7 VR 841 0.85B 763
B47 K5 RELAY-ROTARY LIGHT
GND (G2)
CN.C7
633,634,635 VW 842 8 VW 842
SWP
K6 RELAY-AIR CONDITIONER CONDENSER FAN
1 2
WIPER SW.IN(INT) 11 LR
575,588,589 WV 930 9 WV 930 0.85B 760
1 BL WIPER SW.IN(CNT) 12 YR
BW 720 10 BW 720 0.85Y 476 1
K7 RELAY BATTERY
CN.1
CN.11
V REF 0.85BrY 575 0.85BG 635 2 LW WASHER SW. IN 13 GrR
X23 L
0.85GR 890 11 0.85GR 890
M6
0.85YL 486 K8 RELAY SAFETY
1K 100 1K 0.85PG 598 0.85PG 598
PA
WASHER CONT.(+) 2 WV
0.85LgR 891 0.85LgR 891
0.85B 752 1
H2 0.85BY 496
3
B48 K17 BLOWER OFF RELAY
5 6 7 8 9 12 W 820 2 2
WASHER CONT.(-) 3
THERMO SENSOR(O) 6 0.85OL 415 BrR 840 1 X8 1 2 3 4
WL 812 4 0.85LR 901 13 0.85LR 901 K30 REFUEL PUMP RELAY
CN-B
CN.P6
0.85VG 469 W1 POWER (24V) IN 1 0.85BrR
CN.A8
X9
1 2 3
B21
AMP
1
2
A GND 13 0.85BO 425 BP 690 2 S63 GND 10 1.25B

WV 813 3 WR 980 14 WR 980 24V,107dB K31 REFUEL PUMP STOP RELAY
FUEL SENSOR 14 0.85GL 413 BrG 460 3 OW 458 0.85OL 300 15 0.85OW 300
2 24V,370Hz,111dB K33 MAIN RELAY
WR 391
YW 970
LW 972
0.85BG 621
BY 971
WINDOW CONTROL
BL 973
9
R 222
B 710
SPARE 11(A/D) 15 OG 459 1 GR 982 16 GR 982

REV. SIG. 7 VW M1 STARTER MOTOR
CN.63
CN-A
A Vcc 3 0.85WY 400 YR 940 17 0.85YR 940 0.85VR 900 0.85LR 901
CN.62
2 3
CN-A
B81 M3 WIPER MOTOR

2 3
STOP SIG. VR
1
8
1
P1 SIG. 0.85WL 410 BY 941 0.85BY 941 WV 930
748,759
1 18 1
WINDOW LIMIT SW. 4 B81 M M4 M4 WASHER MOTOR
8
3
9
4
6
2
1
7
5
BW 720
1 2 3 4
P2 SIG. 9 0.85YL 411 WG 448 1 W 820 19 W 820 0.85B 753 0.85B 754 2
CN.28
WIPER MOTOR(CW) 5 GW
M5 MOTOR (AIR CHANGING)
SDL
NEG.CON SIG. 10 0.85L 412 0.85BG 604 2 BrR 840 1 GrR 893 20 GrR 893 0.75Y 485 1 0.75YG(FT) t C
S13
CN.B4
CN-A
WIPER MOTOR(CCW) 6 GR 24V,370Hz 111dB
A GND 2 0.85BW 420 BP 690 3 BP 690 2 S14 0.75P 864 2 0.75RW(Hi) B3 M6 AIR VENT DIRECTION CONTROL MOTOR
2
1
1.25BG 600
5V THROTTLE 11 0.85LY 470 BG 606 BrG 460 3 0.75W 866 3 0.75RB(Lo) M7 MOTOR ACT (AIR-MIX)
24V
SIG THROTTLE VOL. 4 0.85LG 480 0.85BG 645 GrR 893 4 M8 BLOWER MOTOR
X2
DL090
SUMITOMO
4 5 6
1 2 3
CN.P2
CN-A
A GND 0.85BL 490

5
A4 0.85B 745 B 755 B 755 5
M9 AIR CONDITIONER CONDENSER FAN MOTOR
CN.A5
4 5 6
1 2 3
A/D OVER LOAD SIG. 12 0.85PL 417 6
M14 FUEL FEED PUMP MOTOR
CN-A
CN.B5
CN.60
10 bit KEY SW. 7 LgR 542

1 2
58W
M3
2BG 600
2
1
2B 700
SPARE 12(CMP) S51 0.85L 418 Y35 M15 EXHAUST GAS RECIRCULATION MOTOR
16
S15 1 LW 532
3 GR
E1
1
M20 ELECTRIC FUEL PUMP
5V BATT.CHARGE 8 BrR 543 GrG 445 YG 451 2 B 713 0.85LgR 891 1 0.85BL 661 2 S62
0.85B
1 GW
5V BG 605 BG 606 1 VR 240 3 VW 842
M 5 1.25B
0.85B 741 2 24V 70W P1 INSTRUMENT PANEL
CN.T9
SWP
10V YR 830 4 B 714 1.25RG 850 1.25W(INJECTOR POWER1) P2 SWITCH PANEL (LEFT-HAND)
1 2
2 1
OW 301
6 VR
CN.B2
SWP
5V 1.25RW 851 1.25R(INJECTOR POWER2)
1 2
2 P3 SWITCH PANEL (RIGHT-HAND)
CN.2
24V 4 VW
S25 2 E2 3
P4 MONITOR DISPLAY
1 2 3 4
TXD 0.85GR 890 1 0.85GR 890 1 4 CYLINDER #1

CN.61
RS232C
P5 HOURMETER
B 710
SDL
SCI 24V 70W 0.75GW 854 0.75L (INJECTOR ORDER 1)

RXD DRYER & 23 0.85B 740 2 0.85B 740 2 5
0.85B 753
0.85B 754
1.25B 748
SPARE 13(CMP)
27 P 585
R3 S1 222,391,710,970,971,972,973 LG 430 0.75WL 857 6 0.75LR (INJECTOR ORDER 4) P6 AIR CONDITIONER CONTROL PANEL
RECIEVER 2
CN.F0
Tx
B26
CN-A
CYLINDER #6
R1 GLOW PLUG
2
1
Rx 21 PG 586 CONNECTION 240,448 BG 650 1 0.75GB 855 7 0.75LY (INJECTOR ORDER 2)
OFF
20 BP 587 X6 HEAT
ACC VR 240 1 VR 240 830,840,842 2B 758 2B 758 0.75G 856 8 0.75LW (INJECTOR ORDER 3) R3 THROTTLE VOLUME
WR 391
SG B G1 G2 ACC M ST
14 13 12 11 10 9 8 7
3 2 1
LG 570 ON YR 830 YR 830 (YELLOW TAPE) 0.75WB 858 CYLINDER #5 R4 THERMISTOR INNER TEMPERATURE
603,604,636,664
SW. TO ACCESS 28 2 BrG 460 B 759 9 0.75GR (INJECTOR ORDER 5)
CN.C5
HEAT
090
CN.D4
1 2
1 2
SWP
22 WR 571 BrG 460 3 BrG 460 0.75WR 859
PROTECT
S16 BrG 461 10 0.75GB (INJECTOR ORDER 6) R5 FUEL SENSOR
CN.19
ST OFF
1
2
SDL
TXD SERIAL OUTPUT 25 PW 583 BrR 840 4 BrR 840 11

S1 KEY SWITCH
1 2 3 4
CYLINDER #3
3
2
1
SCI PL 584 ACC VW 842 VW 842

19 5
CN.53
RXD SERIAL INPUT 0.85YR 940 1 12

SDL
6 5 4
Y7 S2 TRAVEL MODE SWITCH
2BG 600
GND 26 ON WG 448 6 WG 448 0.85BY 941 2
0.85GR 231
2B 700
1 2
0.85Y
0.85B
0.85L
S3 WORK MODE SWITCH

B 716
TA INPUT 24 LW 532 7 LW 532 YG 431 2 CYLINDER #2
DL090
SUMITOMO
SWP ST
COUNTER 1/4 B27 S4 AUTO MODE SWITCH
9 10 11 12
5 6 7 8
1 2 3 4
GND 17 1 G 450 GrG 445 8 K33 2B 700 BG 651 1
CN.A3
CN.54
18 BG 603 YG 451 9 S5 CUSHION CONTROL SWITCH
1
2
3
TA GND 2 2BG 600

CYLINDER #4
1 2 3 VR 841 B 713 B 713
3 10 S6 ROTARY LIGHT SWITCH
CN.C6
090
1 2
4 5 6
4
2
5
3
6
1
LR 251 1 4 B 711 0.85BG 604 11 0.85BG 604 GW 810 1 GW 810 1

3 2 1 GW 810 S7 AUDIBLE ALARM CUT OUT SWITCH
0.85LY 470
0.85BL 490
0.85L 480
CN-A
S21
CN.3
B 717 2 12 B 767 B 767 2 B 767 2

S8 SWING BRAKE SWITCH
WR 390
1.25LgR 540
SDL
0.85GrR 010
1.25RW 220
WR 390
0.85GR 231
13
WR 391
CN.52
S9 ENGINE EMERGENCY STOP SWITCH
CN.55
CN.50
1 2
CN.B6
CN.H0
60B 798
14
1 2
1 2
SWP
SWP
603,636,664
1.25GR 394
WR 541
S10 WORKING LIGHT SWITCH

B 716
IMMOBILIZER 31 0.85VG 469 B 716 BrY 432 2

1.25LgR 540
0.85GrR 010
2LR 310
OVER LOAD 32 BG 652 1 B22 S11 WIPER SWITCH

LgR 542
M12
SPARE 25(SW.) 33 OW 300 1 S12 WASHER SWITCH
SPARE 16(SW.) 34 1.25RW 220 1 1.25RW 220 1 2 0.85OW 300 1 OW 300 BrR 840 2 Y9 S13 OVERLOAD SWITCH
CN.B0
090
3 5
4
1
2
5
3
1 2
2ND.OPT.PILOT 35 G 464 E52 WR 390 2 WR 390 4 BrR 840 2 BrR 840
S14 BREAKER / CRUSHER SWITCH
CN.G0
36 YG 443 1.25LgR 540 3 1.25LgR 540 G 464 G 464
1 2
BZ. STOP 3
SWP
BG 636
1.25GR 394
YR 552
2LR 310
S15 HORN SWITCH
1.25BG 600
0.85GrR 010 0.85GrR 010 CN.30 BrG 461 BREAKER&CRUSHER
SPARE 17(SW.) 37
R4 B5 4 4
PILOT PRESS. S16 ONE TOUCH IDLE
BREAKER MODE 38 BrG 460 G 450 5 G 450 LY 435 5 LY 435
LgR 503
GrR 504
1
2
1
2
S21 DOUBLE ACTING SWITCH (RIGHT)

0.85LgR 502
TEST 41 VR 841 16 VR 841 BG 655 6 BG 655 BG 641 1

CHECK 42 7
A9 0.85LY 470 6 0.85LY 470 LY 435 GrG 437 2 S55 S25 DOUBLE ACTING SWITCH (LEFT)
0.85OW 331
0.85OB
0.85GY
0.85OB
2
0.85LY
B23
BG 656
G 464
1 2 1 2
CN.B1
S51 HYDRAULIC FUNCTION CANCELLATION LEVER SWITCH
4 5 6
1 2 3
ENG.STOP 43 BrR 530 10 0.85L 480 7 0.85LG 480 BG 655
SWP
1
1.25BG 600
YR 552
CN.B8
SWP
Y 554
CUSHION 44 WG 446 CN. S3 CN. S2 0.85LY 4 0.85BL 490 8 0.85BL 490 S52 AIR CONDITIONING COMPRESSOR CLUTCH SWITCH
1 2
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1 2 3 4 5 6 7
CN.G1
LY 444 0.85GY 0.85GR 231 0.85GR 231
090
SWING LOCK 45 3 15 S53 DOOR LIMIT SWITCH
1 2
9 10 11 12 13 14 15 16 17 18
P6
5 6 7 8
SPARE 19(SW.) 46 OW 458 0.85OB 18 4 B 711 17 B 711 Y 554 OW 300 1

A6 S54 FRONT WINDOW LIMIT SWITCH
SPARE 20(SW.) 47 OG 459 2 0.85LB 0.85LB 1 7 BG 603 18 BG 603 BrR 840 2
SPARE 24(SW.) 48 2B 14 8 YR 560 9 YR 560 G 464 3 G 464 0.85BO 425 1 tC S55 RESERVE TANK LOW SWITCH
1
CN. S0
B2 S61 REFUEL PUMP SWITCH

BG 664
I/O NO USE 40 3 2L 19 1 BY 561 10 BY 561 BrG 461 4 BrG 461 0.85OL 415 2
CN. S1
CAN H 29 0.85P 580 20 2 PL 562 11 PL 562 LY 435 5 LY 435 LY 435 2 S62 AIR CLEANER SENSOR
1 2 3 4
CN. S9
B25 S63 DOUBLE ACTING SWITCH (OPTIONAL)

2 3
39 0.85PL 581 0.85L 3 12 PW 563 BG 655 BG 655 BG 655

8 9 10 11 12 13 14
CAN CAN L 2 PW 563 6 1

1
CN.D3
AMP
1 2
CAN GND 30 0.85YW 5 6 WL 564 13 WL 564 U1 DC-DC (24V-12V) CONVERTER
K2 K5 K6
P 592
BG 656
PL 593
G 464
2 2L 0.85BrW 6 5 BW 565 14 BW 565
W1 ANTENNA
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
M8 M 1 2R 0.85RB 16 0.85R 19
AMP 070 MULTI LOCK
15
X2 ROTARY LIGHT CONNECTOR
10 11 12 13 14 15 16 17 18 19 20
CN.4
2 3
4 5 6 7 8
0.85O
5 6 7 8 9
17 17 0.85G 20 0.85BG 660 1

R5 X3 OPTIONAL POWER CONNECTOR
CN. 51
CN. S8
21 18 0.85W 0.85GL 413 2

1
2
CN.23 LEGENDE
SDL
1 2 1 2 1 2 X4 ENGINE TEST POINT CONNECTOR
22 16 0.85B B61 3 5 3 5 3 5
5
1
2
3
4
5
1
2
3
4
X5 CONTROLLER TEST POINT CONNECTOR
CN.B3
CN. 10
1
AIR CLEANER L 418 G 464 G 464 G 464
SWP
49 1 2R 26 2 2 2
1 2
SDL
SPARE 21(SW.) 50
K17 4 0.85BrR 15 3 0.85WR 1 WL 564
4 4 4 1 2 3 4 5
BG 656 1 BG 656 BG 656 1 B24 X6 CAB SEATCOMPRESSOR MOTOR CONNECTOR
WR 555
0.85BrR
PW 819
2WR 050
GR 982
BrW 260
B 728
B 725
LR 250
LgR 503
2LR 060
GrR 893
BrR 506
TRAVEL PILOT YG 431 BW 565 CN.31 CN.35 CN.34

51 3 0.85WG 0.85RG 30 4 0.85WR 2 X7 LUBRICATOR CONNECTOR
1 2 3 4
CN.G2
CN.M0
SWP
BG 657
G 465
1 2
BEACON VG 447 NOT CONNECTED
090
52 2WG 6 0.85WY 400 2 CONNECTED X8 RADIO CONNECTOR
1 2
2 0.85WL 13
CN. 12
B42
SDL
1 2
L/M MODE 53 OR 455 0.85LgW 25 11 0.85WG 0.85WL 410 3

X9 ANTI-THEFT SYSTEM CONNETOR
CN. S7
AUTO MODE OG 442 LG 430 LG 430 G 464 G 464

1 2
3 4
54 0.85YL 9 7 1 2 0.85BW 420 1

BREAKER PILOT 55 LY 435 0.85GW 0.85R 4 PW 563 060,503,893,982 YG 431 2 YG 431 BG 656 BG 656
X15 ACCESSORY SOCKET
HW090
SUMITOMO
0.85Br 29 12 1
CABLE GROUND X23 CLEAR MEMORY 1
CN.D0
WORK MODE 56 VY 440 0.85YR 13 0.85GW 0.85G 5 PL 562 050,250,260,819 BrY 432 3 BrY 432 BOOT GROUND
1 2
5 0.85LW 12
3
COOLANT 57 GrG 437
M7 1 0.85RG 0.85LgB 24 8 0.85W 6 BY 561 506,555,725 L 418 4 0.85L 418 G 465 2 X24 CLEAR MEMORY 2
12 3 4 5
SPARE 22(SW.) 58 2 0.85WL 0.85YG 8 10 0.85YR 0.85B 7 YR 560 LY 435 5 LY 435 BG 657 1 B28 Y1 SWING PILOT SHUT-OFF SOLENOID VALVE
CN. S4
WR 555
WG 448 (LIMIT SW.DOOR) 0.85O VW 525 GrG 437 GrG 437 (GREEN BAND)
BrR 506
WARNING CHG. 59 3 0.85LgW 0.85RY 28 9 0.85YB 16 6
CN.M1
090
1 2
SPARE 23(SW.) 60 0.85Y (LIMIT SW.WINDOW) 0.85YW 15 VR 524 BrG 461 7 BrG 461 0.85Y 401 2
4 0.85YL 0.85LR 11 1
SINGLE WIRE CONNECTOR HARNESS Y2 PILOT PRESSURE SOLENOID VALVE (BLUE BAND)
SWING PILOT 61 BrY 432 0.85LgR 23 14 (WATER TEMP.SIG) 0.85BrW 14 GY 566 G 464 8 G 464 0.85YL 411 3 B44 Y3 SWING BRAKE SOLENOID VALVE (PINK BAND)
CN.L0
SWP
1 2
UPPER PILOT 62 LG 430 0.85GB 27 5 0.85BR (RECIEVER DRYER) 0.85GW 17 WR 980 0.85GL 413 9 0.85GL 413 0.85BY 421 1
ONE-TOUCH IDLE 63 G 450 (ILUMINATION) 0.85RB 3 0.85GR 567 0.85OL 415 10 0.85OL 415 OW 301 1 (BLUE TAPE)
Y4 2 STAGE TRAVEL SOLENOID VALVE (RED BAND)
CN.B7
1 2 3
0.85BR
K4
HW090
SUMITOMO
K3
SWP
Y16 Y5 POWER-UP SOLENOID VALVE (YELLOW BAND)
CN.D1
TRAVEL MODE 64 BrG 441 (MAIN POWER) 2WG 9 1.25LW 340 0.85BO 425 11 0.85BO 425 VR 841 2
1 2
5 0.85YB
3
I/O (COMP.POWER) 0.85WG 8 0.85YW 270 12 0.85OR 455 INSULATION AGAINST MAGNETISM Y6 CUSHION CONTROL SOLENOID VALVE
M6 1 0.85Br (YELLOW TAPE)
1 2 3 4 5
2 0.85LW (GND) 2B 1 1.25B 701 OR 455 13 0.85OR 455 (LIGHT GREEN BAND)
CN. S5
2 WR 555 14 OW 301 1 OW 301 Y7 MAIN PUMP PROPORTIONAL SOLENOID

0.85WG
RAM 3 0.85LgB
0.85BR
0.85BR
0.85WG
1 2 1 2
2kbyte 10 O 255 15 O 895 VR 841 2 VR 841 OW 302 1 0.85LY 402 2
4 0.85YG 3 5 3 5
Y17 Y8 AIR CONDITIONER MAGNET CLUTCH
5
1
2
3
4
5
1
2
3
4
11 4 4 WR 501 16 WR 501 VW 842 3 VW 842 VW 842 2 0.85L 412 3 B43 Y9 CRUSHER/BREAKER OPTION TWO FLOW
12 0.85LgR 502 17 0.85LgR 502 0.85BL 422 1 CONNECTOR (MALE) CONNECTOR (FEMALE)
GW 290
GW 291
WR 531
LW 532
437, 455, 464, 418, 430, 431, 432, 435
SOLENOID VALVE
CN.L1
0.85GR 890
0.85VR 900
0.85VR 370
0.85VR 371
SWP
1 2
CN.32 CN.33
MT090
SUMITOMO
13 GrR 504 18 GrR 504
HW090
SUMITOMO
Y16 DOUBLE ACTING SOLENOID VALVE (RIGHT)
CN.T6
CN.D2
0.85GR 892
FLASH
1 2
BrR 506 BrR 506
1 2
18 19
10 11 12 13 14 15 16 17 18
E2PROM 5 0.85Y
1 2 3 4 5 6 7 8 9
3
0.85GR 567
Y17 DOUBLE ACTING SOLENOID VALVE (LEFT)

AMP NEW SCCS
0.85LgR 891
MEMORY YR 552 20 YR 552

M5 1 0.85RY
290,370
1 2 3 4 5
Y35 SUCTION CONTROL VALVE

CN.T5
0.85LR 901 0.85P 580 P 580 GR 983

633,634,635,637
8kbyte 2Mbyte 21 1
58X
0.85LR 1 2
CN. 17
2
CN. S6
M
255,413,415,425,501
0.85PL 581 22 PL 581 B 757 2

3 0.85LgR
0.85GB 0.85LY 407 2 0.85LY 407 2 CN. CONNECTOR NUMBER 60 B 001
4
1.25BG 600
CN. 1 CN. 2 CN. 3 CN. 4 B 756 1

M
0.85PL 417 3 0.85WG 417 3 B45
1.25BG 600
530,531,532,567 GR 982 GR 982 2 M9 0.85BG 427 1 0.85BG 427 1 SWP CONNECTOR'S NAME CIRCUIT NUMBER
580,581
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 56 890,891,892,900,901 B 767 (BLUE TAPE) COLOR
HW090
SUMITOMO
CN.R1
CN.D3
1 2 3
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
SWP
AREA
1 2
B 756
3
AMP 040 MULTI LOCK 24V
0.85OW 331
CN.T4
2
58X
2 1
2B 758
1 X7
TABLE OF COLOR SYMBOLS
CN. A0 CN. A1
AMP HYBRID I/O WR 980 WR 980 2
SYMBOL COLOR SYMBOL COLOR
4 5 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 106 107 108 109 110 111 112 113 119 120 121 1.25W 981 1
S52 B BLACK R RED
0.85LgR 502
0.75WG 873
0.75GW 854
0.75WR 484
0.75WR 859
1.25RW 851
0.75BW 689
0.75WB 870
0.75WB 858
0.85BrY 575
0.75RG 477
0.75GR 487
0.75WL 857
0.75RG 855
1.25RG 850
0.75YG 875
0.75GB 871
1.25GR 395
1.25GR 394
0.75WL 483
0.75BR 497
0.85BG 630
0.85BG 631
0.85BG 632
0.75YB 872
0.75RY 478
0.85BY 496
0.75YB 488
0.85OL 482
0.75BY 498
0.75BL 687
0.85YL 486
0.75W 866
0.75W 867
0.75W 479
0.75W 481
0.75W 952
43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 98 99 100 101 102 103 104 105

0.75G 874
0.75G 491
0.75G 950
0.75G 856
0.75R 471
0.75Y 485
0.75P 864
0.75P 865
1.25B 730
1.25B 731
1.25B 732
0.85Y 476
0.75L 953
0.75L 951
3 117 118 W WHITE Y YELLOW

GrR 504
BrR 506
WR 501
Y8
PG 588
YR 552
YR 553
PB 589
62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 90 91 92 93 94 95 96 97
PL 581
BL 956
BL 957
BL 956
P 580
090
SUMITOMO
1 2 81 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 82 83 84 85 86 87 88 89 114 115 116 Br BROWN Lg LIGHT GREEN

CN.B9
1.25W 981 1
1 2
CN.A1 P PINK Sb SKY BLUE

CN.C8
CN. A0
SWP
101
100
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
1
12
13
15
16
22
23
25
26
27
28
34
35
36
43
62
81
10
11
14
17
18
37
19
20
21
24
29
30
31
32
33
38
39
40
41
42
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
83
84
85
86
88
89
95
96
97
91
92
93
94
87
82
90
98
99
1
3
4
2
5
6
7
8
9
V VIOLET L BLUE
G GREEN Gr GRAY
413,415,418,425,430,431,432,437
OP-SC VALVE H1
SP-5V2(BARO)
SG-5VRT2(BARO)
SG-5VRT4(BOOST P)
IA-ACCEL PSTN1
IA-ACCEL PSTN2
IA-SC VALVE L0
IA-BOOST TEMP
OM-EGR MOTOR3 W
OM-EGR MOTOR1 U
IA-INTAKE TEMP
SP-5V4(BOOST P)
IA-BOOST PRESS
IF-CAM ANGLE
SP-5V5(COM.R&EGR)
SG-5VRT5(COMMO.R)
SP-CAM ANGLE
OM-EGR MOTOR2 V
IA-OIL PRESS
OS-PCV1
IA-BARO
SG-SLD5
OP-COM2
OP-COM1
IA-COMMON.R PRESS
IA-COMMON.R PRESS
SG-SLD4(CRANK)
IS-EGR PSTN3 W
OS-INJECTION5
OS-INJECTION6
OS-INJECTION3
OS-INJECTION4
OS-INJECTION1
OS-INJECTION2
OS-PCV2
IS-EGR PSTN1 U
IS-EGR PSTN2 V
IF-CRANK+
IA-FUEL LEAK.TEMP
IS-MODE MAP1
OS-OIL P. LAMP
IF-CRANK-
IA-WATER TEMP
IS-MODE MAP2
OS-STARTER RELAY
IS-MODE MAP0
OS-GLOW RELAY
SP-5V3(OIL P)
OS-GLOW LAMP
SG-5VRT3(OIL P)
ORANGE
OF-TACHO
OS-MAIN RELAY
O
OS-BOOST LAMP
PS-+B
PS-+B
PG-SIGNAL(GND)
PG-SIGNAL(GND)
PG-CASE(GND)
IS-DIAG
CC-CAN-L
IS-IGKEY(START)
PG-POWER(GND)
PG-POWER(GND)
PG-POWER(GND)
CC-CAN-H
IS-MEMORY CLEAR
400,410,411,412,417,418,420,720,730,930
OS-DIAG LAMP
IS-ENG STOP SW
OS-MAIN RELAY
IS-IGKEY(ON)
SG-SLD1
SP-5V1(ACCEL)
IS-IDLE MANU SW
CC-KW2000
SG-5VRT1(ACCEL)
IS-IDLE UP SW
IS-IDLE DOWN SW
A2 5B 796
NOTE : "BR" INDICATES BLACK CABLE WITH RED STRIPE.

M6 M6
CX330, CX350 EXCAVATORS

ELECTRICAL SCHEMATIC - 9-93970 EN
Copyright
22 D1 30
* 27 L1 K1 K2 B45 26 25 28
*
83
D MA MB D
P
L2 B1
*
29 29
* B2
REG
REG
VA VB
ITEM DESCRIPTION PRESSURE SETTINGS
P2
VB VA A= MAIN RELIEF (STANDARD) 34.3 MPa / 343 Bar / 4977 PSI
Dr P3 P2 P2 P3 A= MAIN RELIEF (BOOST) 37.3 MPa / 373 Bar / 5412 PSI

Au T1
B= BOOM RAISING PORT SECONDARY RELIEF 39.2 MPa / 392 Bar / 5688 PSI
X
B1/B2 = RELIEF ON BOOM HBCV 39.2 MPa / 392 Bar / 5688 PSI
186.7 cm3 T1 T1 C= BOOM LOWERING PORT SECONDARY RELIEF 27.4 MPa / 274 Bar / 3976 PSI
D= DIPPER OUT PORT SECONDARY RELIEF 39.2 MPa / 392 Bar / 5688 PSI
106 Pi
D1 = RELIEF ON DIPPER HBCV 39.2 MPa / 392 Bar / 5688 PSI
T2 E= DIPPER IN PORT SECONDARY RELIEF 39.2 MPa / 392 Bar / 5688 PSI
P MB MA P
F= BUCKET OPEN PORT SECONDARY RELIEF 39.2 MPa / 392 Bar / 5688 PSI
Pi Pi
T2 T2 G= BUCKET CLOSE PORT SECONDARY RELIEF 39.2 MPa / 392 Bar / 5688 PSI
P1
21 107 23 16 23 107 21 H= PILOT PRESSURE RELIEF 3.9 MPa / 39 Bar / 566 PSI
I= RIGHT-HAND SWING PORT SECONDARY RELIEF 30 MPa / 300 Bar / 4353 PSI
J I GB
P1 P1
J= LEFT-HAND SWING PORT SECONDARY RELIEF 30 MPa / 300 Bar / 4353 PSI
GA K1/K2 = TRAVEL REVERSE PORT SECONDARY RELIEF 38 MPa / 380 Bar / 5514 PSI
L1/L2 = TRAVEL FORWARD PORT SECONDARY RELIEF 38 MPa / 380 Bar / 5514 PSI
N1/N2 = NEGATIVE CONTROL RELIEF 2.89 MPa / 28,9 Bar / 419 PSI
O/P = SECONDARY RELIEF (2eme OPTION) 23.5 MPa / 235 Bar / 3410 PSI
Mu 57
A A B R= MAIN RELIEF (2eme OPTION) 20.6 MPa / 206 Bar / 2989 PSI
C D W1/W2 = CRUSHER OPTION SECONDARY RELIEF VALVE xxx MPa / xx Bar / xxx PSI
A B Dr P 1
51 = ACCUMULATOR PRECHARGE 1.5 MPa / 15 Bar /217.6 PSI
A
ON 1.2 MPa
194 psi
RIGHT 12 bar
LEFT RIGHT FORWARD LEFT FORWARD OFF 0.9 MPa ITEM DESCRIPTION
RIGHT REVERSE LEFT REVERSE
71
* 130.5 psi
*
B24 * R
9 bar
73 1. HYDRAULIC RESERVOIR
2. BREATHER
B1 A1 4. BY-PASS VALVE
1.8 0.3 MPa 5. SCREEN FILTER

SECOND Pa1
43.5 psi OPTION 6. RETURN FILTER
3 bar 10. MAIN HYDRAULIC PUMP
44 42 73 45 B A Y9 10
15. MAIN CONTROL VALVE
T 16. HYDRAULIC SWIVEL
A A4
21. TRAVEL MOTOR
41 N1 3
N2 C
P
0.1MPa
14.5 psi
* 22.
23.
SWING MOTOR
TRAVEL MOTOR BRAKE
A 1 bar Ps1 Dr T2 T1 T3 T5 T4 Ps2 84 T

25. RIGHT BOOM CYLINDER
26. LEFT BOOM CYLINDER
83 27. DIPPER CYLINDER
X
56
*
85
1 T 2
28.
29.
BUCKET CYLINDER
BOOM SAFETY VALVE
Pb1 30. DIPPER SAFETY VALVE

P
31. DIPPER LOAD HOLDING VALVE
O
Pc1 31 E D *
B28
58 58 42
32.
41.
BOOM LOAD HOLDING VALVE
FILTER (ULTRA-CLEAN)
DIPPER (2) P5 T5 A
10 2 43 59 31 IN Pb9 2.2 42. OIL COOLER
OUT 43. RETURN MANIFOLD
A5 75 P 44. OIL COOLER BY-PASS VALVE
DIPPER (1) Pa9 A B D 45. NON-RETURN CHECK VALVE
B5 ON 1.2 MPa OFF 0.9 MPa
194 psi 130.5 psi 51. ACCUMULATOR
12 bar 9 bar 52. 6 SOLENOID VALVE BANK
0.004 MPa Pb5'
0.07 MPa 53. BOOM & BUCKET CONTROL LEVER
0.58 psi Pb5 IN
10.16 psi 54. SWING & DIPPER CONTROL LEVER
0,04 bar 32
CX330 - CX350 EXCAVATOR

Pa5' Pc2
HYDRAULIC SCHEMATIC
0.7 bar OUT 55. TRAVEL CONTROL PEDAL
56. DIPPER CONTROL SHOCK ABSORBER
D2 Pa5
A8
C 57. BOOM & DIPPER CONTROL SHOCK ABSORBER
A B C D1 52 58. PILOT AND RETURN SYSTEM MANIFOLD
0.105 MPa
D T D3
T
109
*91 B8
59. FILTER
15.24 psi Pb8'
60. PILOT SYSTEM MANIFOLD
Pc3' BOOM (1)
1.05 bar 10
D7 Pc3
110 Pb8 DOWN
71. SECOND OPTION CONTROL VALVE
E 72. CONTROL PEDAL (OPTIONAL)
150 MESH 15
Pa8' UP 73. SECOND OPTION CONTROL VALVE
T1 Pbu Pb4' 43 52 51 60 82 75. FLOW RE-INJECTION BLOCK (OPTIONAL)
D6 Pb4
BOOM (2)
W2 * B Pa8
B7
D1 76.
78.
3-WAY SELECTOR (OPTIONAL)
RETURN FILTER (OPTIONAL)
15 Pb4' 79. CONTROL SHUTTLE BLOCK (OPTIONAL)
Pa8 BUCKET
A7
B3 81. SWING SHUTTLE BLOCK
OPEN Pb7 B T
0.3L 82. PILOT CIRCUIT FILTER
SWING
5 1 4 6 A3
CLOSE C1
83. SHUT-OFF VALVE (OPTIONAL)
Pb3 Pa7 84. T-SHUTTLE BLOCK (OPTIONAL)

RIGHT
85. HAND/FOOT CONTROL PILOT FILTER
Pa3
B6 Y4 Y2 86. PILOT FILTER BY-PASS VALVE
LEFT P3
TRAVEL 90. HYDRAULIC BREAKER VERSION PLUG
B2 BACKWARD A6 10 91. SAFETY VALVE VERSION PLUG
P P0 P
56 D
T A2 BREAKER (H) W1 * F G
Pb6 55
1 0.02 MPa
106.
107.
ANTI PENDULUM VALVE
TWO STAGE TRAVEL VALVE
FORWARD C3 C2 2.9 psi
B 79 Pb2
Pa6 0.2 bar
108. STRAIGHT TRAVEL VALVE
B2 55 109. SWING PRIORITY VALVE

E 79 Pa2 ON
Y5 Y3
B1
P4
90 * 2
P1 P2
110.
B22.
ARM REGENERATION VALVE
SWING PILOT PRESSURE SWITCH
C B23. BREAKER / CRUSHER PILOT PRESSURE SWITCH
*
78 P B1 0.103 MPa
B24.
B25.
SECOND OPTION PILOT CIRCUIT 2 PRESSURE SWITCH
BREAKER PILOT PRESSURE SWITCH
TRAVEL 14.9 psi
0.35MPa
C5 C4 86 1 bar B26. UPPER PILOT PRESSURE SWITCH (YELLOW BAND)
A1
B27. TRAVEL PILOT PRESSURE SWITCH
50.8psi
3.5bar A 55 BACKWARD Y1 Y6 B28. SECOND OPTION PILOT CIRCUIT 1 PRESSURE SWITCH
3 Pb1 B42. PUMP PRESSURE SENSOR (P1)
55 Pa1 FORWARD B43. PRESSURE SENSOR (NEGA-CONT)

B 4 B44. PUMP PRESSURE SENSOR (P2) (BLUE BAND)
108 A B45. OVERLOAD INDICATOR PRESSURE SWITCH
M3. PRESSURE TEST POINT
T T
Y1. SWING PILOT SHUT-OFF SOLENOID VALVE (GREEN BAND)
8 Y2. PILOT PRESSURE SOLENOID VALVE (BLUE BAND)
P1 PT ON 2.0 MPa PP PA ON 1.2 MPa P2 P3 PH Y3. SWING BRAKE SOLENOID VALVE (PINK BAND)
290 psi 174 psi Y4. 2 STAGE TRAVEL SOLENOID VALVE (RED BAND)
20 bar 12 bar
B27 OFF 1.5 MPa B26 OFF 0.9 MPa 15 Y5. POWER-UP SOLENIOD VALVE (YELLOW BAND)
130 psi Y6. CUSHION CONTROL SOLENOID VALVE (LIGHT GREEN BAND)
1 217 psi
15 bar 9 bar Y7. MAIN PUMP PROPORTIONAL SOLENOID
2
Y9. CRUSHER/BREAKER OPTION TWO FLOW SOLENOID VALVE
3
*
83
*
76
*
75
LEGEND
71 71 B42 Y7 10 B44 B43 P1 PUMP

P T
a4 P2 PUMP
A1 Psv A2
P4 P5 T4 T5
PILOT SYSTEM PUMP
OPTION
58 RETURN TO RESERVOIR
P3 P2 P1 T3 T2 T1 E
81 72 * 55 (FRONT)
a1 a2
(REAR) LEAK-OFF-RETURN
P P SUPPLY CIRCUIT
2S 3S 1S
54 85 53 85 TRAVEL (LEFT) TRAVEL (RIGHT) PILOT SYSTEM CIRCUIT

G
T T
BOOM
UP REVERSE FORWARD FORWARD REVERSE

1 T 2 COMPONENT BOUNDARY
H DOWN
S2 S3 S1
P
*
85 Pi1 Pi2
HOSE
PIPING CONNECTION
F
*
B23/B25
DIPPER SWING BOOM BUCKET R PIPING CROSS-OVER
IN OUT LEFT RIGHT DOWN UP OPEN CLOSE T
3 1 3 1 ON 1.2 MPa
A1 S1 A2 H 41 COMPONENT ITEM NO.
B
175 psi
12 bar
*
79 COMPONENT NUMBER
2 4 2 4
B22 OFF 0.9 MPa 140cm3
B1 S2 B2 140cm3
ON 0.5 MPa 130 psi 1 2 4 T 3 15cm3
72.6 psi 9 bar
15 15 M 15
85 85 D OUT
85
DIPPER
5 bar Pa2 Pb2 Pb1

5a4 P
OFF 0.3 MPa ISUZU A3
43.8 psi 6HK1XQB
C IN P T CONNECTION ITEM NO
3 bar
183,9 Kw Dr1
84 15 15 15 15 2000 tr/mn OPTION ITEM NO
30 A Pb6 Pa6 Pa1 Pb1
B1 B3 Dr2 a3
*
Pi
A
57
*
Y9 73 20.4cm3
P A4
A
S
M3 CX330 - CX350 EXCAVATOR
B4
HYDRAULIC SCHEMATIC
Number 9-93960 EN

SM CX330 Tier3 en

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Copyright

CX330, CX330NLC and CX350 Tier 3 Crawler Excavators

Copyright 2006 CNH France S.A.

* Consult the Engine Service Manual

Lep 9-94900EN Issued 05-06

SAFETY, GENERAL INFORMATION

Copyright 2006 CNH France S.A.

Lep 7-27691EN Issued 02-06

Lep 7-27691EN Issued 02-06

To prevent injury always follow the Warning, Caution

WARNING: If you wear clothing that is too

WARNING: When working in the area of the

WARNING: When doing checks and tests

WARNING: When putting the hydraulic

Lep 7-27691EN Issued 02-06

WARNING: When the battery electrolyte is

WARNING: Use suitable floor (service)

Lep 7-27691EN Issued 02-06

STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS

Lep 7-27691EN Issued 02-06

Copyright 2006 CNH France S.A.

TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE .................................................... 3

FLUIDS AND LUBRICANTS ..................................................................................................................................... 4

DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY ........................................................................... 18

DIMENSIONS AND WEAR LIMITS OF ATTACHMENT LINKAGES ...................................................................... 23

SHIMS FOR ADJUSTING ATTACHMENT GAPS................................................................................................... 28

SPECIAL TORQUE SETTINGS .............................................................................................................................. 30

MACHINE OVERALL DIMENSIONS....................................................................................................................... 33

Lep 9-94170EN Issued 02-06

TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE

Serial numbers of the components

Lep 9-94170EN Issued 02-06

FLUIDS AND LUBRICANTS

Transmission component oil

Lep 9-94170EN Issued 02-06

Oil viscosity / Oil range

1) With mineral base

Lep 9-94170EN Issued 02-06

Lep 9-94170EN Issued 02-06

Plastic and resin parts

Lep 9-94170EN Issued 02-06

Complete machine dimensions

Main body dimensions

Lep 9-94170EN Issued 02-06

Capacity of coolant and lubricants

Hydraulic oil filter

Lep 9-94170EN Issued 02-06

Over heat* Battery charge* Faulty electrical system*

Working light Upper: 24V, 70W (1)

Horn; electric horn (2)

Lep 9-94170EN Issued 02-06

Lep 9-94170EN Issued 02-06

Lep 9-94170EN Issued 02-06

Digging force (New JIS)

Travel lower body

Lep 9-94170EN Issued 02-06

Standard arm Super short arm Short arm Super long

Lep 9-94170EN Issued 02-06

Operational speed of each cyl- Open 3.8 0.6 3.9 0.6

Number of drive sprocket revolutions High 16.5 1.5 16.5 1.5

Lep 9-94170EN Issued 02-06

Item Component Name CX330 CX330NLC CX350

Weight information is approximate